Trafo Power Solutions has supplied 40 dry-type mini-substations, as well as seven standalone ring main units, to one of the Africa’s largest and fastest growing copper operations, situated in the Democratic Republic of Congo.

“We are immensely proud to be involved in this mega project,” says David Claassen, Managing Director at Trafo Power Solutions. “Considerable design work and planning went into this contract, with very demanding lead times to keep up with the mine’s rapid expansion.”

The mini-substations include units of between 630 kVA and 1,600 kVA capacity with primary voltages of 11 kV and 33 kV. The secondary voltage configurations are 400 V, 690 V and 1,000 V – and some units have dual-ratio secondaries. Protection against the ingress of water and dust was also designed into the units, with an IP54 ingress protection rating.

Fully designed and manufactured in South Africa, the mini-substations were completed in a streamlined production process that facilitated a fast track delivery in batches of five to six units every 10 days. After the manufacturing and assembly process, each unit went through a programme of intensive testing before it was ready for dispatch.

“The units are designed to be as compact as possible,” he explains. “While many will be used for surface infrastructure, the design had to ensure that they could be used underground, where space is limited.”

Safety regulations

The underground environment is governed by stringent safety regulations and standards, making the dry-type transformer an ideal choice. This technology uses air rather than oil to cool the windings, making it safer with less risk of fire, explosion or environmental contamination through leakage. The windings in dry-type transformers are also encapsulated with cast resin, protecting them against humidity levels up to 95%.

Undertaking both the electrical and mechanical design, Trafo Power Solutions has ensured a limited footprint through the use of air-to-air heat exchangers. Air is channelled through the transformer windings and flows over the aluminium tubes of the heat exchanger, while a fan blows air through the tubes to cool the air on their outer surface.

“The substation design also includes arc protection, which will shut the unit down in the event of an arc occurring – before any further damage can be caused,” he says. Each mini-substation is equipped with a control system that will allow the protection functions to be monitored remotely.

The contract was conducted through a leading South African engineering, procurement and construction management (EPCM) firm, and Trafo Power Solutions ensured that all units were delivered by the end of 2023.

“Our early engagement with the EPCM was important on this project, as it allowed our team to understand the project requirements and develop a cost effective solution,” Claassen says.

During this process, all documentation was strictly managed within an online system, including designs, specifications and test certificates – to which the EPCM and end-client had easy access. In this way, designs could be uploaded, shared and signed off using this platform, further streamlining activities for the fast pace of the project.

“The ring main units are fully motorised and controlled externally by remote pendant switching,” he says. “This enhances safety and ease of management, so that personnel seldom have to open the panel doors which requires the necessary safety equipment and protocols.”

The transformers are rated for Class H insulation – for temperatures up to 180 degrees – while the dual-voltage boards are sizeable for a relatively complex voltage distribution system on each mini- substation.

“The detailed design and variety of solutions within the complete contract package really highlights the technical capability of the Trafo Power Solutions team,” says Claassen. “This can be seen in the mini-substation from the medium voltage side and its control and protection functionality, through to the low voltage distribution and the customised transformer design for these applications.”

He emphasises that the standard attributes of dry-type transformers allow them to operate reliably with very little maintenance. With air rather than oil for cooling, for instance, they do not require any regular oil testing or oil changing.

The robust nature of dry-type transformers makes them well-suited for mining applications, whether surface or underground. Claassen notes that Trafo Power Solutions’ extensive experience in Africa reflects that dry-type technology is becoming more popular in the mining sector. The reasons for this trend include their inherent safety, their reliability and their ability to operate without much maintenance.

The government of Egypt is set to launch a mining portal that aims to provide valuable information for investors interested in minerals projects in various parts of Egypt.

Petroleum and Mineral Resources Ministry will unveil the digital platform that represents a significant step towards promoting the country’s mining sector and attracting investments. The platform, will offer geological data and maps for mining areas across Egypt. This information is crucial for investors as it helps them assess the potential of different regions and make informed decisions about setting up minerals projects.

Goal

The primary purpose of the platform is to facilitate investment opportunities in Egypt’s mining sector. By providing comprehensive information, the portal aims to attract both domestic and international investors interested in establishing minerals projects in the country.

