Mining

The customer was originally supplied with standard liners but the new ESCO liner design doubled the liner life. (Image source: Weir)

African mining operations are increasingly turning to aftermarket optimisation to improve plant availability, control operating costs and extend equipment life. Weir is supporting these efforts through its premium ESCO crusher liners and ENDURON screen panels, backed by local technical expertise and global engineering capabilities

The company's approach focuses on understanding individual mine operations, including their ore characteristics and equipment wear patterns, rather than simply supplying replacement components.

According to Natalie Makhanya, Weir's aftermarket manager for comminution in EMEA, this strategy has delivered extended equipment service life across different mining applications.

"Where customers are dealing with highly abrasive applications, we have been able to extend crusher liner changeout cycles to four to six weeks, while in less demanding environments liner life can extend to four to six months," Makhanya commented. "ENDURON screen media has delivered equally impressive results with wear life ranging from two to four weeks in high-impact feed zones and up to 24 weeks in dewatering applications."

Longer equipment service life helps increase plant availability, reduce maintenance costs, improve shutdown planning and enhance workplace safety by limiting the frequency of maintenance interventions.

South African iron ore operation doubles liner wear life

A recent optimisation project at an iron ore reprocessing operation in South Africa's Thabazimbi region demonstrates the impact of Weir's aftermarket solutions.

When the site's ore proved significantly more abrasive than initially anticipated, Weir collaborated with the customer and its ESCO engineering teams in the United States over six months. The teams analysed wear patterns, assessed liner performance and refined the design to address the operating conditions.

The resulting 25% manganese ESCO liner doubled wear life from two weeks to four weeks.

"The project demonstrates how combining local application knowledge with global engineering expertise enables us to develop solutions that deliver measurable improvements in performance," JD Singleton, comminution director EMEA at Weir, commented.

Other African mining operations have also recorded improvements following equipment upgrades. A South African chrome producer extended crusher liner life from four months to six months after switching to ESCO liners.

Meanwhile, a major iron ore operation in Liberia improved drainage efficiency and classification performance after introducing ENDURON screen panels on its dewatering screens.

Expanding screen technology and local manufacturing

The growing adoption of aftermarket solutions is complementing increased demand for ENDURON crushers and ENDURON Elite screens across Africa.

According to Singleton, the latest ENDURON Elite screens incorporate high-capacity exciter technology capable of generating up to 1.28 mega-newtons of force. This enables large screens to operate with two exciters, compared with the three often required by competing designs, reducing maintenance requirements by approximately 30%.

To meet rising demand, Weir has expanded its South African ENDURON® screen media manufacturing operation from an initial 150m² facility to a 3,500m² production plant.

A further expansion is planned to double production capacity and reduce lead times across the continent, strengthening local manufacturing capabilities and equipment supply to African mining customers.

"Mines are increasingly looking for partners who can deliver technical expertise alongside reliable product supply," Makhanya concludes. "Our focus is on working collaboratively with customers to optimise plant performance, reduce maintenance costs and create long-term operational value."

RUSAL to invest in Ghana's mining sector (Image source: Adobe Stock)

Ghana’s mining industry is set for a major bauxite boost after RUSAL, one of the world’s largest aluminium producers, agreed to develop operations in the West African country

The Russian minerals giant has teamed up with the Ghana Integrated Aluminium Development Corporation (GIADEC) to develop bauxite mining operations with annual output of up to 5 million tonnes.

There are also plans to build an alumina refinery with an annual capacity of 1.2 million tonnes.“Our agreement with GIADEC marks an important step in implementing RUSAL’s strategy to strengthen its own raw material base,” said Evgeniy Nikitin, RUSAL’s general director, after the agreement was signed in Moscow during the Russia–Africa Forum.

“Ghana has some of the largest undeveloped bauxite reserves in West Africa, and we see an opportunity to establish an integrated production chain here – from mining 5 million tonnes of ore per year to producing 1.2 million tonnes of alumina.”

The mining project involves the construction and operation of a bauxite mine at the Nyinahin deposit in the Ashanti Region of southwestern Ghana.

Estimated mineral resources in the area of the deposit earmarked for development exceed 100 million tonnes of bauxite.

The second phase of the project envisages the construction and operation of an alumina refinery with an annual capacity of 1.2 million tonnes, using bauxite from the Nyinahin deposit.

The refinery will utilise natural gas, RUSAL reported.

Two joint ventures, Nyinahini Bauxite and Ghana Alumina Company, are to be established to coordinate the project, with RUSAL taking a majority stake in each.

RUSAL added that the joint ventures will be granted rights to explore for, mine and process bauxite in Ghana as part of the development of Ghana’s Integrated Aluminium Industry.

“RUSAL has been operating in Africa for more than 20 years, and this experience will enable us to implement the Ghanaian projects efficiently, from design through to reaching full production capacity,” added Nikitin.

