In a milestone that is likely to revolutionise mining training and safety practices in Southern Africa, Sandvik Mining and Rock Solutions has provided its state-of-the-art digital trainers to leading mining contractor Redpath Mining South Africa.
“Our digital trainers offer a range of advantages that are set to transform the way mining personnel acquire skills and knowledge,” says Vusi Thobela, Key Accounts Manager at Sandvik Mining and Rock Solutions. “These cutting-edge training tools provide an immersive and realistic simulation of mining operations, empowering trainees to gain practical experience in a controlled environment.”
The strategic partnership between Sandvik Mining and Rock Solutions and Redpath Mining South Africa, under a global framework agreement, signifies a shared vision of promoting excellence and safety in the mining industry.
This innovative technology provides trainees with interactive interfaces that closely resemble the controls and displays found on real mining equipment. This ensures a seamless transition from training to on-site applications for trainees. It also enables them to learn and practice safety protocols and emergency procedures without exposing them to the risks associated with real-life mining activities.
These cutting-edge training tools provide an immersive and realistic simulation of mining operations, empowering trainees to gain practical experience in a controlled environment.
The strategic partnership between Sandvik Mining and Rock Solutions and Redpath Mining South Africa – under a global framework agreement – signifies a shared vision of promoting excellence and safety in the mining industry. According to Sudesh Deonarain, General Manager Engineering at Redpath Mining, the high-fidelity simulations offered by Sandvik’s digital trainers enhance the training experience.
Redpath Mining South Africa recently took delivery of Sandvik simulators for the Sandvik DD422iDC and the Sandvik LH517i to deploy at current projects.
“Our trainees can familiarise themselves with a range of mining environments, equipment behaviour and tasks, allowing them to hone their skills in a life-like setting,” says Deonarain. “From equipment operation and maintenance to troubleshooting and teamwork, they can practice various scenarios, ensuring they are well-prepared to tackle real-world challenges.”
He says these cutting-edge tools help to better equip Redpath’s workforce to navigate the complexities of modern mining operations and to ensure safety and productivity.
Thobela adds that the accurate simulation of mining equipment and processes allows trainees to develop a deep understanding of the intricacies of operating and maintaining the Sandvik machines.
“This supports increased productivity and reduced downtime, ultimately optimising operational efficiency in mining operations,” he says. “Furthermore, the digital trainers may incorporate data analytics capabilities, providing valuable insights into trainee performance, equipment utilisation and operational efficiency.”
He notes that the data-driven approach fosters continuous improvement in training methodologies, contributing to the overall growth and success of mining operations.
“Redpath’s commitment to operational excellence, combined with Sandvik’s leading technology, is paving the way towards enhanced training and safety standards throughout Africa’s mining landscape,” says Thobela.
With well over 100 units already delivered, SEW-EURODRIVE in South Africa is set to continue supplying Ivanhoe Mines’ prestigious Kamoa-Kakula Copper Complex in the Democratic Republic of Congo (DRC), a joint venture with Zijin Mining of China, with a wide range of its X.e-series power packs.
Andreas Meid – SEW-EURODRIVE Head of Engineering.Willem Strydom, SEW-EURODRIVE Business Development representative.
According to Willem Strydom, Business Development at SEW-EURODRIVE, the power packs – which are integrated units comprising gearbox, coupling and motor – will be part of Kamoa-Kakula’s Phase 3 expansion. Since the mine’s first phase of development over five years ago, SEW-EURODRIVE has worked closely with both Ivanhoe Mines and the engineering, procurement and construction (EPC) contractor.
The supply of quality engineered power packs to Ivanhoe Mines’ Kamoa-Kakula Copper Complex from SEW-EURODRIVE continues into the mine’s Phase 3 expansion.
“As in previous phases of the mine’s development, our robust high quality power packs will provide reliable solutions in on-site applications such as conveyors, agitators, and slurry pumps,” says Strydom. “The size range in the order makes use of our wide capability range to provide a total solution, ranging from 55 kW units to 500 kW units.”
