Orders for Potchefstroom drilling equipment supplier HydroPower Systems’ (HPS’) HV212 EOD hydrovessel drilling system are increasing as acceptance of the technology grows on the back of proven success stories.

Recognised at Mining Equipment Manufacturers of South Africa’s 2022 Innovation Awards in April for production improvement in underground mines, with special reference to data integration, the HV212 EOD has helped the Blyvoor gold mine, 70 km southwest of Johannesburg, become profitable.

The mine, which was closed for nearly ten years and deemed unfeasible, is nearing full production using only the HPS drilling system, says HPS marketing manager JP Adlem.

“There are only success stories. Mining crews at all our projects continuously thank our site team for their new quality of life, as for once, they can complete their work on time and surface at regular shift times.”

The HV212 EOD helps mines transition from conventional compressed air drilling systems, which are proven to decrease crew efficiencies and, ultimately, threaten the viability of underground mines and the livelihood of local communities.

The HPS hydrovessel drilling system enables the transfer of energy to mining equipment using pressurised water in a short reticulation system.

As each crew is supplied an HPS system, operating independently and only sharing electricity and water supply, any misuse and downtime is contained to each module. Absolute water control is enabled through the EOD system and, with the application-based monitoring system, miners have full control over a “historical control nightmare”, namely conventional mining, explains Adlem.

“Using water is proven to be a much more efficient method but large amounts of water are necessary to drive piston pumps to generate the pressure required. This made the use of hydropower on scale in compressed air mines problematic and has seen numerous attempts to implement it fail.”

HPS tasked its innovation department with the challenge of developing a pressure delivery system that would allow ultimate water and electricity control, while monitoring activities and conditions of the system using the Internet of Things.

Launched last year, the HV212 EOD was developed during the Covid-19 pandemic lockdown, which created challenges in sourcing electronic components and securing willing customers.

While the HV212 EOD was self-funded by HPS, costs­ and time were saved by basing its design on a less efficient predecessor. Two prototypes were developed before “hitting the sweet spot”, says Adlem.

The HV212 EOD is manufactured at the HPS head office in Potchefstroom, in North West province. Two systems can be produced a day, which accounts for two mining crews, but capacity can be increased as demand requires.

Produced using 80% local content, the system’s electronic components are sourced internationally from reputable and proven brands that are only available from the US and Europe.

“If the equivalent product is available from a South African manufacturer and complies with our standards of performance, we can consider sourcing these locally,” says Adlem.

A manufacturing lead time of ten weeks is needed from date of order, but HPS carries stock to shorten delivery times.  

“Successful delivery rests in the proper planning of a roll-out, and we have been able to meet and exceed every delivery expectation to date,” says Adlem.

Once orders are received, HPS guides mines through a comprehensive change management process to ensure successful, safe and sustainable conversion to the new operating system in as short a period as possible, where aspects such as training, skills development, safety and standards, environmental impact and production are addressed.

While the hydropower drilling method is now a leading practice at privately owned mines and smaller mining groups, HPS has seen confidence increasing among large mining groups where conventional thinking is being challenged, says Adlem.

HPS has exported the HV212 EOD into the rest of Africa, focusing on gold, platinum and chrome mines.

“African countries have a huge drive for sustainability and our system is the preferred drilling system,” Adlem concludes.