Modern Quarrying October-November 2017

QUARRYING OCTOBER - NOVEMBER 2017 www.crown.co.za MODERN

Mining solutions provider sets the benchmark Quality dolerite no problem for Howards Quarry Aspasa substantially broadens membership umbrella

IN THIS ISSUE

QUARRYING MODERN

CONTENTS

14

18

21

Mining solutions provider sets the benchmark

Quality dolerite no problem for Howards Quarry

New heavy tipper from Scania to reduce quarry haulage costs

High quality dolerite aggregate from B&E International’s Howards Quarry at eMa- lahleni is keeping Much Asphalt’s nearby static plant well stocked to produce asphalt for the N4 highway project and developments as far as Nelspruit over 200 km east. 38 GEM augments total product offering 39 MDS trommel screens set the benchmark 40 Large Komatsu wheel loader en route to Zambia 41 HPE launches 20 t crawler excavator 43 Osborn responds to skills deficit MARKETPLACE

The Kersfontein Mine in Kalbaskraal, Malmesbury, Cape Town, was acquired in November 2016. Owned and operated by SPH Kundalila, the sand mine, which is a relatively small operation at the moment, is proving its worth.

As South Africa’s mining and quarrying sector struggles to reduce costs and sus- tain profitability, Scania’s new heavy tipper promises to change the in-pit haulage landscape with its robust, economical and fuel-efficient features.

27

Aspasa substantially broadens membership umbrella

AROUND THE INDUSTRY

4 Junior miners talk new opportunities 5 Hillhead to welcome special guest 6 Bell and Lonagro team up 7 Planning for successful mine closure 8 Sampling award for Wits stalwart 9 Skills development for the disabled

Modern Quarrying recently caught up with Aspasa director Nico Pienaar in Langebaan, en route to a meeting he was attending in the area. We spent quite a bit of time in a question and answer session, dealing with the future of Aspasa, and the reasons behind dropping the Aspasa acronym.

44 LAST BLAST – ‘Natal Crushers’ saves the day

ON THE COVER

QUARRYING OCTOBER -NOVEMBER2017 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

Sandvik Mining and Rock Technol- ogy recently supplied, installed and commissioned a CS440 secondary stage crusher at Afrimat’s Lyttelton Dolomite operation in Centurion. Selected for its size, the unit is pushing out product at an impres- sive rate. Formerly known as the S4800 cone crusher, the new unit is characterised by its large intake capability and high throughput in relation to size. Weighing in at 19,3 t with a maximum power of 220 kW, it is a large machine and it is not often that a quarry takes a crusher of this size. See full story on page 10.

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

Miningsolutionsprovidersets thebenchmark Qualitydoleritenoproblem forHowardsQuarry Aspasasubstantiallybroadensmembershipumbrella

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

INTHIS ISSUE

MQOCTNOV2017 covers.indd 1

10/11/2017 8:58:21AM

1

MODERN QUARRYING

October - November 2017

THE MOST EXPENSIVE TRUCKS ALSO COST LESS.

Only a truly efficient truck can be economical. That’s why ours are engineered to not only be the strongest but also the lightest they can be, to deliver the greatest payloads, fuel efficiency and uptime on the market.

So can you have a truck that’s as impressive in a quarry as it is on a spreadsheet? YES YOU CAN .

AROUND THE INDUSTRY EDITOR’S COMMENT

No confidence vote by industry for DMR Minister

T he Chamber of Mines is still calling for ethical leadership and good governance in govern- ment. Speaking in early September at the African DownUnder Conference in Perth, CEO Roger Baxter had three clear messages for investors: • Mining is important for South Africa. • The South African mining sector is in crisis. • There are solutions to ‘restoring the dream’ of a prosperous, growing and transformed mining sector. He confirmed that key governance and policy chal- lenges in South Africa have eroded business and investor confidence, saying that“policy and regula- tory uncertainty have frozen new investment in the sector. It is extremely difficult to get any company investment committee to approve any new green- fields project in South Africa today.” Real mining GDP in 2016 of R226-billion was less than the R242-billion reported in 1994. Real mining fixed investment has shrunk over the past two years, with large parts of the industry continu- ing to report losses. Baxter said it was very concerning that the Minister of Mineral Resources in his presentation at the same conference, had paid scant attention to this crisis.“Perhaps this is because the DMR has pro- vided no assistance to help the industry through the crisis.”He further noted that the industry is very surprised that the Minister claims to have received positive feedback from any investor on the DMR’s Charter, or the state of the industry. “This has not been the industry’s experience, and it is the industry that engages with investors and raises capital on a regular basis.” He stated that the Chamber and its members have lost confidence in the DMR Minister and in his leadership of the DMR. “Significant corruption allegations against the Minister and the DMR have not been cleared and the proposed judicial commission of enquiry into state capture has not been established. The indus- try does not believe that the approach adopted by the DMR is serving the national interest of the country. The negative impacts of the unilaterally imposed Reviewed Mining Charter, the proposed Section 49 rights moratorium, the non-resolution of the Charter ownership issues, and the imposi- tion of inappropriate Section 54 safety stoppages, for example, have created a major crisis for the sec- tor. The industry is of the firm view that the DMR’s Charter is designed to benefit a select few at the expense of the whole country.” Then, in early October, the Chamber of Mines was criticised for not attending the Joburg Indaba

