Monthly Archives: October 2023

Client Focus

EASTGATE HARVESTS RAINWATER TO BOOST SUSTAINABILITY

Leading black-owned contractor Concor is constructing facilities to harvest and treat rainwater and groundwater at Eastgate Shopping Centre, adding to the centre’s sustainability and reducing its vulnerability to water outages. 

The new facility comprises two segmented steel tanks capable of storing about 200,000 litres of water. Rainwater runoff from the roof top parking area – which currently runs into the city’s stormwater drains – will be piped into these tanks. This will be supplemented by groundwater resources under the centre which will be pumped up and stored. These tanks are linked by a 300 metre water line to the centre’s existing buffer tank. Working in a live shopping centre environment, the water pipe has to be run through a busy parking area and across a public road, requiring careful planning and traffic management.

The tanks will hold over 200,000 litres, demanding a firm foundation. In preparation for this work, test pits were excavated to ascertain the presence of services, piping or ducting – as accurate as-built plans were not available. Concor considers these kinds of processes as vital to risk mitigation at every step of a project. In addition to uncovering various services, the test pits also revealed a concrete crane base some 500 mm in depth, which had to be removed before foundation works could begin.

In this case, geological conditions called for the use of twelve 130 mm micro-piles to ensure the stability of the tanks, following which raft foundations were cast over a 5 metre by 10 metre area. Construction of the foundations and the tanks is in close proximity to an existing LPG gas chamber that serves tenants such as restaurants in the centre. This requires special attention to health and safety procedures, including regulated permissions and certain restrictions on the use of electrical equipment in the area.

The project includes the installation of filtration and treatment facilities, ensuring that the water is potable for use throughout the centre. 

Client Focus

FLSMIDTH LEVERAGES GLOBAL TECHNOLOGY FOR LOCAL IMPACT

Driving its leading technology through a pure play mining strategy, FLSmidth has been optimising its footprint to be closer to customers with local solutions and expertise.

Alistair McKay, FLSmidth’s Head of Site and Service Sales Sub Saharan Africa, Middle East & South Asia (SSAMESA), highlights the CORE’26 mission at the centre of this strategy. CORE’26, explains McKay, is based on the principles of sustainability, technology, service and performance. 

“We go to the market through our five regional structures around the world, which deliver sales, service and order execution,” he says. “The regions are in turn supported by our global organisation and its leading product lines. The global resources are strategically located in countries such as the US, Denmark, Germany, India and South Africa, where we have a concentration of expertise to support our offerings.”

As part of the footprint optimisation, resources have been deployed and infrastructure investments made in key areas, with Johannesburg remaining as the mining hub for the SSAMESA region. World class facilities in the region include the Stormill service centre – for KREBS® pumps, valves and cyclones – and the Delmas manufacturing facility for vibrating screens and other equipment. There is also the fully integrated engineering facility and a service centre at Chloorkop, focused as a centre of excellence on refurbishing high pressure grinding rolls. 

McKay highlights that the manufacturing, assembly and refurbishment capacity of these centres cater for product lines not just for this region but for FLSmidth globally.

The regional footprint includes local sales and services offices in Ghana, Saudi Arabia and India. “Our strategy allows us to get closer to customers around Sub-Saharan Africa, South Asia and the Middle East, while building the local manufacturing base as part of our global supply chain,” says McKay. 

He also emphasises the importance of technical knowledge in successfully building the SSAMESA footprint. “Relevant expertise and know-how remain important enablers to our customers for projects and broader development in Africa especially,” he says. 

The company’s focus on local manufacture in countries like South Africa also means that the domestic economy is supported while local skills are employed and developed. With a focus on skills development, FLSmidth contributes to the training of customers’ staff, while pursuing talent development through learnerships, apprenticeships and scholarships. 

“As a technology provider of world class sustainable offerings across the full flowsheet, the expertise in our regional footprint is key,” he says. “We also prioritise research and development that supports our sustainability ambitions and our customers’ green journey.”

Client Focus

LOCALISED INFRASTRUCTURE UPLIFTMENT WITH LOCAL COMMUNITY PARTICIPATION

Local infrastructure development isn’t just about laying roads or erecting bridges; it’s about creating sustainable avenues for growth, development and integration. The localised upliftment of local road infrastructure connected to the Msikaba bridge Project is a shining example of how infrastructure can be a catalyst for community transformation.

