global review
2016
extraordinary
possibilities
CONTENTS
DRA’s Complete Offering
3
Who Are We
4
We Believe In DRA
5
Our History
6
What We Do
9
Where We Operate
16
Commodity Expertise
19
Projects24
Contact Us
32
1
DRA’S COMPLETE OFFERING
1
WHO WE ARE
WE BELIEVE IN DRA
DRA is a multi-disciplinary engineering group that
delivers mining, minerals processing and infrastructure
services from concept to commissioning, as well as
comprehensive operations and maintenance services.
Over the last 30 years we have strengthened our presence
within the Mining and Minerals industry and believe
our unique project offering is unrivalled in this sector.
Engineering is our passion, our vision travels across
borders and sectors growing our global capabilities and
enhancing our client service offering.
From humble beginnings in 1984, with the inception of
our first minerals processing plant in South Africa, DRA
soon expanded its footprint to include projects across
Africa, and the rest of the world.
We have defined ourselves as experts in engineering
and we continue to redefine the essence of the discipline
to meet the challenges of the global economy in the
21st century. As industry leaders we cover a wide range
of commodities including gold, platinum, coal, ferrous
metals, diamonds, uranium, base metals, potash and
rare earths.
We bring to projects the deep market knowledge and
insights of over 3,000 people in 20 offices worldwide.
Our collaborative community is diverse in culture and
disciplines and includes engineers, project managers,
draughts people, operators and support staff. Many of
our people are recognised as leaders in their fields and
as such, we are able to navigate complexities across
commodities and borders.
Clients continue to choose DRA due our ability to deliver
world-class service to world-class companies across the
globe; we provide a comprehensive list of engineering
services required to advance a mineral project from
concept to commissioning.
We share an uncompromising commitment to excellence,
which explains why our contract operations division
operates and maintains numerous minerals processing
plants, around the world, on behalf of our clients. We are
the distinction; through our expertise we undertake the
design and construction management of surface and
underground mining projects, in both hard and soft rock
design and confidently offer design and implementation
services of associated infrastructure projects, such as
ports, roads, bridges and housing development.
trust
4
Our client service principles grow partnerships beyond
connections to lasting relationships. We not only meet
expectations, on time and on budget, we exceed them! In
2015, our enviable reputation within the market enabled
us to confidently declare DRA as the engineering group
that creates extraordinary possibilities. This is our legacy,
one we are proud to share with the world. Where projects
face seemingly insurmountable challenges DRA finds
solutions.
DRA is present in 20 locations worldwide, our collaborative
efforts enable us to think globally but implement locally,
merging highly skilled minds to deliver bespoke solutions
to a specific market. In 2016, we will intensify our efforts
to diversify and further commit our resources to develop
broad solutions to specific challenges faced by the global
community.
Our key infrastructure focus areas include energy, water,
transportation and social infrastructure solutions. Our
clients range from local communities to government,
private developers, mining companies as well as oil and
gas suppliers.
The core of our corporate mission and values is people our greatest asset. Our culture of safety is intrinsic to the
company and has resulted in a Lost Time Injury Frequency
Rate (“LTIFR”) of 0.099 in 2015, well below the industry
standard. We believe that safety is a prerequisite to any
function on our projects. Our safety culture enables us to
adapt to challenging circumstances to deliver our clients’
projects safely.
As we lay the foundation for future development, we
leverage our talent, geographic reach and resources to
make a positive and lasting impact on many of today’s
social and economic challenges. By diversifying in
expertise and location, we combine our skills to look
beyond tomorrow and remain united in our quest to
discover new potential.
In line with our corporate vision, DRA will strive to advance
sustainable solutions in energy, food and infrastructure
through collaboration:
•
DRA was appointed Lead Study Manager for the Triton
Minerals’ Nicanda Hill project in Mozambique. Not only
will we enhance Triton Minerals’ graphite knowledge, it
is our belief that graphite holds the key to energy
storage which is vital in the development of the
renewable energy sector.
• Further expanding our focus is the exploration of
potash and phosphate, two key commodities for
food security. Earlier this year, we were awarded our
first phosphate project, followed by the completion of
a definitive feasibility study of the project. The project,
due for commissioning in August 2016, is designed
to produce approximately 1.35 Mtpa of phosphate
concentrate.
•
We will aggressively pursue the development of our
infrastructure services and capabilities worldwide,
by expanding on similar work undertaken in the
mining sector.
Paul Thomson – CEO, DRA Group
5
OUR HISTORY
From relatively humble roots in South Africa founded by
engineers with an entrepreneurial spirit in 1984, we have
subsequently built expertise and capacity in the rest of
Africa. This has enabled us to present our total mineral and
mining engineering solutions services to the rest of the world.
1997
1995
1984
1989
1990
DRA’s first
gold project at
Weltevreden.
DRA’s first East
African Project
Williamson
Diamond Mine
in Tanzania.
1993
DRA’s first project
in Canada, a
Dowding Reynard & Associates
is established by Brian Dowding
and Tony Reynard.
diamond plant at
First of the Lonmin
platinum projects.
Yellowknife.
2014
2013
2010
DRA 30 years old.