banquet at which Mineral Resources Minister Mosebenzi Zwane was guest speaker. “It was not an impetuous decision nor was it one based on personal animosity towards the Minister. It was a carefully considered decision based on the current regulatory and judicial situation,” the Chamber says. Speaking at the Joburg Indaba’s preconfer- ence gathering attended by some 300 people, Indaba chairperson and former CEO of Harmony Gold, Bernard Swanepoel, said that the best way of confronting the problems of the mining indus- try was through interaction at events like the Joburg Indaba. And calling him “my brother from another mother,” the Minister thanked Swanepoel for giv- ing him an opportunity to speak to people with mining wisdom. Swanepoel is correct in saying that the indus- try and the DMR need to find common ground, but surely he of all people should realise that had the Chamber attended the event, it would have been forced to engage with the Minister on spe- cific regulatory issues in circumstances that are not conducive to any constructive engagement, other than through the courts; and given the fact that the last time the Chamber shared a platform with the Minister – in Perth – the outcome wasn’t at all constructive. Let’s face it; the Minister has a very question- able history. He came in as Minister seemingly with the primary task of strong-arming a legiti- mate rights holder of a major mining asset, con- spiring with then Eskom leadership to apparently force the sales of a mine to a well-known family that has systematically robbed SA of public funds. This story was comprehensively documented by the Public Protector. Prior to that, in his pre- vious position as Free State Agriculture MEC, his alleged role in channelling hundreds of millions in state funds to the same family for the estab- lishment of a dairy at taxpayer’s expense has also been comprehensively documented with, again, no attempt at an explanation by him. What say you Minister Mosebenzi Joseph Zwane? Can you look at yourself in the mirror every morning and say that you are a good, ethi- cal leader and the right man for the job? We don’t think so.

3

MODERN QUARRYING

October - November 2017

AROUND THE INDUSTRY

While the mood at the recent Junior Indaba mining event was sombre when it came to South Africa’s policy environment, there were some interesting opportunities being mooted for minerals like lithium. Junior miners talk new opportunities

Despite the difficult economic con- ditions, overall sentiment for the coming year is reported as positive; CRU research shows that 53% of respondents are hope- ful about the future, while a substantial portion of around 33% are undecided. “This level of optimism is probably driven by the recovery – in the last quar- ter of 2016 – of the steam coal market and the temporary recovery in ferrous metals,” says Theart. He highlights that while fer- rous metals fell back somewhat during the first part of 2017, the impact was off- set to some extent by an increase in base metal demand. Jeffrey highlights the lessons shared by industry ‘legends’, which include the warning that the while the orebody dic- tates, correct management is still the key to successful mining. “The speakers also encouraged us to get our hands dirty – to put in the hard work and to not expect something for nothing,” she says. “There was also the timely warning that money has no loyalty, and that it will go where the best returns are to be found.” Lack of data sharing amongst indus- try players was discussed, and it was pro- posed that the Council for Geoscience could play a role with other government stakeholders to facilitate an improved access to data. Growing energy demand in the region also inspired presenta- tions on coal and coalfield-linked power generation. www.srk.co.za

H ennie Theart, corporate consultant and partner at SRK Consulting, says he is interested that mineral demand outlook focused on those ele- ments that would play a role in the devel- opment of modern electrical batteries – such as lithium and cobalt. “The absence of the platinum group elements in this outlook is notable, and this may indicate the anticipated move from internal combustion to electric cars,” says Theart.“Given the natural abundance of lithium, however, it is unlikely that the demand for lithium will be linked to a sustained increase in the value of this commodity.” He says it will also be interesting to see whether an extended period of lower fuel prices would slow down this trend. The biggest dampener to the mar- ket’s growth is the slowdown in Chinese investment, followed by risks related to trade policy and geo-politics. This means that the dominant theme among mining corporations for the next year is expected to be technology innovation and automa- tion – both strategies to reduce cost and increase profit. On the South African scene, the main concerns included policy uncertainty and permitting issues, according to Lesley

Jeffrey, principal geologist (coal) at SRK. “Among the issues that the industry is struggling with is the length of time it takes to get mining, water and environ- mental permits from government,” says Jeffrey. “Uncertainty in mining policy is also having a negative impact on invest- ment, especially foreign investment.” Since the Junior Indaba, the June announcement raising various require- ments in the Mining Charter will have added to the concerns about the invest- ment environment. “When speakers discussed which countries are currently popular for exploration investment, they focused on North America, West Africa and Australia,” she says. “It was clear that SA was not seen as a good investment destination at the moment due to the policy uncertainty and permitting issues.” Given the focus of the event on smaller players in the sector, the legisla- tive burden on junior mining companies was raised – even leading to the sugges- tion of a ‘lite’ version of the Minerals and Petroleum Resources Development Act that would ease requirements for small mining companies. In a similar vein, the tax and royalty burden on mining companies also came under scrutiny.

Hennie Theart, corporate consultant and partner, SRK Consulting.

On the South African scene, the main concerns include policy uncertainty and permitting issues.

