Contributed by MEMSA and SAMPEC
Africa’s mineral wealth has long been a cornerstone of economic growth, providing strategic resources critical to the global economy, while creating wealth, investment and employment on the continent. Mining activity for green minerals is set to grow by 600% to satisfy global demand, and much of these resources lie in Africa. Yet, Africa’s advantage may be threatened by climate change, social and governance issues and technological advances.
The Buraaq SD212i is a locally designed, fully mechanised roof bolter for use in underground mining operations. Supplied by Buraaq Mining Services
Future-proofing Africa’s mining industry becomes essential for its long-term resilience. This transformation involves adapting to new technologies, developing local linkages to industry and skills pipelines, enhancing environmental and safety practices, and aligning with Environmental, Social and Governance (ESG) principles. “Mining businesses need to work with innovation partners and equipment suppliers to reshape traditional thinking, redefine operations, and pave the way for a new era of mining that balances profit with progress,” according to Mining Equipment Manufacturers of SA (MEMSA), chair Innocent Masinga.
The SA Mineral Processing Equipment Cluster (SAMPEC), was established to assist local OEMs realise the African vision for the continent of developmental mining. To fully benefit from its natural resources Africa needs to add value on the continent. However, in order to do so we need skills, infrastructure, energy and most importantly capital – something we could potentially leverage off our mineral wealth.
The 2024 MEMSA Mind Shift Conference on Innovation, Digital Technology and Skills in the SA Mining Supply Chain, aptly themed ‘Smart Solutions for People and Planet’, brought together experts and thought leaders from the mining value chain to delve into reimagining the minerals industry, emphasising the importance of local entrepreneurship and innovation in achieving sustainable and technologically advanced mining practices.
Remaining competitive with innovation
Innovation and adaptability have become the heart of the mining industry’s ability to remain competitive in a fast-changing world. Investment in technology to drive efficiencies and improve outcomes and automation, AI, and the IoT are now cornerstones of operations, helping companies streamline processes, increase productivity and reduce costs.
The annual Innovation for Mining Awards which form part of the conference, recognises local innovations developed and commercialised by local OEMs who supply and service the mining industry.
Tools which assist in predictive maintenance and foresee equipment failures can minimise costly downtimes and extend equipment lifespan. Sensors and tracking systems such as Simera Trace Digital Ore Identification create a digital trail and monitor mine conditions in real-time, allowing operators to make quick adjustments to reduce energy use, improve safety and lower environmental impact.
The digital revolution has also spurred companies to redefine operational processes to be more agile and resilient. For African mining operations, where geography and logistical challenges can hinder production, digital twins are revolutionising how mine operations are managed. The Digital Business Case Evaluation and Tracking Tool by Digital Twin uses Excel based calculations and reporting while the app tracks the performance of implemented initiatives against expected benefits. The web-based sensor analytics platform ingests, stores, analyses and displays data, providing digital initiative evaluation (financial/non-financial) at the mine or across several mines.
In addition, cloud computing is enabling African mining companies to store, process, and analyse data more efficiently. With cloud-based solutions, data from different sites can be centralised, allowing teams to make informed, data-driven decisions no matter where they are. For example, mine managers can access performance metrics, environmental conditions, and equipment health in real-time, leading to faster responses to potential issues and fewer delays in production. As digital transformation accelerates across Africa, companies that adopt these technologies are better positioned to thrive in an increasingly competitive market.
A modern water powered rockdrill in action in a South African PGM mine. This proudly South African designed and manufactured mining equipment from HPE, makes for safer and faster drilling at the least possible cost and water
consumption. Supplied by Hydro Power Equipment (HPE)
Environmental sustainability
Mining companies across Africa recognise the growing importance of Environmental, Social, and Governance (ESG) principles. Investors, governments and communities are demanding greater transparency, responsibility and action from the mining sector to address environmental and social impacts. A strong ESG framework is no longer just a regulatory requirement but a strategic imperative to attract investment and secure long-term sustainability. To support effective interventions, the ESG Impacts Lens Dashboard was developed through collaboration by the Mandela Mining Precinct and partners including The Research Institution for Innovation and Sustainability (Riis). The cloud-based application integrates three dashboards to analyse and display data sourced from mining operations, delivering insights on Business Priorities, Socio-Economic Transformation and the Impacts of Automation.
Environmental sustainability remains a top priority. Traditional mining processes are energy-intensive and produce significant emissions and waste. Many African mining companies are now exploring renewable energy sources, such as solar and wind power, to reduce their carbon footprint. For example, the mining industry in South Africa has seen a surge in solar projects, with companies harnessing solar energy to power mining operations in remote regions. These renewable energy initiatives lower greenhouse gas emissions, reduce reliance on fossil fuels and result in considerable cost savings in the long run.
Water scarcity is another pressing environmental concern for mining operations. Some African regions face severe water stress, and traditional mining processes are water intensive. Mining companies are adopting water recycling technologies and more efficient water management systems to mitigate this issue. These solutions reduce water usage and decrease environmental degradation, preserving valuable water resources for local communities. With their Maxi Bolter and PP3 power pack, MEMSA member Hydro Power Equipment (HPE) has developed a safe, fast, environmentally friendly, water wise, and complete roof bolting solution which can be operated remotely via umbilical controls. The power pack delivers high pressure water to operate three maxi bolters in a typical bord & pillar mining section and can be transported via utility vehicle cassette. Our members have demonstrated that – counter-intuitively – water powered equipment consumes less water than pneumatic equivalents. Hydro Power Systems (HPS) were recognised in 2022 for their HD202 Hydrovessel, a piston pump with digital sensors and 4IR capability to enable remote monitoring for greater efficiency.