The portal is designed to promote Egypt’s mining sector not only within the country but also on the international stage. By showcasing the available opportunities and resources, the Ministry aims to attract foreign investments and partnerships that can contribute to the growth of the sector.

The platform will also serve as a source of information on mining project bids. This transparency can encourage healthy competition among investors and contribute to fair and efficient allocation of mining projects. The report mentions that Egypt is rapidly becoming a key metal producer and exporter. In 2023, the country’s metal production reached around 13 million tonnes, with exports exceeding 2.3 million tonnes. This indicates the growing significance of Egypt in the global metal market.

The portal will cover a wide range of metals, including gold, zinc, and iron. This diversity in coverage reflects the rich mineral resources that Egypt possesses and opens up opportunities for investors interested in various types of mining projects.According to the report, the technical evaluation of the new portal has been completed, signaling that the platform is ready for launch. The imminent launch suggests that the government is actively working to create a conducive environment for investment in the mining sector.

Acting Minister of Mines, Fuh Calistus Gentry (pictured), is set to preside over a ceremony on December 22, 2023, to launch the construction of the mine for the globally significant Mbalam iron ore deposit located between Cameroon and Congo.  The “draft program” for this mission signed by the Acting Minister himself on December 19, 2023, does not indicate where the ceremony will take place, nor whether the Congolese authorities will participate. However, it mentions that after the “launch of mine construction work”, “exchanges with local authorities” are planned in Ntam, a Cameroonian town bordering Congo in the Eastern region.

Since August 17, 2022, when the Cameroon Mining Company Sarl (CMC) was awarded the mining permit for the Mbalam iron ore deposit, no information has yet filtered out, either on the financing or on the financial partners of this gigantic mining project. Announcements made by AustSino, partner of Bestway Finance (a Singapore-based investment vehicle with the same parent company as CMC) on the Mbalam mining project did indicate that a group of Chinese companies have joined the project.

They include China Railway 20 Bureau Group Corporation (CR20G), China Machinery Engineering Corporation (CMEC), China Civil Engineering Construction Corporation (CCECC), and China National Chemical Engineering Heavy-Mechanized Corporation Ltd (CNCEHMC), as well as CCC Mining Group Limited. Most of these are construction and infrastructure companies, or mining companies. No financial partners appear on this list. Or maybe, for the construction of the Mbalam mine, Cameroon Mining Corporation is exclusively supported financially by its parent company Coconut Logic Holdings Pte Ltd (which also controls Bestway Finance), an investment vehicle based in Singapore.

Lack of transparency

This situation further complicates the uncertainties surrounding the management of the Mbalam iron ore project, which has faced challenges since the initial developer, Australian Sundance Resources, was unable to see it through to completion. Many observers in the Cameroonian mining sector remain puzzled by how a company (CMC), established on March 16, 2022, managed to secure a mining agreement with the State just two years after its inception (by March 31), followed by the issuance of an operational permit within a mere five months of its establishment. All this on a world-class iron ore deposit.

There is also a lack of transparency surrounding the awarding of this concession, as with all others in the country. In fact, like all the other active mining permits in Cameroon, the CMC mining permit has still not been made public to date, in violation of Article 144 of the 2016 Mining Code (a new one has just been promulgated by the Head of State, ed). This article states that “the acts that enshrine the award, extension, renewal, transfer, farm-out, withdrawal or waiver of an operating permit must be published in the Official Journal and the newspapers of legal announcements.”

As a reminder, the Mbalam iron deposit, which extends to Nabeba in Congo, is considered a world-class reserve. Sundance Resources Ltd, the first developer of the project, planned a two-phase deployment. Phase I involved the annual production of 40 million tons of direct shipping ore over 12 years and phase II to be the extension of the operation stage by over 15 years thanks to the production of a high-grade hematite itabirite concentrate. This project roadmap required an investment of more than CFA5,000 billion. This includes the construction of the mine, a 510 km railway line to the port of Kribi, and a mineral terminal on the same port platform.

Bedeschi, leader in bulk material handling for more than a century, has outstanding experience in realizing complete bulk solutions for the mining sector.

The company can handle any kind of raw materials and additives and provides the design, engineering and manufacturing of integrated solutions covering every company’s needs from quarry extraction to storage, including crushing units, apron feeders, stackers and reclaimers, combined bucket wheel, shiploaders, belt conveyors and pipe conveyors. In particular, in the mining sector, Bedeschi can also offer a wide variety of apron feeders, normal-duty crushers, heavy-duty crushers, stationary units, semi-mobile units and mobile units.