Lesley Jeffrey, principal geologist (coal), SRK Consulting.

4

MODERN QUARRYING October - November 2017

AROUND THE INDUSTRY

Hillhead to welcome special guest

Hillhead 2018 is gearing up for a special appearance from the largest mechanical puppet ever constructed in Britain. The Man Engine, powered by Volvo, was recently voted the UK’s Best Arts Project and presented with a National Lottery Awards trophy by comedian and broadcaster David Baddiel. The 10 m high ‘miner’ made an appearance on the National Lottery Awards show on BBC1 on 27 September, and the organisers of Hillhead are delighted to announce that the spec- tacular mechanical puppet, which is powered by a Volvo L220 wheel loader, will also be in residence for the duration of the 2018 event taking place at Hillhead Quarry, near Buxton, from 26-28 June next year. The Man Engine (www.themanengine.co.uk) will be located in the newly-redeveloped Registration Area, which has been expanded to meet strong demand for exhibition space at the show. The area around the demonstration area at the top of the showground has been redesigned to accom- modate additional stands showcasing working plant, including EvoQuip, a new brand launched in the UK from Terex Mineral Processing. The EvoQuip brand brings a simplified range of equipment to the crushing and screening sector, offering a comprehensive port- folio of products to address the needs of the compact crushing and screening markets. Other companies joining EvoQuip in the new- ly-expanded area include, among others: Weir Minerals Europe Ltd, MDS International, Red Rhino, Rees Machinery Group, MEKA Crushing and Batching Technology, Renault Trucks, Gap Hire Solutions and Indeco. According to event director Richard Bradbury, out- door space is already 90% sold with the newly extended area nearly full.“We are very excited by the changes we have made at the top end of the site to accommodate more exciting working demonstrations which are syn- onymous with Hillhead, and the Man Engine will pro- vide a spectacular focal point to the area.” www.hillhead.com

FLSmidth offices are located in the One Airport Square building, Accra.

FLSmidth goes local in Ghana

FLSmidth is further entrenching its African footprint with the opening of a new subsidiary company in Accra, the capital of Ghana. According to Deon de Kock, FLSmidth country head in South Africa and VP in Sub-Saharan Africa, the move has been made in response to the company’s critical mass of product in the region, and the strategic goal of being closer to customers. “We have done business for many decades in West Africa and have a wide network of distributors and agents,” De Kock says. “This exciting development is our next step in enhancing our capacity as productivity partners with this customer base; as a worldwide group we can leverage our global resources and assets, and with the Ghana office can also be more responsive at a local level.” The new presence in Accra will provide a hub for regional operations as there is already a large installed base not just in Ghana but in other neighbouring countries including Ivory Coast, Burkina Faso and Mali and possibly also Guinea. “We are positioning for growth, not only for FLSmidth but for our cus- tomers in that area,” De Kock says. “Being closer to users and their sites also means that we can gain more detailed insights into their applications and challenges. This, in turn, sharpens how we conduct our service and support activities, and helps us fine tune the ways that we add value to customers’ operations and contribute to their growth. “The office capacity will therefore comprise our own people who will be trained, focused and mentored to expertly represent FLSmidth to our existing and potential customer base,” says De Kock. “This is requir- ing substantial investment in people, infrastructure and systems, but is a crucial part of re-aligning our direct and indirect service channels to better serve our customers. We appreciate the contribution made by our distributor network up to this point, but we must now take the next step in terms of the natural progression of our growth trajectory.” With well-known local expert Joseph Appiah Kubi appointed as the GM, the Accra office will be staffed by Ghanaian nationals. This is in line with the view of FLSmidth that local skills, experience and expertise are vital to ensure a good understanding of customers and local conditions, and to provide optimal service levels. The office is expected to be fully operational shortly. The facility will also be a valuable venue for product and process training for staff and customers, and will provide a well-positioned stop- off point for customers passing through Accra. “It is clear that there are positive signs of recovery in the minerals sector in West Africa, especially in the gold mining segment,” Kubi says. “We look forward to building up our own brand and in-house resources in this region, and working more closely than ever with customers there.” www.flsmidth.com

Heavy equipment manufacturer MDS International is one of the companies exhibiting at next year’s Hillhead show.

5

MODERN QUARRYING

October - November 2017

AROUND THE INDUSTRY

Bell and Lonagro team up Bell Equipment, as part of its group strategy to grow its independent dealer network in select markets, reports that Lonagro Mozambique has been appointed its exclusive dealer in Mozambique and Malawi. Explaining the rationale behind the company’s strategy and Lonagro’s appointment, Bell Equipment’s group marketing director, Stephen Jones, says: “Working through independent dealers has proven to be a model that allows us to provide better coverage and support to our customers in markets where areas are vast, and machine populations are low. In the equipment industry, infrastructure and investment are required to provide

