The Sishen mine produces iron ore with an average iron content of approximately 64%. Credit: Creaturart Images/Shutterstock.

South Africa’s Kumba Iron Ore has approved investment of R7.6bn ($428m) in ultra-high-dense-media-separation (UHDMS) technology at its Sishen mine.

The move aims to boost the quality of iron ore produced and extend the mine’s operational life.

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The investment is in addition to the R3.6bn previously approved in 2021.

The UHDMS project will transform the current dense-media-separation (DMS) plant at Sishen, using specialised ferrosilicon for processing a broader range of iron ore grades and densities.

Kumba expects the UHDMS technology to increase the premium iron ore volume to around 55% of Sishen mine’s output.

Currently, the mine produces iron ore with an average iron content of approximately 64% and maintains a lump-to-fine ratio of 70:30.

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With the adoption of UHDMS technology, not only is the quality of the iron ore expected to improve, but the waste stripping ratio will also be reduced, leading to a decrease in mining costs and a potential extension of the mine’s life up to 2044.

The implementation of the UHDMS technology will be carried out in a modular fashion, with the majority of coarse and fines modules undergoing conversion.

The project is set to begin in November 2024, with the main integration occurring in 2026 and the plant reaching full capacity by the end of 2028.

During the upgrade, unaffected modules and the jig plant will continue operations, supplemented by finished product stock to maintain production levels.

Kumba CEO Mpumi Zikalala said: “Through utilising UHDMS processing technology, we can treble the proportion of premium iron ore product from our world-class Sishen mine. Premium iron ore is increasingly highly valued by our customers because it reduces carbon emissions from the steelmaking process and so plays a key role in green steel production.

“This supports higher margins and a compelling return on investment as well as creating a new pathway to extend Sishen’s life to 2044.

“Notwithstanding this, our work continues with Transnet, the Ore User’s Forum and government through the National Logistics Crisis Committee (NLCC) to improve the logistics performance.”