The latest order includes several X.e Series power packs for conveyor applications, planetary gearboxes for feeder applications, and spare gearboxes. The equipment will be delivered in staggered shipments this year. While the mine typically undertakes the installation of the equipment, SEW-EURODRIVE sends technical teams to site to check final alignment and overall installation parameters.
The tropical climate as well as high levels of sun exposure meant that SEW-EURODRIVE had to take special care in their design, incorporating special breathers, covers and fans.
The company has expanded its after-sales service teams considerably in recent years, allowing it to support the growing base of equipment throughout Africa. Its projects and engineering teams have also grown – developing a depth of experience to assist customers right from design phase onwards.
Strydom notes that SEW-EURODRIVE has significantly developed its infrastructural foundation in South Africa, and plans to develop a physical representation in over 23 other African countries. As a priority country for the company’s strategy, there is expected to be a representative in place in the DRC in 2023, he explains. Field service teams from South Africa are frequently at Kamoa-Kakula to assist with servicing of the existing power packs operating on the site.
SEW-EURODRIVE continues to supply Ivanhoe Mines’ Kamoa-Kakula Copper Complex with reliable solutions in on-site applications such as conveyors, agitators and slurry pumps.
“Our local assembly capability in our new facility in Johannesburg – combined with our ability to source from the group’s other global operations – has allowed us to meet the tight delivery deadlines for this substantial order of equipment,” he says. “Our global footprint and production capacity mean that we can deliver faster than most players in our field, and this is often an important factor for our market.”
While the company previously imported the larger X.e Industrial gearboxes from Germany, it is now able to assemble these in the new South African facilities. As part of its service, SEW-EURODRIVE will also handle the logistics of getting this large volume of equipment to site. The company’s training centre – the Drive Academy – in Johannesburg has also made a valuable contribution by providing training on the equipment and its maintenance.
In this project, the tropical climate was another important factor in the customer’s design requirements. This required the inclusion of certain cooling and paint specifications in the contract. SEW-EURODRIVE Head of Engineering Andreas Meid explains that special breathers were part of the design in response to high humidity levels – and served to ensure no moisture in the gearboxes. In outdoor applications where sun exposure was high, covers were also included to reduce heat build-up. Cooling fans were also optimised in certain cases to ensure optimal performance.
He highlights that Kamoa-Kakula is one of many projects in Africa to request the installation of monitoring equipment on the power packs. This facilitates real-time monitoring, using specialised sensors to measure key indicators like vibration and temperature from anywhere in the world.
“This allows the operation to monitor the equipment remotely, receiving early warnings of any issues in performance,” says Meid. “Responding timeously to this information can prevent serious damage and avoid unplanned downtime.”
As a preferred supplier, SEW-EURODRIVE first delivered a multitude of X.e Series power packs between 2019 and 2021 for the mine’s initial development phase. Motors ranging in motor from 7, 5 kW to 500 kW as well as planetary gearboxes were supplied during this time for feeder applications, together with several spare gearboxes.
For Kamoa-Kakula’s Phase 2 expansion, which doubled the concentrator plant capacity, SEW-EURODRIVE supplied many standard X.e Series power packs for the conveyors as well as planetary gearboxes for the feeders.
Catering for the increased focus on the environmental aspects of surface mining, quarrying and construction, there are now enhanced options available for air filtration on mining and earthmoving equipment.
Well known for its specialised mobile HVAC solutions, Germiston-based Booyco Engineering is now a distributor for Sy-Klone International’s air filtration technology. According to Booyco Engineering’s Field Services Sales Manager Gordon Postma, this brings a range of exciting products to its local customers. The Sy-Klone offerings include enclosed cab filtration, air precleaning for engines and high efficiency air filtration for heavy equipment.
Sy-Klone products can withstand extreme environments, reducing operator exposure to harmful particulates and extending engine life.
“We can offer customers a complete cab air quality system that includes both fresh air and recirculated air systems combined with high-efficiency HEPA and EPA filtration as well as real-time CO2 and pressure monitoring,” says Postma.
“Tighter international standards – embodied in the ISO 23875 global standard for cab air quality – are leading the world’s major mining companies to adopt better air quality control systems for their heavy machinery cabs and other operator enclosures,” he explains. “The trend is also being felt in southern Africa, as mining and construction companies look for more effective dust control solutions.”
