IOTDC, in partnership with Sentinel, helps embed these requirements into operations. With robust field sensors and satellite data, Sentinel delivers round-the-clock visibility of tailings dams, turning raw data into actionable alerts and compliance-ready reports.

• Continuous monitoring: Sentinel combines sensors, satellite and drone data on one platform to track dam water levels, seepage and ground stability in real-time.
• Predictive alerts: AI analysis detects anomalies and long-term trends. Instant alerts meet GISTM’s early-warning requirement.
• Mobile data capture: A mobile application allows field teams to log geo-tagged measurements on-site, even offline.
• Automated reporting: Sentinel auto-generates regulatory-ready reports from GISTM-aligned templates, eliminating manual spreadsheet work.
• Role-Based dashboards: Secure dashboards give executives and boards clear TSF status overviews, while regulators and communities can access approved data.

Governance and accountability. GISTM requires designated leadership and board oversight for tailings safety. Sentinel supports this by streaming up-to-date dam data to management dashboards. Its approval workflows and audit trail reinforce accountability – for example, each reading is time-stamped and manager-approved. This transparency directly supports GISTM’s governance principles.

Real-time monitoring and risk management. Sentinel continuously monitors key factors with live sensor feeds and satellite imagery. The system analyses these inputs to detect any deviations from safe norms. For example, a rapid rise in reservoir level after heavy rain will trigger an immediate alert. These proactive warnings enable early remedial action – directly aligning with GISTM’s emphasis on prevention.

Stakeholder engagement and transparency. GISTM stresses open communication with affected communities. IOTDC’s platform supports this by sharing live TSF data via secure portals. Clients and regulators can log in anytime to view geo-tagged measurements and dam status. Automated alerts and summaries ensure stakeholders receive the same information promptly, building trust and meeting GISTM’s transparency goals.

Emergency preparedness and early warning. GISTM requires specific emergency response plans and early warning systems. Sentinel underpins this by linking sensor alarms to incident workflows. For example, if a stability sensor exceeds a safe threshold, the system automatically notifies on-call staff and triggers a response plan. Incident logs and drill outcomes are recorded in the platform to improve future readiness.

Streamlined reporting and ESG credibility. Sentinel dramatically cuts the compliance burden. Automated data collection and report templates keep tailings performance logs current, rather than relying on delayed spreadsheets. This transparency meets GISTM’s reporting requirements and strengthens a mine’s ESG credibility. Demonstrating real-time TSF oversight improves safety, reassures insurers, and shows investors that risk is actively managed.

The post Achieving GISTM compliance in African mining appeared first on Mining Business Africa.

As an alternative, composite materials – where steel or rubber are meticulously combined with other products – have demonstrated better performance when exposed to abrasive, corrosive, and sharp minerals. However, traditional rubber and steel liners remain vital for specific applications, and leading manufacturers like Tega Industries continue to enhance these alongside advanced composites.

In the rough environments where equipment is deployed for different applications in African mining operations, component wear and tear is unavoidable. Hence, wear liners are expected to offer the first line of protection.

That is why liners made of different materials are used. Traditionally, steel and rubber are most preferred, primarily due to their ready availability, strength, and cost-effectiveness.

However, while these materials serve the purpose, they have their own limitations, as they are also vulnerable to wearing and tearing prematurely. For instance, when exposed to highly abrasive, corrosive, or high-impact materials, traditional steel liners may corrode or crack, and rubber liners may degrade faster.

At the end of the day, as far as industry experience goes, the sober fact is: not all wear materials are made equal. The cost of downtime to mission-critical equipment due to poor wear liners – not to mention the cost of replacements and repairs – has been well documented.

Alternative and Enhanced Wear Materials

This challenge presents an opportunity for discerning manufacturers to create alternative materials and improve traditional ones to meet contemporary industrial needs. One of the companies that has stepped up in this area is Tega Industries, which is amongst the largest manufacturers of mill liners globally, with facilities in India, South Africa, Australia, and Chile.

Material Selection

Tega Industries offers a comprehensive range of liners, combining traditional and advanced materials to suit diverse mining applications. Their portfolio includes:

1. DynaWear Rubber Liners
   These are manufactured from specialised, high-pressure moulded rubber compounds with superior damping, abrasion, and impact-resistant properties. Designed for wet grinding applications like ball mills, DynaWear liners are effective in moderate abrasion environments and can be enhanced with embedded steel plates to extend service life.

