Tag Archives: DRC

Trafo helps power up DRC copper-zinc mine expansion

Base metals, Mine operation news, Mineral project development, Mining equipment, Mining services, Power supply for mines, , ,

Trafo Power Solutions says it is supplying three mini-substations and two transformers to a copper-zinc mine in the Democratic Republic of the Congo as part of an expansion at the operation.

David Claassen, Managing Director of Trafo Power Solutions, says the pressure was on from early in the planning stages to ensure this critical equipment would be available on time – to facilitate the continued mine expansion. From the date of the contract award, the company will deliver the units to the mine site within just four months – despite most of South African industry having taken an annual December break.

“We have conducted projects previously with the end client and the engineering, procurement and construction (EPC) contractor, so have a good understanding of their requirements,” Claassen explains. “This experience – combined with our history in the DRC and in the mining sector – gave us the edge in expediting the whole process.”

The order was for two 2,000 kVA transformers to step down the electricity supply from 6.6 kV to 550 V, as well as three dry-type miniature substations. Two of the mini-substations are rated 315 kVA and 6.6 kV to 400 V, while the third is a 630 kVA unit which also steps down from 6.6 kV to 400 V.

“This equipment is an important part of the mine’s electrical infrastructure upgrade,” Claassen says. “Of particular interest were the dry-type mini-substations, which were quite unique in certain respects.”

As a specialist in dry-type transformer applications, Trafo Power Solutions designed the mini-substations in an IP54 configuration – ensuring that the units are completely sealed from dust and water. This level of insulation usually requires a forced air solution to ensure adequate air movement for cooling.

“For this application, the requirement was for natural air cooling – so the installation would not include external fans and related control instrumentation,” Claassen says. “This option enhances simplicity and further reduces any chance of ancillary equipment needing attention.”

The design of the enclosure and the transformer therefore took account of this configuration, allowing enough natural cooling despite the high ambient day time temperatures in the region. Another demanding aspect of the contract was that the two 2,000 kVA transformers are to replace units in the mine’s existing substation. This required innovative design to ensure that the new equipment fits into the available space.

“Our replacement units have a higher power rating than the ones they will replace, so the design was customised to ensure the mine does not have to re-engineer the space,” Claassen says. “This highlights our flexibility in designing solutions to optimise ease of installation.”

Delivery to site will take place after a factory acceptance test (FAT) has been conducted. While the functional commissioning of the units is not part of Trafo Power Solutions’ scope of supply on this contract, the company offers a standard commissioning and assistance service. This is part of its value-add to any of its contracts.

“The rapid pace of this project indicates a growing trend not only in mining but in other sectors, towards fast tracking new developments and expansions,” Claassen notes. “Clients are expecting their supply partners to deliver on shorter timelines, so one of our key strategies is to learn from each project and apply those lessons going forward.”

This keeps Trafo Power Solutions at the forefront of efficient project execution, focusing actively on quality and communication. This ensures first-time accuracy and customised designs, so that no time is lost by unnecessarily revisiting aspects of the project as it progresses.

“Our non-corporate approach means that we can take decisions and act quickly on matters commercial and technical,” Claassen says. “Our proven skill is in achieving these goals without compromising on quality.”

TLT-Turbo

TLT-Turbo Africa reports on major PGM mine ventilation installation in South Africa

Environmental, Mine ventilation, Mineral project development, Mining services, Precious metals, , , ,

In a move that it says marks a significant technological advancement in the mining industry, TLT-Turbo Africa has announced the successful implementation of a major ventilation project within the Platinum Belt of South Africa.

TLT-Turbo Africa says its latest project emphasises its role as a leader in mining equipment provision, with the project, completed in two phases, including the installation and commissioning of bespoke bifurcated surface fan stations, each with a dual-stage 220 kW fan system. Designed to operate continuously, these fans address the high pressure and efficiency demands characteristic of underground mining operations, according to the company.