RESPA cab air quality systems, available from Booyco Engineering, ensure fresh and recirculated clean air and include a pressure/CO2 monitor making these ISO 23875 compliant.
The new ISO standard will require machine cabs to have a fresh air pressurisation solution, a recirculation system and a monitoring device, he points out. They will also need to be fitted with filtration that exceeds 94% efficiency at 0.3 microns, such as Sy-Klone’s EPA and HEPA filters. Many mining and earthmoving vehicles and equipment are imported with filtration systems that are not suited for the region’s dry and dusty conditions.
“Sy-Klone solutions can be retro-fitted onto vehicles and equipment to provide unsurpassed levels of protection and be in compliance with emerging standards,” says Postma. “Higher levels of filtration also support the safety of machine users, promoting operator alertness and improving productivity.”
The South African market now has easy access to Sy-Klone’s RESPA solutions which are suitable for both large and small machines.
He highlights that the Sy-Klone distributorship is a natural fit with Booyco Engineering’s HVAC specialisation and experience – as more effective filtration for the cab also enhances the performance and lifespan of the air conditioning system.
“This collaboration allows us to offer an even more comprehensive solution to our customers’ needs, harnessing the latest technology to meet rising global standards,” he concludes.
ClickToGo, launched by AfriSam, South Africa’s leading construction materials company, is a gamechanger. This remarkable digital platform is a first of its kind in the construction industry and allows existing customers in South Africa to effortlessly order materials and manage their accounts, providing a seamless experience.
AfriSam’s ClickToGo, a new and remarkable digital platform, is a first of its kind in the construction industry.
The user-friendly online platform, ClickToGo, was developed to provide a digital solution that would ensure convenience and take the customer experience to another level.
“Our goal is to prioritise our customers and drive progress in the industry, and ClickToGo, our innovative e-experience platform, will empower our customers and enhances their interaction with us,” Ilonka de Magalhaes, Customer Experience Manager at AfriSam, says.
ClickToGo offers a range of features designed for ease of use. Customers can easily view their orders, directly order from quotes, review their order history, access essential account documents and credit information and track deliveries effortlessly. Additionally, super users can assign different roles and permissions to staff, facilitating seamless collaboration within organisations.
Almost 70% of AfriSam’s 30-day account customers have already registered and actively use ClickToGo.
Launched in November 2021, ClickToGo has gained significant interest with positive feedback from customers. “We are delighted by the response to ClickToGo,” de Magalhaes says. “Almost 70% of our 30-day account customers have already registered and actively use the platform.”
It is important to note that AfriSam continuously refines and enhances ClickToGo’s functionality based on valuable feedback from customers and front-line employees.
A recent significant development on the innovative ClicktoGo e-platform is the inclusion of cash account customers, extending use of this platform for all account customers and ensuring all can benefit from this streamlined online ordering platform.
Enhancing the customer experience further, AfriSam has integrated ClickToGo with its Online Payment Gateway. Cash account customers can now conveniently place orders and make payments in a single transaction. “Our aim is to provide a smooth and hassle-free experience for our customers,” de Magalhaes emphasises. “We want to make the process as effortless as possible.”
Moreover, ClickToGo enables cash account customers to apply for a credit facility directly through the platform, simplifying the process and making it more accessible. At the same time, 30-day account customers now have the ability to request credit limit increases directly on the platform, ensuring a seamless and streamlined user experience.
AfriSam’s ClickToGo is a significant milestone in the company’s digital transformation journey, aligning with its commitment to delivering an exceptional customer experience. By offering convenience, effectiveness, and transparency, ClickToGo sets a new standard for the construction materials industry.
“We aim to redefine the customer experience and cement our position as an industry leader through this innovative e-experience platform,” de Magalhaes concludes.
As mining companies embark on brownfields initiatives to meet rising market demand for battery and other minerals, the optimising of transfer points presents a valuable opportunity to deliver more output cost effectively.
Alwin Nienaber, Technical Director at Weba Chute Systems, says that when correctly used technology and experience provide a powerful combination when expanding production capacity. Technology can be leveraged to facilitate rapid and accurate scanning of the existing configuration of infrastructure into which the improved chutes are to be installed. Further, he says, the company brings a wealth of expertise to advise on valuable adjustments in the relationship between chutes and other equipment.