dealers as part of a business improve- ment project launched early in the year,” continues Jones. “From the outset it became clear that a closer relationship with Lonagro would provide benefits for Bell, Lonagro and, most importantly, our Bell customers. Synergies are clear with regards to man- agement structures, scarce skills, logistics, facilities, and understanding customers. This gives Bell confidence that Lonagro, as a top performing John Deere dealer with a dynamic and motivated team, is well positioned to support our existing customers and grow the footprint of our machines in the region,” he says. www.bellequipment.com The warehouse floor is an example of excellence in engineering design, inno- vation and precision; the entire floor is based on a post-tensioned cabling system that makes use of 132 km of steel cable. Construction on Phase 2 started in July 2017. Komatsu has, since the com- mencement of the project, become the owner of the land, and Investec Property remains the preferred developer for the entire project, which is estimated at over R1-billion. The new Phase 2 unit is expected to be fully operational by September 2018. Completion of the new Komatsu Campus in its entirety is sched- uled for 2021 to coincide with Komatsu’s 100 centenary celebrations. The 300 000 m² Komatsu Campus site is located in Tunney, Germiston, Gauteng. www.investec.com

support that is essential to users of this equipment. In our experience, synergies develop quickly with dealers that have complementary products that can help support the necessary infrastructure and better weather market cycles.” Lonagro is a division of Lonrho Group, which holds John Deere Agriculture deal- erships in a number of African countries. It has quickly made a name for itself in the highly-contested agriculture equipment market by displaying a willingness to invest and take a long-term view of the countries in which it operates as well as its equip- ment users and future opportunities. “We assessed a number of different business models as well as other potential

Next phase of Komatsu campus development Earthmoving equipment giant, Komatsu, has partnered with Investec Property to consolidate its head office operations, warehouse and distribution centres, workshops and remanufacturing facilities into one centralised campus. As the central hub from which construction and utility markets, not only in South Africa, but all of Southern Africa. The project will put Komatsu’s sales and service functions in an ideal position to capitalise on market resurgence opportu- nities within the short, medium and long term. At the same time, it will serve to improve further the extent of Komatsu’s field and technical service offerings.

Komatsu will direct its extensive oper- ations in Southern Africa, the owner- ship and development of this campus in Gauteng signals the company’s unwaver- ing commitment to doing business in the region. “Our head office and support opera- tions are currently conducted from three different locations, which presents some logistical challenges. By consolidating all functions into one single campus, our ability to provide effective and efficient customer service and support will be fur- ther enhanced – with sufficient space for future expansion,” says Mike Blom, MD of Komatsu Africa Holdings (Pty) Ltd. The requirements for the new Komatsu Campus are substantial and complex; the campus needs to have the space, technology and capabili- ties for Komatsu to serve the mining,

This first phase of development, a state-of-the-art Parts Distribution Centre measuring approximately 22 000 m 2 , was completed in just nine months. The warehouse has the largest floor without a join in the country, and stands 13 m from floor to eaves. As a result, semi-automated turrets operating within the warehouse retrieve items from the highest access points with an unprece- dented degree of accuracy and safety.

Measuring approximately 300 000 m 2 in size, the new Komatsu development will be one of the largest industrial campuses of its kind in the country.

6

MODERN QUARRYING October - November 2017

AROUND THE INDUSTRY

Planning for successful mine closure Doing no harm to the environment is becoming a conscious movement around the globe and in the mining sector this man- tra becomes infinitely more complicated in the context of leaving mining communities better off after mining, than what they were before. This was the topic discussed at a Mine Closure Workshop hosted by Aurecon, The MSA Group and Webber Wentzel in Sandton recently. A common misconception is that mine closure is planning for an event when it is, in fact, a process. South Africa has more than 6 000 abandoned mines. “We don’t have a single case study of a successful mine closure in South Africa, because it is more complicated and more costly than mining companies ever real- ise,” says Robert Appelbaum, Partner at Webber Wentzel. Some of the reasons for this are inadequate stakeholder engagement, concerns around residual risks and therefore lia- bilities and the web of legislation involved. Mining majors with the capacity and resources to close successfully have traditionally sold their assets to junior miners that don’t have the resources or capacity to close successfully. The Financial Provisioning Regulations of 2015 have prompted mining companies to rethink how to effectively plan for closure. These regulations are a game changer for the industry. This law requires mining companies to produce a: • Risk assessment report to determine the potential financial

liability associated with the management of latent environ- mental liabilities post-closure, and considers long-termwater treatment risks. • Annual rehabilitation plan reflecting activities undertaken for concurrent rehabilitation and remediation of the site/opera- tions, year-on-year. • Final rehabilitation plan to identify and assess final post-min- ing land use for the operation, in addition to infrastructure and activities to be decommissioned/remediated upon closure. There is a web of inter-related laws that underpin effective mine closure planning that are aimed at liability reduction and holis- tic post closure sustainability. “The financial provisions required to facilitate a successful mine closure and the accuracy of that forecasted amount needs to find a home in a strictly regulated and audited space if South Africa has any hope of changing its track record. It requires an integrated closure planning process to leave behind a sustainable ecosystem that addresses the inher- ent liability aspect of mine closure,” says Garyn Rapson, Partner at Webber Wentzel. Pieter Scholtz of Aurecon says that “historically the main focus in mine closure planning was environmental rehabilitation but unless stakeholders such as the community, government and unions are also involved, a mine closure will simply not work”. www.webberwentzel.com

