Mining

Exxaro expands Matla coal operations

Exxaro launches New Mine 1 at Matla Coal Mine to strengthen coal supply. (Image source: Exxaro)

Exxaro Resources has officially inaugurated the New Mine 1 operation at its Matla Coal Mine, reinforcing the company’s long-term strategy to maintain coal production, improve operational performance and contribute to South Africa’s energy supply stability

The development follows a 2016 decision to halt operations at the original Mine 1 because of declining safety conditions around the shaft pillars. The New Mine 1 project was subsequently introduced to provide safe access to remaining reserves while extending the operational life of the mine.

The project forms a central component of the broader Matla Life of Mine Project (MLOMP), a R5.236bn (approx. US$319mn) investment programme aimed at ensuring ongoing access to coal reserves, boosting efficiency and supporting coal deliveries under the extended Coal Supply Agreement (CSA) with Eskom. Operating under a cost-plus arrangement, Eskom funds the mine’s operational costs to help secure the lowest overall fuel expenses.

The newly opened mine is expected to supply nearly 4.2 million tonnes of coal annually to the Matla Power Station, supporting energy generation reliability. The Matla Coal Mine workforce currently consists of 6,174 employees, including contractors.

Exxaro CEO Ben Magara stated, “The New Mine 1 is far more than an operational milestone, for us it reflects Exxaro’s disciplined execution, long-term vision, and commitment to South Africa’s future. Our Matla Mine continues to play a vital role in supporting the country’s energy needs while creating meaningful impact through local investment, job creation, and the development of entrepreneurship. Most importantly, this milestone reflects the commitment and resilience of our employees, whose dedication to the company continues to enable us to deliver complex projects on time, to scope and on budget while making a meaningful contribution to the country and its communities.”

The project introduced several infrastructure and operational upgrades, including a box cut providing access to the Mine 1 working area, a tunnel development silo feed conveyor system and an overland conveyor linked to a newly established crushing and handling facility connected directly to Eskom’s conveyor network. Additional infrastructure includes new employee change house facilities, engineering workshops, material warehouses and administration buildings. The project also incorporated a shortwall replacement initiative featuring next-generation mining equipment.

South Africa’s minister of minerals and petroleum resources, Gwede Mantashe, attended the official opening and visited workers underground during the event.

"This is a journey back home for me. I spent six years at this mine, working here and organising here, and during that same period we achieved production records. I was here as a worker, and today I return as a Minister. People have often said that coal is a dying industry because of concerns around pollution. However, the industry continues to evolve, particularly through improvements in mining safety and ongoing investment in innovation and research. Coal miners should never be ashamed of the work they do."

Eskom group CEO Dan Marokane highlighted the significance of the collaboration between the two companies, saying, “the expansion of Matla New Mine 1 demonstrates how strategic collaboration secures South Africa’s energy future. The reliable supply from Matla ensures that, as the grid is decongested to enable rapid renewables penetration, Eskom maintains operational consistency and security of energy supply needed to support South Africa’s developmental and industrial needs. We also negotiated the new contract structure as part of Eskom’s Cost Optimisation and Revenue Enhancement (CORE) programme, which aims to drive efficiencies in primary energy procurement. This milestone comes as Eskom marks 365 consecutive days without load shedding — a testament to the impact of sustained investment, operational discipline, and partnership with Exxaro”.

Earlier in 2025, Eskom and Exxaro signed a memorandum of understanding focused on emissions reduction initiatives, carbon capture technologies and other projects supporting a responsible and balanced energy transition.

In addition to its operational objectives, the MLOMP has generated notable socio-economic benefits within Mpumalanga. The initiative has created around 1,132 local employment opportunities and directed R532mn towards black-owned businesses as part of efforts to support economic transformation. The project has also prioritised support for Small Medium Micro Enterprises and skills development programmes within surrounding communities.

The commissioning of the relocated Mine 1 operation marks a significant phase in Matla Mine’s development, strengthening its contribution to South Africa’s energy sector while reflecting Exxaro’s broader strategy for long-term growth, community development and national economic participation.