Enhancing safety
Safety is paramount in mining, where hazardous conditions can put workers at significant risk. Future-proofing African mining means enhancing safety measures and creating a culture of care and prevention. Modern technologies, including real-time monitoring and predictive analytics, are playing a key role in improving safety standards. MEMSA members have risen to the challenge by bringing improved safety designs to market. GR Mining effectively reduced the time and cost involved in commissioning underground refuge bays, by designing collapsible, easy to erect and legally compliant emergency toilets. Their vent trapdoor is designed to open automatically and improve airflow when dangerous levels of methane are detected.
The patented Mud Rush Chute developed by SKW Project Engineering underscores a commitment to zero harm within the mining industry. The double-door system ensures safety and efficiency, a small feeder door controls the regular flow of ore, while the larger safety door plays a critical role in emergencies, activating to provide an escape for operators during mud rush incidents while also serving as a barrier to prevent mud ingress into the tunnel. Buraaq Mining’s Low Profile Drill Rig, suitable for low profile applications, demonstrates significant safety enhancements and is MHSA regulation Level 9 ready. The programmable safety features include seatbelt and door interlocks and a canopy warning alarm, digital pre-start procedure with operator verification, data logging to track machine events, a six-nozzle automatic fire suppression system and has a wireless remote operation up to 100m.
SME member Khentsa Steel developed a tube pressure testing device, which aids the seam welded tube industry to ensure the safety and integrity of products such as lancing tubes which are used in mineral processing.
Innovations such as these are reshaping safety protocols, reducing accident rates, and promoting a culture of safety across the African mining landscape.
Developing sustainable practice for efficiency
As African mining companies continue to innovate, they are also focusing on developing sustainable practices that meet international standards, increase profitability and increase ‘Life of Mine’ (LoM).
Nkangala Mining’s Intelligent Face-Drill patented alignment system, uses 4 reference point sensors ensuring a 90-degree alignment to the face at all times, even on sloping faces allowing parallel drilling of subsequent holes. Drill accuracy ensures consistent particle size, resulting in improved removal operations, greater efficiency and cost saving. Boasting a Level 4 diesel engine, the drill has automated features meaning less-experienced operators can drill at a more predictable level.
Fabchem Mining’s patented SPT100 SMART Pull Tester for roof support digitises and significantly speeds up collection and reporting of pull testing on bolts and split-sets, while Report Writer software saves time and eliminates human error. Boasting electronic load and displacement sensors and ten load indication LEDs, data can be downloaded to a PC, smartphone or tablet.
DaltronX have patented Drill Steels which surpass traditional rubber ferrules by reducing slippage and coolant leakage. Advanced electric upsetting manufacturing processes, hexagonal cross-section and integrally formed collar ensure a precise chuck fit. The drill steels ‘Bulb/Washer’ ferrule and new Drill Depth Indicator endure 150% more force with superior durability to operational pressures, fewer failures, less downtime, and a safer work environment.
The Trackledon Track Roller Manipulator’s patented dedicated track rolling and manipulating attachment, developed by Machinery Contractors in collaboration with a global OEM. Modular design can be attached to a forklift or fitted to the workshop floor allowing for the safe, remote controlled lifting of tracks. Developed with a cable reeling attachment it offers a safe, efficient and cost effective alternative for workshops.
While in the processing space, Energy and Densification Systems (EDS) designed a compact vertical Multi-Shaft Mill utilising high-speed impacts to break down particles with large reduction ratios, low energy consumption and improved liberation compared to traditional milling methods.
Multotec’s innovative Pulping Chute contributes to significantly lowering costs and reducing downtime in the ore washing and scrubbing process. The chute scrubs ore material in a carrier liquid, liberating unwanted materials such as mud, clay, and slime from the surfaces of the ore; with no moving parts, and by using the potential and kinetic energy of a slurry feed.
Supplied by AZMET Technology and Projects
Circular economy approach
The circular economy approach is another forward-thinking strategy, emphasising the recycling and reuse of materials to minimise waste. By treating mining waste as a resource rather than a byproduct, companies can extract additional value while reducing their environmental footprint. For instance, reprocessing tailings (mining waste) can yield valuable metals while rehabilitating land, transforming what was once a liability into an asset. This aligns with global sustainability goals and creates new business opportunities for African mining operations.
One such example is the Gravitas Minerals Coal Recovery Processes, which spent three years in collaborative development with Fraser Alexander and the end user to giving life to a -6mm coal duff system. The profound impact of the system is reshaping the mining industry, creating environmental and economic opportunities for various commodities such as chrome, iron ore and manganese through extracting value from tailings dams/waste dumps. This puts gravitas®️ at the forefront of ESG.
AZMET Technology and Projects, who have developed a Carbon to Metal Converter in response to the needs of the industry which recovers metal from coarse or fine activated carbon, wood chips and other processing wastes, reducing waste while increasing mine profitability – is another example of environmentally sound innovation for sustainability.
Conclusion
The future of African mining hinges on the industry’s ability to embrace innovation, prioritise ESG principles and create a safer, more sustainable working environment. By leveraging automation, digital twins, renewable energy and blockchain, African mining companies are not only staying competitive but also redefining what it means to be a responsible mining operator. Enhanced safety protocols, community engagement and environmentally conscious practices signal a shift towards a more resilient and future-ready industry.
As African mining evolves, collaboration among stakeholders – including mining companies, governments, local communities and technology partners – will be essential to continue this journey. By integrating new technologies, fostering a commitment to ESG principles and advancing safety standards, the African mining industry can achieve long-term resilience. This journey will ultimately ensure that mining remains a key driver of sustainable economic growth in Africa, contributing to a future where the continent’s rich natural resources are a source of both wealth and well-being for generations to come.