Complying with noise restrictions to minimise the impact on nearby communities was an important achievement for the project, the company noted.

Additionally, the use of TLT-Turbo Africa’s standardised, modular A&B Fan range highlights a shift towards streamlined manufacturing processes that, it says, significantly reduce lead times and promote local availability of spare parts, thus ensuring swift maintenance and repairs.

Katlego Nchabeleng, Sales Engineer at TLT-Turbo Africa, said: “Our ventilation solutions are engineered to ensure the safety, health and wellness of mining personnel while facilitating better underground conditions and ease of maintenance. These installations epitomise our approach to delivering quality and sustainable advancements in mine ventilation.”

With eco-design at the heart of their operation, TLT-Turbo Africa’s fans exemplify their alignment with global environmental standards, focusing on energy-efficient solutions that contribute to the broader environmental imperatives of the mining industry, it says.

The company’s ongoing projects include a notable initiative in the Democratic Republic of the Congo and a forthcoming installation of modular mine fans in South Africa.

DELKOR India to supply vacuum belt filters to two mining operations in the DRC

Base metals, Mineral processing, Mining equipment, Mining services, , , , , , , ,

DELKOR India has been contracted to provide DELKOR Horizontal Vacuum Belt Filters, together with ancillaries, for two operations in the Democratic Republic of the Congo (DRC).

The orders included supply of a 162 sq.m filter for a copper project in Katanga, which was commissioned in 2022, and supply of a 110 sq.m filter for a cobalt processing plant in the Lualaba province. The latter was commissioned in 2020.

The scope of work for both contracts covered design, engineering, manufacture, supply (ex-works) and supervision.

Both filters were designed to achieve maximum recovery of water and produce a drier filter cake, DELKOR says. However, in the case of the 162 sq.m horizontal belt filter, the water is removed from the cake to repulp with acid in the downstream unit operation in preparation for the leaching process.

The filters were manufactured mainly from high-strength and corrosion-resistant stainless steel suited to the process requirements and were supplied in a knockdown state for easy and efficient erection on site.

These two projects reinforce DELKOR India’s long-standing relationship with the client, with earlier contracts including:

  • One 145 sq.m and one 64 sq.m horizontal vacuum belt filter;
  • Various thickeners of several capacities, including a high-rate thickener; and
  • Test work and design for a belt filter and high-rate thickener.

“We are proud to have been part of the establishment of such important projects,” Indu Bhushan Jha, DELKOR Managing Director, says. “These contract awards provide further examples of DELKOR India’s commitment to maintaining the loyalty of its client base through superior service and best-of-breed technologies.”

ERG breaks ground on COMIDE copper-cobalt hydromet plant in DRC

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Eurasian Resources Group (ERG) in Africa has broken ground on a hydrometallurgical plant at its COMIDE asset to produce copper and cobalt in the Democratic Republic of the Congo (DRC)

The plant is designed for phased operational output, with expansion potential to produce approximately 120,000 t/y of copper cathode and 15,000 t/y of cobalt hydroxide.

COMIDE comprises some of the largest known copper and cobalt resources still to be developed globally, according to ERG. Following a technical study, the development potential of its resource base and production capacity were established, paving the way for the project at hand. The COMIDE project includes the construction of a hydrometallurgical plant, an extensive exploration and drilling program, as well as mine development – backed by a total investment of around $800 million.

The start of works was marked by a groundbreaking ceremony held at COMIDE in Lualaba Province on October 12, 2023.

The hydrometallurgical plant, which is expected to be complete by the end of 2025, will be constructed in three phases. During the first and second phases, the plant will produce an estimated 40,000 t of copper cathode and 7,000 t of cobalt hydroxide annually. The third phase is projected to yield up to 80,000 t of copper cathode and 14,000 t of cobalt hydroxide per annum, with the potential for further expansion to reach a production capacity of 120,000 t of copper cathode a year.

