Modern Quarrying January-February 2017

QUARRYING JANUARY - FEBRUARY 2017 www.crown.co.za MODERN

Aspasa steps up its training

Scania optimises hauling efficiencies

Weir Minerals increases capacity at OMV

IN THIS ISSUE

QUARRYING MODERN

CONTENTS

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Weir Minerals increases capacity at OMV

Special Report: Owner vs contract miner

Aspasa to provide comprehensive training

This paper by the University of Johannesburg’s SM Rupprecht, reviews some of the better-known arguments about contract vs owner mining, and offers advice for establishing and managing the relationship between owners and contractors.

Looking at several solutions in terms of its plant, OMV has partnered with Weir Minerals Africa for an upgrade of its sand wash plant. With plant optimisation, the plant is getting 14 t/hour more in the cyclone underflow, which reports as a saleable product.

The Aggregate and Sand Producer’s Association of Southern Africa (Aspasa), is stepping up the amount of training on offer to members aimed at underpinning standards within the industry while simultaneously improving workforce skills.

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Supplier Spotlight: Building a quarrying legacy on trust

AROUND THE INDUSTRY

MARKETPLACE

32 Scania optimises hauling efficiencies 34 Bell TLB sets the standard 35 Osborn exports to Kazakhstan 37 Kwatani puts exiter quality to the test 38 OptimumWeba transfer point design

A three-decade long relationship between a large-scale equipment supplier and a family-run quarrying operation on the West Rand has become a prime case study in the establishment of a successful symbiotic business.

4 Heartening news for miners 5 New MD for Babcock

6 Proposed split for Atlas Copco 7 Conveyor best safety practices 9 B elabela supports early learning

40 LAST BLAST: OPINION PIECE

ON THE COVER

QUARRYING JANUARY -FEBRUARY2017 www.crown.co.za MODERN

Published quarterly by: Crown Publications cc P O Box 140 Bedfordview, 2008 Tel: +27 11 622 4770 Fax: +27 11 615 6108 www.crown.co.za

Editor Dale Kelly

JCB Construction Equipment (Kemach JCB) is in the process of launching two formidable machines to market: the JS305 LC tracked excavator and the 455ZX wheeled loading shovel. These machines have been manufactured at JCB’s state-of- the-art facility in India and are designed to be easy to operate, easy to maintain and to move more material at less cost.

dalek@crown.co.za Mobile: 0834199162 Advertising Bennie Venter benniev@crown.co.za

Design & layout Adèl JvR Bothma

Average circulation 2 521 Printed by: Tandym Print

Circulation Karen Smith Publisher Karen Grant

www.modernquarryingmagazine.co.za

See full story on page 10.

Aspasastepsup its training

The views expressed in this publication are not necessarily those of the editor or the publisher.

Scaniaoptimiseshaulinge ciencies

WeirMinerals increasescapacityatOMV

INTHIS ISSUE

MQ JANFEB 2017 covers.indd 1

2017/02/08 10:13:28AM

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AROUND THE INDUSTRY EDITOR’S COMMENT

Is our 150 th year of mining truly a triumph?

A s a lover of history and this includes min- ing history, I am currently reading Jade Davenport’s book Digging Deep – a history of mining in South Africa – which is a story of how mining gave rise to modern South Africa. It incor- porates visionaries like Cecil Rhodes, Alfred Beit, Barney Barnato (a particular favourite of mine), Sir Ernest Oppenheimer, Sammy Marks and Hans Merensky, all of them pioneers in shaping the development of the mining industry. Interestingly, Jade Davenport is a freelance journalist and a historian with an immense under- standing of the country’s phenomenal mineral rev- olution which spanned more than 150 years, from its earliest commercial beginnings to the present day. Her book incorporates seven of the major commodities that have been exploited. Digging Deep describes the establishment and unparalleled growth of mining, tracing the his- tory of the industry from its humble beginnings where copper was first mined in Namaqualand in the Cape in the early 1850s, to the discovery and exploitation of the country’s other major mineral commodities. It is hard to believe that before the advent of the great mineral revolution in the latter part of the 19 th century, we were a sleepy colonial back- water with a landscape seemingly devoid of any economic potential; while, lying just beneath the dusty surface of the land, lay the richest treasure trove of gold, diamonds, platinum, coal and a host of other metals and minerals that have ever been discovered in one country. Which brings me to Cape Town’s 23 rd annual Mining Indaba and Anglo American CEO Mark Cutifani’s address in particular. He says that the next three to four months will be among themost import- ant in the 150-year history of mining in South Africa. The stage is set. “We need to do things differ- ently to find a new, safe, responsible and cost-ef- fective way to mine the ore bodies to meet the needs of a rapidly urbanising global population; a population which is estimated to reach 9,5-billion by 2050, with an even faster growing consumer class in the emerging world. Talking about the notion of white monopoly capital, he says in today’s world capital has no colour, “it is a powerful tool that can help create a better world for all. He was referring to the SA President’s recent comment that he wouldn’t bow to white monopoly capital amid claims that he was receiving advice from ‘outside business interests’ on various cabinet appointments.