The projects also envisage broad participation on the Ghanaian side.In addition to its equity stakes in the joint ventures, this will include job creation during construction and operations, the involvement of local contractors and suppliers, and the development of transport infrastructure in Ghana, to boost the local economy.

Reindorf Twumasi Ankrah, CEO of GIADEC, said the agreements fully align with its goal of establishing an integrated aluminium industry in Ghana that can process bauxite domestically.

“In RUSAL, a company with extensive technological expertise and many years of successful experience in Africa, we have found a partner capable of delivering on these objectives. The Nyinahin projects will bring investment, thousands of jobs, improvements to rail and port infrastructure, and new opportunities for Ghanaian businesses.”

Liebherr powers Zimbabwe's next platinum mining milestone. (Image source: Liebherr)

The arrival of a 300-tonne Liebherr R 9350 excavator at Zimbabwe's Karo Platinum Project in February 2026 marked a significant milestone in the development of one of the country's major greenfield mining operations.

Standing approximately 8.5 metres tall, the mining excavator represents more than an addition to the site's equipment fleet; it is part of the heavy-duty machinery being deployed to prepare the mine for its future production phase.

The machine was delivered as part of the fleet operated by EPSA Group, an international earthmoving services company awarded the contract for the project. From the beginning of site development, the R 9350 has been involved in large-scale material movement, supporting the preparation of the mine's infrastructure and operational areas.

The deployment comes as EPSA Group prepares for the project's transition towards production, with the first ore expected to be processed in the second half of 2027.

‘EPSA is preparing for the first ore at Karo to be milled in the second half of 2027, and we’re proud that Liebherr machines will play a role in reaching this critical point,’ says Claus Dieter Homberg, regional sales manager, Liebherr-Mining Equipment Colmar SAS.

A major mining project demands high-capacity equipment

The Karo Platinum Project is situated along the eastern and western sections of Zimbabwe's Great Dyke, one of the world's largest igneous complexes and an important geological formation containing the second-largest deposit of platinum-group minerals.

The development is planned as an open-pit mining operation for its first decade, after which activities are expected to transition underground. This phased approach requires a fleet capable of handling substantial material volumes while operating under demanding mining conditions.

For EPSA Group, equipment selection was therefore an important consideration in establishing the project's operational capabilities. The Liebherr R 9350 was selected for its combination of performance, reliability and suitability for intensive mining applications.

Its deployment during the mine's early development phase is expected to support the material handling requirements associated with establishing the operation and preparing for future production.

First mining-class Liebherr excavator delivered in Zimbabwe

The arrival of the R 9350 also represents a milestone for Liebherr, marking the first delivery of a mining-class excavator from the company into Zimbabwe.

Getting the machine operational required coordination between several teams across Liebherr's international and regional network.

The excavator was manufactured at Liebherr's production facility in Colmar, France, which worked alongside EPSA Group to coordinate its delivery to Zimbabwe. Following its arrival at the mine, a product support representative from Colmar supervised the assembly process.

The assembly team primarily comprised personnel from Liebherr-Africa (Pty) Ltd, supported by specialists from Zimbabwean dealer R&S DieselPro Services. The Colmar representative subsequently remained at the project for seven additional weeks, providing technical assistance and practical training to personnel responsible for operating and maintaining the equipment.

This collaborative approach helped establish the technical and operational support required to commission the excavator and prepare the local teams for its continued operation.

Regional service network strengthens equipment support

EPSA Group's relationship with Liebherr spans approximately 15 years, with the two companies having worked together at mining sites across several international markets.

The partnership has developed through experience with Liebherr equipment and its ability to provide machinery and technical assistance across different applications. This established relationship was an important factor in selecting the R 9350 for the Karo operation.

Although Liebherr-Africa is the company's nearest sales and service organisation to the project, its facilities are located more than 800 kilometres away. To ensure timely assistance, R&S DieselPro Services will provide the primary on-site support, covering routine maintenance, technical services and spare parts availability.

The Zimbabwean dealer has been working with Liebherr-Africa since 2017, initially supporting its earthmoving equipment range before extending the relationship to mining machinery in 2025.

Its established familiarity with Liebherr products provides a local support foundation, while Liebherr-Africa remains available to assist with more specialised technical requirements when necessary.

‘Being associated with the commissioning and support of this flagship machine is a testament to our commitment to delivering world-class equipment, technical expertise and after-sales support to Zimbabwe's growing mining sector,’ commented Kevin Wilson, general manager, technical, R&S DieselPro Services.

The partnership between Liebherr-Africa and R&S DieselPro Services is expected to play an important role in maintaining equipment availability and supporting EPSA Group as mining activities at Karo expand.

Additional excavators to support the production ramp-up

The initial R 9350 delivery was followed by a second unit in July 2026, with a third excavator scheduled to arrive before the end of the year.

The additional machines will contribute to the project's ongoing development requirements as it moves closer to its planned first ore processing milestone in 2027.

