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Kibali mine drives sustainable growth and exploration success. (Image source: Barrick Gold Corporation)

Barrick Gold Corporation has reported encouraging exploration progress along the ARK-KCD corridor, reinforcing the potential for further mineral discoveries at Kibali, the largest and most environmentally conscious gold mine in Africa

The latest drill results show expanding mineralisation across lateral and downward extensions within the ARK-KCD system. This suggests significant opportunity to grow the mine’s reserves within its current footprint, Barrick announced during a media event in Kinshasa.

Barrick president and CEO Mark Bristow said the new geological insights point to a well-defined structural zone that could support additional high-grade orebodies.

“Kibali was built with a long-term view and has consistently delivered across production, partnerships and reserve growth. We’ve replaced every ounce we’ve mined and more since Kibali poured its first gold in 2013, and the ARK-KCD corridor shows that there’s still much more to come,” he stated.

Since inception, the Kibali operation has invested over US$6.3bn in the Democratic Republic of Congo (DRC), with US$3.1bn of that paid directly to local contractors and partners. The mine remains the biggest economic engine in northeastern DRC, spanning the provinces of Haut-Uele and Ituri.

Mining operations at satellite pits — Kalimva, Ikamva, and Ndala — are being conducted through contracts with Congolese businesses. Over 700 local companies benefit from supply chain opportunities and capacity-building initiatives. Procurement processes are managed transparently in collaboration with the DRC’s subcontracting authority, ARSP.

“Kibali is more than a mine. It’s a partnership that anchors the regional economy. It’s Congolese-led, Congolese-supplied and built to last. We’re proud of the model we’ve created here — one that delivers shared value every step of the way,” Bristow added.

Operational enhancements underway in the underground section are expected to yield productivity improvements in Q3, with a focus on cost efficiency and performance optimisation. The site’s renewable energy capacity has also been upgraded with the commissioning of a 16MW solar plant and Battery Energy Storage System (BESS), allowing Kibali to operate on 100% renewables for half the year and lifting its total renewable energy usage to 85%.

“This is what the energy transition looks like in practice. It’s a benchmark not just for Africa but for the global mining industry,” said Bristow.

As part of its broader environmental commitments, Barrick is also deepening its involvement in biodiversity restoration. In collaboration with the Congolese Institute for Nature Conservation and African Parks, plans are in motion to relocate 64 white rhinos to Garamba National Park by year-end — a continuation of the rewilding initiative that began with 16 rhinos in 2023.

Meanwhile, the Barrick Academy continues to promote local skills development, with 170 employees participating in training programmes during the second quarter.

Community development is also progressing steadily. Of the 44 projects funded via Kibali’s 0.3% community fund, 41 have been completed, focusing on infrastructure, healthcare, and education. Additionally, US$4.8mn has been invested in executing the mine’s legally mandated social responsibility commitments under the Cahier des Charges framework.

“Kibali is our blueprint for sustainable growth in the DRC. Built on a foundation that is technically sound, socially rooted, and environmentally responsible, it reflects our long-term vision. The experience and lessons gained here in one of the world’s toughest mining environments will guide us as we look to expand our in-country portfolio to include not just more gold but also copper projects,” Bristow concluded.

FLS and University of Newcastle launch energy-saving conveyor in Africa mine. (Image source: FLS)

An African mine will be among the first adopters of the innovative Rail-Running Conveyor (RRC) technology, commercialised by full flowsheet provider FLS in collaboration with the University of Newcastle, Australia

Designed to dramatically reduce energy consumption, improve safety and cut capital and operating expenditure, Rail-Running Conveyors are a gamechanger for mines which must rely on extended conveying distances to move material. Any mine that carries substantial tonnages over more than 500 to 1,000 m can achieve far higher efficiencies using this technology.

The first full-scale operational system will be commissioned in southern Africa in mid-2025. It is designed to carry 5,000 mtph of copper ore over a 3,25 km run, and is expected to save approximately US$1mn each year in power costs when compared to a conventional trough conveyor.

A second system, destined for the same mining customer at a mine in the Americas, has also been under construction and will carry around 13,000 mtph, also delivering significant power savings and safety improvements.

The energy losses incurred by an RRC is anything between one-fifth to one-tenth of those experienced by traditional trough and pipe conveyor systems respectively. The friction losses on a conventional long distance conveyor largely determine the power capacity that must be installed, the size of the structures required and the downtime incurred to maintain and replace pulleys and drives. Reducing these energy losses therefore has a positive knock-on effect on the costs of a range of other aspects.

Customers achieve savings on the scope of the conveyor equipment itself, the cut-and-fill civils requirements, the volumes of concrete used, the strength of the belt and the number of drive stations necessary. Due to the lower tension acting on the conveyor belt, a lower rating of belt is possible. Faster speeds and a deeper trough also mean that a narrower belt may suffice for the same throughput. Importantly, the rating of the drives does not need to be as high.

Where a 6MW drive may be specified for a conventional conveyor, for instance, this technology may allow a 2MW drive to be installed. This then has further positive impacts on the ratings required for motors, transformers, E-houses and power supply.

The head and the tail of an RRC remain the same as in traditional systems with the rail-running section making up the bulk of the distance. The basic mode of transport is steel-wheel-on-steel-rail instead of a belt running over idlers. This fundamental difference is what cuts energy consumption so drastically.