“In our case, 64% of the mines we operate and those we empowered are effectively owned by South Africans – through direct and indirect shareholdings. If I assume 27% black ownership in our mines and add to this the participation by black South Africans in pension funds and directly on the JSE, black South Africans own more than 45% of our South African operating assets,” Cutifani confirms. “Many people still don’t understand that the owners of most South African publicly-listed mining companies are not the Randlords or mag- nates of previous generations, but rather ordinary pension and investment fund owners – that is, average South African citizens of all races: black, white, coloured and Indian.” The Minister of Mineral Resources Mosebenzi Zwane filled the hall for his keynote address, but although his speech was conciliatory towards the mining industry this third mines minister in as many years, once again reinforced government’s commitment to beneficiation – without admitting that this is a challenge that cannot be addressed by the mining sector alone and that almost every- thing government-related is constantly working against the practicalities of setting up new busi- nesses or enabling businesses to operate. He used the very outdated cliché that mining in SA is open for business while as was the case last year, his department has been committed to dates in which the revised Mining Charter and the MPRDA are to be finalised, even while their con- tent is still shrouded in uncertainty. As Cutifani says:“For investors, it goes without saying that regulatory certainty and the sanctity of private ownership under the constitution is paramount. They need to know that their capital is invested in a jurisdiction that has clear, fair and reasonable prescripts on the regulation of mining. Sadly, I believe that despite the fact that the industry as a whole has bent over backwards to meet government demands, it seems set on imposing a revised mining charter containing unrealistic targets, and is bent on extracting its pound of flesh regardless of the cost in lost output and jobs. Clearly mining in its 150 th anniversary should be celebrated and not constantly under threat.

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AROUND THE INDUSTRY

There was heartening news for mines and miners at the recently-held BME Annual Drilling and Blasting Conference, which took place in Pretoria last November – with views Heartening news for miners implemented the world’s deepest emul- sion pipeline, and developed the infra- structure to use emulsion explosives in the narrow-reef environment. “The system at Modder East is the

senior software developer Nicky Klacar demonstrating the power of mobile appli- cations in drilling and blasting. “Tablets and phones can help mon- itor aspects of operations – even under- ground – and improve efficiencies as a result of knowing how well plans were turned into action,” says Klacar. “Even a simple photograph of a drilled round on a stope face – taken with a tablet under- ground – can provide valuable data to be measured and analysed as part of contin- uous improvement practices.” She highlighted BME’s Blastlog Reporter, an app through which mine-re- lated data can be stored and presented according to what the user requires, and avoiding a deluge of unnecessary information. “For an operation to run optimally, staff need to be aware of anything excep- tional that is taking place with production or machinery – or any deviations that indicate a problem somewhere,” she says. “Apps like Blastlog can do this, and even people who are not familiar with comput- ers can use a cell phone.” The BME conference, held annually for the past 24 years, attracted over 450 dele- gates from 15 countries including Poland, Singapore, Australia, Canada, United States, the Czech Republic, Zambia and Botswana. www.bme.co.za

result of three years of hard work, but we’ve achieved what no-one has accom- plished before,”James McArdle, explosives and technical manager at Modder East, told delegates. “While we were already using emulsion explosives in develop- ment operations, we took a bold step forward. We have successfully installed and commissioned the world’s first lon- gest drop Rapid Re-Loading Emulsion System of 318 m to underground storage tanks and now leverage its benefits and cost-savings in day-to-day operations.” Addressing the risk of lightning to mines’ blasting activities, BME technical director Tony Rorke pointed out that, lightning strikes pose significant dangers to South Africa’s opencast mines. Rorke highlighted the potential for especially positive cloud-to-ground (CG) strikes to induce the unplanned deto- nation of explosives, and outlined the advances made in the second generation of the Axxis electronic detonation system – Axxis GII™ – to mitigate the risk of light- ning-induced initiation. The cellular phone was another focus of innovation at the conference, with BME

A ccording to economist Dr Roelof Botha, the volume of total mining production has, in 2016, shown signs of stabilising when compared to 2013 – particularly in terms of platinum and iron ore. “Also in the first quarter of 2016, the demand for gold reached its second-high- est quarterly level in history, which is fan- tastic news,” says Dr Botha. “What is good for gold is, as a rule, good for the South African economy.” Reflecting on activity in the explo- ration sector, BME MD Joe Keenan says there are signs that confidence is return- ing to commodities, and it is unlikely that prices would worsen beyond current levels. However, Keenan suggests that a global economic recovery may still be a couple of years away. Notwithstanding the cyclical difficul- ties, he says BME – part of the JSE-listed Omnia Group – is still forging ahead in terms of cost-saving innovations and opening up new markets. “BME has become very much an inter- national company, operating in over 23 countries while pursuing business oppor- tunities in large markets like the USA and Canada,” he says. “In 2016 we also saw our first delivery of Axxis products to Colombia, and a contract on the expand- ing rail system in Singapore.” The conference focused on techno- logical innovations in the field of blast- ing that could reduce costs in mining in the short term while improving safety levels and productivity. A key advance is in the employment of emulsions in underground mining; BME in partnership with Gold One’s Modder East mine has that commodity prices may be turning, and news of innovations that would save mines money as they struggle to stay profitable.

