Mining

Quarry operators are increasing adoption of PDS and CPS technologies to strengthen safety

Quarry operators are placing greater focus on workplace safety, driving increased interest in Proximity Detection Systems (PDS) and Collision Prevention Systems (CPS)

The shift reflects a growing recognition that safety technologies can support both regulatory compliance and the practical demands of quarry operations.

Anton Lourens, CEO of Booyco Electronics, said demand for PDS/CPS technologies has increased notably over the past six months across the quarrying and mining sectors. The trend points to a wider move towards proactive approaches to managing operational risks, alongside continued attention to legislative requirements.

“Safety has become a strategic priority for many operations,” Lourens says. “Beyond meeting legislative requirements, quarry operators are investing in technologies that help mitigate risk and improve overall operational safety.”

Technology integration is also becoming easier as PDS solutions become more compatible with mobile equipment. Improvements in interface kits, alongside closer cooperation between original equipment manufacturers (OEMs), independent interface providers and technology suppliers, are helping operators deploy collision prevention systems across mixed fleets.

The adoption of the ISO 21815 standard has provided further support for interoperability. Its technology-neutral communication protocol enables different systems to communicate more effectively, helping streamline the implementation of collision prevention technologies across quarrying and mining operations.

However, technology deployment still needs to reflect the specific conditions of each quarry. Lourens said site-specific assessment is essential when determining how PDS/CPS solutions should be configured and implemented.

“No two operations are the same. Every implementation begins with a detailed assessment of the fleet, traffic patterns and operating practices to ensure the system delivers effective detection without compromising productivity,” he explains.

Financial considerations also influence technology decisions, particularly for quarry businesses that may operate with tighter margins than larger mining companies. Booyco Electronics maintains that access to safety technology should not be determined by the scale or financial resources of an operation.

“We do not believe there should be different levels of safety capability for different operations,” Lourens says. “Our focus is on improving our own development and manufacturing efficiencies so that advanced collision prevention technology remains accessible to both large mines and smaller quarrying businesses.”

Effective implementation also requires cooperation between technical and operational teams. Engineering personnel may concentrate on meeting regulatory requirements, while operational managers are often focused on production targets and equipment availability. Aligning these priorities through communication, training and user adoption is therefore an important part of achieving safety and operational goals.

Lourens expects collision prevention technology to develop further as multiple sensing methods are combined rather than relying on a single detection technology.

“The future lies in combining technologies such as low-frequency communication, GPS, radar and camera-based systems etc, to deliver more reliable and adaptable collision prevention solutions,” he says. “As these technologies continue to evolve, the industry will be better positioned to deliver sustainable, cost-effective safety solutions that support the goal of zero harm.”

FLS targets lifecycle optimisation across Africa’s mining industry. (Image source: FLS)

Discussions at Electra Mining Africa pointed to a changing operating environment for mining companies across the continent. With ageing processing assets, tighter capital budgets and increasing expectations around productivity, reliability and sustainability, operators are placing greater emphasis on improving the performance of existing infrastructure rather than committing to major greenfield projects

For FLS, this shift is reinforcing a move towards a lifecycle-focused service model. The company is combining flowsheet expertise with regional service capabilities, optimisation solutions and local technical support to help mining customers improve plant performance throughout the life of a mine.

Bernard Kaninda, President of Sales and Services for Africa at FLS, said conversations with customers at Electra Mining Africa showed that operational improvements are increasingly taking precedence over major capital projects.

"Many operations are looking to increase throughput, improve recovery and extend plant life without committing to significant capital expenditure," stated Kaninda.

"That places greater emphasis on service-led interventions such as process optimisation, audits, upgrades, retrofits and lifecycle support that allow customers to unlock additional value from assets already in operation."

Kaninda said the changing priorities also reflect an evolution in FLS's relationship with mining companies.

"Our objective is to become a long-term lifecycle partner rather than simply an equipment supplier. We work alongside customers throughout the life of mine to improve plant performance, minimise downtime and reduce operating costs while supporting their long-term production objectives."

The need for this approach is particularly pronounced across Africa, where ageing equipment, limited investment capacity and increasingly complex orebodies are creating demand for more comprehensive operational support.

Alistair McKay, vice-president capital sales, Europe, Arabia and Africa, said the continent's varied geology further increases the need for tailored mineral processing strategies.

"The continent encompasses Copperbelt copper-cobalt operations, West African gold, South African platinum group metals, iron ore and numerous other commodities, each presenting unique processing challenges," McKay says. "Supporting this diversity requires far more than individual products. It requires the ability to engineer and optimise complete mineral processing flowsheets tailored to each orebody and operating environment."