Bridging Gaps – Literally and Figuratively

Laurence Savage, Project Director for the Concor Moto-Engil Joint Venture (CMEJV) – the main contractor – says the primary intention behind this project was to provide secondary access routes to and from the Msikaba Bridge for the CMEJV. While this was a pivotal logistical move for the construction phase, it bore more profound implications, he says.

“Firstly, these routes provide seamless access for the local communities, eliminating previous barriers and promoting integration. Secondly, they pave the way for potential economic upliftment. With enhanced connectivity, sectors like tourism now stand to gain immensely, opening the region to new possibilities,” Savage continues.

Scope and Span

The upliftment projects were divided between the North Bank and South Bank of the Msikaba Bridge Project, embracing a wide spectrum of road types. From the rehabilitation of surfaced roads on the R61 to re-graveling existing sandy terrains, the need for these improvements was apparent. But beyond the physical work, the incorporation of stormwater facilities in multiple areas denotes meticulous planning.

However, Savage says, the real triumph lies in the project’s socio-economic impact. “Over 40 local subcontractors were involved, illustrating an unwavering commitment to integrating local expertise and manpower.” 

A Commendable Effort by SANRAL

Notably The South African National Roads Agency Limited (SANRAL) deserves recognition according to Savage who says the involvement of SANRAL and the CMEJV brought a ray of hope to a place where economic activity has been bleak. “SANRAL has not just driven the development of roads but have also actively contributed to job creation in a region that desperately needs it,” he says. 

Key Achievements

The R61 stretch from Port St Johns, passing through Lusikisiki and Flagstaff to the Bazana turnoff, spanning nearly 100 km, has seen transformational change. From immediate pothole repairs to complete surface replacements in sections, the road has been revamped from a hazardous path to a user-friendly roadway.

Between Lusikisiki and the Msikaba Bridge, a combination of re-graveling and the innovative usage of geo-cell concrete roads has made travel safer and more reliable. Especially noteworthy are the taxi routes that were previously inaccessible in unfavourable weather conditions, which have now been made approachable.

Similar advancements can be observed on the Msikaba Bridge’s North bank, where re-graveling, geo-cell installations and stormwater systems have been integrated to better serve the rural communities.

Savage says that an environment-friendly approach was adopted with bush clearing activities, again involving local SMMEs, further pushing the agenda of job creation.

“It is significant that through these projects over 400 jobs have been generated, especially in the geo-cell projects domain. Furthermore, the CMEJV’s approach to training, mentoring and uplifting SMME’s is commendable,” he says. “This initiative not only imparts technical skills but also fosters a culture of quality, financial responsibility and adept project management.”

While the Msikaba Bridge Project and its ancillary developments are still a work in progress, what’s undeniable is the positive change it has heralded. The CMEJV’s pride in this endeavour is palpable and rightly so. Over the past two years, the region has seen more than just infrastructure development; it has witnessed the laying down of the foundation for a brighter, more connected future.

Client Focus

GRINDEX’S MAGNUM PUMP OFFERS UNPARALLELED HEAVY-DUTY DRAINAGE CAPABILITY

In the two decades since its launch, Grindex’s Magnum pump has emerged as the first choice for heavy-duty drainage tasks across a myriad of applications in the construction, mining and quarrying sectors. 

Available from Integrated Pump Technology, the Southern African distributor for this quality international pump brand, there are three distinct configurations – the Magnum L for low head, Magnum N for normal head and Magnum H for high head applications. 

Justin Bawden, Key Account Manager at Integrated Pump Technology, says that despite its robust industrial strength, a notable feature of the Magnum pump is its surprising portability. “The ergonomic design of the pump facilitates easy and straightforward handling which aids ease of installation and movement from site to site.” 

Further, its streamlined construction, characterised by fewer components, simplifies maintenance inspections and servicing, making these not only quicker but also more cost effective. 

Grindex has incorporated a cutting-edge hydraulic design into the pump, ensuring it not only provides high wear resistance but also minimises performance decline after prolonged use. Significantly, according to Bawden, this pump boasts up to three times the wear resistance of its competitors, thanks to this optimised hydraulic design. 

Adding to its resilience, the Magnum pump features an air valve specifically designed to prevent overheating by cooling the equipment during dry runs. This innovative measure ensures prolonged pump life and uninterrupted performance, even under challenging conditions. 

