2013 was a milestone year for diamond miner De Beers. Not only did the company celebrate its 125th anniversary but in that year, it also embarked on an ambitious underground expansion of its Tier One Venetia Mine in South Africa.
Fast track to 2024 and the Venetia Underground Project (VUP) is well on its way to reach nameplate capacity from 2027 onwards. GERARD PETER finds out more from KOBUS VAN DEN BERG, General Manager: Underground Production at De Beers Venetia.
Venetia is synonymous with the South African diamond mining industry. Located in Limpopo, it started production in 1992. Until it ceased open-pit operations at the end of 2022, it contributed 40 % of the country’s annual diamond production. In 2013, De Beers announced that it would invest US$2.3 billion dollars in VUP, marking the single biggest investment in the country’s mining sector in decades. The underground expansion will extend the life of mine to 2046.
The mine is expected to produce up to 5.9 Mt of kimberlite ore annually, to be used in the extraction of nearly 4.5 million carats of diamonds per year. In 2014, Murray & Roberts Cementation was selected as the preferred contractor to undertake the development of an underground operation. The Underground consists of two distinct areas, namely the Top of Mine and the Bottom of Mine. First production will come from the 46 Level rim tunnel which is slightly above the K01 open pit operation, which is located between 450 – 500 m below surface.
The top of the mine will deliver about 4 Mtpa for about four years as operations transition to production at the bottom which will enable the mine to reach nameplate capacity from 2027 onwards. In June 2023, the company celebrated delivery of first production at VUP. “We are currently in the build-up phase and producing 12 000 tpm which is in line with our goal of getting to steady state,” Van den Berg states. First production marked a momentous occasion for Van den Berg on a journey he has been part of since September 2020. He started at the VUP on secondment through Anglo-American and was appointed in his current position in November 2022.
For a mine that was in operation for 30 years, making the transition to an underground operation was no small feat. “Right from the outset, we knew that transitioning to a world-class underground operation which will be mostly automated would not happen overnight. Since inception, De Beers has adhered to an operational readiness framework defined by the four tenets, namely assets, process, systems and people,” Van den Berg explains.
He emphasises that the success of the project relies heavily on its workforce. “Going into an underground operation requires a complete shift in mindset. As a result, we have partnered with a Tier One contractor to teach the necessary skillsets. This is done through the training and assessments of our employees. In this way, we will ensure that no one is left behind and that they have the necessary skills to take this project further.”
A large part of the expansion is to create a fully automated mine – in other words, the mine of the future. This vision is becoming a reality under Van den Berg’s guidance. “Our objective is to have a number of autonomous mining systems performing multiple mining processes by 2027,” he states. It is for this reason that VUP has partnered with Sandvik Mining and Rock solutions who manufactures the i-Series, a full range of intelligent automated mining machines.
This includes trucks, loaders and drill rigs which can be operated underground within access-controlled safety zones or from a control room on surface. In addition, the company recently migrated to its integrated operations control room. This is where all operations will be carried out when the mine is fully automated.
Van den Berg points out that automation at VUP will be done in a phased approach. “The first will be those machines that, even though they have automated functions, still require an onboard operator. The next will be to introduce autonomous machines which do not require an onboard operator. The final phase will be the implementation of a complete autonomous mining system. This comprises of the use of multiple autonomous machines working in harmony which are managed by an integrated central traffic management system.
This first phase includes the introduction of Sandvik’s DD422i automated underground drill rig. Van den Berg states that this is being implemented with the assistance of Anglo American’s technical service department.
“Sandvik is also providing its Automine system for remote operations as well as its Optimine solution for machine monitoring and location tracking. All this will make it easier for us to reach our goal of achieving just under 6 Mtpa of kimberlite ore and at least 4 million carats per year.”
Serving a greater cause VUP is also committed to carbon neutrality. No doubt, the introduction of equipment such as electric LHDs will help in this regard. Another innovation is the introduction of on demand ventilation in its operations.
“We will introduce this system from Level 51 downwards. This will ensure that ventilation is only provided to those draw points where production is taking place. By switching off ventilation in areas where there is no activity, we can significantly reduce our energy consumption,” Van den Berg explains.
Furthermore, the company has pledged to reduce its reliance on fossil fuels. It is projected that by 2030, 85% of all energy consumed will be electrical and only 6% of on-site emissions will be attributed to diesel. It is also looking at battery storage solutions to address emergency energy needs. VUP has undertaken to reduce its Scope 3 emissions by 2030.
Subsequently, it is partnering with OEMs to help it achieve this target. “We have signed MoUs and made contract amendments with our key suppliers to ensure that we can realise this goal,” Van den Berg adds.
Venetia’s underground expansion will solidify the mine’s position as one of the leading diamond producers in the De Beers’ portfolio. However, it not only bodes well for the company but also South Africa. “Our significant capital investment is a concrete example of our commitment to the South African mining industry. While the country tries to build a more diverse economy.
Mining remains an integral part of the aspiration to build a more prosperous and equitable South Africa. We have an exceptional ore body at Venetia. So why should we let it go to waste? Let’s use it to benefit the company, our surrounding communities, and the country as a whole,” Van den Berg enthuses.
Van den Berg is excited about what the future holds for VUP. “I started my career as a conventional miner. Now, it is mind boggling to see how automation is making mining more productive and safer. De Beers had a vision, and we are busy executing it. This is absolutely the right thing to do and for me, it is amazing to see it all coming together,” he concludes.
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