Mining Technology, Research and Innovation: CSIR and Department of Mineral Resources and CSIR briefing

Meeting report

Dr Makhapa Makhafola, General Manager: Research and Development, Mintek, said the Mining Industry Growth, Development and Employment Task Team (MIGDETT)   declaration of 2008 had identified innovation as a key enabler for achieving sustainable growth and meaningful transformation in the SA mining industry.

In 2013 the Department had instructed Mintek to drive this process through to 2030 as there was recognition that mining was a long-term business. Mintek had coordinated the exercise with substantial input from the Council for Geoscience (CGS), the Council for Scientific and Industrial Research (CSIR), and the Centre for Mechanised Mining Systems (CMMS). It had consulted with about 40 stakeholders representing a cross-section of the industry. It had used technology roadmapping methodology.

Technology roadmapping was a strategic plan that described the steps required to achieve stated outcomes and goals. Study parameters included:

• Exploration, mining, processing and cross-cutting technologies;
• Platinum group metals (PGMs), gold, coal, and iron ore (these represent over 85% of labour and sales revenue);
• Emphasis on “low-hanging fruit” – innovation that could be realistically implemented in the next 20 years;
• Small teams of experts were used to identify focus areas, technology needs and strategic projects in each stage of value chain.

He said the mining industry of SA was well established and internationally competitive, but required a focused approach to innovation to meet current challenges. Three research and development goals were prioritised -- enhancing global competitiveness, maximising industry sustainability, and improving investor attractiveness.

A “cascading” approach had been adopted to ensure each goal was adequately addressed. The goal of research was to integrate, automate and optimise resources and data across the value chain. Innovation needed to look at reducing wastage and buffer stocks, reducing planning cycles from months to hours, more efficient use of resources, reconciliation, standardisation, and improving capital efficiency and asset utilisation across the mining sector

Structural recommendations were:

• Avoid fragmentation and strive for critical mass of capacity (identify and support centres of internationally-competitive competence);
• Encourage universities to develop unique and distinctive research competencies;
• Existing research and development structures – the SA Minerals to Metals Research Institute (SAMMRI), Coaltech and CMMS were effective and should be retained, expanded, and supported;
• Strengthen mining technology collaborative structures and create exploration technology innovation structure;
• Support mechanisms for increased university-science council-industry collaboration;
• Continue to support skills development --innovation requires skills for both development and implementation;
• Long-term consistent research and development funding.

Dr Makhafola saidd that taking SA Mining to 2030 was as much about developing a strong research environment as it was about the industry adopting new technologies. Currently, South Africa did not have any single, central entity to guide and coordinate mining industry innovation. It had been suggested there should be a constitution of a “South African Mining Innovation Council” to drive and coordinate collaborative research as a matter of priority.

In the exploration stage, innovation was needed:

• To find new greenfield projects;
• To find new brownfield extensions;
• To revisit old mining dumps;
• To keep abreast of new technologies in exploration;
• To create Centres of Excellence;
• To promote and attract junior participation, including small-scale miners.

In the mining stage, innovation was needed for:

• Improved rock-cutting methods;
• More efficient mining methodologies;
• Improved material management;
• Improved energy efficiency;
• Improved safety;
• Improved human factors and other behavioural issues;
• Improved asset utilisation.

The Department and the Mine Health and Safety Council had launched the introduction of personal protective equipment for women in mining and a DVD on sexual harassment during a Women’s Conference which was held on 5 and 6 August 2015.

With regard to research and development projects, he indicated that Mintek had developed and commissioned a furnace that used coal as a source of energy to assist potters who were located in the rural areas of Letebejane in Limpopo, because they did not have a steady supply of power that was critical for drying their products. Mintek had developed SAVMIN technology to treat acid mine drainage and it had the potential to remove heavy metals and sulphates from acid mine drainage cost-effectively.

Mintek had concluded a manufacturing agreement with an international chemical producer to produce its Nicksyn reagent, which improved nickel recovery on an industrial scale. The University of the Western Cape had launched a hydrogen fuel cell-powered generator. The product had been funded by the Department of Science and Technology.

On the issue of collaboration and building partnerships in research and development, the Department had convened a workshop on 18 and 19 June 2015 at the CSIR to further synchronise mining research and development strategies. The Roadmap and strategies directed at the mining and minerals sector from the Departments of Science and Technology and Trade and Industry were discussed. The participants agreed that in order to enable the mining and minerals sector in SA to thrive, there was a need for a collaborative and directed research and development focus, and a need for an overarching and integrated government strategy for the minerals and mining value chain which identified problems amenable to research and development interventions.

