Tag Archives: South Africa

Rockwell Automation and Energy Drive provide energy, emission savings at Sibanye-Stillwater mine

Rockwell Automation Inc has, as part of an energy-savings-as-a-service partnership, helped reduce emissions and deliver substantial annual energy savings at the Sibanye-Stillwater Driefontein gold mine in South Africa, it says.

Rockwell Automation and Energy Drive, an energy-efficiency specialist with headquarters in Durban, South Africa, recently signed a memorandum of understanding in which they will collaborate on projects designed so that the resulting energy savings offset any investment in technology and systems required to drive the sustainability solutions.

Designed by Energy Drive, the system at the Sibanye-Stillwater mine is central to the new optimised control solution for the mine’s ventilation architecture. The new efficiencies – which have delivered annual energy savings of more than 55 GWh – will help Sibanye-Stillwater address some core goals of its ESG activities.

The ventilation system’s operational parameters have been remodelled to leverage the capabilities of Rockwell Automation’s PowerFlex® 6000T variable frequency drives. Through optimised control of fan speed and air circulation, this new approach has resulted in an average energy saving of 62% in one shaft and 48% in the other, with another shaft soon to be commissioned, according to Rockwell.

Engineers anticipate that the three upgrades will eventually deliver a total energy saving of about 360 GWh over the term of the contract – equivalent to removing 5,000 South African homes from the grid every month. Notably, it will save 379,000 t of carbon over the period, while significantly reducing water and coal consumption.

“We share a common vision to provide the most efficient and sustainable solutions for customers and the environment,” Tom O’Reilly, Global Vice President, Sustainability, at Rockwell Automation, said. “We are excited to address the rapidly growing needs of our customers with this energy-saving-as-a-service partnership, to help them on their journey to greater sustainability and achieving net zero.”

James Hynd, CEO of Energy Drive, added: “Collaboration is at the core of our business, and actualising sustainability is what drives us.”

Describing ‘actualising sustainability’, Hynd explained that a direct result of the energy savings it delivers is the reduction of CO2, which contributes to clients’ sustainability targets, specifically carbon-reduction targets.

Thomas Malomane, Power Control Business manager, Africa, at Rockwell Automation, explained: “A large proportion of global energy is consumed by electric motors, with HVAC applications accounting for a significant part of this. Many motor-based solutions are either running without any form of motor control or are using outdated technology and practices that do not offer contemporary efficiency capabilities. Our PowerFlex range of variable speed drives undergoes continual development to address modern demands and is a core solution for reducing energy consumption across a huge variety of applications globally.”

Howden to deploy Ventsim CONTROL solution at Gold Field’s South Deep

Howden says it has secured a contract for its Ventsim™ CONTROL system at Gold Fields’ South Deep gold mine in South Africa.

The mine is a world-class bulk mechanised mining operation reaching depths between 2,800-3,300 m below surface and is located in the Witwatersrand Basin.

South Deep has invested in key infrastructure to ensure that it operates as a safe, low-cost, bulk and mechanised gold mine and is collaborating with Howden to implement a state-of-the-art ventilation optimisation system, Howden said. The solution will support a safe working environment as well as reducing the mine’s energy consumption, which will contribute towards South Deep’s environmental and operational goals.

Ventsim CONTROL combines ventilation modelling of the mine with a flexible control system and advanced control strategies for monitoring, control and optimisation of underground mine ventilation. The remote and autonomous control of ventilation devices allows operators to view underground mine conditions in real time as well as the ability to act quickly to suit their conditions.

Howden’s ventilation optimisation solution offers varying levels of control to suit the needs of the mine. Level 1 and 2 allows for manual remote control and scheduling of ventilation devices, while the level 4, Ventilation on Demand solution employed by South Deep will allow ventilation devices to react based on feedback from environmental sensors underground, according to Howden. It will furthermore adjust mine airflow in real time based on vehicle and personnel position. The Ventsim CONTROL solution also offers a 3D modelling capability within the software, which helps users to better predict and control air flows based on what is evidenced in the simulation.

Eric Vemer, President of Africa region at Howden, said: “The installation of Ventsim CONTROL will improve the operability and flexibility of the mine’s ventilation system to ensure a safe, healthy and efficient ventilation solution. Ventsim CONTROL will further reduce energy consumption and associated tonnes of carbon emissions. As the system allows the mine to optimise its ventilation based on fully remote vehicle and personnel monitoring, it directly contributes to achieving emissions reduction targets – something of which the Howden team is very proud.”

ARM selects Epiroc equipment to help restart Bokoni platinum mine

Epiroc says it has won a large order for low-profiling mining equipment from African Rainbow Minerals for use at its Bokoni platinum mine in Limpopo Province, South Africa.