Operational challenges also extend beyond processing requirements, particularly for mines operating in remote areas.

"Many African mines operate in remote locations where long supply chains, customs delays and logistical constraints mean equipment reliability becomes inseparable from service capability. Maintaining operational continuity requires local technical support, regional parts availability and lifecycle partnerships that minimise production interruptions."

With operators seeking performance improvements without replacing complete processing circuits, equipment modernisation is becoming an increasingly important tool.

"Many mines are extending the operating life of existing assets through rebuilds, retrofits and targeted upgrades," added Kaninda. "These solutions often deliver significant improvements in throughput, energy efficiency and reliability while requiring substantially lower capital investment than complete equipment replacement."

Digital technologies are also contributing to asset optimisation, particularly where mining operations are geographically isolated.

"Remote condition monitoring, predictive maintenance and digital diagnostics allow customers to identify potential issues before they develop into failures," he says. "These technologies are particularly valuable at isolated operations where specialist technical resources are not always immediately available."

FLS is also expanding its regional service infrastructure to support this lifecycle model. Kaninda points to the expansion of the Chloorkop service centre in South Africa and the establishment of a new service centre in Accra, Ghana, as initiatives intended to bring engineering expertise, repair capabilities, spare parts and technical support closer to mining operations.

"Reducing downtime is not simply about responding quickly when equipment fails," stated Kaninda. "It is about ensuring customers have immediate access to skilled technicians, specialist repair capability, critical spare and wear parts and engineering expertise within the region. Local proximity significantly shortens response times and reduces dependence on lengthy overseas supply chains."

The company is placing particular emphasis on regional teams working directly with customers.

"Our strategy is built around people on the ground who understand local operating conditions and customer requirements. That local knowledge enables faster decision-making, stronger customer relationships and more effective technical support."

For Nico Erasmus, vice-president and head of pumps, Cyclones and Valves (PCV), Africa, equipment reliability needs to be considered alongside the logistical realities of operating mines across the continent.

"In many parts of southern and central Africa, uptime depends not only on equipment performance but also on the ability to support that equipment quickly and effectively," Erasmus says. "A pump or valve failure can stop production for an extended period if replacement parts or repair capability are not readily available. Reliability therefore means resilience across the entire support ecosystem."

FLS's Stormill PCV Service Centre supports this approach by providing specialised repair, refurbishment and technical services for pumps, cyclones and valves in the region.

"Having local service capability allows us to restore critical equipment much faster than relying solely on overseas facilities," hesaid. "It also creates opportunities to develop local technical expertise and strengthen skills within the African mining industry."

Erasmus said rebuilds and upgrades are becoming increasingly relevant as mining companies contend with import costs, currency volatility and longer lead times for replacement equipment.

"Rebuilding and upgrading existing equipment often provides a more cost-effective solution than importing new assets, while extending equipment life and maintaining operational performance."

Resource efficiency is another consideration for mining operations facing constraints around water and energy.

"In many African mining regions, water availability and energy security have become operational constraints. Improving slurry transport efficiency not only lowers operating costs but also reduces water and energy consumption, delivering measurable productivity and sustainability benefits simultaneously."

Kaninda said this approach is consistent with FLS's global CORE’26 strategy, particularly as operators seek to link productivity improvements with more efficient resource use.

"In Africa, sustainability and productivity are closely linked. Improving resource efficiency strengthens both mine economics and operational resilience, particularly in regions facing water scarcity or unreliable power supply."

McKay said the discussions at Electra Mining Africa also highlighted growing demand for integrated partnerships that extend beyond individual equipment purchases.

"Africa's mining industry is focused on extracting greater value from existing operations while building more resilient, efficient and sustainable processing plants," he says. "Delivering that outcome requires more than supplying equipment. It requires long-term partnerships supported by local expertise, engineering capability and service infrastructure that remain close to our customers throughout the life of their operations."

Epiroc Pit Viper 276 boosts rotary blasthole drilling. (Image source: Epiroc)

Epiroc has launched the Pit Viper 276, a new rotary blasthole drill designed for soft rock surface mining applications 

The latest addition to the Pit Viper range combines increased hole depth with enhanced drilling performance and scalable automation capabilities.

The Pit Viper 276 is designed to drill hole diameters ranging from 9 to 10 5/8 inches (229–270 mm) and can achieve drilling depths of up to 239 ft (73 m) with its five-rod carousel. The machine features increased rotary torque, larger P14 pumps and improved levelling capability of up to 10 degrees.

An expanded dust hood has also been incorporated to improve the dispersal of cuttings during drilling. These features are designed to support productivity, flexibility and drilling performance across a range of soft rock surface mining applications.