The system uses small carriages to carry the belt and these are automatically exchanged at maintenance houses when required. This removes the safety risks associated with personnel changing out idlers out along the length of the conveyor. Having fewer transfer points also has a safety benefit as these can be sources of injury during maintenance as well as health threats from dust exposure.

BME's Dryden Innovex manufacturing plant outside of Delmas, Mpumalanga in South Africa (Image source: BME)

BME has outlined its commitment to sustainable mining by incorporating used oil, a hazardous waste, as an ingredient in emulsion explosives

“Through our scientifically rigorous processes, we convert a waste product into a sustainable energy source that can break ground to meet the demands of mining while also promoting environmental sustainability and socio-economic development,” said Sachin Govender, used oil manager at BME.

“Used oil is a major environmental risk. Just one litre can contaminate about a million litres of South Africa’s scarce water resources.”

By consuming up to 20% of all the country’s used oil for the production of emulsions, BME helps to effectively mitigate this risk – while also helping to uplift local communities from where it sources the used oil.

The company utilises used oil as a bioenergy fuel source that is completely consumed in the blasting process — a system it has honed and refined over three decades.

The well-developed and accurate formulations comply with safety regulations and adhere to the company’s ESG goals, said Govender.

He said that while used oil was readily available as it was a waste product, there were various grades, all containing different contaminants and components.

“Therefore, all of the used oil that we collect and process undergoes extensive verification, quality control analysis and validation at our R&D laboratory,” he said.

“The final emulsions that we produce using these technologies are also quality tested to determine their stability, shelf life and efficiency for mining.”

He confirmed that BME was also investigating viable alternatives to traditional used oil.

This would not only enable the company to further pursue greener and more sustainable sourcing, but would also increase its participation in the circular economy.

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Condra hoists and overhead crane. (Image source: Condra)

South Africa’s Condra has received a succession of recent orders for overhead cranes and other lifting equipment that will be deployed across Africa and beyond, as it moves to expand its agent reach across the continent

Among them is an unpack-and-go machine whose shipping containers will become the crane’s gantry, following a deal struck with the company’s agent in Tanzania, Lynx Supply and Services.

The design of this five-ton double-girder crane — a one-off currently under manufacture for mine maintenance — makes use of the two 12-metre delivery containers as gantry supports.

After hoist, crab, girders, end-carriages and other components have been unpacked for assembly, an installation team will position the containers exactly 9.8 metres apart, then bolt rails to their tops to form the gantry.

Lynx, which will carry out the installation and commissioning work, also placed additional orders for wheel blocks, miscellaneous spare parts and a separate 10-ton, 10-metre-span single-girder gantry crane for an unnamed mining house.

Condra’s sub-Saharan agent network also includes Integrated Engineering Services in Zambia, Integrated Engineering Services in the Democratic Republic of Congo (DRC), Namcranes in Namibia and KL Cranes in Botswana.

Management is identifying additional potential agents in Ghana, Mozambique and Kenya, the company said in an update.

Other recent orders received by Condra in sub-Saharan Africa include a 10-ton portal crane for a maintenance application in Ghana.

The design of this crane overcomes floor loading limitations by spreading the machine mass across multiple nylon-treaded wheels at the base of the portal’s supporting legs.

The Ghanaian portal machine is linked to two further crane orders from the same customer, one of them for installation in Saudi Arabia.

Condra noted that it had also received enquiries from Chile and Peru, where the company is reestablishing agency relationships adversely affected by the Coronavirus pandemic.

“Service proximity and availability must be carefully considered alongside purchase price if losses due to downtime are not to negate and even exceed the initial savings of an attractive price,” said a Condra spokesman.

“Condra has long and strong relationships with agents across sub-Saharan Africa to deliver the necessary rapid response time on service calls. Our Johannesburg spares division will deliver parts anywhere in Africa in five days or less, minimising production losses due to crane downtime. In South Africa we deliver in a maximum of 48 hours.”

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FLS enhances African mill liner capacity through Pretoria-based SSRE acquisition to support mining services

Leading mining technology and service provider FLS has acquired Scott specialised Rubber & Engineering (SSRE), a Pretoria-based company known for producing heavy-duty rubber products used across multiple industries, including mineral processing

The move aligns with FLS’s CORE’26 strategy, which emphasises strategic investments to grow its services portfolio. As a global frontrunner in large grinding mill technology, FLS is focused on expanding mill liner capacity, particularly in regions where supply limitations have affected service delivery.

“This acquisition represents an important milestone in our consumables growth strategy. By introducing mid-sized regional capacity in mill liners, we are enhancing our ability to service mining customers across Africa with greater speed and reliability,” commented Alanas Kraujalis, head of consumables at FLS.

Regional expansion 

SSRE’s integration into FLS will enable the local production of rubber and composite mill liners. This change transitions FLS’s mill liner supply chain from an outsourced model to one with dedicated regional capacity.

“The new facility will establish local production of rubber and composite mill liners, shifting our supply model from outsourced to dedicated capacity. This transition will improve control, responsiveness and long-term resilience. Bringing manufacturing closer to our customers enables shorter lead times, more consistent service and strengthened aftermarket support,” Kraujalis added.

The terms of the deal have not been disclosed. The acquisition will not affect FLSmidth’s financial guidance for the full year 2025.

FLS continues to support the global mining sector as a leading original equipment manufacturer (OEM), offering integrated engineering, equipment, and service solutions. Its in-depth knowledge of milling processes ensures customers receive tailored support across the entire milling circuit.

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