Tag Archives: Mogalakwena

South Africa’s hydrogen potential validated in Anglo American-led feasibility study

Anglo American, in collaboration with South Africa’s Department of Science and Innovation (DSI), the South African National Development Institute (SANEDI), Engie and Bambili Energy, has announced the results of a feasibility study to explore the potential for a hydrogen valley anchored in the Bushveld complex of South Africa, along the industrial and commercial corridor to Johannesburg and to the south coast at Durban.

The feasibility study, which was launched in March of this year, identifies three hubs – Johannesburg, extending to Rustenburg and Pretoria; Durban, encompassing the city itself and Richards Bay; and Limpopo province centred around Anglo American’s Mogalakwena platinum group metals (PGMs) mine (pictured) – with a fundamental role to play in integrating hydrogen into South Africa’s economy, and in establishing South Africa and its renewable energy resources as a strategically important centre for green hydrogen production, Anglo says.

Nine key pilot projects have also been identified across these hubs and are recommended to be prioritised by developers. They span the transport, industrial and construction sectors.

Following the publication of the feasibility study results, Anglo says it will work with South Africa’s DSI and the other partners on the implementation of relevant projects, as well as continue to progress its own company-led initiatives towards development of the hydrogen economy.

Anglo is already investing in renewable hydrogen production technology at its Mogalakwena PGMs mine and in the development of hydrogen-powered fuel cell mine haul trucks (FCEVs) – the world’s largest to run on hydrogen.

Natascha Viljoen, CEO of Anglo American’s PGMs business, said: “The opportunity to create new engines of economic activity through hydrogen has been validated through this feasibility study with our partners. As a leading producer of PGMs, we have for some years been working towards establishing the right ecosystem to successfully develop, scale-up and deploy hydrogen-fuelled solutions. These include investing in innovative ventures and enabling technologies, as well as forging wide-ranging collaborations across industry, to fully harness the transformative potential of green hydrogen for our economy in South Africa.”

Master Drilling’s Mobile Tunnel Borer heads to Anglo’s Mogalakwena mine

Master Drilling is readying its Mobile Tunnel Borer (MTB) technology for a contract at Anglo American Platinum’s Mogalakwena mine in South Africa.

The company, which revealed the news during its interim results presentation, said on-boarding for this project deployment was underway, with the start of “decline excavation” due by the end of the year.

Anglo American Platinum said in its own interim results recently that it was working on feasibility studies on the future of Mogalakwena, with completion of these studies expected at the end of 2021. Decisions on the pathway forward are expected shortly after this, however, one of the current key milestones at the asset includes progressing an underground exploration decline.

Master Drilling Executive Director, Koos Jordaan, said during the presentation that the contract with Anglo American Platinum is for a “turnkey operation” with Master Drilling providing capabilities in terms of construction, logistics and project management, in addition to its normal excavation services.

The MTB is a modular horizontal cutting machine equipped with full-face cutter head with disc cutters adapted from traditional tunnel boring machines. Unlike these traditional machines, it is designed to work both on inclines and declines, with the ability to navigate around corners and construct 5.5 m diameter decline access tunnels.

One MTB unit was previously scheduled to carry out a 1.4 km project at Northam Platinum’s Eland platinum group metals operation in South Africa, however this was cancelled in March 2020 due to the pandemic. This deployment followed testing of an MTB unit in soft rock at a quarry just outside of Rome, Italy, in 2018.

Alongside news of this latest MTB deployment, Master Drilling said in its results that it was studying the potential to deploy two of these MTB units in tandem for twin-decline access as part of the technology’s second-generation developments.

“We can already see the benefit of utilising two of these machines to do a twin-decline access to an orebody,” Jordaan said.

Looking to vertical developments, Master Drilling reported that it had received shareholder funding approval from the Industrial Development Corporation for the latest work on its Shaft Boring System (SBS), designed to sink 4.5 m diameter shafts in hard rock down to 1,500 m depths.