2. DynaSteel Liners
   These steel-based liners, often combined with rubber in composite designs, are tailored for high-impact environments such as SAG or AG mills. DynaSteel liners offer robust protection but may require complementary materials in highly abrasive or corrosive conditions.

3. Elastocer Liners
   These feature a highly wear-resistant surface of ceramic rods embedded in a flexible rubber matrix. The ceramic offers maximum abrasion resistance, while the rubber effectively damps impact forces, making them ideal for harsh, abrasive environments.

4. Polyurethane Liners
   These elastomer liners offer a balance of rubber and plastic properties, providing excellent abrasion and impact resistance for mixed environments.

Material-Specific Design

Mining clients have different needs for their respective applications. Accordingly, Tega Industries selects and configures wear-resistant liners based on the specific characteristics of the materials being handled, including particle size, moisture, and abrasiveness. For example, DynaWear rubber liners are suited for wet grinding with moderate abrasion, while DynaSteel liners excel in high-impact scenarios, and Elastocer or polyurethane liners are chosen for extreme abrasion or corrosion.

The Need for Wear Monitoring

Inevitably, mine liners wear over time, and monitoring is vital. Beyond material selection, Tega provides real-time condition monitoring of wear parts to enable predictive maintenance, applicable to both traditional and composite liners.

Traditionally, this task has been conducted through physical inspections. While well-intentioned, this method is not always effective, as it is typically time-consuming and cumbersome.

Intelligent Monitoring

To help mining companies reduce unplanned downtime, Tega integrates smart technology into its products and services to enable data-driven, predictive maintenance strategies. Its holistic intelligent monitoring system includes:

a.    An IIoT-based Monitoring System

An Industrial Internet of Things (IIoT)-based system that monitors liners in real time. Sensors alert operators about a liner’s health, wear rate, estimated replacement date, and operating conditions, whether it’s a DynaWear rubber liner, DynaSteel liner, or an advanced Elastocer composite.

b.    3D Scanning Solutions

Advanced 3D scanning technology minimises risk and maximises cost-effectiveness. It is used for wear analysis of mill liners to accurately forecast replacement dates, ensuring liners are used to their full potential, regardless of material type.

‘Maintenance Only as and When Needed’

Ultimately, by combining smart materials – ranging from traditional DynaWear rubber and DynaSteel liners to advanced Elastocer and polyurethane composites – and advanced digital technology, Tega helps companies maximise equipment uptime, reduce costs, and improve operational efficiency.

Most significant is their role in predictive maintenance. By analysing sensor data, Tega’s systems can predict wear patterns and potential equipment failure across all liner types. This allows clients to perform repairs only when necessary, reducing the frequency of unplanned shutdowns. Maintenance is done as and when needed, shifting it from reactive to proactive scheduling.

The post Smarter materials, intelligent monitoring, improved maintenance appeared first on Mining Business Africa.

WearCheck, Africa’s premier condition monitoring specialist, is pleased to announce the official launch of the website for Lubrigard, its dedicated lubricant management division.

Built in collaboration with WearCheck, the Lubrigard platform clearly demonstrates the company’s commitment to LubricantEnabled Reliability (LER) – the principle that maintaining lubricants in peak condition promotes optimal asset performance, extended equipment life and reduced operational costs.

Lubrigard division manager, Chris Hattingh, has been with WearCheck for more than 15 years, specialising in LER for the past five. He views the new Lubrigard website as a pivotal growth point in Lubrigard’s journey, an extension of his team’s offering, and an important source of information about LER processes, which aids customers with decision-making.

With the new website serving as an efficient business tool, Hattingh is pleased to be able to offer clients clear and simple solutions once key objectives are established, cutting through complexity. Clients now have direct access to Lubrigard’s value propositions in one place, with immediate ability to engage and requested tailored, online support, eliminating the wait for proposals.

‘What’s more,’ says Hattingh, ‘visitors to the new website gain insight into Lubrigard’s FLAC strategy – a comprehensive focus on Fuels, Lubricants, Air and Coolants. Our holistic approach utilises data mining and targeted analysis to highlight contamination in key systems early, before it impacts performance or causes breakdowns.

‘Using advanced sensory technologies and oil analysis data, the Lubrigard team provides real-time insights into the health of both the lubricant and the components it serves. We also offer a range of specialised products tailored to specific applications. Our unique techniques allow us to monitor not only the condition of the oil and fuels, but also the performance of the machinery through improved WearCheck oil analysis data.