Alwin Nienaber, Technical Director at Weba Chute Systems.
“Custom engineered chutes and transfer points have been shown to facilitate smoother flow of mined material, with greater reliability and uptime for a more streamlined and productive operation,” explains Nienaber. “The initial focus when providing transfer point solutions to a brownfields project is usually to take careful note of the physical layout so that chutes are designed with spatial constraints in mind.”
This can be most accurately and efficiently achieved using 3D laser scanning of the existing layout, to rapidly gather detailed measurements of large infrastructure on a customer’s site. Using this data, a precise 3D model can be generated on the basis of which the necessary chutes and componentry can be designed and manufactured.
“This aligns well with Weba Chute Systems’ considerable in-house expertise in chute design, as each chute we build is unique to the application it serves,” Nienaber says. “It is important to remember that every transfer point exists in a relationship to other equipment, such as a screen, crusher or conveyor belt.”
Weba Chute Systems Technical Manager, Dewald Tintinger, using the 3D laser scanner to take dimensions on site.Central belt loading being discharged from a Weba chute at a steel plant in Turkey.Weba chutes installed at a steel plant in Turkey.Weba chutes, with samplers, installed at a steel plant in Turkey.
He highlights that an understanding of this relationship will underpin the productive application of transfer point design and installation. Indeed, while the 3D scanning and modelling technology provides a valuable starting point for design there is also scope for added improvements in the plant layout.
“On so many of the sites that we visit and assess, we can soon identify where changes in the relationship between the transfer points and other equipment can deliver better results,” says Nienaber. “While it is sometimes difficult – even costly – to implement some of these changes, the customer reaps many times the value in terms of uninterrupted volume flow, uptime and productivity.”
The first prize when installing transfer points, he emphasises, is always the optimal solution – which may mean reconsidering the position of the upstream and downstream equipment. In fact, this is always the starting point for Weba Chute Systems’ transfer point solutions: to achieve the most productive result for the customer.
“With our engineered design approach, we always consider the context of where our chutes are going to operate, and our decades of field experience allow us to advise the customer what will work best,” he says. “We might advise on how adjusting the position of a conveyor’s head pulley, for instance, would improve chute performance and overall plant efficiency.”
He notes that, while certain configuration changes might exceed budget constraints, the company’s intervention often allows for positive modifications to be made. A recent example of this was in a contract for a South African iron ore producer in the Northern Cape. Weba Chute Systems was asked to address the mine’s challenge where an existing competitor’s chute needed attention every two days which was severely hampering production.
“We designed and installed the optimal customised chute, but also recommended some related adjustments,” he says. “The design was a split chute, and the plant needed to speed up its conveyor quite considerably – as well as lifting the head pulley slightly – to achieve the necessary results.”
The changes recommended had financial implications, so the customer required considerable certainty that the solution would be successful. To underpin its plan, Weba Chute Systems digitally modelled the proposed design and simulated its operation using software that visualised the movement of material through the chute.
“Used by our skilled designers, this powerful software delivers more than a pretty picture,” emphasises Nienaber. “The simulation presents in video format exactly how equipment will be positioned and how material will flow through the system.”
Fundamental to these kinds of solutions, of course, is a close collaboration with the customer, built on a high level of trust in the company’s past performance. Aligned to this is Weba Chute Systems’ commitment to see through any project it embarks upon, he says.
“Our customers know we never walk away from a project – and this is an important factor in brownfields projects where one is often working within existing constraints rather than a clean slate,” he argues. “We have confidence in our people and our designs, and remain accountable for any solution we provide until it performs to levels we have promised.”
Another important factor in many projects is the level of degradation of mined material, which the company prides itself on reducing through its scientific, streamlined approach to the dynamics of bulk materials handling.
“An example of where this was important was a steel plant in Turkey where we installed a number of our chutes,” he explains. “The customer required minimal ore degradation, and even monitors the ore passing through each chute to ensure fines generation is kept to a minimum.”