In his conclusion, Dr Makhafola indicated that while the Roadmap for research and development addressed the entire value mining chain, it would be enhanced to integrate all other initiatives, including identified specific projects. The recommendations of the workshop on synchronisation of the mining strategies would be incorporated in the Roadmap. The Roadmap could also assist with the Mining Phakisa process. The Department would engage with other stakeholders, including the Treasury and the Departments of Science and Technology and Trade and Industry, on the long-term funding of the Roadmap.

Discussion

Mr J Lorimer (DA) wanted to know what the status quo was regarding Mining Phakisa.

Mr Godfrey Oliphant, Deputy Minister: Department of Mineral Resources, explained that Mining Phakisa was starting in October of 2015. The project was being coordinated from the Office of Monitoring and Evaluation. Intensive consultations had been conducted with the private sector, unions, stakeholders, and government. With regard to legislation, there would be no holy cows with the Phakisa process, because the Department was going to look at pre-exploration, exploration, and up to the end-product. Some mines would close and others would survive. Already there were two mines that had been opened in Limpopo, and one had been opened in the Northern Cape. Coordination was going to be strengthened in the area of research and development.

Mr H Schmidt (DA) wanted to find out why there was a convergence of entities for research and development, yet specialisation was important.

The Deputy Minister said it was important to have certain entities focusing on a certain area. Convergence and specialisation should be there, but duplication should be avoided. New ground needed to be traversed and it was important to have different approaches. One needed to look at the health and safety approaches. For example, a zinc mine that had been opened in the Northern Cape was going to be the biggest in the world. South Africa was going to be the next exporter of zinc. Most zinc mines in the world were no longer in existence. The end result was to have one repository of research and development in the country. The Department of Science and Technology was supposed to be the custodian of this project because there was a lot of duplication.

Mr Z Mandela (ANC) asked what systems were in place to address challenges like job losses in the mining sector.

Dr Makhafola responded that the industry was going through a mechanisation and automation process. There was a need to bring new types of skills. Technology was moving forward so there was a need to up-skill the youth. More jobs would be created for the youth.

The Deputy Minister added there was already a stakeholder engagement regarding the impact of job losses in mines. Legal issues were being looked into. Mining companies had been told to be circumspect on job losses, not for political reasons but for compassionate reasons, because some of the workers had been with the mines for many years. Mining companies should not take short cuts on job losses, but should consider the laws of the country when implementing job cuts. The mining companies must not wait for a crisis to happen and then act. The Mining Charter advocated rehabilitation of the mines – their lifespan and that of their employees. Some miners left the mines being owed a lot of money. The problem was that there was no database of mineworkers. Fortunately, the Department had approached Teba and the Chamber of Mines. There was also a toll-free number that was   being used to locate the whereabouts of ex-mineworkers. It was working. This rehabilitation programme was going to look at the health of the ex-miners. They would be examined every second month in hospitals free of charge.

Mr Mandela asked what the Department was doing to ensure there was meaningful growth in the industry in terms of research, and asked to be educated on the Kloppersbos facility.

Dr Makhafola elaborated that the CSIR had launched the Centre of Excellence. It had partnered with the Universities of Pretoria and Wits. Its aim was to promote research and to make sure it was adopted. There was a great need to improve the level of PhDs and to train workers from a lower level to the next level, gradually.

Professor Mavis Hermanus, NRE Director: CSIR, said the Kloppersbos facility was for testing and training. It was maintained at its current level. It had been instrumental improving safety in the coal-mining sector when there had been many deaths in the industry. That problem had been solved through research and development. The equipment had had to be modified. Those systems were still in place and were still being upgraded. It was a facility that stood between disaster and effective mining in the coal industry.

Adoption of minutes/reports

The Chairperson took the Committee through the minutes of 5 August 2015 document, page by page. Mr Z Mandela (ANC) moved their adoption, and Ms V Nyambi (ANC) seconded him.

The Chairperson took the Committee through the draft report on the oversight visit to KwaZulu-Natal and the Eastern Cape (01 – 06 February 2015) page by page. Mr Mandela moved its adoption, and Mr M Matlala (ANC) seconded him.

The Chairperson took the Committee through the draft report on the oversight visit to the Northern Cape (24 – 27 March 2015) page by page. Mr Mandela moved its adoption, and Ms M Mafolo (ANC) seconded him.

The minutes and reports were adopted.

The meeting was adjourned.