‘Furthermore, at Lubrigard, we use RPVOT (rotating pressure vessel oxidation test) testing to measure lubricant oxidation resistance – especially crucial for turbine oils – demonstrating the depth of its technical capabilities.

‘An added component of Lubrigard is iGard, an IoTbased system, which integrates sensory technology, historical oilanalysis trends and realtime data. The result: a fully integrated view of asset health, early wear warning and proactive maintenance planning.

‘Our site also features Lubrigard’s range of precision-engineered components and best-practice lubrication tools. These include filtration systems for lowpressure systems; a variety of breathers – disposable, rebuildable, desiccant and spinon types; sampling valves engineered for accurate, reliable oil-sampling in diverse environments, and adaptor kits to streamline lubricant handling – from drum or IBC (intermediate bulk container) transfer to connection with filtration units.’

Hattingh adds that Lubrigard emphasises its broader capability in customer training and support – building on WearCheck’s reputation for quality training courses and customer-focused reporting platforms. Lubrigard’s online courses make training convenient for customers who have dedicated training classrooms on site. Certificates are issued following the successful completion of each Lubrigard  course, many of which are accredited through the ICML (International Council for Machinery Lubrication).  Courses include machine lubrication technician I, machine lubrication analyst I and II, and machinery inspection & verification of lube programmes.  Additional courses cover topics ranging from fundamentals and base oils to contamination control, degradation and turbines.

Hattingh states that the website launch marks a key point in Lubrigard’s trajectory to reach a wider customer base, with a larger product and service offering.  ‘The website not only consolidates our service portfolio – LER strategy, FLAC framework, iGard platform and robust product suite – it also brings transparency and confidence to clients seeking reliable lubricationmanagement partners’

The post New platform dedicated to lubricant management appeared first on Mining Business Africa.

Overcoming Challenges in Mining with Robust Bolting Solutions

In the mining industry, equipment must endure vibrations from drilling, crushing, and milling processes. These vibrations can loosen bolts and other fasteners, leading to equipment failure and costly downtime. Therefore, the bolts used in mining must possess superior resistance to vibrational loosening. Swagefast’s vibration-resistant fasteners, such as the Swagebolt Pin and Collar is designed to maintain their integrity even under intense and continuous vibration, ensuring machinery and components remain securely assembled.

Heavy loads are another significant challenge in mining environments. The immense weight of materials handled by mining machinery places substantial stress on their fastening systems. Fasteners used in this context need to have exceptional tensile and shear strength to handle these loads without deforming or failing. Swagefast provides high-strength fasteners made from durable materials that can support heavy loads and enhance the longevity and safety of mining equipment.

Exposure to corrosive substances is a common issue in mining operations, particularly in environments where machinery is subjected to moisture, chemicals, and abrasive materials. Corrosion can significantly weaken fasteners, leading to premature failure. Swagefast offers corrosion-resistant fasteners with different surface coatings, to provide long-term durability in harsh, corrosive environments.

Best Practices for Fastener Maintenance and Replacement in Mining Equipment

To maximise the lifespan and reliability of fastening solutions in mining equipment, regular maintenance and timely replacement are crucial. Best practices for fastener maintenance include periodic inspections to check for signs of wear, corrosion, and loosening. Implementing a scheduled replacement program for critical fasteners can prevent unexpected failures and maintain operational efficiency.

Furthermore improved fastening technology play a vital role in ensuring worker safety, minimal downtime and improved regulatory compliance, these systems contribute to Environmental, Social, and Governance (ESG) goals by reducing waste, supporting other fastener standards such as ISO 9001 for example.

Swagefast’s comprehensive range of fastening solutions are tailored to meet the demanding needs of the mining industry. By choosing the right fasteners and adhering to best maintenance practices, mining operations can enhance safety, reduce downtime, and achieve greater efficiency.

The post Fastening solutions for demanding mining environments appeared first on Mining Business Africa.

The demand for such minerals are expected to triple by 2030 and quadruple by 2040. Demand for lithium is set to increase fivefold by 2040. Cobalt demand will double by then. The total market value of key energy transition minerals is projected to more than double in 15 years’ time.

It is likely to surpass revenue from coal production by more than 50%. This while coal output in Africa is expected to decline by 12.5% between 2024 and 2029 because of reduced investment.