African Rainbow Minerals has ordered drill rigs, loaders and mine trucks for use at the mine, which is restarting after operations were paused for care and maintenance in the past few years.

The machines ordered are built with a low profile well suited for the mine’s low tunnel heights. The equipment includes Boomer face drilling rigs, Boltec and Cabletec rock reinforcement rigs (an Epiroc Cabletec SL, pictured), Scooptram LHDs and Minetruck haul trucks. All machines come with Epiroc’s Certiq telematics solution for automated monitoring of productivity and machine performance. Other advanced features include, for example, the Boomer machines being equipped with a pilot hydraulic control system that further improves drilling accuracy.

The order is valued at more than ZAR200 million ($11.6 million) and was booked in the March quarter of 2023, with deliveries set to beging this quarter and continue into 2024.

“We are excited to once again provide equipment to the Bokoni platinum mine,” Helena Hedblom, Epiroc’s President and CEO, said. “We look forward to supporting African Rainbow Minerals as they restart and operate the mine in the most productive and safe way possible.”

Back at the end of 2021, ARM agreed to buy Bokoni from Anglo American Platinum and Atlatsa Resources, stating plans to restart mining operations in 2023.

Epiroc to provide ‘complete’ collision avoidance systems via Mernok acquisition

Epiroc has agreed to acquire Mernok Elektronik (Pty) Ltd, a South Africa-based company that provides advanced collision avoidance systems for mining companies.

With this acquisition, Epiroc will strengthen its position as a world-leading provider of automation and safety solutions for mining operations, it says.

Mernok Elektronik is headquartered in Pretoria, South Africa. The company designs and produces proximity detection technologies and collision avoidance systems of the highest level (EMESRT Level 9) applicable for either a single machine or an entire mixed fleet of machines regardless of manufacturer or type of equipment, it says. Mernok Elektronik’s customers are primarily in Africa, with its systems designed to significantly reduce the risk of vehicle accidents, strengthening operator safety as well as productivity.

The company’s focus was initially vested in three main areas, namely mining applications, military applications and high-end industrial applications. In 2016, it decided to re-focus the company to service only the mining sector. Back in 2019, it teamed up with Booyco Electronics and Selectronic to bring new generation technology to the proximity detection system space.

Mernok Elektronik has about 45 employees and revenues in the fiscal year ending February 28, 2022, of approximately R80 million ($4.7 million).

“Collision avoidance is critical for the mining industry to strengthen safety and productivity, and Mernok’s advanced solutions complement Epiroc’s existing equipment and automation offering well,” Helena Hedblom, Epiroc’s President and CEO, said. “Together we will provide complete collision avoidance solutions to the highest industry standards to support our customers on their journey towards the safest and most optimal operations. We look forward to welcoming the dynamic Mernok team to Epiroc.”

The acquisition is expected to be completed in the March quarter of 2023.

Trafo Power Solutions overcomes design challenges to fulfil UG gold mine order

Dry-type transformer specialist Trafo Power Solutions has recently been given a ‘hill to climb’ in terms of design and logistics with a request to supply three units to an underground gold mine in South Africa.

The mine required the transformers to operate in the usual demanding conditions of dust, moisture and heat, according to Trafo Power Solutions Managing Director, David Claassen. However, there were a range of other challenges – not least the weight and height restrictions of a deep mine. While two of the transformers are relatively small – 250 kVA and 630 kVA – the third is a substantial 3,150 kVA.

“The transformers are to operate at about 1 km below surface, and will have to be transported through both an incline shaft and vertical shaft,” Claassen says. “Especially with the larger unit, we had to work very closely with our Italian technology partner TMC to reach a design that could be moved within these constraints.”

Trafo Power Solutions also designed the enclosures locally in a manner that would allow them to be transported in manageable components before being re-assembled underground. The enclosure design had to ensure that, while dust and moisture were kept out, there was still enough air circulation to cool the unit. The dry-type transformers will be supplying loads for a refrigeration plant.

“Trafo Power Solutions conducted the complete designs, which were then verified and vetted by TMC,” Claassen says. “This quality control is central to our approach in ensuring fit-for-purpose solutions.”

He emphasised that the design and manufacture of the units was carried out according to schedule and they are on track to be supplied within the customer’s required timeframes.

“On-time supply is an increasingly important aspect of success for mining companies,” he says. “Mines’ capital expenditure is planned according to the expected returns on any project, and supplier delays can undermine these forecasts.”

Trafo Power Solutions also designed the specialised skid bases for the transformers, to facilitate moving the units to their operating destination. These accommodate the considerable weight of the units, particularly the 10-t mass of the large 3,150 kVA unit.