IM witnessed the main cutting mechanism of what was previously billed as being a 45-m long, 450-t machine at the back end of 2019.

The company has since said it will introduce a “smaller scope system” as part of its introduction to the industry.

While busy on the latest slimmed down design of the SBS, Master Drilling has signed a letter of intent with a prospective South Africa project that could see a machine start sinking activities in the first half of 2022, Jordaan said.

Outside of these developments, Master Drilling reported on several contract awards across the globe, including a three-year raiseboring extension with AngloGold Ashanti in Brazil, a joint venture agreement with Besalco Construction to work on Codelco’s Chuquicamata copper mine, an executed contract with Glencore’s Raglan mine in Canada, an agreement with Zimplats in Zimbabwe and a “long-term contract” on the Khoemacau copper-silver project in Botswana.

Zest WEG carrying out EC&I works at Anglo Platinum’s Mogalakwena CPR plant

Zest WEG is installing a range of electrical control and instrumentation equipment at Anglo American Platinum’s Mogalakwena mine in Limpopo province, South Africa, working closely with engineering group DRA Global.

The construction is taking place within the Mogalakwena mine’s existing North Concentrator Plant, around various plant areas. The Electrical Control Instrumentation (ECI) package is being led by Eben Kleynhans, E&I Electrical Project Engineer from DRA.

According to Calvin Fisher, Electrical and Instrumentation Construction Proposals Manager at Zest WEG, the Zest WEG work is being conducted for the mine’s Coarse Particle Rejection (CPR) plant, and will be completed in the second half of 2021.

“In addition to applying the highest level of workmanship and professionalism, we are carrying out the project in line with our client’s Mining Charter requirements on local procurement,” Fisher says. “This means that over 70% of people involved in our scope of work will be drawn from local communities, and we are sourcing a significant level of our supplies from local businesses.”

Equipment to be installed includes three 2 MVA transformers, stepping down from 11 kV to 550 V, and a 630 kVA mini substation for lighting and small power requirements. Containerised motor control centres (MCCs), complete with variable speed drives (VSDs), an HVAC unit, cable racking, cables, lighting and small power also form part of the scope of supply. In addition, two back-up generators will be installed – one of 630 kVA capacity and the other 330 kVA.

“The three new containerised MCCs and VSD sets will be placed on plinths near the CPR feed tank, CPR process water area and CPR building and a steel roof structure erected over the containers,” he says. “The new transformer bay will be constructed next to the MCC, also with a roof over the transformer.”

About 70 km of cable will be laid – ranging from low voltage to medium voltage cable – as well as 3,300 terminations and almost 2.5 km of cable racking. The various structures that Zest WEG will install require some 9 t of steel. The instrumentation to be installed will comprise about 170 instruments including flow transmitters, pressure gauges, level switches, temperature gauges and density transmitters. There will also be around 250 lights installed, mainly outdoors.

Fisher notes that the electrical installation specialists are typically among the last contractors on a project, and must be quite flexible to accommodate certain modifications that may have been required in the civils, structural and mechanical work completed beforehand.

“Wherever necessary, we work closely with the client to implement the plan smoothly while meeting their need for safe access to the equipment being installed, to allow maintenance to be readily conducted,” he says.

In addition to the installation contract, Zest WEG is supplying some of the actual items of equipment for the expansion project, including WEG motors and containerised generators. The electrical installation work is expected to take about six months.

“We are proud of the high level of quality that we bring to projects like this, where we apply our successful model of procurement to support our clients in meeting their critical local expenditure targets,” he says. “This also allows Zest WEG to make a valuable contribution to uplift local companies wherever we can.”

Delta Drone to run UAV surveying, mapping at Anglo’s Mogalakwena

Australia-based drones-as-a-service provider, Delta Drone International Ltd, is expanding its enterprise mining operations after being appointed by Rustenberg Platinum Mines Limited, a subsidiary of Anglo American Platinum, to provide surveying and mapping services at the Mogalakwena PGM mine in South Africa’s Bushveld Complex.

