Coal explorer and developer Canyon Coal is preparing to start construction on its greenfield Bekezela opencast mining project in the first quarter of 2025, subject to market conditions.

The project – for which environmental authorisation was granted in 2019 and the water use licence in 2023 – is situated adjacent to Canyon Coal’s Ukufisa Colliery, in Springs, Gauteng.

The Bekezela Colliery has been designed to reach a monthly production target of 600 000 t of run-of-mine (RoM) coal, once in steady-state. The R1.5-billion project has a life-of-mine (LoM) in excess of 20 years.

“This is a significant project for the company because it will be Canyon Coal’s first megamine, with the potential of creating approximately 800 jobs,” says Canyon Coal holding company Menar head of projects Gerhard Cronjé.

About 320 of the jobs will be sourced from the local community and Canyon Coal also intends to procure local goods and services, wherever possible, from local companies that meet its procurement requirements.

“The presence of a mine in the community will encourage skills development, which is critical for developing the economy.

“The company is dedicated to promoting youth empowerment through bursary programmes. After the mine’s development is complete, internships, learnerships and training programmes will be offered to nurture skills development,” explains Cronjé.

Plant construction will take between 10 and 12 months, with emphasis on the construction of infrastructure for the beneficiation plant, power supply, workshops, fuel storage and ablutions, as well as the development of haul roads.

A 1 000 t/h beneficiation plant forms part of the development of Bekezela, to ensure sufficient supply of the specified grade product.

Steady-state production will gradually be achieved over a six-month period. The new beneficiation plant will be capable of processing the RoM coal into the required saleable product, on site.

Round-the-Clock Operation

To ensure that Bekezela meets its production target, a comprehensive mine plan has been developed to integrate advanced geological surveying, responsible resource management and regular equipment maintenance.

“Strict adherence to the comprehensive mine plan forms a crucial part in managing the projected monthly RoM target of 600 000 t. Bekezela will most likely operate on a 24/7 basis, with clear scheduling to maximise output,” adds Cronjé.

He further explains that a series of drilling campaigns have ensured a high level of confidence in the quality of the coal and geology of the reserve.

“Continuous exploration drilling and adaptive mining methods will help maintain efficiency, adjusting operations to account for unforeseen changes in ore quality while minimising waste and ensuring long-term viability.”

Sampling the RoM coal will ensure consistency in quality: “This is crucial for customer specifications to be met and to optimise pricing,” explains Cronjé.

As for environmental stewardship, the mine will also adopt progressive rehabilitation techniques to ensure that its environmental impact is reduced as mining progresses.

Cronjé tells Mining Weekly that pollution control dams will be constructed on-site to contain contaminated water.

“. . . closed water reticulation systems have been effective at our other operations in ensuring that no contaminated water is released from the sites. Water is channelled and collected in pollution control dams and used for dust suppression within the mine’s boundaries, and pumped from the dams back to the on-site processing plants for reuse.”

Menar’s environmental team will constantly monitor water processes to ensure compliance with all the relevant laws and regulations.

Further, in terms of its social licence to operate, Cronjé says Canyon Coal places “great value” on its relationship with Bekezela’s surrounding communities and is dedicated to fostering positive long-term relationships.

“. . . Canyon Coal recognises and appreciates the role of Bekezela’s host communities as one of the crucial stakeholders in the development of the project. As a result, the mine actively engages with surrounding communities through consultative meetings.”

The project was discussed, and a draft of its social and labour plan reviewed, during a public participation meeting held last month for residents of Ward 12 of the Lesedi local municipality.

Similar engagements with other communities surrounding the mine can be expected as the project progresses, says Cronjé.

A collision-avoidance system (CAS) has been implemented for all Canyon Coal’s opencast mobile equipment across all operations. Following rigorous testing, it was first implemented at Khanye Colliery, in Bronkhorstspruit, Gauteng, and Bekezela will also use the system once mining starts.

“The CAS, developed by software technology company Minetec Smart Mining, prevents accidents by providing machine operators with early audio and visual warnings when near another machine or structure,” notes Cronjé.

Canyon Coal is also exploring new products and technologies that are aligned with a level nine directive on CASs, including blasting software and mine planning technologies.