Paul Thomson succeeds Leon
Phola Coal and DMO
DRA Acquires
Uys as CEO of the DRA Group.
specialist engineering
ARDBEL is established for
company,
large-scale materials handling
Taggart Global.
projects. WAH Engineering
Consultants is acquired to
add shaft structural
design capability.
2012
Brian Bruce is
DRA deliveries Liberia’s
first commercial gold
mine for Aureus Mining
6
2002
DRA’s Winder systems
DRA completes
Platinum Project
2001
projects in one year,
establishes DRA as
DRA builds the
simultaneously.
is established.
Kroonendal
a leader in platinum
world’s largest
concentrators.
floating diamond
six platinum
two of them
plant on a modified
DRA’s first project
marine vessel.
in Australia,
Merlin Diamonds.
2004
1998
DRA’s first venture
1996
Minopex wins the
into mining -
Letseng Diamond
a decline shaft for
Mine operation. DRA
Kroonendal Platinum.
Mining is awarded
Minopex is
established. DRA’s
first large coal
project at Twistdraai
(JV with Fluor).
Marula off-reef
conversion project.
2009
2006
DRA acquires Holly &
establish DRA in the
Associates.
mega-coal projects
DRA is awarded
arena. DRA Mining
its first major
Leon Uys succeeds
acquires LQS.
infrastructure project.
Brian Dowding
as CEO.
DRA Americas is established. DRA is awarded its first project in China
for a coal producer in Xinwen.
BKM Project established
DRA in iron ore. Modular
diamond plants completed
for De Beers’, Snap
Lake and Victor projects
in Canada. Vhumbanai
Projects established.
2005
appointed as chairman
of the DRA Group.
The DRA SA
Group Employee
2015
1999
Broad-Based Trust
is established.
2007
As the business environment has changed we have evolved
from a company that only engineered processing plants,
to one that provides customised mine and infrastructure
engineering, as well as complete operations and
maintenance solutions for clients.
Our passion for excellence in engineering carried us through
the downturn in the industry and sustained our growth from
Africa into the rest of the world.
experience
7
WHAT WE DO
DRA offers a full range of engineering and project services. Our services are tailored to meet the needs of our clients,
delivering both comprehensive and customised project solutions.
“I truly believe that engineering is fun,
building things is fun. Whether it’s a
toy steam engine, a Meccano bridge,
a new substation, a 6 MW winder or
a 600,000 tpm platinum concentrator,
there’s something in building things that
appeals to many kids and those kids
What we deliver:
•
Conceptual design and feasibility studies (including
stock exchange compliant studies)
•
Detailed design and engineering
•
Mine Winder systems engineering and design and
shaft headgear design
•
Mine design and scheduling
•
Customised design of processing plants
•
Electrical control and instrumentation
•
Infrastructure design and engineering plant, mining
and Bulk utilities
•
Project and construction management
•
Commissioning and production ramp-up
•
Contract operations of mineral processing plants
DRA’s contract operations provide feedback to the
design engineers regarding efficiency optimisation as
well as possible areas of improvement. This detailed
review of procedures specifically highlights operability,
maintainability and constructability. As a group we
provide a variety of services, allowing us to meet the
needs of multinational mining companies as well as
medium-sized and emerging producers.
often grow up to become engineers.”
MINERALS PROCESSING
MINOPEX OPERATIONS
INFRASTRUCTURE
WINDERS
engineer
8
STUDIES
EXTERTISE
MINING
OPERATIONS
Brian Dowding, Founder
IMPLEMENTATION
Expertise:
9
WINDER SYSTEMS
MATERIALS HANDLING
In 1999 DRA developed a unique capability in
the design of winder systems and ever since,
our electrical and mechanical Winder Engineers
develop the design framework and establish
the operating specifications. We work alongside
industry specialists to construct new winders,
refurbish existing winders and manage winder/shaft
installations on behalf of the client. Winders which
have been suitably refurbished and modernized can
significantly reduce capital outlay and delivery time
by as much as 50%. As an extension of our service,
we also source new and used winders required
for the development of new shafts or to upgrade
existing infrastructures. All clients benefit from the
technical training we provide to their maintenance
personnel which not only upskills employees
but also reduces reliance on outsourced winder
maintenance services.
DRA provides well-designed, custom-engineered
materials handling systems that increase
throughput, boost productivity and reduce plant
operating costs. From frozen Arctic conditions to
hot and dusty arid environments, we have designed
and built conveyor systems in a variety of climates
and delivered to client expectations regardless of
the circumstance. Our vast experience includes
design and construction of belt feeders, bins,
silos, stockpiles, stackers/ reclaimers and bulk
transfer systems.
Our comprehensive service offering incorporates
unabridged design, project management and
procurement layout services, shaft steelwork,
conveyancing and loading arrangements. As a
dynamic organisation, DRA is able to offer this
integrated solution and tailor services to meet
specific customer requirements.
Over the past three decades, DRA has expertly
designed and installed more than 300 km of
conveyors with some overland conveyors stretching
to 10 km in length and boasting 5500tph capacity.