Keynote address: Dr Roelof Botha speaking at BME’s 24 th Annual Drilling and Blasting Conference.

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AROUND THE INDUSTRY

Engineers concerned about infrastructure spend The recent PPS Graduate Professional Index conducted among 400 South African engineers, indicates that only 4,0% of the respondents believe that the South African government is effectively delivering on its promises on infrastruc- ture spend. The survey was conducted by PPS, the financial services provider focused on graduate professionals. According to Motshabi Nomvethe, should be given the opportunities to work with the State.” According to Nomvethe, it was, how- ever, extremely positive to note that 64% of the respondents indicate that they would encourage their children to enter the engineering profession, with 51% stating that it is because the skills are really needed in South Africa. When it comes to training of engi-

New MD for Babcock Previously Babcock’s sales director of Babcock, Dave Vaughan has been appointed MD – Equipment for the com- pany. He has been with Babcock since 2005 when he joined the company as a regional general manager. Babcock’s equipment business manages the exclusive distribution and support of leading international equip- ment brands in Southern Africa, includ- ing Volvo construction equipment, Terex Trucks, Tadano and Sennebogen cranes, Winget concrete handling equipment and SDLG construction equipment. “With indications of recovering commodity prices, our customers are positive about the outlook for 2017,” Vaughan says. “I have a single goal in mind, and this is to focus on customer service. To this end we will be restruc- turing our regions in the first quarter of 2017 to provide our customers with a quicker turnaround time on service and parts.” www.babcock.co.za

neers, Rimbault explains that it might be worthwhile to include a form of national service as part of the engi- neering degrees, as per the community service year that is a requirement of medical degrees. “Should a newly-grad- uated engineer conduct a year’s service with the Public Works Department, they will obtain invaluable experience that can only be taught out in the field. A pro- gramme of this magnitude would ensure that all our young engineers enter the profession with a foundation of basic experience, which means they can then contribute in a business environment from day one.” When it comes to employment, Nomvethe notes that 36% of the survey respondents are concerned that unem- ployment in the country will encourage skilled professionals to work overseas. Rimbault believes that engineers should consider moving into positions within the small andmedium-sized enter- prises in South Africa as an alternative. “A small manufacturing company might need a professional to give input on their systems. Seasoned engineers will be able to contribute greatly to these types of businesses, which in turn will allow South African businesses to improve their reve- nue through improved systems. “Every economy in the world needs as many skilled engineers as possible and universities can never over-pro- duce engineering graduates. We have to encourage youngsters to study toward an engineering degree and to get rele- vant experience soon after they gradu- ate,” he concludes. www.pps.co.za It has been suggested that it might be worthwhile to include a form of national service as part of the engineering degree, as per the community service year that is a requirement of medical degrees.

technical marketing specialist at PPS, 91% of the respondents indicated that they do not think that the government will meet their infrastructure objectives as set out in the National Development Plan (NDP). In its NDP, government states that by 2030 key services such as com- mercial transport, energy, telecommuni- cations and water has to be strengthened to ensure long-term sustainability. Commenting on the results Vaughan Rimbault, CEO of the South African Institution of Mechanical Engineering (SAIMechE), says that we need proactive collaboration between the government and engineering professionals to counter these issues.“The government is the big- gest potential client for any engineering company, so when massive construction projects are rolled out it is vital that engi- neers with the right engineering skills are chosen to do these projects. Improved collaboration between the government and engineering associations will facili- tate communication and in turn encour- age support from these professionals to have more faith in government’s infra- structure expenditure.” Rimbault states that government also has a responsibility to employ local South African businesses to handle these big projects rather than employing skills from overseas.“There is an abundance of engineering talent in South Africa that

Customer-oriented: Dave Vaughan, MD for Babcock’s equipment business.

IQSA diary Please diarise the following Institute of Quarrying Southern Africa events:

AGM Conference and Exhibition at Coastlands Hotel, Umhlanga: April 20-21

Golf Day: August 1

September Conference: September 14-15

End of Year Function: November 2

www.iqsa.co.za

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AROUND THE INDUSTRY

Proposed split for Atlas Copco The Atlas Copco board is proposing a split of the Atlas Copco Group. The mining and civil engineering dedicated company will include 12 000 employees, comprising all divisions within the Mining and Rock Excavation Technique Business Area plus the division Construction Tools and related service. The rationale is to ensure that both Atlas Copco and the new company are provided with best growth opportunities in their respective market segments. The new company will have a dedicated board and CEO, which will result in a more agile

company governance and faster response to market require- ments. Operationally there will not be any changes to the exist- ing infrastructure, as there already is a solid organisation in place. The structure will further enable investments in growth areas like automation, digitalisation and service excellence. The new company will be listed on the Nasdaq Stockholm stock exchange from mid-2018 following approval at the Atlas Copco AGM in April that year. www.atlascopco.com