The Magnum pump’s dependable design combined with its ease of maintenance has earned it a favoured position among hundreds of customers worldwide and is available in both 50hz and 60hz variants. 

When it comes to environments and applications that demand resilience and efficiency, such as construction sites, tunnels, mines and quarries, Grindex’s Magnum pump stands out as an unparalleled asset. “In essence, for industries that prioritise reliability and a proven track record, the Grindex Magnum pump remains unmatched,” Bawden concludes. 

Client Focus

NORTHERN CAPE MINE SMOOTHS FLOW WITH WEBA CHUTES

Specialist transfer point company, Weba Chute Systems is working with a mine in the Northern Cape to improve material flow. The mine has ordered two custom engineered chutes from Weba Chute Systems, which are expected to improve efficiency at the transfer points. 

According to Weba Chute Systems’ Regional Manager for the Northern Cape, Arnold Archer, the contracts are for an apron feeder discharge chute and a jaw crusher feed chute. Archer says the company had previously supplied the mine with a SAG mill feed chute, and had collaborated successfully to improve performance within that application. 

With run-of-mine material at the mine including large lump sizes of 800 mm to 1,2 m, there is a high risk of blockages if the chutes are not purpose-designed, he argues. The high velocity of the material can also cause considerable damage to chutes as well as create excessive dust. 

To inform Weba Chute Systems’ designs, the company’s team uses technical questionnaires to help gather information from the customer on a range of variables. This includes factors like lump size indicators, belt speeds, feed rates, moisture content and material velocity. The application-specific data paves the way for a design that optimises flow and equipment life.

“On the apron feeder discharge chute, for instance, we designed a swing door that will absorb most of the impact of big lumps moving at high velocities,” he says. “This also helps to protect the wear plates on the jaw crusher.”

The aim of the design will be to assist the mine reduce the incidences of chute blockages, spillage and excess dust – making the process more streamlined and less labour intensive. He points out that the mine aims to achieve higher uptime through optimal chute performance. The reduction in spillage and dust also contributes to the mine’s high standards of health and safety. 

“Our philosophy is that every transfer point on a mine has its own specific challenges, so the chute for each transfer point will be different to the next one,” he says. “We work with customers to understand the detail of their material flow through these points, so that our design takes all the key factors into account.”

He notes that most mines will have the necessary data gathering systems in place to inform the correct chute design – as they have tachometers on their conveyors, blocked chute detectors and feed monitors. The issue is just that this information is not always systematically considered during chute design. 

“We are proud of the chutes we design and manufacture, and stay close to our customers to ensure that the chutes’ performance is up to expectation,” Archer explains. “Our staff is passionate about getting everything right, and being there to follow up where necessary.”

Among the improvements made on the SAG mill feed chute at the mine, for example, were changes to the liner composition and pattern. Rather than removing all the liner segments to reach the middle row, the pattern change now allows this row to be removed without loosening all the other liners, he says. 

Weba Chute Systems can also install its own chutes, but provides supervision and assistance where the mine arranges the installation itself, he concludes. 

Client Focus

AFRISAM PUTS SKILLS DEVELOPMENT FRONT AND CENTRE

To stay ahead in the industry’s war for talent, AfriSam has over the years placed skills at the forefront of its people development initiatives. With its several training programmes, the company has successfully created a pool of talent, not only to the benefit of its operations, but the industry at large. 

Glenn Johnson, General Manager Construction Materials at AfriSam, believes it is fundamental for the construction materials industry to develop people. The industry, he says, needs strong technical skills at the core of its operational excellence.

With that in mind, AfriSam has over the years invested significantly in its in-house training initiatives, namely the Engineer-In-Training, Artisan Learnerships, Trainee Works Manager programmes and general operational training. This has recently been expanded with the introduction of the Trainee Operational Managers programme for the readymix business unit.

Johnson explains that the Engineer-In-Training is a structured training programme for young graduates who have come through AfriSam’s bursary pipeline. “Selected individuals – those who demonstrate the best aptitude for the aggregates and readymix businesses – are integrated into the programme with the aim of developing a pipeline of electrical, civil, mechanical and mining engineers,” he says. 

AfriSam has a two-pronged approach to developing its Engineer-In-Training graduates further. They are either given a chance to move into line management or to stay in their chosen technical discipline, be it mechanical or electrical engineering, or a multifunction of the two disciplines.