In the past year Bedeschi has completed the supply of a tailor-made plant in Takoradi Port in Ghana boosting its production and revolutionizing the management of the whole terminal.

In 2019, the Ghana Ports and Harbors Authority (GPHA) started the upgrading and mechanization of the Takoradi Bulk Jetty Terminal to significantly increase the throughput of bulk minerals for both export and import. In 2021, Bedeschi was awarded the supply. The scope of works included the design, procurement, manufacturing, supply, construction, supervision to installation, testing and commissioning and staff training for the Cargo Handling Equipment in the Port of Takoradi.

The scope of the project was the supply of handling equipment and services for bauxite and manganese in export and clinker and other materials that are imported.

Bedeschi supplied:

Belt conveyor systems for a total length of av. 3 km;
Two shiploaders A-Frame type mod. 50/1400;
One eco-hopper.
The 2 shiploaders and the eco-hopper were delivered fully erected from the company shipyard directly to the client jetty with a dedicated heavy lift vessel after the Cold Test, to reduce site works and allow the end user to start the operations in a very short time once the machines reached the site.

Delivery of full-erected equipment
The project involves state-of-the-art equipment in terms of environmental standards (dust collection and de-dusting system specifically designed for this application). All the conveyors are closed, including the section where tippers and eco-hoppers are operating, reducing drastically dust emissions.

During the engineering phase, the company designed the machines to facilitate the operation and meet the highest health and safety standards.

The scope involved also, the provision of a computerized control system. Eventually, the machines, managed by VFD, are designed to increase the handling capacity of the bulk jetty terminal by 25%.

With Bedeschi’s proven experience and know-how, the client has complete support on the project execution, from the design to the commissioning.

Before the mechanization of the dry bulk handling, loading was carried out at the new jetty, via barges from the old Clinker jetty as well as at berth no. 2 of the old jetty. Berth 2 provided the possibility of mechanized manganese loading of vessel up to 25,000 DWT (Handy size Class). A Jetty at the north also provided the possibility of berthing vessels up to 100,000 DWT (Capsize Class) but it was not mechanized and used vessels’ own gears for berth operation and trucks for the horizontal transport between berth and stockpiles.

The historical Bulk Jetty Terminal had only the possibility to deliver the minerals from trucks to the vessels only by grab cranes, with limitations on the operational performances.

The same was for the import of clinker and other materials, with delivery directly to the trucks.

Additionally, the layout was prone to serious dust and noise pollution from loading and stevedoring activities.

The terminal before Bedeschi supply

Photo showing original plan of Bulk Handling Jetty

Area A – the new bulk jetty with the following major characteristics:

800 m Quay Wall at -16 m CD depth, divided into 3 berths of equal length, one berth for Clinker, one for Bauxite and one for Manganese ore.

Area B – Bauxite stockpile area.

Area C – Manganese Stockpile area.

The design, procurement, shipping, installation, and commissioning of the equipment covered a period of 18 months. This was a major achievement despite COVID-19 related challenges.

Belts Conveyor under construction

Upon completion of the installation of the equipment, in December 2022, the President of Ghana, his excellence Nana Addo Danquah Akuffo-Addo, participated in the Sod-Cutting ceremony with other dignitaries to earmark this ambitious effort to expand and boost the export of bauxite and manganese and import of clinker to support the industrialization of Ghana.

Opening Ceremony with the President of Ghana

Manganese storge loading hopper

Loading capacity for Manganese export now 2,000M T/H

Loading capacity for Bauxite export now 2,000M T/H

Loading capacity for clinker import now 1,900M T/H

Aerial view of the terminal before and after the supply of the conveyor lines

The Takoradi Project is a clear example of how Bedeschi can offer tailor-made solutions to meet and enhance clients’ needs providing the best solutions possible focusing on environmental protection, energy efficiency and pollution prevention.

Major miners like BHP, Rio, MMG, and Codelco are stopping material losses in the supply chain. Sealed in a container at the Pit and opened in the ship, CBH saves 2% material loss and has no pollution.