Navigating B-BBEE Codes “Companies concerned about how the revised Codes of Good Practice will affect their scorecard rating and their business, need not be concerned, as it is feasible to intelligently increase your company rating at a negligible cost,” says Yolandie Botha, head of Innovative BEE Solutions. There are now only three compul- sory categories in the Broad Based Black Economic Empowerment (B-BBEE) Codes. Two of the three codes make it possible to earn considerable tax rebates and points by redirecting mandatory expenditure. The updated B-BBEE codes came into effect from May 2015. The revised codes have much stricter rules when it comes to the scoring process and harsher implica- tions for business owners. “The Department of Labour has become more aggressive in implement- ing the Employment Equity Act 2014, which has far stricter penalties for employ- ers who don’t comply with the Act. Many smaller companies without dedicated resources to manage the B-BBEE pro- cess have simply thrown up their arms,” explains Botha. Yet the situation can be managed in a manner which can cost them virtually nothing while potentially improving their competitiveness when tendering for certain contracts. The revised codes of Good Practice will most affect companies that have a revenue of more than R10-million. The Code’s categories for compliance have been condensed from seven to five cat- egories, three of which are regarded as compulsory and must be adhered to in order to be compliant. Botha identifies the three compul- sory categories as Ownership, Skills Development and Enterprise & Supplier

earn points for Code scorecard purposes,” explains Botha. The Codes contain a list of such services which qualify for rand value, including interest-free loans and pre- payments for other services. Other ser- vices commonly bartered in this manner are the provision of protective cloth- ing and equipment, and in-house skills development. Innovative BEE Solutions’ first step when consulting with a new client is to evaluate the company and determine its current status and degree of participation. “If a company has an annual turnover of less than R50-million, it is relatively easy to increase their rating even in the current year. However, when the turnover is above R50-million it is usually necessary to restruc- ture it more substantially for an improve- ment in the following year,”says Botha. “Many business people regard B-BBEE and labour regulations as onerous on small and medium sized enterprises – and they are often surprised to find how easily it can be used to their advantage,” concludes Botha. www.beeratingsolutions.co.za

Development. The broad-based BEE lev- els range from one (the highest) down to eight or non-compliance. She outlines two ways in which com- panies can benefit from the new Codes at short notice. “If a company registers for learnerships, they can immediately receive R40 000 a learner as a tax rebate. This is provided that the learners find employ- ment after their learnership, are black Africans and under the age of 35. In addi- tion to this rebate at the start of the learn- ership, companies can receive another R40 000 at its conclusion. The company also pays a stipend to the learners, which similarly gives a tax rebate,” she adds. “Furthermore, companies are required to pay 6,0% of their payroll towards exter- nal training for black South Africans. This amount can also be claimed back with a Workplace Skills Plan (WSP) from SETA.” Another inexpensive means of improving a company’s B-BBEE rating is to better structure its enterprise devel- opment. Botha says that most companies are typically doing something and incur- ring expense in this category without earning the points. “For instance, companies may occa- sionally use a contractor, but if that con- tractor is not a registered company they earn no scorecard points. On behalf of our clients, Innovative BEE Solutions will look at all your legal requirements and imple- ment the necessary steps to ensure that your contractors are B-BBEE compliant. We also provide the assistance needed to build and grow your business in order for you to earn maximum points and bonus points. It is also possible for each party to provide services to the other for which no money passes hands, but which

Two of the three revised Codes of Good Practice make it possible to earn considerable tax rebates and points by redirecting mandatory expenditure.

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AROUND THE INDUSTRY

Conveyor safety best practices A global leader in the advancement of conveyor safety has announced the publication of the world’s first aggregation of global best practices, dedicated to reducing conveyor risk and injuries. Modelled after the company’s respected Foundations reference volume now in its fourth edition, Foundations for Conveyor Safety from Martin Engineering provides an unprec- edented collection of information assembled specifically to help conveyor system operators achieve safe production.

To assess the true value of safety, the book includes ground-breaking method- ology for calculating the payback from safety investments, sometimes referred to as ROS (Return on Safety). “This work is based on the premise that the extraction and processing of bulk materials can be done safely and profit- ably by applying global best practices for conveyor safety and design,” says Martin Engineering chairman Ed Petersen. “The first step to true productivity is safety; if a conveyor or and industry is not safe, it cannot maximise productivity.” www.martin-eng.com Martin Engineering’s Foundations for Conveyor Safety edition is a global roundup of best practices to keep workers safe on or around belt conveyors.

NewWearCheck people WearCheck’s oil analysis and reliability solutions services, has boosted its capacity with the recent appointment of three professionals:

Jacques Blignaut is the new chemist in WearCheck’s Pinetown laboratory. The capacity for this position has developed as the laboratory becomes busier due to the company’s expansion around Africa. Blignaut holds a Masters Degree in Chemistry, and will be assisting with research and development work for the company.

Paul Nhlapo has been promoted to handle business development and technical support for WearCheck

Jacoba Schwartz is WearCheck’s new agent in Kathu, covering the areas from Kuruman to Upington and surrounds, and develops sales, processes quotations and collects filled sample bottles to dispatch to the laboratory.