The Trainee Works Manager programme exposes candidates to all the critical aspects of works management on aggregate operations, including legal training, blasting certificates, financial management and, more importantly, people management amongst others.

The Trainee Operations Manager programme follows the same pattern, but with a specific focus on readymix concrete production, including technical specifications, product application and customer interface. Candidates are also exposed to the financial and operational aspects of the readymix business.

The Artisan Learnership Programme targets candidates who have completed their National Qualification Framework (NQF) courses, be it internal employees (18.1 learners) or external candidates (18.2 learners).

“AfriSam has recorded massive success with these programmes,” Johnson says. “To provide context, since 2012, a total of 83 artisans – both 18.1 and 18.2 learners – came through the system.”

Despite the recent challenges brought about by the Covid-19 pandemic and the continued downturn in the construction sector, Johnson says the company continues to show the resolve to develop people. “I also urge other industry players, who have generally lagged behind, to play their part in developing skills the industry needs, now and well into the future,” he concludes.

Client Focus

SEW EURODRIVE SA SECURES WORLD-FIRST X.e AGITATOR GEAR UNITS ORDER

After the recent X.e series agitator unit launch in July 2023, SEW-EURODRIVE South Africa secured an order for nine units earmarked for the mining industry – a world-class first!

SEW-EURODRIVE has an extensive and proven reputation for providing reliable high performance solutions for mixing and agitation applications in various industries globally. Significantly, the X.e agitator units have proven suitable for mixing and blending liquids and other materials in the harsh African operating environment. 

“The X.e agitator units are ideal for applications where high power ratings are required for stirring and mixing materials, and what is significant is that we can customise these agitator units to suit the customer’s specifications,” Jarrod Futter, Engineering Manager at SEW-EURODRIVE explains. “For example, we offer various bearing and shafting options and modular systems for the unit which can be selected to meet the customer’s budget and expectations.” 

Due to the customer’s requirements for nine low-ratio and moderately high torque and force application, the X3FSM240e HD version was selected. The selection process depends on multiple factors, including the input speed, motor power, loading distance, axial loading and most importantly, the radial loading in the application and required output speed,” Futter adds.

The X.e agitator differs completely from previous X Series vertical drives. The X.e agitator unit is purpose designed for mixing and agitation, focusing on a stronger and dynamically improved housing. This allows for higher radial load applications, with a maximised bearing distance and an intelligent housing split above the maximum oil level to minimise potential leaks completely and offer better servicing and maintenance capabilities. The X.e agitator also features a new robust, integrated foot design with multiple aligned foot holes to allow for easy mounting and stiffness as well as huge strides in thermal improvement.

During the X.e agitator design process, SEW-EURODRIVE applied the ‘digital-twin’ concept that ties real-world testing to a digital Finite Element Analysis. Explaining the process, Futter says this methodology allows the matching of real-time figures during testing to the digital analysis, achieving the same results. “This enabled many cost benefits, minimised the need for physical testing and allowed the team to see and solve problems before they happened. The digital-twin concept is a more energy efficient and environmentally friendly solution for development and testing, and minimises potential waste,” Futter adds. 

As an example, he says that the extended bearing distance could be further optimised along with the oil flow characteristics. Using fluid simulation the piping could be optimised internally, allowing the designers to see how the flow occurs before creating a physical unit to evaluate the theory. The simulation results could then be checked with real-time tests to ensure the oil flow occurs as designed and optimal lubrication is achieved.

The X.e agitator unit has a unique application-specific reinforced and extended bearing distance concept, with the distance between the lower and upper output shaft bearing mounted further apart. This creates a greater shaft distance between these loading points, which allows the low speed shaft to handle higher radial forces. “In layman’s terms – the lever has been made longer to move a larger load,” Futter says.

The X.e  agitator unit not only features a pressurised internal lubrication system that allows for continuous oil flow to all upper bearings and gears to ensure the units are well lubricated, but the unique labyrinth seal ensures protection from external particles that may damage the oil seals. Offering three sizes with various torque ranges and gear units, SEW-EURODRIVE offers client-specific products all safely encapsulated inside the gearbox for client and product protection.

SEW-EURODRIVE is committed to sustainable engineering solutions, and the X.e agitator unit is testament to this. The housing has been developed for easy servicing and maintenance, attributed to sustainable long term use. Therefore, components are easily replaceable. The efficiency gains are attributed to using the X.e series gearing, which has been extensively adapted from the original X-series. Using standard existing components, the X.e agitator series required less design time to achieve the final product.