Delivery of the transformers is expected to take place by the end of the year, with Trafo Power Solutions supervising the installation and commissioning process.

Rio Tinto’s Richard Bay Minerals to go solar with help of Voltalia, BEE partners

Rio Tinto’s 74%-owned Richard’s Bay Minerals (RBM) business will soon be supplied with renewable solar power through an agreement with international energy company Voltalia and local Black Economic Empowerment (BEE) partners, for its operation in KwaZulu-Natal, South Africa, Rio says.

Under the agreement, Voltalia will begin construction of the Bolobedu Solar PV renewable energy project in 2023, at a site in the province of Limpopo. The power plant is scheduled to be complete by 2024 and will deliver an annual generation capacity of up to 300 GWh. It will feed into the national power grid to supply RBM’s smelting and processing facilities through a “wheeling agreement”.

The renewable power supply is expected to cut RBM’s annual greenhouse gas emissions by at least 10%, or 237,000 t/y of CO2e, Rio says.

Rio Tinto Minerals Chief Executive, Sinead Kaufman, said: “The agreement, which is a first step towards reducing RBM’s carbon emissions, is a major milestone and one that is in line with Rio Tinto’s decarbonisation strategy. As this solar energy project progresses, we will continue exploring additional renewable solutions that further reduce our emissions in South Africa and make Richards Bay Minerals a contributor to our net zero commitment.”

Voltalia CEO, Sébastien Clerc, added: “We are very pleased to support RBM in its decarbonisation journey. The Bolobedu photovoltaic power plant will be our biggest project in Africa, after performing construction of a series of other solar plants for us or for clients, in the continent (Zimbabwe, Burundi, Tanzania, Kenya, Mauritania and Egypt). This project is the first of our South African large solar-and-wind portfolio under development, in areas with grid connection available, that will be ready to support our clients to overpass the actual energy crisis with affordable, clean and stable electricity.”

Voltalia will work to ensure the Bolobedu Solar PV project creates local employment opportunities for the surrounding communities. A total workforce of more than 700 people is expected during construction, with a workforce of around 50 people once the plant becomes operational.

The project will also provide skills development opportunities for members of the surrounding communities, and a bursary program for young local learners. In support of South Africa’s growing renewable energy sector value chain, Voltalia will work to source its goods and services locally.

The Bolobedu Solar PV power plant will be 51% black-owned through BEE partners, with a minimum 10% stake going to black women, while the host community will also have a participation.

Anglo American, EDF Renewables establish regional renewable energy ecosystem in South Africa

Anglo American has joined forces with EDF Renewables to establish a new jointly owned company, Envusa Energy, aimed at developing a regional renewable energy ecosystem (RREE) in South Africa.

In March 2022, the two companies signed a Memorandum of Understanding to explore the ecosystem’s development, designed to meet Anglo American’s operational power requirements in South Africa and support the resilience of the local electricity supply systems and the wider
decarbonisation of energy in the country. The RREE is also expected to catalyse economic activity in South Africa’s renewable energy sector, supporting the country’s broader just energy transition.

As part of the agreement, Envusa Energy is launching a mature pipeline of more than 600 MW of wind and solar projects in South Africa – a major first step towards the development of an ecosystem that is expected to generate 3-5 GW of renewable energy by 2030, Anglo American says. This first phase of Envusa Energy’s renewables projects is expected to be fully funded – including by attracting debt financing that is typical for high quality energy infrastructure projects – and ready for construction to begin in 2023.

Envusa Energy is expected to supply Anglo American with a blend of renewable energy generated on Anglo American’s sites and renewable energy transmitted via the national grid. This energy portfolio approach will aggregate energy from geographically-dispersed renewable generating assets and allocate this energy optimally to meet the load demand for Anglo American’s sites, the company explained.

Nolitha Fakude, Chair of Anglo American’s Management Board in South Africa, said: “I’m delighted to confirm our ground-breaking partnership with EDF Renewables to form Envusa Energy. This is a significant milestone in Anglo American’s global decarbonisation journey and another step forwards for South Africa’s clean energy future. We are making great strides towards our 2040 target of carbon-neutral operations, while contributing to South Africa’s just energy transition through our responsible approach.

“We believe that the energy transition presents a fresh opportunity for South Africa and the rest of the region to build a clean and inclusive energy ecosystem that can create significant new economic opportunities. I am very encouraged by our progress – affirming Anglo American’s commitment to South Africa’s next phase of development towards a low-carbon future.”

