Tag Archives: Venetia

Murray & Roberts Cementation hits shaft sinking milestone at Palabora

Base metals, Explosives and blasting, Mine operation news, Mine shafts and equipment, Mineral project development, Mining services, , , , , , , ,

The Murray & Roberts Cementation shaft sinking team responsible for delivering a new ventilation shaft at Palabora Copper Mine (PMC) recently celebrated the achievement of a major milestone – reaching the 800 m mark.

This milesttone represents two-thirds of the shaft’s final depth of 1,200 m.

The ventilation shaft forms part of the copper producer’s Lift II project, which will extend mine life by more than 15 years. Originally an open-pit mine, the Palabora mine transitioned to underground block cave operations in the early 2000s when Lift 1 was commissioned.

PMC is located within Phalaborwa, in the Limpopo province of South Africa, and the extension of the life of mine will increase shareholders’ value and sustain jobs and livelihoods of the surrounding communities, according to the company. The mine has also initiated several wildlife management programs to minimise the impact of its operations on the environment as well as promote the harmonious co-existence of people, industry and wildlife.

Murray & Roberts Cementation’s contract to sink the 8.5-m diameter shaft was awarded in February 2019. According to Fred Durand, the company’s Senior Project Manager, the shaft sinking is currently making good progress, with 40-or-more lined metres of advance being completed on average each month.

“Shaft sinking operations should be completed by the end of this year with final handover of the shaft to our client, PMC, taking place at the end of the first (March) quarter of 2024,” he says.

Ground conditions have presented a challenge on the project. This has resulted in the shaft lining being taken right down to the blasted face, says Jas Malherbe, Murray & Roberts Cementation’s on-site Project Manager.

“Normally, we would line the shaft to within 12 to 18 m of shaft bottom and support the sidewalls temporarily with split sets and mesh,” he explains. “In practice, this did not prove viable, prompting us to change our approach. The method we’ve adopted is unconventional but has proven to be highly effective.”

Drilling is undertaken by two twin-boom Komatsu electro-hydraulic jumbo drill rigs. These are slung down the shaft from surface and nested in the four-deck stage for drilling the shaft bottom, a procedure which is repeated for each 48-hour blast-to-blast cycle.

Another key piece of equipment is a Komatsu excavator with a 0.3 cu.m bucket. It is lowered from surface through the stage to shaft bottom and is used for lashing. All the waste rock is loaded into a 11 t kibble, which transports it to surface.

The ground conditions at the shaft are such that blasting tends to produce large rocks that can be difficult to handle.

Malherbe said: “We break these up using the excavator, which has a quick coupler which allows it be fitted with a hydraulic breaker within a few minutes.”

The methods being used at Palabora are based on the Canadian shaft-sinking method Murray & Roberts Cementation has pioneered in South Africa at its Venetia mine contract for De Beers Group.

“We have adapted the method because of the very different conditions we’re facing but many elements remain the same or are very similar,” Malherbe said. “In particular, the high degree of safety offered by the Canadian method has not in any way been compromised.”

The number of Murray & Roberts Cementation personnel deployed per shift is 25. The total labour complement on site is currently just over 120 people, 46% of them recruited from local communities.

Murray & Roberts Cementation has a vigorous CSI program running in conjunction with its contract. It is being implemented in close association with PMC and has mainly focused on supporting local schools in the Phalaborwa area with infrastructure such as ablution facilities, fences, water storage tanks and boreholes.

Durand said: “In addition, we have trained nearly 80 youths from local communities at our Bentley Park Training Academy, near Carletonville. Another 20 are currently undergoing training. This program is giving them skills which are in high demand in mining, and which could lead to them securing permanent employment within the mining industry.”

SEW-EURODRIVE helps gear up scrubber project at De Beers Venetia mine

Equipment maintenance, Mine operation news, Mining equipment, Mining services, , , , , ,

Drive technology specialist SEW-EURODRIVE says it is installing four of its large segmented girth gear systems at De Beers’ Venetia Diamond Mine in Limpopo province, South Africa.