Weba Chute Systems was required to incorporate samplers in its installations in this plant, and these samplers generate the data to verify the chutes are performing to expectation. The company’s custom design allows greater control over the direction, flow and velocity of material, whose volume and characteristics are specific to each application.
Dry-type transformer specialist Trafo Power Solutions has broadened its offerings to include modular substations – leveraging the company’s depth of experience in designing and providing custom engineered electrical solutions.
“Since our entry into the market supplying dry-type transformers, we noticed an increasing demand for complementary systems related to their application,” says David Claassen, Managing Director of Trafo Power Solutions. “Our evolution began with customer recognition of the level of our in-house expertise, and requests for packaged solutions which included our dry-type transformers.”
Dry-type transformer specialist Trafo Power Solutions has broadened its offerings to include modular substations.
Customers needed a reliable supply partner with the competence and experience to understand the specific demands of each project and application, says Claassen. Trafo Power Solutions has proven itself in this role, right from the concept and design stage of a project through to facilitating the manufacture, delivery and on-site commissioning.
He notes that modular substations, often referred to as E-house, are prefabricated or modular structures that house electrical equipment and systems. They are designed to provide a centralised and secure environment for critical electrical components and infrastructure. Often used in industrial settings, power plants, mining operations, oil and gas facilities and other applications where reliable and efficient electrical power is essential, an E-house would house a variety of electrical equipment such as switchgear, transformers, motor control centers, distribution panels, and other power distribution and control devices.
Modular substations are built and tested in controlled workshop conditions, making the process more streamlined and cost effective, and ensuring optimum quality.The attraction of the modular structure is that it can be more easily transported and installed on site – and having a built-in transformer just makes sense.Modular substations are designed to provide a centralised and secure environment for critical electrical components and infrastructure.Modular substations, often referred to as E-house, are prefabricated or modular structures that house electrical equipment and systems.
“Most significantly, modular substations are built and tested in controlled workshop conditions, making the process more streamlined and cost effective, and ensuring optimum quality,” he continues.
“Dry-type transformers are perfectly suited to the philosophy of modular substations, as they can be safely accommodated inside the compact structure enhancing the benefits that modularity brings,” he says. “The attraction of the modular structure is that it can be more easily transported and installed on site – and having a built-in transformer just makes sense.”
Traditional oil-cooled transformers must be installed in a purpose built structure for safety reasons, as there is a risk of leakage, fire or explosion. This often means extra civil engineering construction on site, adding time and resources to the project. The cabling arrangement between the external transformer bay and the substation must then also be accommodated.
“The inherent safety of the dry-type transformer allows it to be installed close to the switchgear inside the modular substation, so there are shorter cable runs and easier installation,” he explains. “The extra cost and management of on-site civils work are also avoided this way.”
Increasing its solutions offering has bolstered the standing of Trafo Power Solutions in the market, as it no longer supplies just a single component, he continues. The company now provides a packaged and integrated solution that minimises its customers’ points of contact during their projects – be they an end-user or an engineering, procurement and construction management (EPCM) company.
“Not only does this save them time, but it also considerably reduces the risks associated with integrating the different aspects of electrical projects,” says Claassen. “There is certainly a trend in the market where customers are looking for more integrated solutions, which allows better quality control and ease of installation.”
He notes that the transition to a broader offering has been quite natural as Trafo Power Solutions has never just provided standard off-the-shelf transformers. It has always customised this equipment for each specific application, requiring an in-depth understanding of the customer’s needs before tackling the design process.
“Within our company, we have strong engineering expertise and experience so it was a spontaneous transition into dealing with the other aspects of modular substations,” he says. “We were always well acquainted with these broader elements in any event, as they informed the design of our transformers.”
This has opened up opportunities for Trafo Power Solutions in a range of industries, many of which may not previously have considered the modular substation concept in their project planning. Increased interest is evident in sectors such as data centres, oil and gas, food and beverage and renewable power generation.
The company has in recent years designed and supplied containerised transformer solutions for mining customers including the remote Bisie mine in the north-eastern Democratic Republic of Congo. So successful were these units that the mine recently ordered three more substations, again equipped with dry-type transformers.