Middelburg and the surrounding areas.

www.wearcheck.co.za

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AROUND THE INDUSTRY

Belabela supports early learning Early childhood education in Botswana has received a welcome boost in the Kgatleng District near the capital Gaborone, with the Belabela Quarries’ funding of a new building for reception-grade children at Matebele Primary School. The building and furnishing of the reception block was funded by a substantial donation from Belabela Quarries. Started in 2003, the quarry was acquired in 2015 by Raubex company B&E International, and sales have grown following investment in plant, equipment and skills. It is now the largest quarry in Botswana, with a production of 70 000 t of aggregate/month. Speaking at the official opening of the reception block in January, Botswana’s Minister of Basic Education, the Honourable Dr Unity Dow, highlighted the importance of preschool facilities in government schools. “In other countries, by the time kids sit their final exams in pri- mary school they would have had nine years of schooling and prepa- ration, including preschool. In Botswana it is only seven years. This puts our kids at a disadvantage in an increasingly globally competitive environment.” She says the new block, sponsored by Belabela Quarries, will also ultimately help to improve the pass rate at the school. Blackie Marole, local non-executive director of Belabela Quarries, says the quarry’s growth has allowed it to consolidate and expand its corporate social responsibility. “Belabela is now in a position to con- tribute more significantly to the community. We trust that the recep- tion block will improve the academic performance of the local kids for generations to come.” Serving all the major building and civil contractors in the Gaborone area, as well as brick manufacturers and readymix concrete suppliers, the quarry produces G1 base course, railway ballast, 37 mm concrete stone, 19 mm concrete stone and 13,2 mm concrete stone. It also pro- duces road stone for surfacing and crushed sand. All the stone produced at Belabela complies with Botswana Bureau of Standards requirements – as well as those of the South African Bureau of Standards – for road, rail and building construction. www.beinternational.co.za

From left, Matlho J Kgosi, director Belabela Quarries; Redemption Mosala, finance manager Belabela Quarries; Hon. Dr. Minister Unity Dow, Minister of Basic Education; Dewald Janse Van Rensburg, director Belabela Quarries; Blackie Marole, director Belabela Quarries; and Mrs Mokgadi, school principal.

ON THE COVER

JCB Construction Equipment, solely represented in South Africa by Kemach Equipment (Pty) Ltd (Kemach JCB) is in the process of launching two formidable machines to market; these being the JS305 LC tracked excavator and the 455ZX wheeled loading shovel. Dale Kelly visits national support and marketing manager Mark Senyard at the Jet Park head office, to talk about these rugged workhorses. Making things easy

fuel quality and an engine and hydrau- lics designed with productivity in mind,” Senyard says. At its heart is a formidable 7,2 ℓ Dieselmax engine that produces huge amounts of power and torque. Key fea- tures include: • The six-cylinder engine produces its peak power (165 kW) and torque (960 Nm) at a low1 300 rpm. This allows fuel-efficient matching of the engine and hydraulics. • With a massive 222,6 Nm of bucket tearout, fast cycle times are assured in all applications. The intuitive multi- function operation makes simultane- ous tracking and excavating smooth and fast. • The JCB JS305 provides a solid, stable work platform for fast cycle times. Senyard says the control valve optimises hydraulic oil supply to different functions during combined operation. This multi- function prowess guarantees fast cycle times. “When you’re tackling tough applica- tions and difficult working conditions, one needs a durable and reliable machine. The JS305 offers exactly that with high-qual- ity components along with simple and robust mechanical fuel injection. The Dieselmax engine has a mechan- ical in-line Bosch fuel injection system which allows work in areas where fuel quality is poor. The machine benefits from a multi-stage fuel filtration system which protects against a wide range of contam- inants as small as two microns. “We use high tensile strength steel to construct the reinforced boom and dipper and internal battle plates help to ensure long-life durability, as do the heavy-duty wear strips at the dipper end,” he tells MQ adding that the advanced manufacturing and assembly processes help to guaran- tee an extremely high level of precision and quality in the components. “The JS305 is built to last. With a heavy-duty lower frame and upper

E stablished in 2003, Kemach J CB i s a j o i n t ven t u r e between the shareholders of BH Botswana and Muscat Overseas in Oman. Both these companies are the sole JCB dealers in their respective countries. As a leading earthmoving solutions dealer, Kemach JCB supplies high-calibre equipment to the mining, construction, quarrying and plant hire industries, as well as the central government. A focused dealer of distinguished equipment and support, Kemach JCB continuously strives to put the customer at the heart of its business, fixated on meeting each client’s unique needs. Senyard says that both machines have been manufactured at JCB’s state-of-the- art facility in India and are designed to be easy to operate, easy to maintain and to move more material at less cost.

Referring to the JS305, Senyard says the first two units have arrived with another two on the way. “Further orders have been placed for additional machines to ensure our order pipeline is in place to fulfil what we believe will be an increased demand for this machine. The JS305 has been on test in India and in South Africa, where it is on trial by a customer. “The feedback we’ve had both from India and here in South Africa has been excellent particularly in terms of fuel con- sumption. The unit slots in with the JS205 that JCB launched many years ago.” The JS305’s Dieselmax engine is built for the African and Middle East market as well as for lesser-regulated countries. “It’s not a Tier 4 engine and is ideal especially in terms of fuel consumption, and that goes for the 455 as well. “The 305 has a simple mechanical fuel injection system that tolerates lower

The JS305’s Dieselmax engine is built for the African and Middle East market as well as for lesser-regulated countries.