As an industry leader, DRA brings the latest in
innovation to its clients and offers technologically
advanced Discrete Element Modelling design and
simulations on all chutes and transfer points. In
order to calibrate our models specific material flow
test work is undertaken; we are confident of our
solutions and our customers are confident of our
commitment to their success.
customised
10
ELECTRICAL, CONTROL
AND INSTRUMENTATION
SERVICES
IIncluding high, medium, low-voltage and light
current electrical designs, surface and underground
reticulation, as well as power supply systems
for remote mines, our electrical, control and
instrumentation services afford both customisation
and variety.
Our systems are designed by in-house specialists
who develop all instrumentation and control
software. This process ensures maximum efficiency
and minimal room for error. We design, procure,
programme and commission complex systems for
mining and broad industrial applications.
STUDIES
Planning brings the future into the present and
each step taken brings a goal closer to fruition.
Almost all of the studies that DRA has undertaken
have resulted in the successful implementation
of projects, these projects were undertaken for
both local and global clients and often, due to our
efficient service delivery, resulted in DRA providing
ongoing operational support and guidance. Our
comprehensive study service includes; conceptual,
pre-feasibility and bankable feasibility studies, for
the full range of commodities and all consistent
with the appropriate international stock exchange
compliance codes and standards.
11
HEADGEAR AND SHAFTS
With the acquisition of Walker Ahier Holtzhausen
(WAH) in 2013 DRA added numerous highlyspecialised capabilities to its service offering and
ever since, we have supplied the best in mine
headgear and shafts to our clients. Conceptualised
and designed following decades of experience
in South Africa’s deep underground mines, DRA
continues to extend the value
PROJECT
IMPLEMENTATION
DRA’s ability to successfully implement projects
across Africa and throughout the world has
earned the organisation its enviable reputation.
This success is owed largely to our smart, ‘fit
for purpose’ engineering and design which is
complemented with strong project management
skills and knowledge. Our value added services
provide flexible and project specific implementation
plans and contracting models tailored to meet the
unique project requirements of clients to clients.
Our contract models are typically based on EPCM,
EPC or hybrid solutions.
DRA’s client service principles not only integrate
our people across the globe but also integrate
our people and our clients. Our firmly established
relationships with global industry suppliers and
contractors afford us reliability and quality and
ensure the consistent delivery of cost effective
solutions to our clients.
Our project models have proven to be very
successful, delivering challenging projects within
stringent and varied constraints such as time, cost,
quality, risk, safety and client satisfaction.
12
OPERATIONS
As the leading contract operator of mineral
processing facilities in Africa, we specialise in the
commissioning, operation and maintenance of
mineral processing plants. Our expertise extends
to both greenfield and brownfield operations, we
are able to provide the most time efficient and cost
effective solutions. With our unrivalled experience
in facility improvements it is clear why customers
have, and continue to choose DRA as the firm
of choice.
Our collective knowledge is a culmination of
experience and knowledge; it is the collective
expertise of our process engineers, specialist
maintenance, asset management, training
and safety management teams across various
commodities. Additional operational services
include a full suite of laboratory services, as well
as the operation and maintenance of tailings
deposition facilities and water treatment plants.
Over the past three decades, DRA has mastered its
capabilities to operate plants across the globe in
temperatures ranging from -50 ˚C to +50 ˚C.
The extensive experience of our people ensures
that our client needs are met timeously, regardless
of how these needs may evolve in scope of work
and project duration. We are experts in what we
do and our knowledge ensures that we deliver
exceptional service, at a competitive rate while
reducing risk and improving productivity.
OUR FULL SERVICE
OFFERING
DRA has specialist capabilities in the design
of mineral processing plants for a wide range
of commodities. Our process expertise in
comminution, flotation, gravity concentration and
hydrometallurgy is highly regarded throughout the
industry and attests to our integrated approach to
mine design.
Our vast experience in mine design ranges from
the exploitation of deep-level gold deposits on the
Witwatersrand of South Africa, to the ore bodies
situated in northern Canada and Russia.
The DRA mine design and engineering team
is an integration of expertise from our mining,
mechanical, electrical, control, instrumentation and
winder specialisations. Our comprehensive service
offering includes engineering, procurement and
construction management (EPCM) as well as
lump-sum turnkey (LSTK) solutions.
The team’s engineering design work is
supported by in-house drawing offices located
in Johannesburg, India and Canada. Our highly
advanced software ensures that the team produces
the highest quality 2D and 3D designs.
The above capabilities are complimented by
our proficiency in design and construction
management, specific to mining-related
infrastructure for both surface and underground
operations. Our scope of work within this
specialisation is varied; we deliver standalone
infrastructure such as bridges, roads, dams,
schools, hospitals and offices as well as larger
and more complex projects such as township
development, complete ports and airports,
railway lines and hydropower plants.
full service
13
WHERE WE OPERATE
We started as five engineers in 1984 and have since
grown to a global organisation with a diverse service
offering in 20 locations worldwide. While our roots
originated in South African soil, we have crossed
borders and oceans to service the needs of our
global customers.
It began at our offices in Sunninghill, Johannesburg
and, to this day, these same offices form the heartbeat
of the organisations global operations. We have grown
exponentially throughout the continent and today, we
are present in 13 locations throughout Africa.
level of service to our customers in the Americas. The
Brisbane, Perth and Beijing operations enable us to
extend our total service offering to clients throughout
the Pacific Rim. DRA has also established offices in
Kazakhstan and India which continue to grow.