CBH is a zero-loss dust-suppression logistics solution that allows the exporting of dry bulk from any port and any crane type. It can be started in six months with low capex.

CBH – a proven dust-free bulk handling solution

The CBH solution is already a  proven solution to the issues of dust generation during the transportation and handling of dry bulk commodities.

By using sealed open-top containers for transport and storage, the CBH system also uses a rotating spreader called ‘revolver’ to handle the container and remove the lid before gently rotating the container 360 degrees to decant the commodity at its destination.

Environmental best practice

The solution is environmentally best practice, as the commodity only sees the light of day immediately before being decanted, with a dust suppression system around the ship’s hatch containing the dust plume generated during the unloading process.

The dust suppression system produces microscopic droplets, creating a wall of dry fog around the ship’s cell to contain the commodity.

Box clever: Zero material loss

Not only does Revolver CBH protect the environment and reduce particulate matter, but it also protects valuable commodities from loss or contamination.

Most bulk logistics systems lose between one and three percent in the handling process with multiple handling and dust generation; CBH stops this. RAM has saved customers more than two million USD annually for mineral concentrates using the CBH system.

Lifting the lid on bulk handling

CBH follows a simple and easy handling process of load & seal, transport, store, and unload. From its initial process of loading the bulk into open-top containers, a lid is placed locking the commodity, where it is transported either by road or rail, then can be stored without stockpiles or storage sheds, and finally picked up and unloaded by the ‘revolver’.

The ‘revolver’ locks onto the container as a standard spreader does, removes the lid from the sealed container before rotating the container and replaces the lid back onto the empty container, completing the lift cycle.

Low CAPEX – Fast to market

CBH is a highly flexible logistics solution, enabling all types of dry bulk to be exported from any port, allowing export from the nearest port, shortening the entire support chain and allowing ports to store multiple types of commodities without stockpiling or cross-contamination.

With most equipment readily available at the port, CBH bulk export can be launched quickly with the RAM ‘revolver’ and sealed open-top containers is all that is required to begin exporting.

A global success – 10 years of Operations in Africa

Since its introduction in Australia in 2011, with the same machine still in operation today, the RAM CBH system has also been used in Africa for over ten years, with the first unit deployed in Port Elizabeth for Elitheni handling coal. Other RAM CHB projects followed in the Democratic Republic of Congo, Mozambique, Eritrea and Mauritania.

Today, ‘revolver’ CBH has gained worldwide popularity, supporting the operations of some of the largest mining companies in the world, including the UAE, Europe, the Americas and Asia.

Telephone:           +44 (0) 1695 556355

Telefax:                +44 (0) 1695 556356

E-mail:                  p.draper@ramspreaders.com

Web:                    www.ramspreaders.com

Michael S. Regan, U.S. Environmental Protection Agency (EPA) Administrator tours the LPG bottling facility

Puma Energy Ghana, a leading energy company, has reiterated its commitment to enabling access to energy and specifically clean cooking solutions as the U.S. Environmental Protection Agency (EPA) Administrator, Michael S. Regan, visited its affiliate LPG (liquified petroleum gas) bottling facility.

The visit, attended by Mr. Michael S. Regan, the Second Lady of the Republic of Ghana, Her Excellency Samira Bawumia, and U.S. Ambassador to Ghana Virginia Palmer, was aimed at familiarising them with Puma Energy Ghana’s LPG operations and the important role it plays in enabling access to LPG in Ghana.

Energy solutions

In sub-Saharan Africa, where an estimated 970 million people lack access to clean cooking fuels and technologies according to the International Energy Agency (IEA), LPG plays a vital role in the energy mix. Many households rely on solid fuels such as wood and charcoal, or kerosene, leading to environmental and health hazards. Household air pollution, predominantly from cooking smoke, is linked to 2.5 million premature deaths globally, while the use of wood also contributes to deforestation.

Puma Energy provides safe, reliable and affordable energy solutions across sub-Saharan African Africa, and is encouraging the transition to cleaner cooking fuels and solar power. Its commitment to enabling access to lower carbon emitting fuels is evidenced by the company’s recent acquisition of Zambian-based Liquid Petroleum Gas (LPG) supplier OGAZ, and its purchase of a 49 percent stake in MBHE, which provides renewable energy project development, implementation and maintenance across southern Africa. Both acquisitions will strengthen Puma Energy’s capacity across its key markets.