As the Karo Platinum Project progresses from initial site preparation towards full operational readiness, the expanding Liebherr fleet is expected to support the material movement requirements of the open-pit operation.

The deployment also demonstrates the importance of combining high-capacity mining equipment with reliable technical assistance and an established regional service network, particularly for large-scale greenfield developments.

‘Behind every Liebherr machine is a team committed to keeping it performing at its best,’ says Homberg. ‘We’re looking forward to supporting EPSA Group as operations at Karo continue to grow and evolve over the coming years."

Conceptual image of remote monitoring using a fixed-wing VTOL drone Image courtesy of Aerosense Inc. (Image source: OC Global)

Oriental Consultants Global Co., Ltd. (OC Global), in collaboration with MSC Partners Inc., has begun supporting a demonstration project led by Aerosense Inc. to introduce remote mine monitoring services using fixed-wing vertical take-off and landing (VTOL) drones in Zambia and the Democratic Republic of the Congo (DR Congo)

The initiative has been selected under Japan’s Ministry of Economy, Trade and Industry (METI) “Global South Future-Oriented Co-Creation Project” for fiscal year 2025, funded through the supplementary budget. The programme covers small-scale demonstration initiatives and feasibility studies aimed at fostering international cooperation and developing solutions to shared economic and industrial challenges.

The project will assess how Japanese-made fixed-wing VTOL drone technology can improve oversight of mining operations across the Copperbelt region, which spans Zambia and the DR Congo. By enabling large-scale remote surveillance and collecting critical site data, the initiative aims to strengthen mining governance and improve the reliability of critical mineral supply chains, particularly those involving copper and cobalt, which are essential to Japan’s industrial and economic interests.

Addressing mining oversight and environmental risks in the copperbelt

The Copperbelt is internationally recognized as a major source of copper and cobalt, two minerals that play a vital role in global industrial production and emerging technologies. However, monitoring mining activities across this extensive region presents significant logistical challenges. The large geographical coverage of mining sites and their distance from capital cities can make effective supervision difficult, highlighting the need for greater operational transparency and more dependable mineral supply networks.

Mining operations also face environmental and safety concerns, including potential failures of tailings storage dams containing mining waste and water, as well as water contamination resulting from chemical leaks. These hazards underscore the importance of continuous monitoring across broad areas to identify potential risks, protect surrounding ecosystems and improve safety conditions for mine workers.

Through the demonstration project, the participating companies aim to evaluate drone-based monitoring as a practical solution for improving visibility into mining activities while supporting responsible resource management.

Deploying Japanese-made VTOL drones for remote mine surveillance

Aerosense’s Japan-manufactured fixed-wing VTOL drones will be deployed at selected mining locations to demonstrate three principal capabilities.

• High-resolution aerial monitoring: Equipped with high-resolution and infrared cameras, the drones will capture detailed imagery of mining sites and help assess changing operational and environmental conditions.
• Real-time video transmission: Live aerial footage will be transmitted to relevant government agencies in capital cities through LTE networks and other communication methods, enabling authorities to access information remotely.
• Topographical and environmental data collection: Surveying instruments, LiDAR technology and other onboard equipment will be used to gather terrain information and environmental data to support mine oversight and risk assessment.

These capabilities will be evaluated for their potential to improve monitoring efficiency, strengthen information sharing with government authorities and facilitate earlier identification of environmental hazards across extensive mining areas.

OC Global builds on its critical minerals expertise in Southern Africa

OC Global brings regional experience in infrastructure development, strategic planning and critical mineral supply chain studies across Southern Africa. Among its previous initiatives is the “Study for Formulating a Master Plan for the Critical Minerals Supply Chain Sector Centered on the Copperbelt,” conducted under METI’s “Global South Master Plan.”

The current drone-based mine monitoring demonstration is one of five strategic initiatives identified in the master plan developed through that study. Building on its established relationships with local governments and relevant organizations, OC Global will contribute its project management capabilities and regional expertise to support the implementation and advancement of the initiative.

Working alongside MSC Partners Inc. and Aerosense Inc., OC Global will help advance the demonstration project and assess opportunities for developing a sustainable business model for remote mine surveillance and data provision.

Strengthening critical mineral supply chains through drone technology

The project aims to establish a viable service model that uses drone technology to provide wide-area mine monitoring and reliable operational data. Improved access to timely information could help strengthen transparency across critical mineral supply chains while supporting more effective environmental oversight and risk management.

By identifying potential environmental threats and improving monitoring capabilities, the initiative also seeks to enhance workplace safety and protect the lives of local mining personnel. Its broader objectives include promoting responsible mining practices, preserving the surrounding land and environment, and strengthening the resilience of copper and cobalt supply chains connecting Southern Africa with international markets.

Through its participation in this demonstration, OC Global is advancing technology-driven solutions for mining oversight and contributing to the development of more transparent, secure and sustainable critical mineral supply chains in Zambia and the Democratic Republic of the Congo.