Kumba accelerates mines with renewable energy partnership

Kumba Iron Ore advances decarbonised mining through renewable energy, wheeling innovation and community inclusion

The launch of the Koruson 2 (K2) renewable energy cluster in South Africa’s Eastern Cape highlights Kumba Iron Ore’s continued focus on sustainable mining and cleaner energy solutions through its collaboration with Envusa Energy

Envusa Energy, a joint venture between Anglo American and EDF power solutions, is advancing the delivery of dependable and competitively priced renewable energy for South Africa’s energy-intensive sectors. The K2 cluster adds 520 MW of combined wind and solar capacity to the grid and forms part of the company’s wider target to develop between 3 GW and 5 GW of renewable energy by 2030.

For Kumba, the partnership is already generating measurable environmental, operational and financial gains.

“Our partnership with Envusa Energy allows Kumba to decarbonise our operations while strengthening the resilience and competitiveness of our business. It is a practical demonstration of how renewable energy can support both mining and South Africa’s economic future,” said Mpumi Zikalala, CEO Kumba Iron Ore.

At the Kolomela Mine in the Northern Cape, renewable energy now supplies around 72% of the site’s electricity demand, significantly lowering dependence on carbon-intensive grid power. Alongside emissions reductions, the mine also achieved financial savings, with approximately R600,000 (approx.US$30,000) saved during March alone.

Through the Sishen Iron Ore Company Community Development Trust (SIOC CDT), local communities are able to share in the value generated by both mining and renewable energy developments. The Trust maintains equity ownership in Kumba and is also set to hold a 10% stake in the Sishen solar project, supporting long-term investments in healthcare, education, infrastructure and livelihood programmes.

The K2 cluster also showcases how cooperation between industry, communities and government can help tackle South Africa’s energy constraints. Using an innovative wheeling model that enables renewable electricity to move across the national grid, the project is expected to strengthen energy security while supporting faster decarbonisation across major industries.

Small Chutes making big impact on mining performance

This engineered Weba Chute Systems head chute ensures stable material presentation onto the conveyor, helping to reduce wear and improve long-term operational reliability. (Image source: Weba Chute Systems)

As mining operations push for higher throughput, longer equipment life, and tighter environmental control, the design of transfer points is emerging as a critical factor in overall materials handling efficiency

No longer viewed as a minor component, chute systems are now recognised for their direct influence on plant performance.

According to Dewald Tintinger, technical director at Weba Chute Systems, inadequately designed transfer points can significantly disrupt operations, affecting material flow, belt loading, dust levels, spillage, and the wear rate of downstream equipment.

“A transfer point should never be treated as a static piece of infrastructure,” commented Tintinger. “It is an engineered flow control solution that plays a direct role in throughput stability, maintenance intervals and overall plant reliability.”

He explains that in modern processing environments, transfer points are increasingly being treated as vital control nodes within the entire materials handling system. Poorly managed material movement between conveyors, crushers, screens, or stockpiles can quickly escalate into broader operational challenges.

“Inconsistent flow patterns can lead to uneven belt loading, mistracking, excessive dust and spillage, and accelerated wear on liners, idlers and conveyor belts,” he explained. “These issues inevitably translate into increased maintenance requirements and, in many cases, costly production interruptions.”

Tintinger highlights that successful chute design starts with a thorough assessment of the material itself and the operating conditions. Variables such as particle size distribution, moisture levels, bulk density, abrasiveness, and cohesiveness all influence how materials behave during transfer.

“There is no one-size-fits-all solution,” he said. “Every application must be engineered around the specific flow behaviour of the material as well as the plant’s throughput requirements and space constraints.”

A central design objective is to ensure accurate and stable loading onto the receiving conveyor. If the material trajectory or discharge speed is not properly controlled, it can lead to uneven distribution, causing belt damage, excessive wear on idlers, and reduced conveyor efficiency.