Speaking on behalf of ERG Africa’s Acting Chief Executive Officer, Sergei Verbitckii, Chief of Staff, Joachim Nzuzi, stated: “The design of this project was developed with innovation and sustainability top of mind. The plant will be equipped with the latest technology to ensure that we maximise recovery, while reducing the impact on the environment.”

The ERG Clean Cobalt & Copper Framework – which guides production of these two critical minerals – will be extended to COMIDE.

Nzuzi added: “Aligned to ERG’s commitment to environmental stewardship, we are not only celebrating the building of a plant and the development of a mine today. We are also committing to a greener tomorrow, not only through our approach to responsible mining and producing the critical mineral required for the green energy transition, but also by restoring the ecosystems on our site and in the surrounding areas. Thus, before we have even started construction work, we teamed up with the University of Lubumbashi to establish a nursery that will provide the trees we will plant to ensure that after our mining activities eventually cease, the site will house many more trees than before we started the project. We already have 700 trees in our nursery and are currently seeding 2,000 more.”

During the development and construction phase of the project, COMIDE will provide approximately 2,000 direct and indirect jobs for DRC nationals, predominantly hired from its surrounding communities, ensuring that its community members will be the primary beneficiaries of COMIDE’s activities, while contributing to the broader economic upliftment of the country.

Once COMIDE becomes operational, with an estimated initial 20-year life of mine, its surrounding communities will stand to benefit through direct and indirect employment and supplier opportunities, the communities’ contribution fund and royalties towards social development initiatives, in addition to the projects outlined in its community development plan agreement [Cahier des Charges] and other social contribution initiatives contemplated to be developed in the context of the operation, ERG says.

BJD Crushers wins Hammermill order from DRC copper producer

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BJD Crushers Limited, the UK-based manufacturer of crushing and size reduction equipment, has recently supplied a major order of its crushing machinery to a new copper mine and smelting plant in the Democratic Republic of the Congo.

The order includes the manufacture of two BJD 24 x 30 Hammermills with 90 kW drives, both running at 40 t/h. The machines will be used for processing copper concentrate from rotary dryers at the Kamoa-Kakula mine in the DRC, IM understands.

Used worldwide in the reduction of friable and fibrous materials, BJD’s Hammermill crushers can be supplied with adjustable breaker plates, produce high reduction ratios and feature capacities of up to 500 t/h, depending on duty, the company says. The whole project at the plant is due for completion in 2024/2025.

The contract, which was awarded following BJD’s successful completion of a similar project for Poland’s largest copper mine, took eight months from the initial order to shipment. It was delivered on schedule and within budget.

Peter Mills, Senior Project Consultant at BJD Crushers, explains: “We were honoured to supply BJD Hammermills to one of the world’s largest copper mining projects following previous success in this sector. The customer envisages a 19 Mt/y production scenario and required industry proven machinery to service this high-grade copper mining operation. The BJD Hammermills will be used to reduce the copper concentrate oversize material to a predicted 2mm particle size.”

BJD Crusher’s experience in the design and manufacture of crushing and size reduction equipment spans more than 80 years and covers a wide variety of applications, it says. Its equipment can be found working successfully in primary, secondary and tertiary applications around the world.

Trafo Power Solutions bolsters dry-type transformer contingent at Alphamin’s Bisie mine

Base metals, Environmental, Mine operation news, Mining equipment, Mining services, Power supply for mines, , , , , ,

Five years since Trafo Power Solutions supplied Alphamin’s Bisie tin mine in the Democratic Republic of Congo with two dry-type transformers, the mining company has now ordered another three of these modular substations equipped with dry-type transformers to keep up with the mine’s expansion.

“This latest order is testament to the operational performance of our dry-type transformers at Bisie mine over the past five years,” David Claassen, Managing Director of Trafo Power Solutions, said. “There were numerous challenges that our design had to accommodate, not least of which is a very arduous section of road in the journey to the mine.”