The contract, secured via Delta Drone’s Rocketmine brand, will see it manage end-to-end mine surveying and mapping services at the mine, including blast monitoring and inspection services. The 2021 contract is expected to generate some A$120,000 ($87,919) in revenue.

Mogalakwena’s PGM production increased by 11% year-on-year to 308,400 oz in the June quarter, owing to higher concentrator throughput, and no COVID-19 impact on production, Anglo American Platinum reported today.

Anglo American to collaborate on ‘hydrogen valley’ study in South Africa

Anglo American has announced a collaboration agreement to complete a feasibility study to develop a “hydrogen valley” anchored in the platinum group metals-rich Bushveld geological area in South Africa.

Spearheaded by South Africa’s Department of Science and Innovation (DSI), the collaboration agreement also includes energy and services company ENGIE, the South African National Development Institute (SANEDI) and clean energy solutions provider Bambili Energy.

The proposed hydrogen valley will stretch approximately 835 km from Anglo American’s Mogalakwena platinum group metals (PGMs) mine (pictured) near Mokopane in Limpopo province in the north of South Africa, along the industrial and commercial corridor to Johannesburg and to the south coast at Durban.

This collaboration follows the launch in 2020 of the South African Hydrogen Society Roadmap, aimed at integrating hydrogen into the economy by capitalising on the country’s PGM resources and renewable energy potential to revitalise and decarbonise key industrial sectors. The study will be conducted by ENGIE Impact and will identify tangible opportunities to build hydrogen hubs and explore the potential for green hydrogen production and supply at scale.

Natascha Viljoen, CEO of Anglo American’s PGMs business, said: “The transition to a low carbon world is an opportunity to drive the development of cleaner technologies, create new industries and employment, and improve people’s lives. Anglo American was an early supporter of the global potential for a hydrogen economy, recognising its role in enabling the shift to greener energy and cleaner transport. Our integrated approach includes investing in new technologies, supporting entrepreneurial projects and advocating for policy frameworks that enable a supportive long-term investment environment for hydrogen to deliver that potential.”

The regional PGMs industry will be central to such a hydrogen valley, with PGMs playing an important role both in Polymer Electrolyte Membrane electrolysis used to produce hydrogen at scale and in fuel cells themselves, Anglo says.

Anglo American is already investing in renewable hydrogen production technology at its Mogalakwena PGMs mine and in the development of hydrogen-powered fuel cell mine haul trucks – the world’s largest to run on hydrogen.

Dr Phil Mjwara, DSI Director-General, said: “The Department’s hydrogen valley partnership with Anglo American, Bambili Energy and ENGIE is an example of leveraging investments made in the Hydrogen South Africa Programme to create mechanisms for the uptake of publicly financed intellectual property. The hydrogen valley is among the projects that will be implemented in partnership with the private sector to support the Platinum Valley Initiative, which is aimed at supporting small, medium and micro enterprises to take advantage of opportunities in the green economy in support of a just transition.”

The public-private partnership is aligned to the South Africa Government’s Economic Reconstruction and Recovery Plans, with science, technology and innovation playing a key role in supporting the country’s plans to revitalise its economy.

Sebastien Arbola, ENGIE Executive Vice President in charge of Thermal Generation and Energy Supply activities, said: “ENGIE is delighted to be part of the hydrogen valley study. We are keen to share our knowledge and expertise encompassing the entire hydrogen value chain to accelerate hydrogen solutions’ deployment in South Africa and beyond. We already have a demonstration project under way to supply the hydrogen for the world’s first hydrogen mining truck being developed by Anglo American at the Mogalakwena PGMs mine.”