“We expect the trend towards modular substations to continue strongly,” says Claassen. “We have, for instance, delivered multiple modular substations to a large data centre in Johannesburg. Here, we have provided a full medium voltage modular solution including switchgear and transformers, complete with cooling and control systems.”
Trafo Power Solutions is also engaged in the manufacture of almost 40 mini-substations with dry-type transformers, following a large order from a copper mine in southern Africa. In all its transactions, the company is able to design and provide the required equipment with a quick lead time, ensuring customers of on time delivery and on budget, he concludes.
Sandvik Rock Processing, a global leader in the mining and rock excavation industry, has marked a significant step in its expansion across Africa with the successful completion of its first South African-manufactured screen package. This milestone project was undertaken at the company’s world class Spartan facility in Johannesburg, which already produces the Kwatani and Schenck products as part of Sandvik’s screening solutions offering. The capability to also produce the Sandvik original screen range signals a new phase in Sandvik’s African presence and growth.
Riaan Steinmann, Europe, Middle East and Africa (EMEA) Operation Director Screening Solutions at Sandvik Rock Processing, showing the grizzly bars which were manufactured using VRN500 high manganese durable plates, equivalent to AR500 plates. The grizzly gazettes determine the specific cut size of the ore.
Riaan Steinmann, Europe, Middle East and Africa (EMEA) Operation Director Screening Solutions at Sandvik Rock Processing, says the achievement is a testament to the facility’s local design and engineering prowess. He emphasises the South African facility’s capability to build high quality vibrating screens from raw materials, which also includes a range of exciter gearboxes using locally procured castings. This innovative approach enables the company to maintain strict quality control and facilitates shorter delivery times for their customers, thereby improving the customer experience significantly.
The screen package that marks this milestone was specifically ordered by a gold mining client located in North-East Africa. It includes a vibrating grizzly screen with a motor-driven exciter, five feeders, and two custom-engineered feed-in chutes. Steinmann praised the facility’s streamlined processes and the benefits of local procurement, which collectively allowed the project to be successfully completed within an impressive timeframe of three months.
Showcasing Sandvik’s unique model coding numbering and safety decal stickers on one of the screens which made up the first Sandvik screen package manufactured in South Africa.Sandvik Rock Processing’s Quality and Assembly Managers working together to achieve the best quality screens and feeders.The Sandvik screen package included the supply of five feeders.
“Manufacturing screens in South Africa represents the same standard as those produced in Europe or India,” Steinmann says underscoring the global quality benchmark. He also notes the multiple benefits including reduced shipping times and costs due to Southern African Development Community (SADC) trade agreements. Moreover, he highlights the positive impact on the local economy through exports and increased capacity leading to job creation.
Steinmann’s team adheres to strict standards and procedures during the manufacturing process. They are particularly careful in selecting the correct assembly and welding requirements for each component, ensuring fabrication and welding is aligned with the company’s stringent internal controls.
“Importantly, we aim to serve not only the African continent but also other regions within the Sandvik Rock Processing group,” Steinmann concludes. “The successful execution of this first Sandvik screen package has not only underscored our position as a world class manufacturer but also underlines our ambition to become Africa’s preferred screening solution partner.”
AfriSam, leading construction materials group, places safety at the forefront of its operations, acknowledging the importance of safeguarding its people and the communities within which it operates. As both a responsible employer and corporate citizen, the company’s unwavering commitment to safety extends beyond its own operations and into the realm of rail safety, particularly at level crossings, where road and rail networks intersect.
Deputy Minister of Transport, Mr Lisa Mangcu, spent the early morning engaging with motorists and pedestrian at the AfriSam Ulco plant level crossing.
In collaboration with Traxtion, Africa’s largest private freight rail operator, and the Rail Safety Regulator (RSR), AfriSam was actively involved in promoting International Level Crossing Awareness Day (ILCAD) campaign in June 2023. This global initiative, championed by the International Union of Railways (UIC), unites railway communities from 28 countries raising awareness of level crossing safety.
AfriSam’s commitment to “Zero Harm” reflects its strong belief in prioritising the safety and well-being of its employees and the community. This informed the company’s contribution to ILCAD with its focus on recognising the potential risks and hazards associated with level crossings on a day dedicated to saving lives and preventing accidents.