While we have traversed borders and continue to
grow our global presence, our professionals, based
in Johannesburg, not only share insights and best
practices across borders and projects but also assist
with the execution of large projects globally, making
DRA a cost effective solution for international clients.
With our offices in Pittsburgh (USA) and Toronto
(Canada) we are able to provide the same superior
africa
AMERICAS
india
PACIFIC
Our extensive experience
throughout Africa has
earned us our exceptional
reputation within the
market and our unmatched
standard of project delivery
has secured us as the
firm of choice across the
continent. We are not only
able to complete projects
according to customer
specifications, we also
significantly reduce the risk
associated to projects we
undertake. DRA is fortunate
to serve both local and
international tenement
holders in Africa.
DRA has proven capability
in project execution across
regions and in extreme
environmental conditions.
Undertaking projects in
remote, largely inaccessible
locations of the world,
requires specialised
logistical planning, as well
as expert design and project
execution skills but this is
exactly how DRA creates
extraordinary possibilities.
Our drawing office in India
produces cost effective
design work for our clients
on any project, throughout
the globe. We also provide
process engineering plant
technology and general
engineering services to the
Indian mining industry.
For over a decade, DRA has
successfully operated in
Australasia. Our Mandarin
office in Beijing, supports
global procurement and
our offices in Perth and
Brisbane support the local
mining industry as well
as clients with African
tenements.
Snap Lake
Diamonds
Fe
Labrador
Iron Mines
Groundhog
Coal
Black Otter
Coal
Almarty
Kazakhstan
Toronto
Canada
Beijing
China
Pittsburgh
USA
Au
Au
Muscat
Oman
Edikan
Gold
Liberia
Ghana
Kibali
Gold
OBOTAN
Gold
KINSENDA
Copper
Tati
nickel
Ni
KAROWE
DIAMOND
Tanzania
KonKola
North Copper
Zambia
Namibia Zimbabwe
Botswana
Mozambique
JHB
South
Africa
PACIFIC
india
Cu
DRC
africa
Vallabh Vidyanagar
India
Au
Au
NEW LIBERTY
Gold
AMERICAS
tongxin
Coal
Cu
coobina
chromite
Cr
tweefontein
Coal
Perth
Australia
Brisbane
Australia
Pt
Booysendal
Platinum
14
15
COMMODITY EXPERTISE
“As the organisation further expands
its global footprint and continues to
diversify its expertise in commodities,
we are able to address nuances of
local markets and deliver world-class
services to our clients across a broad
spectrum of projects.”
Johann de Bruin, Managing Director
DRA Projects
GOLD
DRA has a long association with the gold mining
industry. As a result, we are able to meet the design
requirements of gold mines and gold plants, for any
application. Our success is owed to our team of
leading gold processing engineers and their ability
to supply gold plants to Africa and the rest of
the world.
Now comprising the collective knowledge of more
than 60 process engineers, and their relative
design and plant operation expertise, our process
department adds significant value to our clients’
gold projects.
Our gold specialists are experts in the testing of
refractory ores and specifically in gold processing
through cyanide destruction resulting in the delivery
of optimal and cost-efficient process designs, for
even the most challenging projects. Due to the
relationships we have established with equipment
suppliers and commercial laboratories, worldwide,
DRA’s cutting-edge technology enables us to
deliver the best in gold processing plants and
mine designs.
FERROUS METALS
Our ferrous metals processing capabilities include
iron ore, chromite, manganese and vanadium
projects using crushing, screening and milling,
washing and scrubbing, gravity concentration,
magnetic separation, flotation, pressure leach and
dry separation processes. We have designed and
built numerous processing plants and projects
within this sector.
DRA has designed and constructed processing
plants for ferrous metal operations in Australia,
Canada and Kazakhstan with Khumani Iron Ore
being our flagship project in South Africa.
Our partnership with the mine dates back to 2006
and ever since DRA has provided mining-related
infrastructure development for the entire operation,
including the load-out system and tailings handling
facility. We have most recently upgraded the
hematite iron ore through a process of crushing,
screening, jigging and WHIMS (Wet High Intensity
Magnetic Separation).
Clients have become accustomed to our high levels
of customer service and often request our plant
operations team to train in-house operators, in the
commissioning and running of gold plants.
safety
16
Paul Thomson – CEO, DRA Group
17
PLATINUM
DRA is the world leader in the development
of platinum concentrator projects and we are
renowned for our service offering and delivery.
Within this unique field of mineral processing
we undertake the necessary testwork, design
concentrators for specific ore bodies, implement
plant modifications, to increase recovery and
throughput, and offer both plant design and
construction.
Characterised by the in-house comminution design,
our platinum processing plants offer an advanced
level of process control and automation. Our
engineers prioritise efficiency and as such, our
solutions offer the most cost-effective plants in
the industry.
We have also distinguished ourselves in preconcentration technology; by pioneering the use
of dense medium separation in PGM concentrators
in the processing of UG2 ore, with a high chromite
content, we set ourselves apart from others in
the industry.