Tristan de Drouas, CEO at EDF Renewables in South Africa, said: “We are very pleased to be part of this very innovative venture and look forward to bringing our global expertise in renewable energy infrastructure development, design and delivery to Envusa Energy. This partnership with Anglo American confirms our long-term perspectives in the country: this 600 MW first tranche of projects will be added to the almost 1 GW that EDF Renewables will be building or operating in the country by 2023 – including 420 MW of wind projects in REIPPP Bid Window 5, whose PPAs were signed with Eskom and the DMRE on September 22, 2022.

“Together, these projects further EDF Group’s CAP 2030 strategy, which aims to double our net renewable installed energy capacity worldwide (hydropower included) from 28 GW in 2015 to 60 GW by 2030.”

The roll-out of the RREE will also serve as a clean energy source for the production of green hydrogen for Anglo American’s nuGen™ Zero Emission Haulage Solution (ZEHS) – a planned fleet of hydrogen-powered ultra-class mine haul trucks (the original prototype pictured at Mogalakwena above) – significantly reducing on-site diesel emissions towards a carbon neutral future while also supporting the development of South Africa’s Hydrogen Valley, Anglo American said.

Through the formation of Envusa Energy, Anglo American and EDF Renewables are committed to supporting South Africa’s economic transformation and empowerment goals. The process to identify an appropriate Black Economic Empowerment (BEE) partner for Envusa Energy is expected to begin in the fourth quarter of 2022.

Furthermore, and in line with both companies’ commitment to a just energy transition, Envusa Energy is exploring a range of community partnership models that will enable host communities to share in the benefits created by the development of the RREE, along its value chain, Anglo American said.

Maelgwyn opens new 4,000 sq.m premises in Johannesburg

Maelgwyn Mineral Services says it has officially opened its new combined Maelgwyn Africa and Maelgwyn South Africa premises in Boundary Park in Johannesburg, South Africa.

The new facility offers over 4,000 sq.m of floor space housing state-of-the-art offices, workshops, metallurgical and analytical laboratories, together with a world-class metallurgical pilot facility, the company says.

The metallurgical lab and pilot plant mostly undertake commercial mineral processing evaluations for process design and development purposes to bankable feasibility study level with bespoke solutions and fast reporting times undertaken by experts in the field of minerals processing, Maelgwyn explained.

The laboratory facilities also support the company’s proprietary technologies, including Imhoflot Flotation and the Aachen Reactor. These technologies have found favour across the globe in associated processes such as Leachox for precious metal recovery, Aachen Assist Leach and MMS-CND cyanide destruction.

Sandvik and FLANDERS to develop ARDVARC-iSeries drill rig digital interface

Sandvik Mining and Rock Solutions and FLANDERS have agreed to develop a Digital Interface between FLANDERS’ ARDVARC® Autonomous Drill System (ADS) and Sandvik iSeries rotary blasthole drills.

The development of this digital interface is a direct response to growing customer demand for agnostic automation systems in surface mining, the pair say.

The digital interface will enable the operation of Sandvik rotary drills via the ARDVARC ADS system with no modification to the drill rig, effectively a plug-and-play solution that allows for easy deployment of Sandvik drills to mine sites, FLANDERS explained. This open-architecture approach simplifies the installation and commissioning process while ensuring the customer retains OEM warranty and aftermarket support.

This agnostic approach to delivering digital solutions allows customers to select the value-added solutions that best meet their needs, whether that be the drill or the operating system powering the drill, FLANDERS added.

ARDVARC improves drill productivity by up to 30% and provides a significantly safer working environment for workers operating in complex or hazardous conditions, according to FLANDERS.

With its autonomous operating technology, FLANDERS helps its customers pro-actively optimise drilling and increase plant availability. The introduction of autonomous technology at the mine adds significant environmental gains for diesel machines, reducing fuel consumption and CO2 by up to 7.3% compared with a manned operation.

With its autonomous operating technology, FLANDERS helps its customers proactively optimise drilling, improve fragmentation, improve loading and hauling productivity and increase plant throughput.

The first deployment of the FLANDERS/Sandvik Digital Interface is scheduled for the December quarter of 2022 with further deployments being scheduled soon after that.

Sandvik in its statement says it “will continue to develop and support AutoMine® Surface Drilling solutions for remote and autonomous operation of the full range of Sandvik iSeries drills”.

FLANDERS added that it has signed a deal with Anglo American to incorporate ARDVARC on all new and existing drills at Anglo’s Mogalakwena mine in South Africa, including the recently purchased Sandvik DR410i blasthole drills.

The third (of four) brand new Sandvik 410i drill is currently being converted to an ARDVARC Autonomous system at the state-of-the-art facility in Middelburg, South Africa.

FLANDERS has already deployed ARDVARC Autonomous drills to Mogalakwena, converting Epiroc Pit Viper 271 XC drills.