The mine’s location in the Walikale Territory of DRC is remote, being about 180 km northwest of Goma. Like the initial order, the three 3,000 kVA, 400 V/11 kV substations will be supplied in standard 6 m containers to facilitate transportation. However, specialised steel bracing is required – to withstand the challenging road conditions, especially over the last part the journey.

“These conditions make the road almost impassable by any vehicle other than a six-wheeled Unimog,” Claassen says. “There is intense vibration and tilting of the cargo on these trailers, so our design and bracing is done with this in mind.”

He notes that the mine had considerable foresight in specifying the first dry-type transformers, especially given the relative novelty of this option at the time. At that stage, it tended to be standard practice to use oil-filled transformers for this type of application. Apart from the logistics, the substation solution also had to withstand the equatorial climate and frequent lightning strikes.

“The region where the mine is located is ranked in the top five most vulnerable to lightning strikes, so there is a high risk of damage to equipment related to electrical surge,” Claassen says. “We therefore designed robust surge protection solutions on both the medium voltage and low voltage sides of the substations, and for the transformers.”

Given the warm climate, Trafo Power Solutions designed a fully redundant N+2 cooling system for the transformers; this means that each transformer is cooled by two fans, with another two fans on standby. Among the advantages of dry-type transformers in this climate is that the MV winding is completely cast in resin, so is highly resistant to humidity.

Zest WEG to supply Ivanhoe Mines with range of electrical, energy solutions for Kipushi

Base metals, Comminution of minerals, Mineral project development, Mining consumables, Mining equipment, Mining services, , , , , , , , , , ,

As part of Ivanhoe Mines’ refurbishment of the historic Kipushi zinc-copper mine in the Democratic Republic of Congo (DRC), Zest WEG is to supply a range of electrical and energy solutions.

Ivanhoe Mines acquired its 68% interest in the Kipushi project in November 2011; the balance of 32% is held by the DRC’s state-owned mining company, Gécamines.

According to Luveshen Naidoo, Business Development External Sales Engineer for Mining and Industrial at Zest WEG, this includes a 14 MW power plant, motor control centres (MCCs), WEG medium voltage (MV) variable speed drives (VSDs) and a WEG 1,200 kW MV motor for the mine’s ball mill. The company is also the preferred supplier of low voltage (LV) motors, and will supply these to a range of mechanical OEMs servicing the mine. Delivery of the equipment is expected to begin in the September quarter of 2023.

“Our diesel powered plant, which will provide the mine with backup energy, has been designed to comprise 12 generator sets – each rated at 1,587 kVA and 400 V,” Naidoo says. “Assembled at Zest WEG’s specialised Cape Town facility, the plant includes MV switchgear, six 3150 kVA ONAN type 400V / 6.6 kV step-up transformers, a 40,000 litre fuel tank and an automated fuel system.”

He highlights that splitting the plant design into smaller generating units ensured engines and alternators were readily available, securing a quicker delivery time. The configuration of the plant in this way also gives the mine greater energy security in the case of maintenance or breakdown. The gensets can also be transported to site using conventional trucking, without the need for abnormal load vehicles.

The MCCs are being supplied for use in an established substation on the Kipushi zinc-copper mine, as well as for a containerised substation elsewhere on the site. To accommodate space constraints, the MCCs are designed for a back-to-back configuration with a compact bucket size, Naidoo explains.

“This ensures that the equipment will fit in the available space while still meeting the client’s specification and stringent IEC standards,” he says.

For the mine’s SAG mill, Zest WEG is providing the WEG W60 MV motor rated at 1,200kW – a unit for the demanding applications and aggressive environments found in the mining sector, Naidoo says. The reduced motor weight holds distinct benefits, he notes, including a compact base plate or plinth onto which it is mounted – and lower installation costs. The motor’s IP55 rating ensures the motor is well protected from dust or water ingress.

