Tag Archives: Lesotho

BME’s AXXIS Silver electronic initiation system passes the test in Lesotho

High in the mountain kingdom of Lesotho, explosives and blasting specialist BME recently achieved the first blast outside of South Africa with its new AXXIS Silver™ electronic initiation system.

BME, a member company of the JSE-listed Omnia Group, is assisting a diamond mine customer to conduct quality blasts in all weather. According to BME’s AXXIS™ Support Manager, Hennie du Preez, BME has been active on this mine since 2016. Located at an altitude of over 3,000 m, the operation frequently experiences snow and sub-zero temperatures.

“This means blasting under challenging conditions, including extreme cold, snow and ice,” du Preez said. “BME provides everything from the emulsion explosive to the detonation equipment, which all continues to function well under these conditions.”

The AXXIS Silver initiation system employed at the mine is a leaner version of BME’s flagship product AXXIS Titanium™. The company conducts the priming, logging and firing of the blasts, and ensures a regular supply of emulsions to the site.

“Among the benefits of AXXIS Silver is its thin, copper-cladded downline wire, which de-coils easily for use in small diameter holes – even when they are waterlogged,” Du Preez said. “Due to their robust quality, our electronic detonators were able to remain in the holes for two days before blasting, in temperatures below zero where the hole collars froze solid.”

Despite the conditions, there were no issue encountered with the wire or the connector. BME’s latest logger, the TDC 600, also performed as normal in these cold and wet conditions, with no signs of screen lagging. Its battery lasted the entire duration of the logging and the firing of the blast, according to the company.

“We kept our blasting boxes in the vehicle until blasting time, and they switched on without any problems,” du Preez said. “Neither did the cold conditions cause any sluggishness of the screens.”

He confirmed that firing the blast went ahead as planned, with smooth communication between the logger and the blasting boxes. In the final communication check, there was no instability detected.

“This was another confirmation of the resilience of our system in cold climates and freezing weather,” du Preez said. “We have had AXXIS successfully tested in the US for operating in temperatures below minus 40°C, in anticipation of growing business opportunities in the US and Canada.”

AXXIS Silver allows up to 1,800 holes to be detonated in a single blast, initiated from two blast boxes linked.

du Preez noted that mines are increasingly asking for larger blasts to reduce downtime from pit stoppages during blasting. BME is expecting to apply AXXIS Titanium at the Lesotho operation, which can raise the number of detonators in a single blast to 20,000 – or 20 blast boxes firing up to 1,000 detonators each.

An added benefit of the copper-cladded wire, du Preez said, is that the steel wire responds to a magnetic field. After a blast, this allows remnants of wire in the blasted material to be removed by magnetic separators on the conveyor belts before entering the crushing and milling phases. It, thus, prevents potential damage to comminution equipment and contamination of mined material.

BME has also been supplying various Lesotho mine with up to 500 t of emulsion explosive each month. This involves the monthly movement of over 15 tankers through steep mountain passes to keep them supplied with fresh emulsion.

WEC Projects devises sewage treatment plant plan for Mothae diamond mine

WEC Projects, a South Africa-based EPC contractor specialising in water and wastewater treatment solutions, says it will soon complete the installation of a new WEC Model B packaged sewage  treatment plant at the Mothae diamond mine in Lesotho.

The mine is 70% owned by Lucapa Diamond Company and 30% by the Government of Lesotho.

Rudolf de Koning, Sales Representative at WEC Projects, says: “The mine lacked a sustainable sewage solution. Producing 60 cu.m of domestic raw sewage per day, Mothae utilised honeysuckers – sewage trucks – to dispose of the sewage at the nearest disposal facility, almost 130 km away. This was obviously a very costly method of sewage disposal. WEC proposed the installation of its Model B conventional activated sludge treatment plant with a daily capacity of 80 cu.m, which allows for future upgrading and expansions of the mine operations.”

The R3.2 million ($194,817) installation is a combined activated sludge and clarification treatment plant. Its modular design simplifies the logistics involved in transporting to the site and simplifies assembly as well as ensures a smaller overall footprint, according to WEC Projects. The Mothae installation also integrates a Wastemaster that includes screening, de-gritting and oil removal to cope with fats and oils present in the sewage which could adversely affect the aerobic process in the plant’s reactor. The Wastemaster removes the oils, fats and non-biodegradable material upstream from the treatment process. The plant will treat the mine’s grey and black water piped to the current septic system.

“Besides the high fat and oil levels, another factor which could affect the treatment plant’s effectiveness was the high altitude of the site which results in low, fluctuating temperatures,” de Koning explains. “The biological population growth occurs optimally at around 19°C and above. In order to ensure the proper ambient temperature is maintained, the plant will be assembled within a larger enclosed facility.”

In addition to making the mine more environmentally compatible through the effective treatment of its domestic sewage, the plant also reduces the costs of transporting waste to the nearest disposal facility, it says. Another consideration is that water availability reduces considerably in the area during the winter. The new plant can help the mine reduce its water consumption.