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ON THE COVER

in a hard world

BHL global market. The new JCB 455ZX offers premium quality and reliability; the process we’ve used in its design and manufacturing will ensure a reliable work horse, and we’ve already had a lot of inter- est shown in this machine,” Senyard says. “We use state-of-the-art manufactur- ing processes like robot machining, pre- cision paint technology and innovative assembly techniques to achieve the high- est levels of build safety.” Finite element analysis and rig testing ensure superior structural strength and durability, and the machine has under- gone rigid hot and cold climate testing. Recessed rear lights are protected within the solid counterweight; the counter- weight and cast quarter pillars also pro- tect the cooling pack and the back end of the machine from damage. Other features include: • JCB Dieselmax engines feature a heavy-duty cast iron cylinder block, cylinder head and forged crankshaft to provide high strength and long life.

structure, as well as a high-strength boom and arm, this excavator is designed to excel in tough quarry applications. We use finite element analysis with extensive rig and endurance testing to make key components last longer.” All round-visibility is superb, with a large glass area on the right hand side and top corner of the cab. An innovative low-level bonnet allows clear rearward views. Operators are kept abreast of key information via the 3,5”display, which can be accessed via a new rotary controller. A spacious stowage area behind the seat provides plenty of room for an operator’s personal items. JCB’s optional rear view camera dis- plays an uninterrupted rearward view for improved operator confidence while slewing. The bonnet opens front-to-rear for easy and safe engine service access. JCB’s Safety Level Lock fully isolates hydraulic functions to avoid unintended move- ments. The 2GO system means a new JCB JS305 can only be started in a safe locked position via two separate inputs. LiveLink telematics are fitted as stan- dard. This is an innovative JCB feature designed to maximise security and fleet utilisation, allowing the monitoring of information such as fuel usage on differ- ent shifts. “In the past, we had the JS290, the 240, the 360 and 370, which are UK-built machines – and the 30 t market is one that we haven’t really got into in South Africa. However, we believe that with the 305, we are ready to tackle that now,” he says. “Both machines are very competi- tively priced and the enquiries and leads are coming in.” JCB 455ZX wheeled loading shovel “If one looks at the backoe loader mar- ket, we are probably some 10-15 market share points ahead of the closest com- petitor. JCB is very proud of the fact that we are pretty much just under 50% of the

• Precision machining provides high tolerances and accurate location of the 455ZX’s pins and bushes. • There are top quality components fit- ted to the 455ZX such as the ZF trans- mission and axles, Rexroth pumps and a Parker valve block. • The articulation joint has a heavy- duty box section (much stronger than a single plate with a boss), a heavy- duty centre pin and oversized bush, as well as twin taper roller bearings on the bottom box joints. This setup can tolerate both vertical and horizontal loadings for durability and rigidity. Steering rams are positioned high up and protected from damage. • The JCB Dieselmax 672 is equipped with high-capacity multistage fuel filtration designed specifically for reliable operation in territories where fuel quality cannot be guaranteed. This consists of water separation and a unique 3-stage filtration system dealing with water in fuel, fine and

The JCB 455ZX is designed to move more material for less and to this end, the engine, axles, driveline and hydraulics have been built to work in harmony.

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January - February 2017

ON THE COVER

Bay, Bloemfontein, Mthatha, Cape Town, East London, Port Elizabeth and George. To guarantee seamless operations throughout Africa, Kemach JCB’s network of distributors and service dealers are also strategically positioned inWindhoek, Nelspruit, Swaziland, Polokwane, Upington, Schweizer Reneke, andVryheid. “We get good support from JCB itself with a local team based here to support us. We have direct contract with our fac- tories so there is support from the OEM itself,” Senyard confirms. “I must say that I have visited the fac- tories in the UK and in India, and have been blown away by the high-tech facil- ities. Whether in India or anywhere in the world for that matter, it is the same level of professionalism throughout. “Our customers are seeing the value in the product, they are seeing the value in resale and it is our customers who are putting us ahead of everybody else,” Senyard says, adding that the involve- ment of senior management is tremen- dous. “Our CEO Les Lothian attends events and product launches, locally and internationally, and is very much involved in meetings and discussions with our cus- tomers. From a customer point of view this is invaluable.” In conclusion, Senyard says that although the company doesn’t have mining equipment as such, there is a lot of support equipment that goes into the mines. “The JS305 and 455 machines are ideal for the quarrying environ- ment, “typically for aggregates loading, stockpiling, feeding the bins, etc. I see a great opportunity for aggregates han- dling with these products. Our dealer in Sweizer Reneke has moved of couple of the 455ZXs to the diamond diggers and again, the fuel consumption figures have been tremendous.” The company offers the best in earth- moving equipment, ranging from the backhoe loaders to skid steers, wheel loaders, excavators, telescopic handlers, rough terrain forklifts, and compaction equipment. In addition to the equip- ment itself, Kemach JCB distributes the full range of JCB parts, while skilled field service technicians and expert product support engineers ensure that assistance is available at all times on a 24/7 basis. www.kemachjcb.co.za