"The Pit Viper 276 combines proven performance with the flexibility customers need to meet today's production demands. From increased hole depth capability and improved leveling performance to higher torque, the PV-276 helps customers maximise productivity while maintaining the durability and reliability that have made the Pit Viper series an industry benchmark," remarked Cynthia Rodriguez, global product manager - Large Blasthole.

Scalable automation for surface mining

The Pit Viper 276 comes as standard with Epiroc's Rig Control System (RCS), providing a range of automation capabilities. These extend from onboard automation to teleremote operation and fully autonomous drilling.

Using the established RCS operating platform, the drill allows customers to select the level of automation suited to their operational requirements.

Safety and maintenance features

Safety features are integrated into the Pit Viper 276 design, including a FOPS-certified operator cab and RCS safety interlocks. An optional Live Work Elimination package is available to help reduce operator and technician exposure to hazardous tasks while supporting maintenance efficiency and machine availability.

The optional Automatic Bit Changer and Live Work Elimination solutions are designed to reduce manual intervention during drilling operations and routine maintenance.

Cable feed system supports drill string life

The Pit Viper 276 uses Epiroc's patented cable feed system with automatic cable tensioning. The system is designed to reduce wear on critical components and extend drill string life, helping to lower total cost of ownership over the machine's operating life.

With increased drilling depth, higher rotary torque, improved levelling, automation and safety features, the Pit Viper 276 extends Epiroc's rotary blasthole drill offering for soft rock surface mining.

The launch also highlights Epiroc's focus on applying automation, serviceability and machine performance improvements to specialised mining applications. By combining established Pit Viper platform features with new capabilities, the Pit Viper 276 is designed to support productivity, safety and operational performance in soft rock drilling.

Pump specification is critical to successful mine dewatering (Image source: Integrated Pump Technology)

As mining operations across Africa continue to face increasingly complex water management challenges, the correct specification of dewatering pumps has become one of the most important factors influencing operational efficiency, safety and production continuity

While pumps are often viewed as standalone pieces of equipment, successful dewatering requires a detailed understanding of site conditions, water characteristics, duty requirements and long-term operational objectives.

Incorrectly specified equipment can lead to excessive energy consumption, reduced pump life, frequent breakdowns, production interruptions and significantly higher operating costs.

According to Jordan Marsh, managing director of Integrated Pump Technology, many dewatering challenges experienced by mining operations can be traced back to pumps being selected based solely on flow rate requirements without sufficient consideration of the broader application.

“Effective dewatering is about much more than moving water from one point to another," said Marsh.

“Every application has unique characteristics and unless these are properly assessed, the selected pump may not deliver the required performance or reliability."

He said that factors such as pumping distance, total dynamic head, solids content, water chemistry, seasonal fluctuations, power availability and installation conditions all need to be evaluated during the specification process.

“Two applications may require the same flow rate, but the actual pump solution could be completely different depending on the site conditions. This is why a detailed assessment is critical before any equipment is selected.”

Marsh said that as mining operations move deeper underground and surface mines become larger, dewatering systems are often required to operate over longer distances and against higher heads.

These conditions place additional demands on pumping equipment and require careful consideration of pump design, motor sizing and overall system configuration.

The increasing focus on sustainability is also influencing pump selection decisions.

Mines are under pressure to reduce energy consumption while maintaining production targets, making efficiency an important consideration during the specification phase.

“A correctly specified pump will not only deliver reliable performance but can also significantly reduce energy costs and maintenance requirements over its operational life,” said Marsh.

Integrated Pump Technology works closely with mining customers to evaluate individual site requirements before recommending suitable dewatering solutions.

The company supplies a range of Grindex electric submersible pumps and Godwin diesel-driven pumps designed for demanding mining applications across Africa.

Its dewatering portfolio includes Grindex electric submersible pumps ranging from approximately 1 kW to more than 90 kW, covering drainage, sludge and slurry applications.

Its Godwin diesel-driven pump range incorporates both automatic self-priming and high-head pump technologies with capacities capable of delivering flow rates from a few litres per second to several thousand cubic metres per hour, depending on the application.

This breadth of offering allows the company to match equipment precisely to site conditions, pumping distances, head requirements and water characteristics.

Marsh added that the most successful dewatering projects are those where the pump supplier is involved early in the planning process.

“When pump selection is approached as part of the overall mine water management strategy rather than simply an equipment purchase, operations generally achieve better reliability, lower lifecycle costs and more effective water control,” he noted.

As mining operations continue to contend with groundwater ingress, seasonal rainfall and increasingly demanding production environments, ensuring that pumps are correctly specified from the outset remains a key factor in achieving safe, reliable and cost effective dewatering performance.

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