Thato Tsephe, Project Foreman at Mothae, says: “We worked closely with WEC Projects on-site to develop a sustainable solution. WEC Projects had previously installed a sewage treatment plant at the neighbouring Letseng Mine and it was that facility that encouraged us to approach them. What is critical for us, what is critical for us is to complete the civil works and installation and commissioning of the plant during the winter season with the harsh climate posing many challenges.”

Integrated Pump Rental up for southern Africa pit dewatering challenge

As open-pit mines continue to get deeper with the maturing of operations, pit dewatering is becoming more vital, with ground water not only posing an operational challenge but also a potential safety hazard if not attended to appropriately.

In this scenario, it is not a case of one pump fits all dewatering application requirements and it is advisable to deal with a reputable pump supplier to ensure the most appropriate solution is selected, according to Integrated Pump Rental.

Lee Vine, Managing Director of the company, said each application requires a site-specific solution.

“There are numerous options available in terms of the actual pump and ancillary equipment, as well as the choice between rental and outright purchase,” he says. “The differentiator that our team offers is the ability to assess a given application and provide a pit dewatering solution with the correctly sized pump.”

There are several factors that can have an impact on the pump selection, and this includes available power sources; the volume of water to be pumped; and the condition of the dirty water, including size and type of particles in the water.

“What adds complexity to pit dewatering applications is that, in many cases, the need to dewater a pit can be urgent and customers are forced into making an incorrect pump selection or tying themselves into a contract that does not work in the longer term,” Vine says.

While the decision to hire or purchase is an important commercial one, so is the actual selection of the pump itself, he said.

“If the pump is not sized correctly for the dewatering application at hand, it will not perform as required. This, in turn, leads to further operational challenges including production losses and sometimes even the need to change the pump resulting in further costs.”

One of the most important factors to consider is the available energy source. If there is no access to power, options such as diesel-driven or pumps fitted with hydraulic power packs must be explored.

When selecting the pump, it is also important to understand the specifics of the water ingress conditions and whether this is a long-term issue or simply a short-term challenge. This scenario will dictate the pump size, its rated output and what ancillary equipment is required.

As an example, Vine points to a recent dewatering application on a mine in Lesotho where a constant flow of water into the mine’s pit area demanded that water be urgently and reliably pumped out.

Over time the pit depth had increased, and the groundwater level had been exacerbated by the winter snowfall in the highlands of the country. As a result, the total dynamic head for the duties of the installed dewatering pump installation changes and the mine required an urgent solution.

Initially a Sykes XH150 diesel driven pump was deployed, pumping at 120 l/s at 150 m head. Subsequent to this, a second Sykes pump was dispatched to site to ensure the level of water remained at an acceptable level.

With the two Sykes pumps on site, the mine was assured of enough pumping capacity, should the groundwater level increase.

The call from this mine came in and, within 24 hours, the first Sykes pump was installed on site, according to Vine.

“This is very significant, when one considers that the mine is situation some 500 km from the company’s front door and across the border into a neighbouring country.”

Integrated Pump Rental not only rents out Sykes diesel driven pump sets, the company is also responsible for the sale of these dewatering pumps across southern Africa. The robust units are designed for reliable performance, under even the harshest operating conditions, according to the company.

Integrated Pump Rental keeps its head during Lesotho mine dewatering project

Integrated Pump Rental says the quick deployment of its dewatering solution has allowed a Lesotho mine to keep operating as normal.

A constant flow of water into the mine’s pit area demanded water be urgently and reliably pumped out, according to the company. A fuel-efficient Sykes Xtra High Head pump set was chosen for the job, pumping into a 200 mm HDPE line with a head of 127 m to a holding dam.

According to Integrated Pump Rental’s Andre Strydom, timing was of the essence to the customer: “We secured this dewatering contract due to our quick and effective response. The Sykes XH150 unit was on site and commissioned just 24 hours after receiving the call from the customer.”

Strydom highlighted that, as mines and quarries go deeper, conditions require a solution like the Sykes XH150. With its automatic priming and solids handling capacity, it is designed to dewater more efficiently and effectively.

“The unit has one of the best shaft stiffness ratios of any automatic priming pump on the market,” he says. “Sykes engineers have ensured that the enormous pressures and heads associated with such performance do not compromise seal integrity through shaft flexing.”

All models have the ability to operate unattended at high discharge heads, with the pumps able to be primed with long suction hoses and the ability to manage suction lifts of up to 9 m.

“The units can even run dry for extended periods due to the oil bath mechanical seal assembly,” the company said. “Designed for robust and reliable performance with high volumes of water, Sykes pumps have an established reputation for the fast and effective control and removal of sub-surface water.”