To meet the client’s needs for the MV VSD to drive the ball mill motor, WEG’s MVW3000 unit is being supplied – a compact design with an integral dry-type transformer. To facilitate the dissipation of heat, Zest WEG designed a ducting system for this 1,200 kW VSD which will reduce the need for cooling of the substation.

As the client’s preferred brand of LV motors, the WEG W22 motor is being made available to Kipushi’s mechanical supply OEMs. Among the key benefits of this WEG IE3 motor is its energy efficiency, Naidoo says. This preferred brand strategy makes it more cost effective for the mine to keep the necessary consignments of spares for maintenance and servicing.

In putting together its proposals for the client, Zest WEG worked closely with the engineering consultant METC Engineering in the detailed design stage.

First-line support for Zest WEG’s equipment will come from Panaco, the company’s Value Added Reseller in the DRC.

More SEW-EURODRIVE X.e-series power packs on their way to Kamoa-Kakula

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With well over 100 units already delivered, SEW-EURODRIVE in South Africa is set to continue supplying Ivanhoe Mines’ Kamoa-Kakula copper complex in the Democratic Republic of Congo, a joint venture with Zijin Mining of China, with a wide range of its X.e-series power packs, the company says.

According to Willem Strydom, Business Development at SEW-EURODRIVE, the power packs – which are integrated units comprising gearbox, coupling and motor – will be part of Kamoa-Kakula’s Phase 3 expansion. Since the mine’s first phase of development over five years ago, SEW-EURODRIVE has worked closely with both Ivanhoe and the engineering, procurement and construction contractor.

“As in previous phases of the mine’s development, our robust high quality power packs will provide reliable solutions in on-site applications such as conveyors, agitators and slurry pumps,” Strydom says. “The size range in the order makes use of our wide capability range to provide a total solution, ranging from 55 kW units to 500 kW units.”

The latest order includes several X.e series power packs for conveyor applications, planetary gearboxes for feeder applications and spare gearboxes. The equipment will be delivered in staggered shipments this year. While the mine typically undertakes the installation of the equipment, SEW-EURODRIVE sends technical teams to site to check final alignment and overall installation parameters.

The company has expanded its after-sales service teams considerably in recent years, allowing it to support the growing base of equipment throughout Africa. Its projects and engineering teams have also grown – developing a depth of experience to assist customers right from design phase onwards.

Strydom notes that SEW-EURODRIVE has significantly developed its infrastructural foundation in South Africa, and plans to develop a physical representation in over 23 other African countries. As a priority country for the company’s strategy, there is expected to be a representative in place in the DRC in 2023, he explains. Field service teams from South Africa are frequently at Kamoa-Kakula to assist with servicing of the existing power packs operating on the site.

“Our local assembly capability in our new facility in Johannesburg – combined with our ability to source from the group’s other global operations – has allowed us to meet the tight delivery deadlines for this substantial order of equipment,” he says. “Our global footprint and production capacity mean that we can deliver faster than most players in our field, and this is often an important factor for our market.”

While the company previously imported the larger X.e Industrial gearboxes from Germany, it is now able to assemble these in the new South African facilities. As part of its service, SEW-EURODRIVE will also handle the logistics of getting this large volume of equipment to site. The company’s training centre – the Drive Academy – in Johannesburg has also made a valuable contribution by providing training on the equipment and its maintenance, it says.

In this project, the tropical climate was another important factor in the customer’s design requirements. This required the inclusion of certain cooling and paint specifications in the contract.

SEW-EURODRIVE Head of Engineering, Andreas Meid, explains that special breathers were part of the design in response to high humidity levels – and served to ensure no moisture in the gearboxes. In outdoor applications where sun exposure was high, covers were also included to reduce heat build-up. Cooling fans were also optimised in certain cases to ensure optimal performance.

He highlights that Kamoa-Kakula is one of many projects in Africa to request the installation of monitoring equipment on the power packs. This facilitates real-time monitoring, using specialised sensors to measure key indicators like vibration and temperature from anywhere in the world.