Africa can play a key role in the energy transition, but in order to capitalise on this advantage, it must invest in not only the mining but also the processing of these minerals. By adding value through processing it will ensure that it can exchange its begging bowl for a seat at the table with those who have traditionally and are currently exploiting its natural resources for their benefit and their benefit alone.

The post Invest more in energy transition minerals appeared first on Mining Business Africa.

Mining is a three-stage materials handling process: excavation, liberation and separation. After the ore has been excavated, comminution takes place to liberate the valuable mineral particles from the gangue, whereafter any one of several separation methods are used to separate valuable particles form gangue. No matter how well-optimised the comminution circuit, some valuable particles will always be over-ground, thus creating the many inevitable fragments that are too fine for conventional technologies to effectively recover.

Invert, always invert.

Rudy Niemoller, FineTech’s geologist and founder, formulated FineTech’s InverSep® process trying to answer the question: how does one unlock the remaining value in the massive tailing dumps seen around Gauteng and the Northwest, where the expensive excavation and liberation have already been done? It soon became clear to him that the remaining value in both historic, and current-arising tailings lies within the ultra-fine fraction, where valuable particles smaller than 100 microns pass through conventional processes directly to tailings.

Starting out in a little corner rented from Mintek, Rudy developed FineTech’s novel flowsheet, planning to use commercially available separators in a novel manner. It soon became clear that conventional separators would not be effective, and the long-time Charlie Munger fan invented the BerthaSep separator, an inverted up-flow separator, forming the cornerstone of FineTech’s IP.

From Waste to Value

FineTech’s proprietary technology targets the ultra-fine fraction that conventional plants cannot. The patented BerthaSep® separator, designed for selective recovery of particles under 106 microns, consistently delivers chromite recoveries above 75%. These modular, plug-and-play plants operate alongside host facilities, requiring no additional feed or excavation — only slurry, water, and power. The result: new revenue streams at no capital cost to the resource owner, plus reduced environmental footprint and rehabilitation liability.

FineTech’s first commercial-scale plant, commissioned at Clover Alloys’ Rietfontein Chrome Plant, has proven both technically and commercially successful. The plant also doubles as a profitable test bed, where ongoing refinements to the InverSep® process drive even greater efficiency.

Continuous Improvement and Operational Excellence

At its Pretoria research facility, FineTech continues to refine its process through extensive laboratory and pilot-scale test work. Numerous trial campaigns have been completed across commodities such as UG2 and LG6 chromite, cassiterite, iron ore, and ferrochrome tailings. This pipeline of ongoing R&D ensures that FineTech’s plants remain at the cutting edge, delivering ever-higher recoveries while lowering environmental impact.

The company’s commitment to operational excellence is also evident in its partnerships. FineTech works hand-in-hand with resource owners to design flowsheet solutions tailored to each site’s mineralogy and tailings profile. This approach not only maximises technical performance but also ensures commercial viability for both parties. 

Skin in the game

FineTech believes in true alignment with its partners. Rather than charging for technology access, the company provides fully-funded solutions or joint venture partnerships that share both risk and reward. Host mines supply slurry, water, and power — FineTech brings the process, the plant, and the operational expertise.

This “skin in the game” model means resource owners can unlock immediate value from ultra-fine tailings without incurring upfront capital expenditure. In return, FineTech benefits from long-term revenue sharing agreements that reflect actual plant performance. The result is a partnership structure where both sides are invested in sustainable success.

A Strategic Partner for African Mining

With successful commercial operations already in place and technical collaborations underway with leading players across the Bushveld Igneous Complex, FineTech is positioning itself as a strategic partner in Africa’s mining future. By converting waste into value, the company not only strengthens profitability but also supports the sector’s ESG commitments — reducing waste, lowering rehabilitation liabilities, and ensuring more efficient use of mined resources.

For African mining operators, the message is clear: in a world of rising costs and tighter margins, the next frontier of value lies not in new ore, but in what has already been mined. FineTech Minerals is unlocking that frontier.

The post Fine-mineral recovery unlocks untapped value appeared first on Mining Business Africa.

Alternatively, using its Elios technology, Steinmüller Africa offers autonomous inspections in areas where GPS signals cannot be picked, and eliminates the use of scaffolding or Rope Access. It has clientele in diverse sectors across Africa.

By Jimmy Swira

Ideally, mines expect the drone services they procure for safety and maintenance, inspections, and post-incident investigations in all environments to operate smoothly: delivering data as and when needed. However, the reality is different: frustratingly, most GPS-guided drones on the market fall short in complex, confined, and dangerous spaces – particularly around buildings, structures, and other landmarks – not delivering at all.