Our expert knowledge is a culmination of 10
years’ experience gained through the design
and construction of over 40 concentrators in the
Southern region of Africa. Having been instrumental
in 80 percent of platinum plants in South Africa and
Zimbabwe, in the past 20 years, with a combined
throughput of approximately 40 Mtpa, attests to our
superior solutions and insight
18
BASE METALS
DIAMONDS
DRA provides the base metals sector with stateof-the-art technical solutions and is known in
the industry as the expert in concentrator plant
design. We offer practical solutions in processing
strategies, including comminution circuit design,
flotation, leaching, solvent extraction and
electrowinning. We understand feasibility and
apply this to our design of orebody-specific
processing plants. We acknowledge the importance
of flexibility in the implementation of plant
modifications to boost recovery and throughput.
We know that innovation must move beyond
current and we drive this by pioneering the use of
dense medium separation (DMS) technology in the
pre-concentration of base-metal ores.
DRA is a leading contractor in the design,
construction and commissioning of diamond
recovery and dense medium separation (DMS)
plants. The vast experience of our team of
engineers, the application of our extensive technical
knowledge and the use of the best in technological
innovation, ensure that our clients receive
engineered processing plants beyond compare.
Our services are as varietal as our experience;
testwork programme management, conceptual
and final process-option selection and
engineering development, complete processing
plant and infrastructure engineering design and
implementation management, electrical and control
systems design, and the design and construction of
mining infrastructure.
One of the many notable applications of our
expertise was the successful design of the Nkomati
Nickel plant’s Phase 2 expansion project. The
expansion was necessary for the mine to process
two minerals, nickel and chrome, through one
plant. Following the upgrade, plant production has
increased from 100,000 tonnes per month (tpm) to
250,000 tpm.
Our clients vary in operation size and geographic
location, we are proud to have supplied diamond
processing plants to the largest diamond
producers on five continents. These unit processes
include liberation by primary, secondary and
tertiary crushing using jaw, gyratory, cone, high
pressure grinding rolls (HPGRs), scrubbing and
milling. Waste sorting in pre-concentration is also
becoming increasingly prevalent.
Final diamond recovery is achieved through any
combination of wet or dry magnetic separation,
X-ray sorting and the use of greasebelts. DRA
recently acted as the engineering, procurement and
construction management
(EPCM) contractor on the Karowe Mine Diamond
Project for Boteti Mining in Botswana. The Karowe
processing plant is the first in Southern Africa to
use autogenous milling as a primary liberation
technique.
COAL
DRA are experts in the design of coal processing
plants.
Over the last 30 years, DRA has expertly designed
processing plants producing approximately 50%
of washed coal in South Africa. Our involvement
in over 350 coal processing projects globally,
complete with materials handling facilities, confirms
our ability to deliver only the best. Our enviable
credentials in this commodity extend beyond
Africa and into China, USA, Australia, India, Russia,
Trinidad and Indonesia.
DRA provides the full spectrum of coal processing
services – from feasibility studies and plant
design, through to project implementation and
processing plant commission. We are regarded as
world leaders in the delivery of turnkey solutions,
particularly in coal washing plants.
We are able to deliver varied- and multiple-stage
washing plants, including gravity or pump-fed DMS
plants, drum plants, spiral plants, flotation plants
and jig separation plants.
The award of the Merlin Project in Australia by
Ashton Mining confirms our status as costcompetitive, world-class designers of diamond
plants. This accolade was further supported by
DRA’s subsequent award of the Namibian sub-sea
diamond recovery contract for the construction of
the world’s largest sea-borne DMS.
comprehensive
19
RARE EARTHS
URANIUM
From upfront beneficiation and concentration,
through to the production of either rare earth
oxides or chlorides, or purified rare earths, DRA
has thorough knowledge in the development of rare
earth hydrometallurgical projects in Africa.
Another of our specialist areas of expertise is the
uranium sector and although we are able to offer
a comprehensive solution, we continue to improve
on our offering. DRA has successfully completed
uranium scoping or preliminary economic
assessment (PEA), pre-feasibility and feasibility
studies (NI 43-101 and JORC compliant) for Mantra
Resources, Uranium One, Rockgate Resources and
Peninsula Energy, as well as a 2.3 million tonnes
per month tailings retreatment study for Goldfields.
Rare earth beneficiation and concentration
capabilities include crushing, radiometric or
X-ray fluorescence (XRF) sorting, dense media
separation, gravity separation, milling, low intensity
magnetic separators (LIMS), wet high intensity
magnetic separators (WHIMS) and flotation.
Extending beyond conventional hydrometallurgical
processing, our experience also includes more
complex rare earth extraction technologies
such as caustic and sulphuric acid cracking,
whole ore hydrochloric leaching, recovery of
reagents, complex solid or liquid separation,
thermal decomposition, selective precipitation
and redissolution, double salt formation, solvent
extraction, ion exchange, acid retardation,
nanofiltration and flowsheet simulation.
These studies explored a variety of production
rates and processing methods, including acid heap
leach, acid and alkali agitated leaching, resin-inpulp (RIP), ion exchange (NIMCIX, Fixed Bed IX and
others), counter-current decantation (CCD), solvent
extraction (SX), nanofiltration, energy recovery
systems and various back-end precipitation circuits
(ADU, SDU and Peroxide).