Puma Energy’s LPG strategy for the sub-Saharan Africa region is to ensure availability, accessibility and affordability. This involves centralising supply management; setting up mobile cylinder-filling plants managed by local communities to bring the LPG closer to the end user; and working with regulators to allow consumers to buy LPG in small quantities that they can afford as they would charcoal, wood or kerosene.

During the visit, Mr. Regan acknowledged the importance of enabling access to sustainable energy. “Access to clean and affordable energy is essential for economic development, reducing poverty, and mitigating the effects of climate change,” said Administrator Regan. “Cleaner cooking solutions are not just better for the environment, they are better for your health.”

Subsea oil and gas pipelines are frequently constructed by joining concrete-coated segments together. During construction, concrete-coated pipe may sit for six months to several years before installation.

Capital spares are often ordered at the same time as the initial pipes but with a designed preservation life measured in decades of idle time. To ensure that these capital spares do not deteriorate prematurely, Cortec ® shares several technologies and tips for preserving concrete-coated pipes from corrosion.

Challenges of Protecting Concrete-Coated Spares

Subsea pipe spares are often stored near the coast due to material handling difficulties. An incredibly long storage period and an aggressive environment combine to pose a frequently overlooked risk for long-term integrity. Although the concrete coating will initially protect the outside of each steel pipe segment, the concrete will absorb moisture, chlorides, and carbon dioxide over time, eventually leading to corrosion. Extreme temperature swings and sporadic inspection intervals can exacerbate the problem. To complicate matters, the concrete coating makes it difficult to access and treat the OD (outer diameter) of the steel pipe.

Migrating Corrosion Inhibitors to the Rescue

Migrating Corrosion Inhibitor ™ (MCI ® ) Technology is typically used to protect reinforcing metals embedded in concrete because of its ability to travel through concrete pores to reach the surface of the underlying metal. The same mechanism makes MCI ® suitable for protecting the metal pipe OD of concrete-coated pipe. Migrating Corrosion Inhibitors applied to the outside of the concrete pipe can gradually migrate as much as several inches into the concrete to form a protective anticorrosive molecular layer on the steel OD.

Custom engineered chutes are scientifically designed and simulated prior to manufacturing by Weba Chute Systems to give customers optimal uptime – but the company has also innovated ways to keep these transfer points well maintained.

Channeling the flow of mined material is among the most onerous tasks on any mine, and Weba Chute Systems designs and manufactures its solutions to withstand these demanding applications. The considerable wear on the components in a transfer point, however, requires constant monitoring and attention. The company has therefore developed a range of responses to help customers to manage this important responsibility.

According to Izak Potgieter, ISO Systems Manager at Weba Chute Systems, a vital role is played by the company’s technical advisors, who visit customers on a regular basis to check the operation and condition of the chutes.

Chute inspection app

“To make their work efficient, and to quickly provide the customer with relevant information, we developed our own chute inspection app for our technicians,” says Potgieter. “This allows them to capture the necessary data and photographs from their inspection, to generate an automated report to guide the customer in their decisions.”

Across the diverse commodities landscape of Africa, the demand for vibrating screens and feeders is on the rise. Sandvik Rock Processing, a prominent player in the industry, has observed a noticeable surge in brownfields projects aimed at replacing existing equipment in various operations.

Frengelina Mabotja, Business Line Manager Screening Solutions at Sandvik Rock Processing, attributes this increased interest to the company’s strong reputation for delivering fit-for-purpose screens and feeders meticulously engineered to meet specific application requirements.

As one of the leading Original Equipment Manufacturers (OEM) specialising in screening solutions on the African continent, Sandvik Rock Processing stands out with its capability to provide optimised solutions that comprehensively consider every aspect of a process plant’s operation. Mabotja says that at the core of this capability lies the company’s formidable engineering team, playing a pivotal role in tailoring solutions to meet the unique needs of each customer.

Customization

“Unlike a one-size-fits-all approach, Sandvik Rock Processing takes a customised approach, recognising that each process plant possesses a distinct configuration and processes ore with its own characteristics. In essence, we position ourselves as a partner to our customers, offering bespoke screening solutions tailored to their specific operational requirements,” she explains.