“This allows the operation to monitor the equipment remotely, receiving early warnings of any issues in performance,” Meid says. “Responding timeously to this information can prevent serious damage and avoid unplanned downtime.”

As a preferred supplier, SEW-EURODRIVE first delivered a multitude of X.e Series power packs between 2019 and 2021 for the mine’s initial development phase.

For Kamoa-Kakula’s Phase 2 expansion, which doubled the concentrator plant capacity, SEW-EURODRIVE supplied many standard X.e series power packs for the conveyors as well as planetary gearboxes for the feeders.

Duratray Suspended Dump Bodies on their way to Kibali gold mine

Equipment maintenance, Mining equipment, Precious metals, Steel and iron ore, , , , , , , ,

A new fleet of Duratray Suspended Dump Bodies (SDB) for Caterpillar 777-05 mining trucks has been completed and shipped to the Democratic Republic of the Congo (DRC) for use at the Kibali gold mine in the country.

Following manufacture in Turkey, the steel frames will be transported on sea to Kenya, then 1,800 km overland through Uganda until reaching their final destination at the Kibali mine.

Kibali is owned by Kibali Goldmines SA which is a joint venture company effectively owned 45% by each of Barrick and AngloGold Ashanti, and 10% by Société Miniére de Kilo-Moto. The mine is operated by Barrick.

Duratray International Project Manager, Csaba Nagy, said the Kibali contract represented the first post-COVID collaboration with the company’s fabriactor in Turkey, which had resulted in great success, despite current challenges such as labour shortages and high demand for steel. Simultaneously, the rubber wearmat kits, fixings, special tools and spare parts were shipped from Duratray’s principal manufacturing facility in Melbourne, Victoria.

The four Caterpillar 777-05 dump bodies will be transported in preassembled parts. Steel frame assembly then rubber component installation will take place at Kibali mine by a Duratray International Field Service crew from South Africa.

Metso Outotec to supply direct blister furnace to Kamoa-Kakula operations

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Kamoa Copper SA has selected Metso Outotec to supply a high-capacity direct blister furnace to the company’s copper mining complex expansion project in the Democratic Republic of Congo.

The value of this type of a delivery is typically between €30-40 million ($30-40 million).

Metso Outotec’s scope of delivery consists of key equipment and automation for the direct blister furnace designed for the production of blister copper in a single flash furnace without the need for separate converting stages. The 500,000 t/y copper throughput furnace will have the largest licensed flash smelting capacity in the world, according to Metso Outotec.

The scope also includes intelligent safety and monitoring automation systems for the furnace.

Jyrki Makkonen, Vice President, Smelting at Metso Outotec, said: “Non-ferrous metals play a key role in the green transition, and a major increase in global copper production is required to support this transition. We are pleased to support Kamoa Copper in their ambitious expansion project, in which high capacity and reliable, sustainable processes play a vital role. Our collaboration has been excellent throughout the initial stages of the process, including the initial study work, basic engineering as well as pilot testing.”

Metso Outotec has delivered more than 60 flash furnaces around the world since the 1950s, with the technology being the most used in pyrometallurgical copper production. The Metso Outotec Flash Smelting Process is, the company says, the cleanest smelting method available and part of the company’s Planet Positive offering.

Last month in its quarterly report, Ivanhoe Mines, which has a 39.6% interest in Kamoa-Kakula, said a new 500,000 t/y direct-to-blister flash smelter was to be constructed as part of the Phase 3 expansion at the mine.

Upon commencement of Phase 3 production, the Kamoa-Kakula Mining Complex will have a processing capacity in excess of 14 Mt/y, with increased copper production capacity of approximately 600,000 t/y. This production rate will position the Kamoa-Kakula Mining Complex as the third-largest copper mining operation in the world, according to Ivanhoe.

Commissioning is expected in the December quarter of 2024.