We are fortunate to have comprehensive heap
leach experience which includes both static and
dynamic heap leaching with uranium recovery via IX
and SX. Our process engineers have managed and
supervised uranium test work campaigns in South
Africa, Australia and Canada, offering customers
their expert insight into the design, execution and
commissioning of uranium projects that process
ores from deposits in South Africa (ADU precipitate)
and Namibia (SDU precipitate).
Our close and established relationships with key
contractors, suppliers and consultants in the
global uranium industry facilitate our production
of comprehensive trade-off studies on processing
options. During project development, from the
conceptual phase through to construction and
commissioning, we focus on economic value-add
and risk mitigation.
commodities
20
21
extraordinary
possibilities
PROJECTS
Booysendal Platinum Mine, South Africa.
BOOYSENDAL PLATINUM
“We taylor our services to meet the needs of our clients, offering both total solutions as well as
customised project solutions.
Our ability to draw on our engineering and support staff in Johannesburg to assist with the
execution of large projects, makes us cost-effective.”
Paul Howard – Global Business Development
22
DRA was appointed as the mining and mineral processing
EPCM (engineering, procurement and construction
management) contractor for the Booysendal Platinum
Project for Northam Platinum. We successfully completed
the detailed design and construction management of
the complete mining complex, including two declines, a
187.5 ktpm platinum group metals (PGM) concentrator
and all supporting infrastructure.
The typography of the project and the environmentally
sensitive surroundings of the Dwars River Valley
presented various challenges to the project team. Our
three decades knowledge afford us the confidence to
navigate even the most difficult territories and make
informed decisions; DRA’s effective management of
multiple elements of the project, significantly contributed
to its success.
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Karowe Diamond Mine, Botswana.
Lubambe Copper Mine, Zambia.
LUBAMBE COPPER
As the EPCM contractor for the Lubambe Copper Project
at the Lubambe Mine in Zambia, DRA was involved in the
conversion of a shaft, mothballed for 50 years, to support
an operating mine.
By replacing the existing steelwork, refurbishing the
shaft’s two winders and designing and managing the
construction of a new winder, we were able to meet client
expectations. In addition, DRA engineers also designed a
Karowe DIAMOND
new decline and designed and managed the construction
of a materials-handling system, a tailings dam and
related infrastructure. Finally, the beneficiation plant was
designed and built, including a sophisticated milling and
flotation system. The entire project was completed two
weeks ahead of schedule with the Lubambe concentrator
producing its first concentrate on 20 September 2012.
After a successful commissioning in 2012, Boteti
approached DRA to complete the Phase 2 upgrade of
the Karowe process plant in 2014. DRA again utilised
Kinsenda COPPER
innovative engineering design to integrate specialised
X-Ray technology into a new diamond recovery circuit that
will identify and recover carbon-specific diamondiferous
material. This unique XRT technology will enhance
Boteti’s ability to recover larger diamonds, prior to the
DMS, whilst mitigating the risk of downstream damage.
Within the first year of the plant upgrades, this innovative
process plant design has assisted in the recovery of a
1,111 carat gem quality diamond, the second largest
diamond recovered in history.
KIBALI GOLD
In 2015 DRA completed construction of one of the
world’s highest grade copper deposits, Metorex’s
Kinsenda copper project in the Katanga Province of the
Democratic Republic of Congo. DRA was appointed to
refurbish the current shafts and erect a process plant,
onsite, to improve process efficiencies of mining copper
resources in the DRC.
mandate
included,
multidisciplinary
engineering
design, procurement of equipment and building
materials, logistical delivery to site and the construction
management of contractors actively assisting with the
project implementation. DRA designed the plant to
process the 700 kt resource extending to both sulphide
and oxide copper ore.
The project scope includes the construction of a new
600 ktpa processing plant, a decline development, a
new winder as well as surface and underground mine
infrastructure for the re-opening of the existing mine.
By using local labour and applying our contract
management skills to oversee over 950 people on site,
the processing plant was commissioned in early in 2015.
DRA ensured short term deliverables were met on time
and within budget and disclosed impeccable safety
records for the duration of the project.
As the EPCM contractor, DRA implemented our pit
to port service on yet another project in Africa. Our
Commissioned in Q2 2015 DRA brought various unique
elements to this diamond plant designed constructed for
Boteti Mining. Located in Botswana, DRA began work
on Phase 1 of this greenfields 2.5 Mtpa process plant
project in 2010, and incorporated autogenous (or AG)
milling technology into the innovative design, a first in the
Southern African diamond processing region.
Kibali Gold is one of the largest gold plants on the continent
of Africa. DRA delivered the design, procurement
and project management of the metallurgical plant,
infrastructure, a 45 MW backup power system, tailings
system for a 6.1 Mt lined concentrate tailings dam and
7.6 Mt float tailings dam. Although DRA was awarded
the process plant EPCM contract, two-thirds of the
project was infrastructure-related. The first phase of the
project also included the 22MW Nzoro hydropower plant.
(DRA is currently managing construction of the second
12 MW hydropower plant – Ambarau). During the peak
construction phase of Kibali, DRA was responsible for
more than 4500 contractor personnel on site, achieving
9.8 million consecutive injury free hours.
Kibali Gold Mine, DRC.
Kinsenda Copper Mine, DRC.
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innovation
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New Liberty Gold Mine, Liberia.