This is a problem that Steinmüller Africa has ensured that its Elios technology addresses, as two of the company’s technical team, Fanie Smuts and Carel van Aswegen, assure mining operations.

Challenges with GPS-guided drones

To underline the relevance of Steinmüller’s Elios technology, first demonstrate the challenges with GPS-guided drones when deployed in tight spaces. Van Aswegen: “When inspecting certain mining areas for safety and maintenance purposes, particularly where there are buildings, structures, and others, the GPS signal cannot be picked. The loss of signal has significant implications: the drones would then not be able to locate its current position. This could result in the loss or damage of the drone.”

Steinmüller’s Elios Drone Solution

In addressing this challenge, Steinmüller’s Elios drone solution does not make use of GPS coordinates as a navigation tool. Instead, it employs an optimised radio frequency, FlyAware SLAM Engine, and LiDAR mapping software to track and see surroundings, as well as for its autonomous ‘Return to Home’ function.

Enabled by a Wide Range of Features

Smuts points out that the Elios drone is able to function effectively in such a challenging environment due to the wide range of features and technologies it incorporates. Specifically, these include but are not isolated to:

• Built-in: Visual inspection payload
• Add-Ons: UT, Surveying, RAD, Flammable Gas Sensor
• LiDAR-based Stabilization
• Live Situational Awareness
• Location-Tagged Data
• Collision-Resilient
• Confined Space Access
• GPS-Denied Flights
• 4K Camera (Built-In):
  • Sensor: 12.3 MP, 1/2.3″ CMOS
  • Video Resolution: 4K / 30 fps
  • GSD Resolution: Up to 0.18 mm/pix
  • Focal Lens: 2.71 mm
  • FOV: 180° Tiltable Camera Pod
• Thermal Radiometric Camera:
  • Sensor: Lepton 3.5 FLIR
  • Resolution: 160 x 120
  • Accuracy: ±5°C or ±5%
  • Frame Rate: 9 fps
  • Thermal Sensitivity: ≤50 mK T
• Lighting System:
  • Light Output: 16,000 Lumens
  • Modes: Normal, Dustproof Lighting, Oblique Lighting
• Surveying Payload (Add-On):
  • Sensor: Configuration Ouster OS0 128 Beams REV 7
  • Accuracy: From 0.1% Drift
  • Precision: 1σ +/- 6 mm, 2σ +/- 12 mm
  • Range: Up to 100 m
  • Scanning Rate: 1.3 M pts/sec
  • Photon Sensitivity: 10x
  • Handheld Functionality
• In Post-Processing:
  • Software: FARO Connect (Partner Solution)
  • Features: Data Alignment, Georeferencing, Point Cloud Filtering
  • Export Formats: LAZ, LAS, E57

A Wide Scope of Services

Using this revolutionary technology, Steinmüller Africa currently offers confined space inspections for areas where scaffolding or rope access would be required. This is in Boilers, Vessels, Tanks and Structures.

Worth mentioning, the drone can be flown in areas where a permit for entry is not yet issued, meaning time for inspections is significantly reduced. This makes it up to the task, stresses van Aswegen:

“The drone cuts cost and time significantly.”

Steinmüller is always eager to increase the scope of solutions offered to clients. Currently, it is busy working with software that is compatible with the drone software, in aim to provide services like stock yard measurements and detailed 3D mapping of components to be able to measure location deviations, etc.

The post Drones make inspections in GPS-denied areas possible appeared first on Mining Business Africa.

As Africa’s mining activities intensify to meet surging global demand for minerals – spanning gold, copper, lithium, cobalt, and platinum – the imperative for operational efficiency, sustainability, and cost competitiveness grows ever stronger. In this context, process instrumentation (PI) is not just supportive, it is foundational. Anton Paar stands out among the leading innovators in PI, offering high-precision solutions tailored to the challenges of African mining.

From Data to Decisions: PI as the Functional Backbone

Mining today faces declining ore grades, extending operations to remote terrains, and ever-tightening environmental oversight. Navigating these pressures demands real‑time, accurate measurement across the production chain, from ore preparation and flotation to leaching and tailings management. PI systems – integrating sensors, inline analysers, rheometers, and automation-translate critical metrics (flow, density, pH, reagent concentration) into actionable intelligence, optimising recovery, reducing downtime, and cutting reagent and energy costs. 