Nathi Shoba, AfriSam’s Quality Assurance Manager, expresses the company’s resolute commitment to safety, stating, “This is all about saving lives, and for this reason, we were extremely proud to play our part in International Level Crossing Awareness Day (ILCAD).” AfriSam’s involvement in the campaign reflects its dedication to proactive engagement, education and fostering a culture of responsible behaviour at level crossings.
Deputy Minister of Transport, Mr Lisa Mangcu, addressing the learners of Ulco Primary School.
Madelein Williams, Executive: Media and Communications and spokesperson for the RSR in South Africa, emphasises their primary objective of enhancing rail safety, a goal that often faces challenges when motorists and pedestrians fail to adhere to level crossing regulations. Williams expresses concern over the recorded 47 injuries between 2020/21 and 2021/22, as this undermines the RSR’s efforts to raise awareness and promote rail safety at level crossings.
To commemorate ILCAD, Traxtion, RSR and AfriSam collaborated on a private siding line connecting to the Transnet line, specifically selecting the bustling Ulco crossing in Northern Cape. This crossing serves both pedestrians, including school children, and motorists, posing potential risks and making it a vital location to address level crossing incidents.
The learners of Ulco Primary School sharing warm hugs with the Deputy Minister of Transport, Mr Lisa Mangcu.
“We call upon all rail operators to join us following this awareness campaign to ensure compliance with safety regulations for the sake of the public and railway operators at level crossings,” urges Thando Makoyi, SHEQ Compliance Manager at Traxtion and a former train driver.
AfriSam, together with its partners, remains dedicated to promoting rail safety, saving lives and fostering a culture of responsible behaviour at level crossings. By actively engaging stakeholders, raising awareness and advocating for adherence to safety measures, they aim to make a significant and lasting impact on rail safety in South Africa and beyond.
Mining is fast embracing various automation and digital technologies, but to keep up with the rapid pace of operational change that this trend demands, everyone must keep learning.
This is the message from Sandvik Mining and Rock Solutions Human Resources Development (HRD) Manager, Vusi Mnguni who warns that skills development as an enabler is pivotal to effective change management process.
Technology such as the Digital Driller allows Sandvik to deliver ‘real life’ training in a simulated working environment.
As a result, the company invests heavily in employee and customer development through its training academy at its Khomanani head office. This is made possible through a variety of specially developed programmes, with most of these conducted in collaboration with tertiary institutions such as the University of Pretoria, Tshwane University of Technology, Colliery Training College, Sandvik Training Academy and other qualified skills development providers.
“Innovation in mining means that more changes are coming, but change is only possible with new competencies,” argues Mnguni. “Unless you have prepared your employees with the requisite skills to drive the change you want, that change process is doomed – as many people will resist what they do not know.”
Sandvik recently celebrated the graduation of employees for Project Management through MSC Business School.
Citing Sandvik’s purpose being “We make the shift – advancing the world through engineering”, he highlights that this requires the business to identify the skills it needs now – and those it needs in the future. Training in the necessary competencies must begin now, to enable the company to move forward towards meeting its strategic objectives.
“This approach also makes an important broader contribution to the mining sector because tomorrow’s skills need to be in place before we can introduce our latest technologies to the market,” he explains. “The application of technology is really a change management process, which rests on the leadership, technical and organisational capacity of all involved.”
To achieve this, Sandvik Mining and Rock Solutions is engaged in a wide range of training initiatives in technical, managerial and other skills. Mnguni emphasises that change is driven by leadership, and skills are developed at this level in terms of adaptability, agility and change management.
“Another key aspect of learning among our staff and in the mining sector generally today is around data,” he explains. “It is increasingly expected that decision-making is data driven, so everyone needs to be literate at the level that they interact with data to understand and analyse the growing volume of data available.”
Mechatronics competency is the way forward and a focal point for Sandvik Mining and Rock Solutions. Indeed, it is already demanded in the current working environment, as the company is a leader in developing intelligent machines for mining.