“Correct belt loading is fundamental to conveyor health,” remarked Tintinger. “By controlling the flow path and discharge velocity of the material, we can significantly reduce wear and improve the overall reliability of the conveying system.”

He further notes that well-engineered transfer points also contribute to environmental compliance and workplace safety. By managing dust and spillage at the source, operations can maintain cleaner sites, minimise hazards, and reduce environmental impact.

“Dust and spillage are not simply housekeeping issues; they are often symptoms of poor flow management,” he commented. “By engineering the transfer point correctly, these risks can be mitigated at source rather than managed downstream.”

As mining companies continue to focus on maximising uptime and operational efficiency, transfer point design is shifting from a reactive maintenance issue to a proactive engineering priority.

“Ultimately, every transfer point must support predictable, controlled and efficient material flow,” Tintinger concluded. “When this is achieved, the benefits are seen across the plant in reduced downtime, lower maintenance costs and improved throughput performance.”

Weir strengthens Africa mining with risk reducing pump solutions

Africa’s largest installed base of mining pumps is supported by Weir’s technical know-how and reliable service network. (Image source: Weir)

Weir has built the most extensive footprint of dewatering and slurry pumps across Africa’s mining landscape by supporting customers in reducing operational risk

This is achieved through a combination of advanced engineering, ongoing equipment refinement and a service network grounded in a fully compliant social licence to operate.

Marnus Koorts, General Manager – Original Equipment at Weir, explained that the company’s market position is shaped not only by the strength of its pump technologies, but by a comprehensive value chain approach that addresses risk throughout the lifecycle of mining operations.

“Mining is continuous and extremely capital intensive, so equipment must perform reliably and optimally,” said Koorts. “It is no surprise, therefore, that mines are risk averse when partnering with solution providers – they need to deal with partners they can trust.”

He notes that meeting the demanding uptime and performance requirements of modern mines calls for deep process knowledge and engineering capability, supported by a widespread service presence across the continent.

“Our customers’ first question is often about our references in a specific country or commodity,” he said.

“Thanks to our extensive footprint and vast experience, we’re almost always familiar with their operating environments – from the minerals being mined and processing conditions to the local regulatory landscape.”

Koorts points out that Weir’s large installed base provides a key advantage, generating valuable operational data across diverse commodities, climates and working conditions. This data is continuously fed back into product development and refinement.

“We are continuously releasing new variants of components based on feedback from the field,” commented Koorts.

“We are also digitally monitoring a large portion of our installed base, so it is not just physical site visits, but smart monitoring that allows us to improve performance, longevity and total cost of ownership.”

These insights enable Weir to deliver practical solutions, including equipment standardisation across multiple sites. In one recent West African gold project, the company recommended a minor design modification that allowed two operations to adopt a unified mill pump configuration.

Drawing on experience from the first site, Weir advised the engineering contractor on aligning motors and gearboxes, resulting in significant savings on spare parts inventory while lowering the risk of downtime.

“We have this capability due to our institutional knowledge of hundreds of projects and product applications,” remarked Kroots.

“This is a crucial part of the value that we bring as an OEM where we can collaborate with customers in applying the best solutions possible.”

Koorts also emphasises the importance of regulatory compliance across different African markets, where procurement frameworks vary widely. Ensuring adherence to these requirements is critical for maintaining a strong and dependable value chain.

“Weir’s service network in Africa is staffed by local engineers, account managers and process specialists,” Koorts says. “We employ and empower local people, and we invest heavily in skills development.”

The company’s graduate programmes play a key role in this effort, recruiting talent from regional universities and developing young engineers into long-term professionals within the organisation.

“This is all part of being a good corporate citizen and it ensures that our customers are supported by experts who understand the terrain, the language and the mining culture,” he says.

Weir’s continued success in Africa reflects its understanding that supplying pumps is only one part of the value it delivers. This is reinforced by engineering expertise, a strong local presence, continuous performance data and governance systems that support a sustainable social licence to operate.