Venetia mine, in operation since 1992, is upgrading its two primary scrubbers and two secondary scrubbers, and the girth gear replacement is an integral element of this project, according to SEW-EURODRIVE.

According to Bruce Farthing, Project Engineer at SEW-EURODRIVE, the order was placed in 2020 and all four units were manufactured and delivered within six months. This short lead time was achieved despite the global disruptions caused by the COVID-19 pandemic.

“We have planned the installations in close collaboration with Venetia mine, making sure our teams are ready when the mine’s shutdown periods allow,” Farthing says. “The first girth gear was installed on one of Venetia’s secondary scrubbers in September 2021, confirming the accuracy and duration of our installation procedure.”

The expertise of the installation team was brought to the fore by the scrubber’s specific design. The bearing design in particular makes it impractical to bring the whole drum to ground before changing over the girth gear, according to the company. Instead, the replacement has to be conducted with the drum in situ, at a height of about three storeys high.

“In the first installation, we, therefore, assembled the girth gear on the ground, lifting it into position once the old components had been removed from the scrubber,” he says. “The challenge, of course, was to ensure no damage to any of the new components, which we managed with careful planning and experienced execution using large overhead cranes.”

These large girth gears measure 5.3 m in diameter and weigh about six tonnes each. Given the scale of the equipment, the segmentation of the gear makes for easier transportation and handling. He explains that each girth gear is made up of 10 identical segments which are easily assembled on site.

“The segments allow for relatively quick assembly with less lifting equipment,” Farthing says. “A further advantage is that individual segments can be kept in stock and used as replacements in the event of a breakdown – keeping downtime to a minimum.”

The second and third installations – to be conducted on the two primary scrubbers – are scheduled for later this year. With the limited time available during a plant shutdown, the installation team adopts a 24-hour work cycle.

The contract includes the supply of SEW-EURODRIVE’s large two-stage industrial gearboxes and the external pinions to drive the girth gear. The motors are coupled to the gearboxes using a fluid coupling on a purpose-built, drop-in baseplate. Smaller gearboxes from SEW-EURODRIVE’s X series range are also coupled to the main gearbox as auxiliary drives for commissioning and maintenance.

Farthing notes that the company’s segmented girth gear systems have recently been a popular choice for South African customers, with six orders being received within about a year. Apart from the four supplied to De Beers Venetia Diamond Mine, SEW-EURODRIVE also recently supplied these solutions to applications in a paper mill and a cement mill.

Concor to construct new pollution control dam at Venetia Underground Project

Diamond mining, Environmental, Mineral project development, Mining services, Water management, , , , , , ,

Leading South Africa-based, black-owned contractor Concor is engaging on a 17-month project to construct a new pollution control dam at De Beers’ Venetia diamond mine, South Africa’s largest diamond producer.

The well-advanced Venetia Underground Project (VUP) will extend the mine’s life span to at least 2045, and the new dam – Pollution Control Dam 3 (PCD3) – is the main containment facility in its Storm Water Management Project (SWMP). The SWMP is a key part of the mine expansion, ensuring compliance with the Government Notice R704 on the protection of water resources, preventing the possibility of flooding and ensuring the safety of people working in the new underground mine.

Concor Operations Executive, Christo Schoeman, explains that PCD3 will cover some 27 ha to the west of the mine and will be constructed to a maximum height of 13 m. This will equip the facility to hold over 1 million cu.m of water. The water will emanate from upstream catchments including runoff from the adjacent coarse residue deposit and fine residue deposit, as well as potential overflow from the other upstream water containment facility. It will also contain water that has been pumped out the of mine’s open-cast pits and the VUP underground workings.

“Zero harm to our employees and the environment whilst executing our projects remains our principle objective,” Schoeman says. “In order to prioritise these endeavours and ensure that construction work does not impinge on the mining operation itself, among the first tasks required will be to secure the works by installing a new security fence, and upgrading the existing access road to our temporary site facilities which will ensure optimised access to our site and help streamline our workflow.”