Zanele Mavuso Mbatha, CEO Bambili Energy, said: “The initiative to develop the South African hydrogen valley and the collaboration between Bambili, Anglo American, ENGIE and the South African government is significant as it will build material public awareness, confidence and support for the hydrogen economy. This collaboration is illustrative of Bambili’s view that a public-private partnership is critical in the development of this industry in the South African economy.”

Anglo’s Quellaveco to receive the coarse particle recovery treatment

Anglo American has approved the construction of a coarse particle recovery (CPR) plant at its in-development Quellaveco copper project in Peru.

The announcement came within the company’s 2020 financial results, which showed Anglo generated underlying EBITDA of $9.8 billion and a profit attributable to equity shareholders of $2.1 billion for the year.

CPR, Anglo says, is one of many significant breakthrough technology initiatives that has the potential to increase throughput and productivity, while simultaneously reducing environmental footprint, through rejection of coarse gangue (near-worthless waste material), dry stacking of sand waste, minimising the production of traditional tailings and reducing overall water consumption.

The CPR plant signoff at Quellaveco follows a full-scale demo plant installation at the company’s El Soldado mine in Chile – which is ramping up to full capacity by mid-2021 – and the decision to construct a full-scale system at the Mogalakwena North PGM concentrator in South Africa.

The El Soldado plant used the HydroFloat™ CPR technology from Eriez’s Flotation Division. Here, a single 5 m diameter HydroFloat cell, the largest in the world, treats 100% of mill throughput, with the objective of proving the waste rejection process at full scale.

Anglo said of the Quellaveco CPR plant: “This breakthrough technology will initially allow retreatment of coarse particles from flotation tailings to improve recoveries by circa-3% on average over the life of the mine. This investment will also enable future throughput expansion which will bring a reduction in energy and water consumption per unit of production.”

The capital expenditure of the CPR project is around $130 million, with commissioning of the new plant expected in 2022. DRA Global previously carried out a feasibility study for the CPR plant at Quellaveco.

In terms of Quellaveco project progress, Anglo said today that, despite the COVID-19-related slowdown, first production was still expected in 2022. This was, in part, due to the excellent progress achieved prior to the national lockdown, and based on optimised construction and commissioning plans, Anglo said.

Key activities in 2021 include the start of pre-stripping, which will see the first greenfield use of automated hauling technology in Peru; progressing construction of the primary crusher and ore transport conveyor tunnel to the plant; completion of the 95 km freshwater pipeline that will deliver water from the water source area to the Quellaveco site; completing installation of the shells and motors for both milling lines; and completion of the tailings starter dam.

The mine, owned 60% by Anglo and 40% by Mitsubishi Corp, comes with a production blueprint of 300,000 t/y over the first 10 years of the mine.

Anglo American Platinum’s modernisation drive to continue into 2021

Anglo American Platinum says it is looking to deliver the next phase of value to its stakeholders after reporting record EBITDA for 2020 in the face of COVID-19-related disruption.

The miner, majority-owned by Anglo American, saw production drop 14% year-on-year in 2020 to 3.8 Moz (on a 100% basis) due to COVID-related stoppages. Despite this, a higher basket price for its platinum group metals saw EBITDA jump 39% to R41.6 billion ($2.8 billion) for the year.

As all its mines are now back to their full operating rates, the company was confident enough to state PGM metal in concentrate production should rise to 4.2-4.6 Moz in 2021.

Part of its pledge to deliver more value to stakeholders was related to turning 100% of its operations into fully modernised and mechanised mines by 2030. At the end of 2020, the company said 88% of its mines could be classified as fully modernised and mechanised.

There were some operational bright spots during 2020 the company flagged.

At Mogalakwena – very much the company’s flagship operation – Anglo Platinum said the South Africa mine continued its journey to deliver best-in-class performance through its P101 program.

Rope-shovel performance improved to 26 Mt in 2020, from 15 Mt in 2019, while drill penetration rates for big rigs increased from 15 m/h, to 16.7 m/h. Alongside this, the company said its Komatsu 930E truck fleet performance improved to 298 t/load in 2020, from 292 t/load in 2019.