With five production plants worldwide and a footprint in more than 50 countries, SEW-EURODRIVE offers a quick turnaround in aftersales support and aggressive lead times. “We are looking forward to making history with delivering the first nine X.e agitator units in the world and offering world-class aftersales support,” Futter concludes.

Client Focus

SANDVIK ROCK PROCESSING DRIVES MANUFACTURING AGILITY TO MEET RISING DEMAND

To keep pace with record equipment orders, vibrating screen and feeder original equipment manufacturer (OEM) Sandvik Rock Processing is driving manufacturing agility at its South African facility. Director Operations for the EMEA (Europe, the Middle East and Africa) Region, Riaan Steinmann, says the goal of agile manufacturing is to respond quickly to customer and market demands, while maintaining production output and quality.

“We have recorded a solid growth in the past three years in our screens product range. As a result, Sandvik Rock Processing Solutions South Africa is now well positioned as one of the leading vibrating equipment suppliers not only in South Africa, but in Africa at large,” says Steinmann. “We have also made strong inroads in other regions such as Europe and the Middle East.”

In fact, Sandvik Rock Processing South Africa’s exports have increased significantly with numerous screens being shipped across the African continent and internationally. A case in point is the recently completed order to supply over 72 screens and associated equipment to a large copper mining operation in Central Asia.  

To meet this rising demand for its equipment, which has seen Sandvik Rock Processing South Africa producing about 60 machines a month in recent times, the company is driving agility within its manufacturing environment. Being agile has allowed the company to easily adapt to changing market conditions and meet or even exceed customer expectations.  

“On the back of the significant growth of our screening offering in recent years, we have seen the need to continuously review and optimise our internal processes,” says Steinmann. “For example, our workshop layouts are based on job-shop lean manufacturing processes to cater for any customised components. We make use of in-house designed precision engineered jigs and fixtures to increase our production efficiencies and at the same time secure quality of these components.”

To further drive agility, Sandvik Rock Processing has adopted a strategic outsourcing programme for non-core components to alleviate pressure on its own manufacturing facilities and help ensure timeous customer deliveries. Some of the non-core components being outsourced to carefully selected service providers include cleats, bearing covers, gearbox shafts and housings, amongst others. 

“We work closely with these suppliers, most of whom are within a 10 km radius of our Spartan manufacturing facilities. While we conduct regular quality inspections at their facilities, most of them have worked with us for many years and now have a strong understanding of our quality standards,” says Steinmann. “We also hold significant stock of various critical components to make sure our customers get the best availability and service.”

What makes the Sandvik Rock Processing South Africa manufacturing team even more agile is that the production and engineering teams work in close collaboration with each other to swiftly resolve any design and manufacturing discrepancies that might occur during manufacturing. 

“Over time, our production and engineering teams have developed strict in-house quality standards which include, but are not limited to, welding procedures, fastening sequences, torquing of bolts, levelling, sequence of assembling subcomponents, shot blasting and paint specifications,” explains Steinmann. 

In addition, Sandvik Rock Processing invests in its people to ensure its employees are trained to adopt an agile mindset. This allows them to meet the company’s evolving production needs at any time, whilst ensuring maximum productivity and efficiency. 

“Upskilling our people allows us to build on our competence and stay ahead of industry needs,” says Steinmann. “We have an above average percentage of highly skilled and qualified staff, including boilermakers, artisans, certified welders and engineers. Having the right skills, however, is one thing, but being able to retain them is quite another. A positive working culture has been instrumental to our low staff turnover rate and a good retainment of skills.”

The impact of the current energy crisis in South Africa has been detrimental to local manufacturers, says Steinmann. The current fragmented factory operations, which are situated at different locations, make it a bit challenging to install backup generation capacity. 

“We have, however, invited local suppliers to tender for the supply of alternative power supply sources for all our workshops. This will require a significant investment, but on the upside it will help ensure we continue to be the same reliable and agile supplier we have always been to our customers,” he says. 

Sandvik Rock Processing Solutions, which includes the Kwatani screen products, the Schenck Process Mining screens and Sandvik’s original screening products, is well positioned to become the leading screening solutions provider with global best manufacturing practices in place. In addition, the company has a well-established global distribution and service network. 