Tweefontein Coal Mine, South Africa.
TWEEFONTEIN COAL
The Tweefontein Optimisation Project is, to date,
one of DRA’s largest EPC (engineering, procurement
and construction) contracts. The project involved the
replacement of three existing coal preparation plants,
at Glencore Xstrata’s Boschman site, which collectively
yielded a 9Mtpa output from a single plant. The coal
preparation plant (CPP) has been designed for a raw coal
feed capacity of 12.5 Mtpa and features two 1,000 tph
modules, a two-stage, primary and secondary dense
medium cyclone facility, for coarse coal, and a spiralbased unit for fine coal processing. Both primary export
and secondary, local, product is produced. Construction
New Liberty GOLD
began in August 2012 and is currently on schedule for its
completion date in the first quarter of 2015. DRA;s scope
Further extends to include all infrastructure associated
with the 18 MVA power-consuming CPP, starting from the
ROM tip all the way through to the rail load-out facility.
During this projects DRA has made use of virtual
construction simulation software in order to ensure the
designed connections cater for simplified assembly of
workshop or ground assembled sections. This integrated
software allowed DRA to greatly mitigate risks, improve
safety and optimise constructability
TATI NICKEL
Appointed as EPCM contractor to maximise profitability
at Tati Nickel’s Phoenix Mine in Botswana, DRA designed
and built the first ever dense medium separation (DMS)
pre-concentration plant for nickel. Our innovative
application of DMS technology produced a significant
increase in the viable mineral reserve and simultaneously
reduced the overall production cost.
DRA is extending our African gold track record through
the EPCM contract of the New Liberty gold project for
Aureus Mining. New Liberty is located within the BeaMDA property, in Grand Cape Mount County in the northwestern portion of the Republic of Liberia, approximately
100km north-west of the capital, Monrovia.
New Liberty, is currently the only gold mine under
construction in West Africa with first gold pour targeted
for Q2 2015.
The project objective is to provide a gold processing
facility that will be capable of handling a nominal tonnage
of 90 000 tpm throughput of ore. The process consists
of a two-stage crushing circuit and a primary mill with
regrinding using VERTIMILL® technology. Gold is leached
in the carbon-in-leach circuit and gravity gold is leached
with an intensive leach reactor.
DRA has been involved at the New Liberty project
since its inception in May 2011, and will be on site until
commissioning in 2015. This will be yet another project
where DRA are responsible for various service offerings
from total mine infrastructure development, processing
plant to the diversion of the Marvoe Creek away from the
open cast pit, and the tailings storage facility.
Despite some of the extreme challenges of implementing
a project in Liberia DRA has managed to mitigate all risks
and is on target to handover the plant to Aureus Mining
for full production Early in Q3 2015.
BLACK OTTER COAL
DRA provided turnkey design, engineering, procurement,
erection and startup for Signal Peak Energy’s bituminous
coal handling and washing facility in Montana, USA.
Signal Peak Energy’s Black Otter Mine employs longwall mining to produce 7,000 tph of run-of-mine
(ROM) coal, which is conveyed to a stacking tube
for ground storage. Reclaimed at 3,500 tph, the ROM
coal is conveyed to a screening and crushing building for
reduction to 2” top size and is then transported to a raw
coal stockpile. Flexibility has been provided to direct the
reclaimed raw coal to the preparation plant or, directly to
the clean coal storage area, depending on quality.
Black Otter Coal Mine, USA.
26
technology
27
Tati Nickle Mine, Botswana.
Kumani Iron Ore Mine, South Africa.
Black Rock Manganese Mine, South Africa
BLACK ROCK MANGANESE
Since 2010 DRA has been the EPCM contractor
responsible for upgrading the Black Rock Manganese
project. The purpose of the upgrade is to increase
processing capacity from 3.2 Mtpa, to 4.6 Mtpa. In
addition, the client, Assmang, requested the improvement
of efficiencies to ultimately result in the reduced operating
costs. DRA is currently responsible for the design,
supply, installation and commissioning of new crushing,
screening and materials handling facilities at the existing
Nchwaning Mine. We have successfully undertaken
studies on alternative approaches to expand the capacity
of the Black Rock Mine Operations of Assmang since late
2010 and the upgrade is currently being executed
In addition to our current work at Black Rock, we have
over several years carried out the studies and execution
projects for Assmang’s major iron ore project, Khumani,
also located in the Northern Cape. These projects and
others firmly place DRA on the world stage of expertise
and project delivery capability in manganese and iron ore.
TONGXIN COAL
DRA commissioned a 1 900 Mtph coal preparation plant
at the Tongxin Mine in Datong, Shanxi Province in the
People’s Republic of China for the Datong Coal Mining
Group, during 2009. With an annual processing capacity
of 10 million tonnes of raw coal, the plant was designed
to produce both high and low quality steam coal along
with a commercial kaolinite product.
The scope of supply included the entire production
facility and all ancillary systems, from the run-of-mine
coal conveyor, through to the railcar loading station.
Construction of the Tongxin Plant began in May 2008
with plant commissioning in September 2009.
KUMANI IRON ORE
Tongxin Coal Mine, China.