This means that the traditional artisan skill sets must be taken further, he says. Collaborating with the Tshwane University of Technology, the company upskills millwrights and electricians through a mechatronics programme that deals with the marriage of mechanical, electrical and computer science. This is one of only two institutions in Africa who can offer this specialised course.
“In fact, we have changed our apprenticeship programme to our Millwright Extended Programme which makes Artisan 4.0 a focal point. This includes basic skills in PLC programming and working with autonomous robots/vehicles,” he says. “This helps to equip the kind of artisan that industry really needs, as it is no longer enough to be specialised in the traditional trades. While regulated apprenticeship modules are generic, the apprentices need additional specialised training to be ready to work on modern mining equipment.”
Various training modalities are appreciated by Sandvik, Virtual, In- Class, Instructor Led , Self-Paced , Nano Learnings , Simulated , On the Job Training , Coaching , Augmented and Virtual Reality.
He adds that it is essential that all role players align their programmes with the technology trends. This is what Sandvik Academy does, not only as a pipeline for its own skills but also for customers that request it. Such is the legacy of skills development at the company, that it has trained more than 1,000 apprentices over the past 22 years – at a 100% absorption rate into employment.
“These people are gold to the industry and have been taken up not only in South Africa but in countries like Zambia, Tanzania and Zimbabwe, as well as abroad,” Mnguni concludes.
Efficient operation and minimal downtime are crucial for maintaining productivity and profitability in grinding circuits. To address these challenges, many operations are opting for the KREBS® SmartCyclone™ technology from FLSmidth.
Abrie Schutte, senior applications engineer, product business line KREBS® pumps, cyclones and valves at FLSmidth.
According to Abrie Schutte, Senior Applications Engineer at FLSmidth responsible for the KREBS® pumps cyclones and valves product business line, this innovative technology combines advanced monitoring and automation features to optimise closed-circuit grinding operations.
“SmartCyclone™ integrates various components and software to provide a comprehensive solution for grinding circuit management, and significantly incorporates roping sensor technology, wear detection technology, a wireless controller system and ECS/ProcessExpert® process control software,” Schutte says. “End-users have found that by leveraging these elements, maintenance planning is enhanced, wear reduced and there is an overall improvement in grinding circuit performance.”
The wear detection technology of SmartCyclone™ employs specialised sensors to monitor the wear status of cyclone components. This real-time information enables operators to proactively plan for part replacements and schedule maintenance activities, minimising unexpected downtime caused by component failures.
KREBS® hydrocyclones are engineered for reliable operation in the recovery of minerals.The KREBS® SmartCyclone™ Wireless System is a gamechanger for process plants.Installation of a KREBS® gMAX15 cyclone.
Schutte further explains that an automated monitoring system is a key feature of SmartCyclone™. “This is important as it allows operators to detect wear and troubleshoot issues from a centralised control room, eliminating the need for manual equipment inspections with a reduction in associated risks.”
By promptly identifying and addressing potential problems, process disruptions are minimised, ensuring optimal performance of the grinding circuit.
The SmartCyclone™ system also includes a roping detection feature, which identifies and corrects disturbances known as “roping.” Overloaded cyclones or those experiencing roping can lead to increased bypass of coarse solids to the overflow and greater particle size variation.
“This accumulation of slurry can adversely affect downstream equipment, such as flotation cells. By monitoring and detecting roping, operators can confidently operate the plant closer to its limits, thereby increasing production capacity and improving mineral recovery,” he says.
By integrating SmartCyclone™ with ECS/ProcessExpert software, the grinding circuit’s performance can be further optimised. The system dynamically adjusts variables such as water addition, pump speed and the number of operating cyclones based on real-time data from SmartCyclone™ sensors. This continuous optimisation enhances particle size distribution, maximises mineral recovery and improves the overall efficiency of the grinding circuit.
SmartCyclone™ offers a comprehensive solution for closed-circuit grinding operations. By leveraging advanced sensor technologies, automated monitoring and process control software, this innovative system empowers operators to enhance maintenance planning, reduce wear, and optimise the performance of their grinding circuits.
“With its ability to detect early warning signs, troubleshoot potential issues and dynamically adjust variables, SmartCyclone™ sets a new standard for smart and efficient grinding circuit management,” Schutte concludes.