The pumps can even operate in “snore” condition, Integrated Pump Rental says, which accommodates fluctuating suction levels. “In these conditions, the pump will snore until the liquid is available for the pump to fully re-prime itself automatically,” the company added.

Namakwa enlists FLSmidth pumps to cut downtime, costs at Kao diamond mine

The installation of a FLSmidth KREBS millMAX™ pump at Namawka Diamonds’ Kao mine, in Lesotho, is, according to the mining equipment maker, providing the miner with significant cost savings through increased impeller, casing and back liner wear life.

FLSmidth’s engagement at Kao started when the mine required a pump conversion in the field – an undertaking that can be difficult and time consuming, according to the mining OEM. “It is also a high-stakes operation as a cyclone feed is critical to the overall process and ability to generate returns. A wrong decision can mean a lot of lost revenue,” the company said.

It was the potential for cost efficiency that convinced Kao diamond mine to implement the KREBS millMAX Pump. After initial discussions, the first trial pump – a millMAX 8×6 centrifugal seal (C/S) – was installed in a cyclone feed application (DMS 2 pump 1).

Initial results after seven months showed the millMAX was performing extremely well on the wear side, according to FLSmidth.

“So, once you get the green light, you need to confirm the duty details and measure up the existing installation to ensure that when you begin to install the pump there are no surprises,” the company said.

Brad Moralee, Head of Product Unit Pumps, Cyclones and Valves at FLSmidth, said: “It’s high pressure for us: you are typically given a window of opportunity during a shutdown to complete the change, after which the new pump must run as expected when the plant is re-started.

“You need the combination of a great product but, more importantly, great technical understanding of the duty to be able to propose the correct solution. We understand what is at stake from the customer side.”

The change produced impressive results in comparison with the previous solution from another supplier, according to FLSmidth, with the millMAX increasing the wear life by nine times, across impeller, casing and back liner. “This has seen Kao make significant cost saving on direct replacement costs, reduced downtime and saved labour expenditure,” the company said.

While Kao mine operators were impressed with the benefits from the switch, a slight gland leakage was causing concern, according to FLSmidth. To resolve this, FLSmidth suggested running a one-month trial with the slurryMAX, which had just recently arrived on the South Africa market.

“The slurryMAX trial was based purely on its sealing capabilities as Kao were confident of the hydraulic performance of the pump and had no concern about wear as they were confident the slurryMAX would show predictable and even wear life across all wet-end parts,” the company said.

Kao’s confidence also came from the fact the slurryMAX design is based on the millMAX range, whose wear ring technology has created an efficient and long-lasting slurry pump.

The main difference between the millMAX and the slurryMAX is that the millMAX is an all-metal pump meaning it does not have an outer casing and an inner wear liner (the casing itself is made from the high chrome wear material), while the slurryMAX is a split casing design that has a replaceable inner liner. The purpose of this design is that multiple material liner options are available to fit in the same outer casing.

“The slurryMAX features an improved, more efficient impeller and an optional water drain plug for easier maintenance, allowing water that might have settled at the bottom of the pump to be drained quickly,” the company said.

Leigh Rieder, FLSmidth Sales Engineer, concluded: “Kao is extremely happy with the hydraulics and lack of excessive wear of our pumps, which has meant that their cost of ownership is low. We have recently received an order from the customer for two more slurryMAX pumps and they have expressed interest in our slurryMAX 6×4 and slurryMAX 10×8 pumps.”

Commissioning of Gem Diamonds’ PET and electric pulse technology pilot plant set for Q2

Gem Diamonds looks to be only a matter of months away from commissioning a pilot plant that could help reduce diamond damage at its flagship Letšeng mine in Lesotho.

In the company’s December quarter trading update, it said the $3 million pilot plant could reach the commissioning milestone at the end of the June quarter.

The plant is set to test out both positron emission tomography (PET) to identify diamonds within kimberlite prior to the crushing process, and electric pulse technology to liberate the diamonds at the operation.

During the company’s Capital Markets Day presentation last year, Gem Diamonds said it had carried out due diligence on the PET technology, a sensor-based sorting system that could be applied to scan kimberlite to identify the diamondiferous rocks.

The technical due diligence concluded that the physics of the PET technology applied in the minerals industry was sound and functional, the scalability challenges identified could be addressed in the development and engineering phase, and value engineering was required to optimise the material handling and associated capital expenditure.

In tandem with this, the company has looked at ways to liberate the diamonds identified by the PET technology without causing damage.

In collaboration with the University of Johannesburg, it has developed a non-mechanical crushing system that uses electrical power to break the kimberlite. During last year, a prototype of this electric pulse technology was developed and successfully tested in Johannesburg, with further testing at higher altitude already being carried out at Letšeng.

Gem said on its website: “The group believes that the advancement of these and other technologies to detect and liberate diamonds within kimberlite will change the future processing paradigm, with a commensurate increase in the overall profitability.”

The pilot plant is initially expected to process tailings as part of the development of these technologies.