As part of the bulk earthworks operations, the topsoil over the dam area will be stockpiled during the excavation operations, to be used later for slope protection and to ensure the regrowth of flora once construction is completed.

“In line with environmental requirements and legislation, the excavated structure will be lined with am HDPE geomembrane to prevent any seepage into the groundwater system,” he says. “A specialised service provider will supply and install the lining.”

Concor’s scope of work includes the construction of a pump station and dam spillways, as well as the installation of a 2.5 km return water pipeline to the mine’s processing plant. This will allow significant volumes of water to be efficiently recycled and re-used in processing, it says.

Schoeman highlights that the project contains a strong local procurement, employment and skills development component. He notes that Concor has always been committed to local enterprise and skills development initiatives in the areas where it undertakes projects.

“We are working closely with our client to source general workers and suppliers locally, who we will, where necessary, upskill with training, supervision and mentoring,” he says. “Certain aspects of the project can be subcontracted to these local enterprises, following the systematic process of identification and engagement.”

Concor supervises the work of subcontractors closely as part of its enterprise development commitments, he notes. Combined with dedicated mentoring, this ensures not only a quality outcome in each deliverable, but also higher levels of sustainability amongst subcontractors once the project is complete.

De Beers taps Sandvik expertise for Venetia underground diamond mine transition

Automation, Bulk handling, Communications in mining, Diamond mining, IoT, Mineral project development, Mining equipment, Mining services, , , , , , , , , , , , , , , , , ,

De Beers Group has ordered 19 units of high-tech equipment from Sandvik Mining and Rock Technology for its Venetia Underground Project (VUP), in South Africa.

According to Simon Andrews, Managing Director at Sandvik Mining and Rock Technology Southern Africa, the company will supply a range of intelligent equipment including LHDs, ADTs, twin-boom drill rigs, roof bolters and cable bolters. Amongst the advanced models are the 17 t LH517i and 21 t LH621i LHDs, 51 t TH551i ADTs, DD422i face drills, DS412i roof bolters and DS422i cable bolters.

Partnership will be the watchword in the technological collaboration between the global diamond leader and mining OEM.

South Africa’s largest diamond mine, Venetia has been mined as an open pit since 1992. De Beers Group is investing circa-$2 billion to start mining underground from 2022, extending the mine’s life beyond 2045. The VUP represents the biggest single investment in South Africa’s diamond industry in decades, according to the company.

Allan Rodel, Project Director of the VUP, says the use of new technology is critical in building the mine of the future and will ensure the safety of its people, as well as create unique employment opportunities.

He adds that the successful implementation of this technology holds the key to further improve the mine’s productivity and cost effectiveness, enabling the quality and accuracy required for precision mining. This will also provide real-time geospatially referenced data that supports digitalisation of processes and provide a wealth of data for analysis and continuous improvement.

The underground mine will use sublevel caving to extract material from its K01 and K02 orebodies. Initially the ore will be hauled to surface using a combination of underground and surface haul trucks. As the operation matures, the hauling systems will transition to an automated truck loop in combination with vertical shafts for steady state production.

Sandvik’s Andrews said: “As important as the equipment itself is, De Beers Group was looking to partner with a company who would support them through the VUP journey. Taking a mine from surface to underground has many challenges, including the change in operational philosophy.”

Andrews highlighted that change management processes are as crucial to success as the capacity and performance of the mining equipment. The implementation of the new technology is seldom a straightforward process, and always requires a collaborative effort.

“The expectation of the customer is for a strong relationship with a technology partner who will help them to apply, develop and fine-tune the systems they need, over a period of time,” he says. “This way, the technology is assured to deliver the safety, efficiency and other positive results that the new mine will demand.”

Andrews believes Sandvik Mining and Rock Technology leads the pack from a technology point of view, having introduced its intelligent i-Series machines to enhance remote operation capability. This advanced range combines automation with data management capacity, aligning with the philosophy that De Beers Group has applied to this world-class operation, which prioritises the safety of its people.