health details, service requirements, operating information, etc. • Optional three-spool hydraulics enables various attachments to be used for extra machine versatility. • Air conditioning comes as standard. • Internal noise in the cab measures a mere 74 dBA. • Useful storage behind the rear seat, keeping the forward operating area uncluttered and safe. Maintenance is simple, with access to the engine bay and cooling pack achieved with wide-opening gullwing doors. Daily checks and grease points are accessible from ground level; while the cooling pack is a single-faced unit, allowing excellent access for cleaning. “The new JCB 455ZX is designed to move more material for less and to this end, we’ve built the engine, axles, drive- line and hydraulics to work in harmony with each other,” he says, “with safety being a priority.” The 455ZX’s cab is isolated from the chassis by rubber mounts, which keeps noise and vibration levels to a minimum. It is also compliant with ROPS/FOPS stan- dards, and positively pressurised against dust. “This purpose-designed unit is built to cope with demanding environments,” Senyard says. “We have units in the coun- try and have quite a few sold already. The results we’ve had from the demos and the machines that are working, especially in terms of fuel consumption have been impressive. “In two different applications where the customer has run competitive machines, we’ve had a 20-30% better fuel consumption figure. When one looks at those numbers, this is a R30-50/hour sav- ing on fuel.” As with the JC305 excavator, the inno- vative LiveLink software permits remote management of the machine either online, by email or by mobile phone. Access from everything from machine alerts to fuel reports and history informa- tion, is stored at a secure centre. Discussing service, Senyard says this is ensured through the company’s extensive African footprint, including its national office based in Gauteng, and regional offices situated in Johannesburg, Pretoria, Middelburg, Durban, Richards

large particles as well as increasing capacity for filter life. “The new JCB is highly productive,” Senyard says. Its engine offers high power and torque, while its hydraulics and loader end are set up to keep cycle times short and working shifts long.” A state-of-the-art engine manage- ment system offers optimised perfor- mance and fuel efficiency. The Dieselmax 672 engine offers the latest generation EcoMax lean-burn combustion system. The six-cylinder 7,2 ℓ engine achieves higher power (165 kW) and peak torque (1 000 Nm) at low revs. “There is a 310 ℓ fuel tank as standard on the 455ZX, along with extremely effi- cient matching of hydraulics,”he says. “This combination ensures maximum uptime between refuelling; a welcome feature when you’re working in remote areas where diesel has to be transported in.” Discussing loading productivity, he says the Z-bar loading geometry is capable of exceptional productivity, due to com- prehensive penetration into the pile, high breakout forces, good roll-back angles and faster dig times.“There is an added benefit from reduced tyre wear and superior fuel efficiency, making this machine a good investment for any business.” The innovative electronic manage- ment system controls tractive effort via the transmission; diverting maximum power to the loader hydraulics and reducing service brake wear and fuel consumption. The 455ZX is fitted as standard with limited slip differentials that are perfect for soft, muddy terrain with reduced trac- tion. Its selectable loader arm detents enable operators to set loader arm height limitations, return to dig and float func- tion for improved safety and productivity. “Keeping operators fresh and alert all day long results in increased safety and productivity,” Senyard confirms. “The 3,0 m 3 cab is roomy, easy to access and quiet. It also has excellent visibility and an intuitive, ergonomic control layout.” Other features include: • The 455ZX is fitted with an easily adjustable tilting and telescopic steer- ing column. • A stylish, modern central dash display combines analogue dials and a colour LCD screen – this can display machine

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MODERN QUARRYING

January - February 2017

AT THE QUARRY FACE WITH OMV

Weir Minerals increases capacity at OMV

From a small mining operation, extracting limestone in the Hennenman area, Oranje Mynbou en Vervoer (OMV) has grown into an industry leader, specialising in the mining and beneficiation of various minerals. Looking at several solutions in terms of its plant, the company has partnered up with Weir Minerals Africa for an upgrade of its sand wash plant. MQ recently travelled to the company’s Stilfontein operation with JD Singleton, Weir Minerals’ GM for Trio® and Enduron® equipment.

T he sand wash plant upgrade is for the -6,0 mm product and includes a Warman® WBH slurry pump, a Cavex® cyclone with Linatex® feed hose and an Enduron® dewatering screen. “The whole idea behind the pro- gramme was utilising the existing infra- structure and increasing capacity by sending less slimes to the slimes dam,” Singleton explains. “The heart of the sand wash circuit is utilising the most optimum cyclone to recover the maximum solids in the underflow without having misplaced material in the overflow.” He says this makes Cavex cyclones, which are known as the most preferred and efficient cyclones in the world, the perfect fit for sand washing. “We speci- fied the cyclone and selected the most efficient Warman WBH pump in terms of power consumption, hydraulic efficiency and as a result, reduced spares consump- tion is a function of that. We added the proven Linatex rubber hoses together with the Enduron dewatering screen.” Travelling through to Stilfontein gave MQ the opportunity to find out more