In 2004, DRA was contracted by Assmang to manage and
design their greenfields Khumani Iron Ore Project near
Kathu, South Africa. The project was delivered ahead
of time and under budget and resulted in a brownfields
expansion.
Kumani Iron Ore is DRA’s cornerstone project, boasting a
total production capacity of 16 Mtpa, with 22 Mtpa ROM
processing capability. Initially appointed as the study
manager, DRA was subsequently appointed as the main
engineering, procurement and construction management
(EPCM) contractor for detail design and engineering. Our
specialised project team was tasked as the lead contractor
for end-to-end project management and integration of
the crushing facility, processing plant, stockyards and
infrastructure, which included power, water, roads, rail
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sidings and on- and off-site accommodation during the
construction phase.
In addition, DRA was commissioned to design and
integrate mine and plant control systems using a
comprehensive management information system (MIS),
which accurately monitors production by way of realtime data. Site clearing started in mid-2008, with the first
product stockpiled in the 12 months that followed.
Due to this highly successful implementation, DRA
was contracted to manage various other phases of the
project, including the EPCM contract for a super fines
beneficiation plant at Khumani in 2011. This plant uses
WHIMS technology to process -1 mm super fines for the
extraction of saleable product.
performance
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Phola Coal Mine, South Africa.
Nkomati Nickel Mine, South Africa
Nkomati Nickel
Phola Coal
At the Nkomati Nickel Mine in Mpumulanga Province in
South Africa, DRA was contracted to design the plant’s
Phase 2 expansion project to enable the mine to process
nickel as well as chrome through a spirals plant. The
upgrade increased plant production from 100 000 tonnes
per month (tpm) to 250 000 tpm.
As part of the project, DRA upgraded the tailings thickener
and designed and built a spiral processing plant to treat
the chrome ore. This spiral plant is a high-end system
that shares infrastructure with the MMZ plant. We added
a new conveyor system and a new stockpile that is 90 m
long, 11 m wide and 35 m high.
The mine’s older plant had been designed to process ore
from the Main Mineralised Zone (MMZ) but it was proven
more profitable to mine Peridotic Chromitite Mineralised
Zone (PCMZ) ore at the time. The Phase 2 plant was
therefore designed to process PCMZ ore, which is lower
grade nickel ore with a high chrome content.
One of the challenges that DRA met was the timely
upgrading of the plant equipment – we completed this
preparation work according to schedule over a 14-week
shutdown period.
Pilanesberg Platinum
Following the completion of a bankable feasibility
study in March 2007, Boynton Investments contracted
DRA to build a new US$170 million concentrator for
the Pilanesberg Platinum Mines Project located on the
Western Limb of the Bushveld Igneous Complex adjacent
to the Pilanesberg Dome. The operations of one open pit
mine fed around 365 000 tpm of < 300 mm run of mine
ore into the concentrator.
The plant treats two types of ore: UG2 at 65 000 tpm
gets processed in the UG2 concentrator section;
the Merensky (300 000 tpm), which itself consists of
two types, contact reef and pothole reef, goes to the
Merensky concentrator section. BHP Billiton Energy Coal South Africa (BECSA) called for
the design and construction of a 16 Mtpa coal processing
plant.
DRA was awarded the US$100 million Phola Coal
project in 2007, the largest coal washing facility in
South Africa. This followed our successful study of the
engineering design, procurement, project management,
construction management and commissioning of
the project.
The plant consists of two 8 Mtpa DMS, fine coal spirals
modules, and probably the largest coal slime filter
press filtration section in the world, in order to meet the
stringent environmental standards. It serves both BHP
Billiton’s Klipspruit colliery and Anglo Coal’s colliery
at Zondagsfontein.
During construction, the Ogies area experienced some
of its heaviest rainfall for two years in a row, the first
coinciding with the peak of civil construction and the
second with the structural steel erection. However
DRA’s project management ensured that the plant was
completed on schedule in June 2009.
Obotan Gold
During the first half of 2009 commissioning of the
Pilanesberg Platinum Concentrators were completed.
Three million LTIF hours were reached from inception to
April 2009, with site personnel peaking at 1 950 at the
beginning of the year.
DRA was responsible for the process, civil, structural,
mechanical, electrical and instrumentation design,
construction and commissioning of the entire
concentrator complex from the ROM receiving bins
through to the tailings dam.
DRA was awarded the EPCM contract for the 3 Mtpa
gold processing plant located 36 km west of Obuasi in
the Amansie West District, Ashanti Region of Ghana. This
is DRA’s second gold plant in Ghana and third in West
Africa over the past 4 years. The project was confronted
with extremely high rainfall during the construction
period.
Nonetheless, we are on schedule to pour gold in Q1 2016.
DRA managed 2 400 employees and contractors on site.
Once commissioned the process plant will produce
190 000 oz of gold per annum. DRA also implemented all
associated mine infrastructure.
Pilansberg Platinum Mine, South Africa
Obatan Gold Mine, Ghana.
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processing
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extraordinary
possibilities
CONTACTS
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DRA PACIFIC (PTY) LTD
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E-mail: info@DRAglobal.com
DRA GLOBAL (PTY) LTD)
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E-mail: info@DRAglobal.com
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GLOBAL REVIEW
DRA Group Holdings (PTY) LTD
DRA GR Q1 V1