Also included in the package for VUP is the Sandvik OptiMine® control system which enables continuous process management and optimisation, focusing on key areas such as face utilisation and visualisation of the operation in near real time. Using data generated by the i Series machines, OptiMine helps mining operations to achieve the lowest operating costs and highest levels of productivity.

Andrews noted that Sandvik Mining and Rock Technology is not new to the Venetia site, having worked with Venetia’s surface operations for some years, providing tools for drilling as part of a performance contract.

“We’ve been following the VUP with great interest and were ideally placed to contribute as we have extensive South African experience with mining customers in transitioning from opencast to underground,” he said. “This has involved providing equipment, implementing the systems and getting a full operation running with the latest equipment.”

He added: “Sandvik Mining and Rock Technology has successfully completed numerous large and ambitious projects, and it reflects our experience in applying automation technologies from first principles. The learnings from these projects will be seen in the VUP as the mining systems are rolled out. We will take the very latest technology and assist the mine to implement it in an underground environment through a collaborative approach using local skills and supporting it from a local base of expertise.”

He emphasises that the automation will be applied through a phased approach, beginning with manual operation and closely monitoring performance through data analytics. Automation can be gradually introduced with the necessary training and experience, ensuring consistency of operation which is the key to success.

“This will allow costs to be driven steadily lower, using the data from the operation of the fleet to guide the transition to automation,” he says. “We will work with the mine to introduce automation and further data management as work progresses deeper into the mine, and as mine employees become more comfortable with this way of working.”

Sandvik Mining and Rock Technology (soon to be Sandvik Mining and Rock Solutions) is geared to support the trackless systems implemented at the mine through the full lifecycle of the machines by supplying spare parts, tooling and components from an on-site Vendor Managed Inventory stockroom and its other South African based facilities.

Worley out to help miners on their open pit to underground mining transition

Bulk handling, Diamond mining, Explosives and blasting, Mine operation news, Mine shafts and equipment, Mineral project development, Mining services, Mining software, Precious metals, , , , , , , , , , , , , , , , , , ,

As open-pit mines reach their economic end of life, mine owners are considering the viability of transitioning their open-pit operations to underground.

Drawing on its deep level mining expertise in South Africa, Worley helps mine owners around the world to explore the feasibility of underground life of mine extensions and identify the most efficient and safe underground mining methods.

Among the driving factors in the transition to underground mining are declining ore grades, deeper ore deposits, and an increase in demand for minerals required for the global energy transition, such as copper, lithium, manganese and nickel, Worley says.

“Worley’s centre of excellence for copper in Chile has been supporting open-pit copper mine customers for nearly three decades,” the company said. “The company is gearing up its underground capability as these mines shift their operations to below surface to access deeper ore reserves.”

Going deep in South Africa

Worley’s South Africa operations is one of the company’s mining centres of excellence with niche experience in deep level mining.

Mining has been the mainstay of South Africa’s economy for well over a century, and a major source of employment as well as foreign investment. Consequently, Worley has grown its South Africa mining team in one of the best mining environments in the world, with a collective experience of over 120 years in deep level mining and process expertise.

Robert Hull, Vice President for Mining, Minerals & Metals in Africa, says Worley’s South African operation is recognised for its deep level shaft experience, and the company also has experience across most commodities including base metals, coal, platinum, gold, diamonds and ferrous metals.

Hull says Worley has a strong global workshare philosophy and culture of collaboration. The specialist skills in South Africa gained from working on some of the biggest underground projects in the world are an integral part of Worley’s mining, minerals and metals global project delivery offering.

Deep level mine skills

Some of South Africa’s specialist deep underground skills include shaft design, ventilation and refrigeration shafts, high pressure pumping, and deep level hoisting.

Worley says it is one of the few companies in the world that has the expertise to design hoisting systems for mass hoisting, such as at the Venetia Underground Project, which will hoist approximately 6 Mt/y of rock.