ASPASA

7

MODERN QUARRYING

October - November 2017

AROUND THE INDUSTRY

Sampling award for Wits stalwart Professor Dick Minnitt, JCI Professor of Mineral Resources and Reserves at Wits University’s School of Mining Engineering, has received the Pierre M Gy Sampling Gold Medal at the Eighth World Conference on Sampling and Blending 2017 in Perth, Australia. The award was sponsored by Australia’s government research agency CSIRO and the Australasian Institute of Mining and Metallurgy (AusIMM). The award – given in recognition of excellence in the teaching and application of the theory of sampling – cele- brates the contribution of Paris-born chemist and statistician Pierre Maurice Gy, who had made huge strides in sampling theory since the mid-1900s. His work was driven initially by the need to be more exact in the sampling and valuation of minerals – to ensure the fairness of financial transactions in mined products. Professor Minnitt teaches sampling theory at both undergraduate and postgraduate level at theWits University School of Mining Engineering, and is busy writing a book on the subject – with Dr Pitard – which will be published by the Southern African Institute of Mining and Metallurgy, (SAIMM).

Professor Dick Minnitt (third from left), JCI Professor of Mineral Resources and Reserves at Wits University’s School of Mining Engineering, received the Pierre M Gy Sampling Gold Medal at the Eighth World Conference on Sampling and Blending 2017 in Perth, Australia. The award was sponsored by Australia’s government research agency CSIRO and the Australasian Institute of Mining and Metallurgy (AusIMM). Photographed with Professor Minnitt are previous award winners: Professor Pentti Minkkinen (far left) from Lappeenranta University of Technology in Finland; Dr Francis Pitard (second left) of Francis Pitard Sampling Consultants in the US; Professor Kim Esbensen (third right) of KHE Consulting in Denmark; Dr Dominique Francois-Bongarçon (second right), President of AGORATEK International Consultants in Canada; and Dr Ralph Holmes (far right), Chief Research Scientist at CSIRO Mineral Resources Australia.

About the Wits School of Mining Engineering – www.wits.ac.za/miningeng/ The School of Mining Engineering, within the Faculty of Engineering and the Built Environment at Johannesburg’s University of the Witwatersrand in South Africa, is recognised as one of the top mining engineering schools and departments throughout the world. It is the only mining school in South Africa which appears in the top 50 of the Engineering – Mineral & Mining segment of the QS World University Rankings, where it is ranked 22 nd .

Metso global award for Pilot Crushtec Pilot Crushtec International – the Southern Africa distributor for Metso aggre- gate and mobile products – has been recognised by its principal for deliv- ering exceptional levels of customer service and support at the company’s September global conference in Tampere, Finland. The Jet Park-based crush- ing and screening specialist received the accolade for ‘Best New Services Distributor’, a performance VP Distribution AGG Business Line, Adrian Wood, describes as an achievement of note. www.pilotcrushtec.com

Comprehensive analysis of amended Charter In light of the temporary suspension of theMining Charter and the dialogue that needs to continue, Deloitte has published a comprehensive analysis of the amended Charter which unpacks key stra- tegic implications of the changes and suggests concrete steps the industry can take in response to them. The report also flags the high level of mis- trust stemming from all stakeholders in the min- ing ecosystem, cautioning that this remains an unfortunate barrier to true and meaningful trans- formation, a reference to the Chamber of Mines’ urgent application to interdict the Minister, the Department of Mineral Resources (DMR) and its officials from implementing the changes. For the link to the report, please visit: https://www2.de- loitte.com/za/en/pages/energy-and-resources/articles/ the-amended-mining-charter.html?id=za:2el:3pr:a- wa_AMC:AMC_pr

Sandro Scherf, CEO Pilot Crushtec International; Adrian Wood, VP Distribution AGG business; and Grant Gehrung, national sales manager,

Pilot Crushtec International.

8

MODERN QUARRYING October - November 2017

AROUND THE INDUSTRY

Skills development for the disabled Atlas Copco South Africa is committed to playing a meaningful role in creating employment. The company recognises the importance of two fundamental elements of job creation, developing skills and providing experience in the workplace and has hosted a number of learnerships and internships over the years with great success. While there is a tremendous need for skills development and experience in abled persons, these needs are even greater for the disabled who are faced with so many challenges in their daily lives. Recognising these challenges, Atlas Copco decided to implement a one-year learnership programme for 12 disabled learners from the Skills Development Corporation (SDC). “Our learnership and internship programmes are leading to a fruitful relationship for both the learners and our organisation and the resounding success of the last two internships further moti- vated this latest learnership opportunity,” says Kathryn Coetzer, corporate communications and Academy manager for Atlas Copco South Africa. “This time round we wanted to specifically provide entry-level experience to young, unemployed disabled learners due to the massive need for skills development in this arena,”explains Coetzer. Atlas Copco Secoroc (production facilities) previously hosted three female disabled learners so it is not the first time that Atlas Copco has offered a programme for the disabled. This is however, the first time that the company is hosting such a large number of disabled learners at the same time at its disabled-friendly head office facility in Jet Park, Johannesburg. The company approached the SDC as it is an accredited learn- ing institution which offers need-specific functional training to maximise skills opportunities in any company. The learnership programme consists of a NQF Level 3 Learnership in General Management which is being presented to disabled male and female learners between 18 and 30 years of

age. “At the end of the 12-month period the learners will not only armed with this qualification, they also have the benefit of a year’s invaluable workplace experience,” notes Coetzer. “We also provide the learners with workplace professionalism and computer skills training, wellness training and testing, and access to a mentor. Our objective is that upon completion of the programme, the learners are well-rounded, confident individuals. It is a win-win scenario because while learning and gaining experience, the learners are also lending assistance to us.” www.atlascopco.co.za

Atlas Copco’s financial partner Innovent, recently donated laptops to students in the disabled learnership programme.