Anton Paar: Precision Instruments for African Mining

Anton Paar offers a wide-ranging portfolio of advanced measurement solutions relevant to mining applications:

• L‑Dens Inline Density Meter: A compact, accurate inline device for measuring concentration in precious‑metals refineries. It supports improved recovery by maintaining optimal density and integrates seamlessly into pipelines using durable materials like Hastelloy and Tantalum.
• L‑Sonic 5100 Inline Sound‑Velocity Concentration Meter: Delivers maintenance‑free, highly accurate (±0.02 %) inline concentration readings of acids and bases. Its robust design, featuring 24‑k gold plating or Hastelloy, ensures durability in harsh mining environments. It is ideal for monitoring lixiviant or reagent concentration in gold, copper, uranium, and platinum processing .
• L‑Cor Coriolis Flowmeter: Estimates mass flow and density of fluids with precision, enabling tight control or automation of chemical dosing (e.g. cyanide or NaOH). This supports real‑time optimization of reagent usage and enhances gold recovery while reducing waste

Combined, these instruments improve process control, reduce labor-intensive sampling, and minimize reagent waste—boosting both efficiency and profitability. 

More Than Analytics: Advanced Lab and Process Integration

Beyond inline sensors, Anton Paar’s lab and engineering solutions enable holistic process control. Its process systems and integration involve turnkey, skid‑mounted modules that combine sampling, monitoring, analysis, and control. Pre‑configured and factory‑tested for easy deployment, they integrate Anton Paar’s sensors into streamlined process workflows – even in challenging operational conditions.

The laboratory & analytical instrumentation spans density, refractive index, CO₂, rheometry, viscometry, and sample prep systems, supporting both upstream R&D and QA in mining operations. Coal and raw materials analysis incorporates specialised tools such as microwave digestion systems and electrokinetic analysers, supporting environmental monitoring and control of raw material quality in coal and mineral applications.

Operational Benefits Across Africa

For African mines Anton Paar innovations yield tangible advantages. Optimised reagent use & recovery use real‑time measurement of leach solutions or acid concentrations ensures precise chemical dosing-critical in the face of volatile reagent costs. Automation & day‑night continuity eliminate inline meters’ dependence on laboratory sampling, enabling 24/7 operation and reducing response times to process shifts. Robust field‑ready designs employ wear‑resistant materials (Hastelloy, gold plating) and compact form factors designed for harsh mining environments. Anton Paar Southern Africa has expanded significantly, with branches in Johannesburg, Western Cape, KwaZulu‑Natal, and technical coverage across Tanzania, Ethiopia, and Cameroon. Their 70‑plus‑person team provides sales, applications support, certification‑grade service, and training – ensuring smooth integration and ongoing operation of their PI systems.

Driving Digitalization & Sustainability

Anton Paar’s sensors serve as the data foundation for broader digital ambitions in African mining. Advanced process control (APC) becomes feasible through real‑time feedback loops from inline measurement systems. Predictive maintenance is enabled through integrated PI data, feeding into health monitoring systems. Sustainability tracking means process emissions, water usage, chemical efficiency can be quantified and managed more precisely. Remote monitoring is increasingly critical for geographically dispersed operations; Anton Paar’s robust inline sensors empower control-room oversight.

Strategic PI for Africa’s Mining Future

For African operators and investors, the message is clear – process instrumentation is not an optional add-on, it is a strategic enabler of operational excellence. When combined with Anton Paar’s precision measurement tools, integrated process systems, and regional support capability, it forms a powerful platform to enhance recovery, reduce costs, and strengthen sustainability. By embedding Anton Paar’s advanced PI into the heart of mining operations, Africa’s mining sector can not only compete but lead in the increasingly demanding global mineral economy.

The post Empowering Africa’s mines with precision appeared first on Mining Business Africa.

A standard bottle roll test, based on the Elsner equation for gold dissolution, usually requires 24–48 hours to reach maximum extraction. This lag creates a bottleneck across the mining cycle, from early exploration through to operational decision-making.

That bottleneck is now obsolete. Mineral Process Control (MPC) Pty Ltd has redefined assay practice with LeachWELL^TM 60X—a proprietary accelerant that doesn’t just speed up bottle rolls, it transforms them.

The Bottleneck: Time and Variability

Bottle roll assays simulate full-scale leaching to predict potential recovery of gold and silver. They inform plant design, economics, and resource reporting. But confidence has always meant waiting until the leaching curve flattens. Stopping early risks underestimating recoveries; waiting too long wastes valuable lab time.