The De Beers Venetia Mine in South Africa is the biggest source of rough diamonds in the country, according to Worley. The mine is in the process of transitioning from open pit to underground, to extend its life by some 25 years.

As engineering procurement and construction management contractor for South Africa’s largest mining execution project, Worley is using 3D designs for the project infrastructure to provide 3D models for the entire project’s surface and underground infrastructure, it said.

Intelligent mines

Hull says Worley is leading the way in developing digital solutions for the planning, design and execution of mining projects, with the South Africa office having played a key role in the design and development of much of the group’s digital technology in mining and minerals processing.

Hull (pictured) cites the Wafi-Golpu (owned by Harmony Gold Mining and Newcrest Mining) feasibility study update, in Papua New Guinea, where the South Africa team drew on SmartPlant design technology, which uses rapid prototyping and Building Information Modelling. The technology allowed the entire project team to visualise project objectives as never before, greatly improving operational efficiency in a dynamic time and cost-saving environment, according to Worley.

The Wafi-Golpu project is ranked as a world-class deposit in terms of its size and the grade of gold and copper within it. If developed, it will be the largest, deepest and most complex underground mine in Papua New Guinea, with a mine life of 28 years, Worley says.

Integrated project delivery teams

Worley’s South Africa team is also supporting its Australia counterparts to project manage the delivery of the deepening and expansion of an underground gold mine. This includes construction of a 1,460 m shaft, additional capacity in the processing plant, and supporting infrastructure to enable profitable recovery of ore at depth to 2 140m below surface. IM understands the project in question is the Newmont-owned Tanami Expansion 2 project, in the Northern Territory of Australia.

Mega machines for mega mines

Hull says every underground project Worley has executed has drawn on the company’s large material handling capabilities.

“In South Africa, we have a dedicated materials handling department that has the latest tools including discrete element modelling and finite element analysis, and advanced simulation tools for conveyer design,” he said.

Coenie Mynhardt, Winder Engineering at Worley, adds that mine payloads have increased dramatically in the last two decades in pursuit of higher productivity rates. Mines such as Impala and Phalaborwa, in South Africa, with an approximate 12-t per skipload, were considered ‘mega mines’ in their day. The mines of the future are more than double that size.

“The mega mines of the future need mega machines to be able to handle such big payloads,” Mynhardt says. “Materials handling technology for such deep, high tonnage operations will test current technology for capacity and reliability to bring the ore from the production levels to surface. We have the skills and expertise to find the solutions to these challenges.”

Global project delivery

“Countries such as Chile have immense potential for transitioning from open pit to underground if the geology supports it,” commented Hull. “With the wealth of experience across locations and over 4,000 staff in our mining, minerals and metals business line, we can safely and successfully deliver our customers’ underground mine assets through collaborative development of the mine and associated infrastructure anywhere in the world.”

Metso equipment to rough up diamonds at De Beers Venetia mine

Comminution of minerals, Gem stone mining, Mine operation news, Mineral processing, Mining equipment, , , , , , ,

Metso is to install high-performance crushing and material handling equipment underground at the De Beers Group’s Venetia diamond mine, in South Africa, as part of an order booked in the September quarter.

In the throes of a transition from open-pit mining to underground operations, Venetia is reported to produce around 4 Mct/y, making it one of South Africa’s biggest diamond mines.

In 2013, an underground extension project commenced with plans to start producing carats in 2022, climbing to full production in 2025 and extending the mine life to 2046.

Metso said Venetia approached Metso to deliver two primary jaw crushers and a number of feeders. All the equipment will be installed underground, which is a very challenging installation, especially given the shaft constraints (dimensions) and weight limitations for transportation underground, the company added.

Venetia decided on Metso’s Nordberg® C Series™ jaw crusher range as the pinned and bolted design of the crusher allowed for the extensive disassembly, Metso said. “This enhances ease of transportation and installation, especially where there are critical space constraints such as an underground installation – as is the case with this project.”

The Metso apron feeders, meanwhile, are used for extracting or feeding ores that are wet, sticky, dry or even frozen.