“Working with Weir gives customers access to our knowledge, our compliance and our ability to mitigate their operational risk. Our market leading products are just the visible part of a complex value chain,” Koorts concludes.

Pilot Crushtec secures Metso EMEA dealer honour

Metso crushing and screening equipment in operation, backed by Pilot Crushtec’s strong regional service network and technical expertise. (Image source: Pilot Crushtec)

Pilot Crushtec has been named Metso’s Best Dealer in the EMEA region, a prestigious international accolade recognising the company’s strong commercial performance, customer support strength and long-standing commitment to delivering high-value crushing and screening solutions across Africa

The award positions Pilot Crushtec among Metso’s top distributors globally, while specifically recognising its leading performance across Europe, the Middle East and Africa. It also reflects the company’s sustained sales success, technical capability and customer-focused service approach across its Southern and sub-Saharan African territory.

According to Francois Marais, sales and marketing director at Pilot Crushtec, the recognition marks an important milestone for the business and highlights the collective effort of its people.

“This recognition is a significant achievement and a powerful testament to the commitment, expertise and passion of our entire team,” commented Marais.

“Being recognised on an international stage among leading distributors including others across Europe, the Middle East and Africa reinforces our position as a trusted partner and industry leader.”

Marais says several factors contributed to the company securing the award, including continued market growth across Southern and sub-Saharan Africa, robust aftermarket support capabilities and deep product and application knowledge.

“Our consistent sales performance and market growth across Southern and Sub-Saharan Africa has been a key contributor,” explained Marais.

“Despite challenging market conditions in many sectors, we have continued to grow the presence of Metso’s crushing and screening solutions in the region.”

He adds that Pilot Crushtec’s established service teams, technical expertise and parts availability ensure customers receive dependable support throughout the full equipment lifecycle.

“Our team works closely with customers to understand their operational requirements and provide solutions that optimise productivity, efficiency and long-term value,” said Marais.

The recognition follows the recent five-year renewal of Pilot Crushtec’s distributorship agreement with Metso, further underlining the strength of the partnership and ensuring customers across Southern and sub-Saharan Africa continue to access globally recognised crushing and screening technology.

“The five-year renewal of our distributorship agreement with Metso is extremely significant for Pilot Crushtec’s long-term strategy and reinforces the strength and stability of our partnership,” Marais says.

Through the renewed agreement, Pilot Crushtec will continue supplying Metso’s static and mobile crushing and screening equipment to customers operating in some of the region’s toughest mining and quarrying environments. It also supports ongoing investment in technical training, spare parts availability and support infrastructure.

Customers benefit from the combination of world-class technology and strong local backing, with Pilot Crushtec maintaining strategic stock of equipment, wear parts and critical components to minimise lead times and maximise uptime.

“Our highly trained service teams work closely with Metso to ensure that customers receive expert installation, commissioning, maintenance and troubleshooting support,” Marais explained. “This ensures machines operate at optimal performance levels throughout their lifecycle.”

The company’s aftermarket portfolio includes genuine spare parts, wear parts, service agreements, technical upgrades and operator training, helping customers maximise productivity and long-term returns.

Looking ahead, Pilot Crushtec plans to build on the latest recognition by expanding its footprint across Africa and further strengthening its support and service capabilities.

“Our priority is to continue delivering exceptional value to our customers and strengthening our position as a leading provider of crushing and screening solutions in Africa, while continuing to build our broader presence and reputation in the global market.,” Marais commented.

This will include broader reach across Sub-Saharan Africa, increased equipment availability and continued enhancement of its aftermarket support network to deliver fast and reliable service wherever customers operate.

“We will also continue investing in skills development and technical training to ensure our teams remain at the forefront of industry expertise and are fully equipped to support the latest technologies from Metso,” he concludedPilot Crushtec Secures Metso EMEA Dealer Honour.

By combining deep regional understanding with global technology partnerships, Pilot Crushtec continues to support the growth and performance of Africa’s mining, quarrying and construction sectors.

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