Name and Location
Impumelelo replacement coal project, Mpumalanga, South Africa.

Client
Sasol.

Project Description
The move to develop the mine forms part of what Sasol has previously described as an “intense capital replacement” programme involving four significant projects – Thubelisha, Impumelelo, Shondoni and Tweedraai – which will replace the long-serving Twistdraai, Brandspruit, Middelbult and part of the Syferfontein operations respectively.

Impumelelo, in Secunda, Mpumalanga, will replace the old Brandspruit mine and produce coal for the Sasol Synfuels plant.

The project involves the construction of a new 8.5-million-ton-a-year coal mine, which is upgradeable to 10.5-million tons a year.

The No 4 and No 2 coal seams will be mined simultaneously at the project, with the thinner and more complex No 2 seam lying below the No 4. The final shaft depth will be about 225 m below the surface.

After the first section is delivered in 2014, the mine will build up to full production, with 13 continuous miners and six stonework sections in 2019.

The project includes the development of service, ventilation and decline shafts, materials handling systems (including a 28 km overland conveyor, surface surge bunkers, underground conveyors and surge bins) and all the mine infrastructure needed to support operations.

The conveyer system will deliver coal to the Synfuels complex, becoming the longest conveyer system of its kind in the southern hemisphere.

The 11.7-m-diameter men-and-materials shaft will be 210 m deep, with a four-sided station on the No 4 seam.

The 6.7-m-diameter ventilation shaft will also be sunk to 210 m, with access through the four-sided station to the coal production sections.

The shaft complex has been designed to operate for a minimum period of 35 years.

Net Present Value/Internal Rate of Return
Not stated.

Value
The project is estimated at R4.6-billion.

Duration
Sasol expects Impumelelo to reach beneficial operation in the first half of this year.

Latest Developments
The Impumelelo colliery achieved beneficial operation in October 2015 and within budget, despite various project delays.

There were project delays during the year ended June 30, 2015, owing to a slower-than-expected shaft-sinking process and a mining contractor having to deal with a four-month labour dispute.

Key Contracts and Suppliers
RSV Enco-Goba coal joint venture, or JV (engineering, procurement and construction (EPC) management implementation); Murray & Roberts Cementation (men-and-materials and ventilation shafts, as well as decline coal seam development on the No 2 and 4 seams); Concor Civils (subcontracted to provide temporary civil works for sinking and development); ELB Engineering Services (EPC – materials handling conveyor); Veyance Technologies (manufacture and delivery of steel cord conveyor belting); Cascade Logistics (transportation of belt rolls); Goodyear Engineered Products (cover compound) and Flexco (manufacture and delivery of a new vertical belt reeler).

On Budget and on Time?
The project was delivered within budget.

Contact Details for Project Information
Sasol group media manager Alex Anderson, tel + +27 71 600 9605 or email alex.anderson@sasol.com.
RSV Enco-Goba JV, tel +27 11 498 6010, fax + 27 11 498 6210 or email enco@rsvenco.com.
Murray & Roberts Cementation, tel +27 11 201 5000, fax +27 11 201 5500 or email info.cementation@murrob.com.
ELB Engineering Services, tel +27 11 772 1400 or fax +27 11 325 6680.
Cascade Logistics, tel +27 11 234 2943 or fax +27 86 614 3758.
Veyance Technologies, tel +27 11 248 9300 or fax +27 11 248 9380.
Flexco, tel +27 11 608 4180.