about the complete circuit provided to OMV. “We designed the circuit with the most technically feasible products and presented a financial case to OMV explaining how it would work, and they then installed the equipment working in close cooperation with Weir Minerals. “We worked closely with the client in installation and commissioning and with optimisation the plant is getting 14 t/hour more in the cyclone underflow, which reports as additional saleable product. This is just by selecting the best equip- ment and using the application. It’s as simple as that,” he says, adding that it has a permanent effect on OMV’s bottom line by producing more sand every hour from a reduced operational cost base. It was an absolute pleasure catch- ing up with OMV CEO Oscar Goudriaan once again, and clear to see that he is as committed as ever to the success of his operation. Originally started in 1952 by Oscar’s father, the late Klaas Goudriaan, the com- pany has a long and interesting history. “Obviously we have been doing some- thing right,” he says. “We’ve had our ups

and downs but by and large, it’s been good to us. Although the industry is a tough one, it is a good one to be in at the moment. It’s not easy, your margins are very low and containing costs is abso- lutely vital. “One of the single-biggest problems I have in the company and I’ve spoken to other CEOs as well, is the availabil- ity of spares and good, reliable service,” Goudriaan says. “I always say we built this company on service; we are not always the cheapest but our word is our bond.” Primary plant: Rock dump from the mine heap is fed into the jaw crusher and screen from there to produce CK 19, 38 sand and ballast. OMV CEO Oscar Goudriaan says his company is proud to be part of the Raubex Group and that the transition had added value to both OMV and Raubex.

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MODERN QUARRYING January - February 2017

AT THE QUARRY FACE WITH OMV

30-40% more than it was designed to do, and it is handling it well,” he says. “As JD says, the components are more expen- sive, but this is offset by the lifetime. “For me, capex is a small part of the equation while operational expenses are key. I would rather spend more capex as it is a once-off. Operational expenses are a lifetime cost.” Product excellence Interestingly, August 2016 heralded the 20-year anniversary of Weir Minerals’ iconic Cavex hydrocyclone. In 1996, a team of engineers from Warman International in Australia got together to develop the ‘next big thing’ in hydro- cyclones. What they came up with was revolutionary. The unique inlet geometry removed all sharp angles from the feed chamber, allowing slurry to move through the hydrocyclone smoothly, which greatly reduced wear while increasing its effi- ciency. The new generation of hydrocy- clones easily delivered up to three times the wear life of the old technology. The streamline feed chamber is still in use today. When Weir Group plc acquired Warman International in 1999, it brought

with it a myriad of improvements and modifications designed to ensure Cavex hydrocyclones provide excellent wear life along with maximum productivity, regardless of the application. In 2010, Weir Group plc acquired Linatex rubber products, which brought with it a range of highly specialised dewatering cyclones and superior rub- ber products for lining. This was signifi- cant for Cavex hydrocyclones, because it enhanced the portfolio and improved the hydrocyclone wear rates. The supply and installation of Linatex screening equipment spans a number of decades. The first Linatex dewater- ing screens were supplied in 1983 in a coal application in South Africa to Anglo American Coal’s Kleinkopje operation. The Linatex screen range evolved into the Enduron screen range under the Weir banner. Last year,Weir Minerals introduced the Cavex 700CVX hydrocyclone, designed specifically to meet the demands of cus- tomers, and which has been proven to achieve up to 50% higher throughput capacity than other competitor cyclones in the range, due to its larger inlet and vortex finder configuration.

Quoting Obama, he says “it’s a ‘we can do’ attitude. Even if you have to stretch yourself sometimes, this is where you build your company and where you build your name. So yes, it’s not easy but I believe that as long as the good times remain more than the bad times, we will continue to succeed. “There is an old adage that there is always someone who will be able to do it better than you can, but in the long term the sweetness of a good price is over- whelmed by the bitterness of poor service and poor quality. It is the same with Weir – they are not the cheapest around.” And Singleton agrees. “This is exactly what we stand for. We can’t do it cheaper and we can’t compete against every man with a welding machine. But if you look at the tonnage throughput that you have now,” he tells Goudriaan, “this is what we offer. Achieving maximum throughput at minimum downtime requires more than just purchasing quality equipment. It is all about total cost of ownership at the end of the day.” Weir Minerals is known for its design, engineering and manufacturing capa- bilities and this plays an important role in ensuring that its products play an important role in providing reliable per- formance while reducing the overall cost of ownership. Ironically, OMV used to have a large engineering works in the Free State where most of its plant was built from under the control of Klaas Goudriaan. “This is where we did all our major repairs and built our plants,” Goudriaan explains, “so we never really had the need for outside engineering.” With Goudriaan Senior passing away a few years ago, the company battled to replace those skills and eventually sold the engineering works to a large transport company, which uses the premises as its depot. “So we had to look at outsourcing our engineering work and Weir was the first major project that we entered into. It has turned out extremely well,”Goudriaan confirms. “I am not easily impressed but I am more than satisfied. “What Weir has said this plant can do it has done. When we were designing the plant we made a modification to the crushing process and added that sand into the plant as well. It is actually producing

The pump of the future: The development of the revolutionary WGH centrifugal slurry pump has extended over four decades, providing Weir Minerals with a vast knowledge bank in slurry pumping technology. The pump offers less maintenance, less power usage, longer wear life and higher performance.

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MODERN QUARRYING

January - February 2017