Ore variability complicates this further. With nuggety gold, large samples—500 g to 2 kg—are required to ensure representativity. This makes time and consistency even more critical.

LeachWELL^TM 60X resolves both problems at once.

The Solution: LeachWELL^TM 60X’s Transformative Kinetics

LeachWELL^TM 60X is more than an additive—it’s a catalytic accelerator that changes the kinetics of cyanidation.

The Dual Advantage:

1. Speed: It accelerates the dissolution of gold and silver by up to 60 times. Tests that once took 48 hours now achieve maximum recovery in just 1–2 hours. This reduction in turnaround time is the single greatest efficiency gain available to labs.
2. Consistency and Cyanide Efficiency: The formula suppresses cyanide losses to competing reactions (e.g. sulphides), preserving free cyanide for gold dissolution. The result: higher recoveries, greater repeatability, and confidence that results are both reliable and fast.

It’s no surprise that “LeachWELL assay” is now often used interchangeably with “bottle roll” in exploration reports and corporate disclosures worldwide.

Safer, Smarter Assaying: The Role of AssayTabs

To ensure consistency and safety in the lab, MPC has developed AssayTabs^TM—a simple, pre-measured tablet that combines LeachWELL^TM 60X with sodium cyanide. Instead of handling powders or liquids, operators can now drop a tablet directly into the bottle roll.

This innovation delivers three critical benefits:

• Safety: Eliminates manual handling of cyanide powders and reduces operator exposure.
• Accuracy: Each tab contains the precise reagent dose required for a standard bottle roll, ensuring consistent results across batches.
• Efficiency: Simplifies preparation, standardizes workflow, and ensures laboratories adopt best-practice methodology with minimal training.

AssayTabs are now regarded as the safest and most effective way to apply LeachWELL^TM in routine bottle roll assays, making high-speed, high-precision testing both accessible and sustainable.

Real-World Impact: Proof in the Field

The transition from traditional fire assays and slow bottle rolls to LeachWELL^TM methods—particularly with AssayTabs—has delivered tangible benefits across projects worldwide.

Case Study 1: Unlocking Value in West Africa

A gold explorer in Mali re-analysed drilling samples using a 2 kg LeachWELL^TM bottle roll with residue fire assay, comparing it to a 50 g fire assay.

• Fire Assay Result: 5 m @ 3.75 g/t Au from 84 m
• LeachWELL^TM Result: 5 m @ 6.14 g/t Au from 84 m

The larger, faster LeachWELL^TM sample captured coarse free gold missed by fire assay, boosting recovery by 150%. This directly increased the reported resource base and improved project economics.

Case Study 2: Precision Grade Control in British Columbia

A Canadian project adopted a 1,000 g LeachWELL^TM bottle roll with AssayTabs for grade control in a high-grade starter pit. Results included:

• High Repeatability – confirming mineralization continuity
• High Recovery – 96.5% gold and 69.3% silver

The speed, safety, and precision enabled better grade selectivity, lower dilution, and tighter mine scheduling—essential for the project’s early production phase.

The Benchmark for Modern Assay Practice

LeachWELL^TM 60X, delivered via AssayTabs^TM, allows labs to test larger, more representative samples (up to 2 kg) with unprecedented speed, accuracy, and safety. Whether refining exploration targets or setting daily plant throughput, mining decisions can now be based on the most reliable and timely data possible.

When project viability hinges on rapid, accurate recoverable metal data, there is only one choice: LeachWELL^TM 60X with AssayTabs.

The future of bottle roll assaying is here.

Contact Mineral Process Control (MPC) Pty Ltd today to optimize your lab efficiency and accelerate your path to discovery.

The post LeachWELLTM 60X is the new standard in gold assaying appeared first on Mining Business Africa.

By Jimmy Swira

There is a perception – amongst some suppliers of products and services – that mining companies are not the most dynamic of clients when it comes to embracing new technologies that can add value to their operations. Arguably, this could be the case with other products, but not in the usage of unmanned aerial vehicles (UAVs), commonly known as drones.

Unprecedented Growth

Notably, in the area of UAVs, there has been unprecedented growth in their usage in the past decade in Africa. UAVs are being deployed across the entire mining cycle – from exploration, daily operations, to mine closure and rehabilitation.

This trend is more or less similar to other mining jurisdictions globally. However, on the continent, mines are using drones to address unique challenges in their respective operations. And strong indications are that more is yet to come.