“Our facility is set to become the global engineering and manufacturing base for vibrating equipment for both local and international customers who are looking for quality cost effective screening solutions that will enable them to achieve the total lowest cost of ownership,” concludes Steinmann. 

Client Focus

THE IMPORTANCE OF SKILLED CUSTOMER SUPPORT TECHNICIANS IN CRUSHING AND SCREENING

Crushing and screening on mines and quarries often entails 24/7 operations where downtime is out of the question. The importance of skilled customer support technicians in maintaining high machine uptime cannot therefore be stressed enough, states Jorge Abelho, Director Technical Support at Pilot Crushtec International. 

“Given that South Africa is a major global producer of several minerals such as gold, platinum group metals (PGMs), chrome and manganese, amongst others, it is vital that the crushing and screening sector plays its part in keeping the industry running smoothly,” Abelho says. “Skilled customer support technicians are therefore a non-negotiable in crushing and screening operations.”

Given that these Pilot Crushtec individuals spend most of their time at different sites and environments, customer support technicians develop profound knowledge of machines and applications. Crushing and screening customers, says Abelho, should therefore tap into this knowledge bank for advice on equipment setup, operation and efficient maintenance. This helps minimise equipment failures and subsequent downtime which, by its very nature, is costly.  

With the crushing and screening industry constantly evolving on the back of advancements in technology, Pilot Crushtec invests heavily in training to keep its customer support technicians up to date with the latest equipment and industry trends. 

“As machines get more complex incorporating more automation, onboard diagnostics and remote telemetry solutions, we continue to invest in the multiskilling of our technicians to enable them to diagnose and set up machines quickly and safely,” he says. “This builds trust with our customers knowing that we can deliver and support our equipment. Our customers, both experienced and inexperienced, appreciate this level of technical expertise and that in turn has been key to the growth of our business.”

“In my opinion, the starting point is training. We have developed a very detailed training matrix for the customer support team – a live document which we update on a monthly basis. Our Corrective Action Request (CAR) is also an engrained process in the organisation that often provides input into our training matrix,” Abelho explains. 

Pilot Crushtec’s matrix identifies training requirements within the customer support team, indicates which individuals are being trained and which technicians are already competent. The company also conducts formal weekly training sessions, which vary from a formal structural training session to less formal discussions about an activity or experience gained during the week.

In addition, as the Southern Africa distributor for Metso crushing and screening equipment, Pilot Crushtec has access to this global player’s online eLearning portal with well over 100 courses. The goal is to get RICO certification for every Pilot Crushtec customer support technician, which takes about a year to acquire and requires a formal assessment by a Metso engineer. 

While training presents a prime opportunity to expand the knowledge base of field service technicians, it is, however, not cheap – it takes time and money to develop technical skills. Given the dearth of these skills in the industry, Abelho notes that it is a challenge to retain skilled technical people as they are in great demand globally. 

“Some years ago, we had to come to terms with the fact that there is a massive technical skills shortage in the country and the world at large. Instead of moaning about it, we decided to be part of the solution. We therefore invest in a training programme for university of technology students which has, over the years, provided us with a sustainable pipeline of technical skills,” he says. 

During the past 13 years, more than 70 engineering students have gone through the practical phases of their mechanical and electrical engineering studies at Pilot Crushtec’s Jet Park, Gauteng facility. The programme plays a critical role in developing Pilot Crushtec’s talent pipeline and is also a deliberate effort to foster skills development and transformation in the engineering and mining sector as a whole. 

“About 10 of these graduates were permanently employed by Pilot Crushtec after demonstrating an in-depth understanding of our products’ mechanics, electronics, performance and maintenance. For these efforts, Pilot Crushtec has received the coveted Employer Excellence Award from KwaZulu-Natal-based Mangosuthu University of Technology for the practical support it continues to give to engineering students, which is testimony to our efforts to plug the technical skills gap in the country,” concludes Abelho. 

Client Focus

WEIR MINERALS’ LINATEX SCORES ITS CENTURY OF SERVICE

It is now a full century that mines and industry have been relying on Linatex® rubber products from Weir Minerals to protect equipment from abrasion, impact and corrosion. 