9

MODERN QUARRYING

October - November 2017

ON THE COVER

Sandvik CS440 cone crusher – a complete solution application

Sandvik and Adam is remarkable. When it was commissioned we underesti- mated the capacity of the machine. It was selected for a bigger feed size and we opened up the jaw to allow for this. But this resulted in a knock-on effect because the belt and feeders were affected. These problems have now been rectified; the crusher is phenomenal and working at the expected capacity.” Explaining the reasons behind the purchase of such a large machine, he says the mine needed a secondary crusher. “Production wise, there was a smaller HP300 tertiary but this couldn’t handle the 300 mm oversize material and we needed to open the jaw to a 176 mm closed-side setting (CSS) to enable more production. We needed a 50% mtph from what the old crusher provided.” Taylor explains further: “Every part of the quarry process has an impact on the final result. Control over the crushing process is necessary in order to secure the

Sandvik Mining and Rock Technology recently supplied, installed and commissioned a CS440 secondary stage crusher at Afrimat’s Lyttelton Dolomite operation in Centurion. Modern Quarrying travelled to the operation to see this impressive machine and to find out more about its features and benefits.

A ccording to Adam Taylor who is the technical sales and support specialist for Sandvik Crushing and Screening, the CS440 is the ideal machine for Lyttelton Dolomite. “Weighing in at 19,3 t with a maximum power of 220 kW, it is a large machine and it is not often that a quarry takes a crusher of this size.” Formerly known as the S4800 cone crusher, the new unit is characterised by its large intake capability and high throughput in relation to size. Looking at some of the benefits of the CS440 Taylor says it has a hydraulically supported main shaft that is supported at both ends. “It has a robust crusher design,

adjustable eccentric throw and a con- stant intake opening. This crusher is ideal for any high-capacity secondary crushing operation. “Its high performance provides the lowest total cost of the operation,”he tells MQ. “Its versatility allows full control over the crusher processes. It is reliable, and easy to maintain and handle.” Discussing the Afrimat Lyttelton Dolomite order as a whole, he says it wasn’t the easiest of projects. “However, I believe that a lot of projects that go through teething problems often end up being the best, and this is true of this one.” Lyttelton Dolomite mine manager Piet Ackerman agrees. “It was difficult at first, but the support we receive from

The Lyttleton Dolomite in Centurion is owned and operated by Afrimat.

10

MODERN QUARRYING October - November 2017

ON THE COVER

most profitable output, minimise wear and avoid downtime.” He says that one of the critical factors is achieving the optimum closed-side setting (CSS) for the desired output. The key is to balance yield with production profit; certain fractions are always more valuable. “So now the CSS on the jaw is running at 177 and recently we ran it at 240 CSS,” Ackerman says.“We had a few other issues because the feeder also became a prob- lem together with the transfer points. We have now brought it back to 175 where it is supposed to be and our tonnage is 100 t/hour more than previously. “There are knock-on upgrades being carried out in the rest of the plant. We know that we can run at 300 mm easily. Sizing wise, we are getting to where we want to be and this machine can really crush. “My personal feeling is that it is a bit oversized but the capacity is there,” Ackerman confirms, “and if we want to increase our crushing capacity, we can. The beauty of this machine is that it doesn’t have to be kept full, it can take surges and can handle fluctuations because of its design.” He says the material produced is excellent. “We can see the difference with the naked eye. Another benefit is the ASRi (Automated Setting Regulation) system, which allows us to set our CSS easily and to keep it constant.” Taking this further, Taylor says that while the basic machinery used in rock processing has remained fundamentally unchanged for many years, the industry has nevertheless become considerably more high-tech. “You may not be able to

crush rock with your PC, but you can cer- tainly use advanced technology to ensure that crushers are performing optimally, that your product quality is high and con- sistent, and that machinery downtime is minimised. “The ‘i’ in ASRi means intelligent and the reason behind this is that it not only helps you to monitor operations, but over time enables you to become so familiar with your crushing equipment that you can truly optimise its usage while protect- ing it from damage. “Regardless of whether a quarry is a simple one-crusher operation, or a larger, more complex plant, the Sandvik ASRi is guaranteed to improve results. One can decide on which system to use, how fre- quently and at what capacity, all of which makes the system not only intelligent but very flexible. “The other benefit of the ASRi is that you can set your CSS and it’ll maintain it for you. As your lining wears, it automat- ically compensates and keeps it there, so the material doesn’t end up as oversize on your stockpile. It’s a constant product all the time. For example, you can also set it to run on a 13 mm for an hour and then to run for a 19 mm product. It’s like utilising the perfect operator,” he says. Getting back to the machine itself, Ackerman says the industry is used to the old generation crushers, “but once they understand the CS440 and work with it, it is actually a very simple crusher to use. “We are so happy with the CS440 machine that we’ve brought a CH440 back here from Mozambique. It’s an old Sandvik has a very strong relationship with quarry owners, with trust being the key. Photograph shows technical sales and support specialist Adam Taylor on the left with Lyttleton Dolomite quarry manager Piet Ackerman.