These were contributing factors to concentrator recoveries increasing by two percentage points in 2020 over 2019.

During the next few years, the company has big plans to further improve Mogalakwena’s performance.

In 2020, the mine invested R500 million in operating and capital expenditure, which included commissioning a full-scale bulk ore sorting plant, coarse particle rejection project and development of the hydrogen-powered fuel-cell mining haul-truck (otherwise referred to as the FCEV haul truck).

First motion of the 291 t FCEV haul truck is still on track for the second half of 2021, with the company planning to roll out circa-40 such trucks from 2024.

Anglo Platinum said the bulk sorting plant (which includes a Prompt Gamma Neutron Activation Analysis and XRF sensor-based setup, pictured) campaign at the Mogalakwena operation is due to end this quarter.

The company’s hydraulic dry stacking project is only just getting started.

This project, which involves coarse gangue rejection before primary flotation for safer tailings storage facilities, is expected to see a construction start in the June quarter, followed by a campaign commencement and conclusion in the September quarter and December quarters, respectively.

On another of Anglo Platinum’s big technology breakthrough projects – coarse particle rejection for post primary milling rejection of coarse gangue before primary flotation – the company plans to start a campaign in the December quarter of this year and conclude said campaign by the end of the March quarter of 2022.

The company also has eyes on making progress underground at Mogalakwena, with a hard-rock cutting project to “increase stoping productivity and safety” set for Phase A early access works this year. This project is set to involve swarm robotics for autonomous, 24/7 self-learning underground mining, the company said.

Lastly, the company’s said the digital operational planning part of its VOXEL digital platform had gone live at Mogalakwena. VOXEL is expected to eventually connect assets, processes, and people in a new digital thread across the value chain to create a family of digital twins of the entire mining environment, the company says. Development is currently ongoing.

Looking back to 2020 performance at the Unki mine, in Zimbabwe, Anglo reflected on some more technology initiatives related to R26 million of expenditure for a digitalisation program. This included installing underground Wi-Fi infrastructure, as well as a fleet data management system to track analytics on primary production equipment. The company says these digital developments will enhance real-time data analysis, improve short-interval control and overall equipment effectiveness.

To step up mechanisation of its PGM operations at Amandelbult, Anglo American Platinum is also investing in innovation.

This includes in-stope safety technologies such as split panel layouts to allow buffer times between cycles, creating safer continuous operation and reduced employee exposure; improved roof support technology and new drilling technologies; a shift to emulsion blasting from throw blasting; and safety enhancements through fall of ground indicators, 2 t safety nets, LED lights, and winch proximity detection.

Meanwhile, at the company’s Mototolo/Der Brochen operations, it is working on developing the first lined tailings storage facility at Mareesburg in South Africa to ensure zero contamination of ground water. The three-phase approach adopted for construction of this facility will be completed this year.

Komatsu to start hydrogen development program for mining haul trucks

Mining equipment major Komatsu has made plans to leverage hydrogen power across its fleet of haul trucks, according to a report from The Nikkei.

The financial newspaper reported that the company will start its hydrogen development program in 2021, with plans to have the trucks ready for practical use by 2030.

One of Komatsu’s 291-t payload 930E haul trucks is already being setup for hydrogen power use at Anglo American Platinum’s Mogalakwena PGM mine in South Africa.

This vehicle, which is a conversion to hydrogen fuel cell and lithium battery operation, is set for first motion in the second half of the year, the mining company reaffirmed in its 2020 financial results today.

Komatsu has set a target of halving CO2 emissions from its construction and mining equipment by its 2030 financial year, compared with its 2010 financial year levels.

Anglo American could use ‘green’ hydrogen power at Queensland open-pit coal mines

Anglo American has eyes on producing ‘green’ hydrogen to power the haul fleet at not only its Mogalakwena platinum group metals mine, in South Africa, but also at least one of its open-pit coal mines in Queensland, Australia, IM has learned.