“The remarkable qualities of natural rubber in a range of demanding mining and processing applications have made Linatex integral to our customers’ success over the past 100 years,” says Boitumelo Zimba, Rubber Product Manager at Weir Minerals Africa. “The product breakthrough which has differentiated us in the market is our proprietary liquid phase compounding (LPC) process. This is a gentle process that retains all the valuable qualities of the high quality natural latex which is our central ingredient.”

The more common processes, used by competitors in the market, effectively change the molecular structure of the natural rubber, resulting in shearing that undermines the resistant qualities of the final product, she explains. By contrast, Linatex® Premium Rubber exhibits outstanding strength, resilience and resistance to cutting and tearing, giving superior performance in wet abrasion conditions.

“The LPC process gives us a product that is 95% natural latex – and we are the only company producing rubber this way,” she says. The applications are well known, from impact liners in transfer chutes to abrasion resistant lining in pumps and hoses. Over the decades, the applications have broadened as the company applies its research and development to various potential modifications.

Proven value

Over the course of the last century, there have been plenty of success stories in mining. What has become increasingly crucial, however, is the quantification of the benefits that Linatex® Premium Rubber can bring to specific applications, argues Zimba. As mining embraces increasing levels of technology and digital monitoring, it becomes easier to monitor equipment performance and cost of ownership.

“One of our mining customers in central Africa needed to extend the service life of their tailings pipeline,” she explains. “Due to the abrasion resistant qualities of our Linatex Premium Rubber, the customer was able to save over US$110,000 per annum on their tailings pipeline, after ceramic liners were replaced by a 12 mm layer of Linatex Premium Rubber.”

This meant that the pipeline would last 36 months instead of nine months, reducing the cost of liner replacement and downtime. In another successful application, Weir Minerals Africa used a nitrile-based rubber compound in a mining customer’s flotation tanks, which were previously lined with ceramic tiles. The results were again dramatic, increasing the replacement intervals from two months to 36 months. 

“This ultimately saved that customer almost US$570,000 a year, reducing downtime considerably,” she says.

In another successful application, Linatex® modular panels has solved the challenge of high wear rates on a mine’s hydrocyclones in Kazakhstan. KAZ Minerals’ Bozshakol copper mine was facing difficulty with wear rates on the rubber and ceramic-lined launders in its primary hydrocyclone clusters. This resulted in costly downtime every two to three months, when time consuming rubber patching would have to be carried out by the Bozshakol maintenance team.

After conducting 3D scanning of the cyclone cluster launder, Weir Minerals wear experts proposed the wear resistant 25mm Linatex® steel-backed bolt-down modular panels with high open area. The modularity of these panels allowed KAZ Minerals to replace the worn parts one by one, without the need to patch-repair.

The Linatex® modular anti-abrasion panels were installed in October 2019, and it was an impressive 21 months before some of the panels were finally ready to be replaced. This meant an increase in wear life of 584%, saving on downtime as well as on about 450 labour hours in maintenance. The success achieved at Bozshakol led other KAZ Minerals mines to also order the Linatex® modular antiabrasion panels.

At its copper, gold and silver mine in the Grasberg minerals district, PT Freeport Indonesia was also experiencing the challenge of high wear rates. In this case on its SAG mill discharge box dart valve seat liners. With the incumbent liners lasting only three months, the mine was forced to conduct early shutdowns as the SAG mill maintenance interval was every six months.

The Weir Minerals solution was to introduce superior Linatex® rubber material and mould the product into the existing dart valve seat configuration. The team also re-engineered and

introduced a taper shape to give extra impact absorption for the rubber-lined product. This extended its life to up to seven months, allowing the SAG mills to run uninterrupted for the full six months between scheduled shutdowns.

Quality production

The specialised science of processing natural rubber latex has been maintained at the company’s global production facility in Kuala Lumpur, Malaysia – ensuring the highest levels of quality are consistently delivered in a continuous production process. The progressive manufacturing expansion ensure a reliable supply for the worldwide market, she says. The supply chain for the natural rubber is also based on sustainable principles, ensuring that the trees are not destroyed and that the harvesting process is environmentally responsible. 

“As the most significant input to the Linatex products, the latex we use is tested extensively before processing – first at our suppliers’ facility and again at our manufacturing facility,” she explains. “Each batch of rubber produced is sampled and tested, and customers have the option to request a product test certificate.”

Zimba concludes that Weir Minerals will continue to find innovative ways for Linatex® Premium Rubber to add value to customer applications, ensuring that the distinctive quality of this market leading product range finds new and exciting uses.