Sandvik Mining and Rock Technology recently supplied, installed and commissioned a CS440 secondary stage crusher. This machine is suitable for any high-capacity secondary crushing application.

2007 model and needs a bit of work, but we’re going to use it in a tertiary crusher application. It is also a bit overdesigned for that, but it has the capacity.” Taylor says that the CH looks to be more or less the same size as the CS unit. “The bottom shell is identical, but the top and the shaft differ. It uses the same 220 kW motor but in terms of capacity, because it is a tertiary machine, the mate- rial remains in the chamber a lot longer than the S machine. It will produce a finer material and give shape, etc.” Talking about the mine, Ackerman says it is doing very well. “We went through a dip when Highveld Steel closed down, as that was about 35% of our busi- ness. However, we are focusing on the aggregate market and we have seen some good growth in this sector. “The industry is competitive and we are trying to keep our prices stable with stock on the floor. We have cut down our product range from 14 to six products, which is why we needed the new crush- ing technology.” Ackerman says the mine is doing well. “Since April, the machine has provided comfort in providing more than sufficient capacity to ensure stock on the ground. I am delighted at the efficiency of the new machine. The crusher is creating a lot of fines which is essential for producing the sands we are manufacturing. It is making a huge difference to our production.” Brief history of Lyttelton Dolomite The mine was established in 1938 by Amcor for the purpose of supplying

11

MODERN QUARRYING

October - November 2017

ON THE COVER

late 1980s the mine was approached to manufacture aggregate for the local construction industry. One of the first projects that it supplied to was the new Defense Headquarters on Pretorius Street in Pretoria. In 1998 it became a private company through a management buy-out. In 2007 the mine was integrated into Infrasors. The company was initially listed on the AltX of the Johannesburg Stock Exchange on July 31, 2007 after it was formed on April 19, 2007. With effect from March 1, 2007, Infrasors acquired Lyttelton Dolomite (Pty) Ltd, Delf Sand (Pty) Ltd and K&F Bricks. On February 1, 2010, Infrasors moved onto the main board of the Johannesburg Stock Exchange housed under the ‘General Mining’ sector. On March 1, 2013 the JSE Ltd-listed entity Afrimat Ltd obtained a majority shareholding in the Company. The mine, being situated in a built-up area, has always had a working relation- ship with the surrounding community. Currently communication and under- standing of its business is conducted through a liaison forum which meets reg- ularly to discuss the mine’s progress. Sandvik Crushing and Screening Catching up with Sandvik Crushing and Screening’s business line manager Glenn Schoeman at the Jet Park premises once again was a real pleasure. We had an interesting discussion about the positive changes in this well-known and respected company. He says it has been a challenge to bring the customer focus back into the crushing and screening business. “In the old Sandvik Rock Processing era, we were one company and it didn’t matter whether the business was in mining or in quarrying. It worked well and we were ascending our market position. Our sub- sequent separation created some con- fusion in the marketplace and we had to work hard to mitigate that confusion. Mining wasn’t a problem because in the bigger mining regions it was business as usual but that split affected our custom- ers to a certain degree. “From a quarrying perspective it gave

Sandvik’s ASRi system allows the mine to set the CSS easily and to ensure that it remains constant.

metallurgical grade dolomite to the iron and steel industry. The metallurgical grade dolomite had specific properties that allowed it to be used as a flux agent in the making of iron and steel. Ownershipwas passed onto Samancor Limited who ran the mine for most of its early life. During this time the manufac- ture of powders was introduced. In the

The installation of the CS440 secondary stage crusher has resulted in knock-on upgrades to the plant.

As can be seen on the far right of the photograph, the mine is very close to surrounding communities.

12

MODERN QUARRYING October - November 2017

ON THE COVER

We’ve got the technicians and the people that we need, a lot of whom are experts in their field of work. What we have real- ised is that our people are key to our suc- cess, and the quarry owners trust them completely.” He says it’s been challenging,“but our success is testament to the people work- ing here.” Discussing the latest acquisition by Afrimat Lyttelton Dolomite of the CS440 cone crusher, he says it really is a com- plete solution application and the right machine for the job.

us a pinpoint accuracy focus because if the quarries did well, so did we. We couldn’t default back to mining. And so we developed into No 1 and 2 positions in some segments and we got to know and understand our industry better than ever before.” Schoeman says from that point of view the segmentation was a benefit.“We were up there with the best in the indus- try. Now coming together, we still have that but without the segmentation. “My job is to build up the business and we are well underway with that,” he says. “We’ve had some good sales and are working hard at our after-market support.