The miner is part of the Macquarie Corporate Holdings Pty Limited shortlisted application for the next stage of the Australian Renewable Energy Agency’s (ARENA) A$70 million ($49 million) hydrogen funding round, a spokesperson confirmed.

BHP is also on this short list, all of which have been invited to submit a full application for ARENA’s funding for renewable hydrogen development projects in Australia.

While it is early days for the Anglo and Macquarie decarbonisation project, the spokesperson said the company’s approach in Queensland could be like the one the miner and ENGIE are developing at Mogalakwena.

The project in South Africa involves the delivery of a new Fuel Cell Electric Vehicle (FCEV), set to be the world’s largest hydrogen powered mine truck, and the ‘green’ hydrogen generation solutions to power it.

The 300 t payload FCEV haul truck will be powered by a hydrogen Fuel Cell Module paired with a Williams Advanced Engineering scalable high-power modular lithium-ion battery system. This arrangement, which replaces the existing vehicle’s diesel engine, is controlled by a high voltage power distribution unit delivering more than 1,000 kWh of energy storage.

Nel Hydrogen Electrolyser AS, a subsidiary of Nel ASA, is to deliver a 3.5 MW electrolyser to ENGIE as part of the project, while Plug Power Inc is to build a first-of-its-kind full compression, storage, and dispensing system to service the new hydrogen-powered vehicle.

In Queensland, where there is no shortage of solar power to provide this ‘green’ hydrogen, Anglo has two open-pit coal mines – Dawson (pictured) and Capcoal – that could potentially benefit from this solution.

In response to the ARENA shortlisting announcement, Anglo American said: “Anglo American has pioneered the development of hydrogen power solutions for mining operations and we are working on a number of hydrogen projects around the world as part of our pathway to carbon-neutral operations by 2040.

“We welcome ARENA’s potential support and will continue to work on this particular project’s feasibility over the coming months.”

Applicants invited to the full application stage by ARENA will have until January 2021 to prepare their application, with the agency expecting to select the preferred projects by mid-2021. Successful projects are expected to reach financial close by late 2021 and commence construction in 2022.

All applicants may also be considered for financing from the Clean Energy Finance Corp (CEFC) under the CEFC’s A$300 million Advancing Hydrogen Fund.

Nel to provide electrolyser for Anglo American hydrogen-powered haul truck

Nel Hydrogen Electrolyser AS, a subsidiary of Nel ASA, is to deliver a 3.5 MW electrolyser to ENGIE as part of a project to deliver the world’s largest fuel cell haul truck for Anglo American.

The electrolyser, which splits water into hydrogen and oxygen using electrical energy, is scheduled to be installed during 2020, fitting in with Anglo American’s plan to complete “first motion” of the haul truck next year.

Earlier this month, Plug Power Inc confirmed it would provide a custom refuelling system for the hydrogen-powered mine haul truck, following a deal signed with ENGIE.

Henning Langås, Sales Director of Nel Hydrogen Electrolysers, said: “We are of course delighted that ENGIE has chosen our electrolyser to integrate the renewable hydrogen solution, which will fuel the truck. When scaled up, more than 100 MW of electrolyser capacity will be needed for this mine alone, representing an attractive new market opportunity.”

The ENGIE-Anglo American project involves retrofitting a mining haul truck operating at Anglo American’s Mogalakwena platinum group mine (pictured), in South Africa, to become a 100% zero-emission fuel cell electric truck, Nel said.

“Electricity for hydrogen production will partly come from local solar power and the grid, and the electrolyser capacity surpasses the daily demand of the truck, enabling storage for fuelling during night time or moments when solar radiation is poor, maximising the renewable share of the hydrogen,” it said.

“If successful, the long-term target is to convert the entire fleet of haul trucks at the mine to hydrogen, as well as at Anglo American’s other mining operations around the world.”