Solution for Unique Challenges

Based on recent activities on the continent, a vivid picture of the various applications of UAVs throughout the mining cycle emerges – conspicuously in the following areas:

i. Mapping and Surveying

Specialised UAVs equipped with LiDAR and high-resolution cameras are able to produce accurate 2D and 3D maps and generate models for surface and underground operations. This eliminates the need to send personnel to manually inspect areas that would otherwise expose them to hazards.

In South Africa, Palabora Copper Mine uses UAVs for LiDAR scans of underground voids. This enables surveyors to work from a safe distance of up to 100 metres.

At Exxaro’s Grootegeluk mine, Rocketmine uses UAVs for surveying and mapping. This ensures that surveyors can avoid hazardous areas, significantly increase data accuracy, and improve turnaround time by providing real-time data on a shift-by-shift basis.

ii. Volumetric Measurements

By conducting frequent aerial surveys, UAVs can rapidly and accurately calculate the volume of stockpiles and help determine the movement of material.

Exxaro Resources Group, in partnership with Johannesburg UAV service provider Rocketmine, uses UAVs for a wide range of activities at Grootegeluk mine – among them are stockpile inspection and blast monitoring.

Rocketmine UAVs monitor stockpile movement at Rössing Uranium mine in Namibia, providing accurate data.

iii. Safety and Asset Inspections

UAVs perform a range of tasks, such as visual inspections of machinery. The data collected helps in instituting suitable maintenance programmes. In the end, this prevents failure and enhances asset availability.

In addition, UAVs are used in the inspection of infrastructure like haul roads and hazardous areas such as tailings dams. This helps mining companies take suitable measures to mitigate accidents.

In South Africa, Kumba Iron Ore uses UAVs to survey drilling sites and monitor overall site conditions.

iv. Security and Anti-Illegal Mining

The scourge of illegal mining is becoming a challenge for gold mining companies and authorities on the continent. Illegal miners, who are mostly armed and will stop at nothing to get their way, are encroaching on designated areas, vandalising infrastructure, accessing minerals, and threatening the lives of employees and surrounding communities.

A case in point is Ghana, where the Minerals Commission has implemented a system that uses 28 UAVs and an AI-powered control room to monitor illegal mining hotspots.

v. Environmental Monitoring

The use of UAVs in environmental monitoring has been phenomenal.

UAVs gather data to help monitor the impact of mining activities on the environment. These include – but may not be confined to – assessing reclamation efforts, monitoring land cover, and tracking water quality and sediment flow.

Key Benefits

Through the abovementioned, among some of the applications, UAVs bring benefits to mining operations once regarded as unattainable – mostly in the following ways:

1. Improved Safety

Safety is, without doubt, a major driver of adoption through removing employees from some of the hazardous and dangerous tasks on mine sites.

2. Increased Efficiency and Cost Savings

Efficiency and cost savings are the buzzwords in mining operations. The use of UAVs plays a part in making this a reality.

Manual or helicopter-based surveying is time-consuming and costly. In contrast, UAVs cut down the time and expenses usually associated with these methods. Eventually, this leads to operational improvements and a reduction in costly downtime.

3. Confidence in Data Accuracy

With traditional methods, there are always questions about the accuracy of data, as an element of human error could be factored in. There is always a possibility that conditions under which the data was collected have changed.

Instead, by providing more accurate and frequent data, UAVs give more confidence and lend more credibility to the data. This allows for better decision-making in the respective applications where they are used.

Data provided by UAVs is securely stored in cloud-based platforms. This makes it easy to process and share.

There is no question that the growth niche of UAVs in African mining is unprecedented – bringing about many benefits – and set to add more to the range.

There is a blot, though – if you ask any UAV operator, getting the necessary paperwork to operate can be frustrating – sometimes, unnecessarily so.

The Licensing Barrier

While a free-for-all scenario is not good for operations, there is a perception that strict UAV licensing regulations are a barrier that prevents industry access and involvement in activities that grow economies.

For instance, one UAV solutions provider at a recent exhibition lamented the strict UAV licensing regulations in South Africa, where non-compliance can lead to fines and legal issues.

For one thing, this disconnect between innovation and regulation is worrying: it highlights the need for a more enabling environment that balances safety, accountability, and access.

Once this barrier is removed, there is no question that UAV adoption can continue flying African mining to new heights – supporting growth and transformation.

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