Report and photographs by Dale Kelly

Lyttleton Dolomite is focusing on the aggregate market and has seen some good growth in this sector.

The Lyttelton Dolomite mine was established in 1938 by Amcor for the purpose of supplying metallurgical dolomite to the iron and steel industry.

At this stage the huge pit is 120 m deep with vast potential.

Afrimat’s Lyttleton mine manager Piet Ackerman.

13

MODERN QUARRYING

October - November 2017

Living the SPH-K way of life: The Kersfontein Sand Mine in Kalbaskraal is the cleanest sand mine operation MQ has ever visited (courtesy SPH-K).

AT THE QUARRY FACE WITH SPH-K

Mining solutions provider sets the benchmark The Kersfontein Mine in Kalbaskraal, Malmesbury, Cape Town, was acquired in November 2016. Owned and operated by SPH Kundalila, the sand mine, which is a relatively small operation at the moment, is proving its worth. Modern Quarrying recently travelled to site and met up with its manager Jean Martin, a proud SPH-K man with sand in his veins.

T he mine, which previously utilised very outdated mining methods, has left Martin with several challenges. “At this stage, we don’t have a grader and utilise our old ADT tyres by chain-drag- ging themover the gravel by water truck to maintain our hau lroads.”He showed MQ a video of the operation prior to the acqui- sition, where a truck was shoved over the sand by an excavator to load at the stock- pile, and then pushed back onto the road; something which must have been a major disaster in the rainy season. “However we have improved since we acquired the mine,”Martin says.

environmental impact of our operations and are committed to the latest legisla- tion in this regard. We pride ourselves on our safety which we consider to be of par- amount importance. We have invested a considerable amount of money and time on safety and in all the mines we are com- missioned to work on, we strictly adhere to all legislative rules and regulations.” Rehabilitation is carried out on a con- tinual basis and the quarry takes care of its fauna and flora. Martin tells MQ about a Cape Wag Tail, which built its nest in an excavator during the Christmas shut-down period. “We held back on using this exca- vator until the chicks were out of the nest.”

This editor has been to many sand mines and must point out that this mine is the neatest sand quarry I have ever seen. Congratulations have to go to the team who more than live the SPH Kundalila way of life, and clearly show pride of place. Martin, who has a long history with the company, started off about 15 years ago in the Industrial Relations depart- ment. He later worked as a consultant for a period of five years, rejoining the company again in 2010 at Bridgetown Dolomite in Moorreesburg, some 90 km from Cape Town. “As a company, we recognise the importance of minimising the

14

MODERN QUARRYING October - November 2017

AT THE QUARRY FACE WITH SPH-K

mine limestone for the then Anglo-Alpha in Saldanha in the Western Cape. SPH- Kundalila continued to expand its service offering and geographical base during the ensuing years. In 1997, the company ventured into commercial aggregate quarrying and acquired a hard rock aggregate quarry in a joint venture with the Raubex Group in 2001. This eventually led to Raubex acquiring SPH Kundalila in 2007 when it listed on the JSE. The company is a full subsidiary of the Raubex Group – an affil- iation which provides it with access to capital and to leading engineering skills within the industry. SPH Kundalila supplies material han- dling solutions to themining industry with an excess of well over 300 items of earth- moving equipment, including back-up capacity. Interestingly, the company is the largest owner of Cat 950 front end loaders in the Southern Hemisphere and is spread across South Africa from Aggeneys in the Western Cape, to Saldanha, Malmesbury and Moorreesburg on the West Coast. It operates in Carletonville, Klerksdorp, the Orkney region and in Thabazimbi, Pilanesberg and Rustenburg in the North. The company’s clients include most of the blue chip mining companies and it prides itself on its long-term partnerships. SPH Kundalila has a large modern

The sand deposit at the quarry is in the region of about 3-million m 3 with the life of mine being some 15 years at this stage. “We are fortunate in that our sand is a very high quality material with low water demand. It is very clean,” he says. The mine produces road stone in the var- ious sizes, concrete stone, base and sub- base, together with crusher sand. “Our material is laboratory tested for its quality in our own laboratory together with an independent laboratory on a reg- ular basis.” People are the foundation of the SPH Kundalila group, and this is certainly evi- dent in the five people on site, some of whom have worked for the company for 20 years. To date, equipment on site consists of a 325D excavator, two 95H front end load- ers, an ADT and a Bell B18 D water tanker. “Yes, we do have challenges, but it is my aim to bring this sand mine from its infancy to adulthood, while ensuring that we make a profit in a sustainable and envi- ronmentally friendly manner,”Martin says. A proven track record Looking back at the history of the SPH- Kundalila group, in 1969, two entrepre- neurs – Tony Petter-Bowyer and Alan Carnegie – started up the business. The company initially secured a contract to

Aspasa awards: Danny de Villiers, group HSE manager at Raubex, takes the award for SPH Kundalila being the Top Performing Group. His team achieved the highest average score out of 13 participating quarries (courtesy Aspasa).

Proud SPH-K Kersfontein mine manager Jean Martin.

Owned and operated by SPH Kundalila, the Kalbaskraal sand mine is a relatively small operation at the moment (courtesy SPH-K).

15

MODERN QUARRYING

October - November 2017