The 2024 Global Innovation Index reveals a serious concern: as global mining competitors forge ahead with innovation, South Africa continues to lag at just 69th of 133 countries – well behind mining powerhouses such as Brazil (50th) and Australia (23rd).

Furthermore, as a 2024 report by the Human Sciences Research Council demonstrates, while 58.4% of South African mining and quarrying businesses invested in innovation between 2019 and 2021, this even falls short of the 61.8% average across all local sectors, pointing to a growing innovation gap within the mining industry.

According to Johnny Coetzee, an engineering advisor at TDS Projects Group, a leading EPC firm in Africa, this points to the increasingly critical role of engineering skills and contributions to bridge the gap and enhance local mining competitiveness.

“Rather than a setback, we see the innovation gap as an opportunity to assist companies in overcoming both new and longstanding challenges, and enhance their international competitiveness. In fact, local engineers have a particular knack for innovating, and adapting existing inventions and technologies to suit unique local needs and requirements.”

With over 160 years of local mining history, there is also a wealth of knowledge and experience in the industry – especially in deep level mining, where a proud legacy of problem-solving continues today, he says.  

“More recently, local engineers have specifically been recognised globally for their work in advanced technology, such as automated devices that boost productivity and safety while minimising injuries and lost time, helping companies avoid cost overruns. Beyond mining, engineers are also finding innovative ways to address broader national challenges, such as water scarcity, by creating more efficient technologies that benefit traditionally water-intensive industries such as mining and farming – which both play a major role in the local economy.”

Local challenges driving creative solutions

The industry is currently facing multiple pressures which are forcing rapid adaptation and changes. One significant trend is the emigration of engineering talent seeking opportunities abroad, pushing mining companies to rely more heavily on the services of expert engineering firms. This shift has had an unexpected benefit for smaller engineering firms.

“Smaller companies are able to offer clients the benefit of a more focussed team for greater flexibility and faster turnaround times than larger firms,” Coetzee explains. “This, in turn, often translates into positive benefits for lead times in process innovations.”

Stricter regulations have intensified the need for engineers capable of creating safer work environments through the integration of innovative designs and technology. Mining companies are also seeking out-of-the-box solutions and fixes as opposed to traditional open-pit, deep-level mining approaches as they seek to optimise resource extraction while containing costs, especially when faced with declining ore grades.

“Managing costs and cash flow is a particularly notable challenge in the industry given the volatility of global commodity prices and a highly competitive environment.

“In response, we’re seeing greater emphasis on smart infrastructure and equipment that relies on automation, as well as data analytics with real-time monitoring to enhance productivity. Companies are also turning to eco-friendly innovations to maximise material reuse, reduce dependency on new raw materials, and lower operational costs. We see examples of this in water conservation and reduction technologies, along with improved water management systems.”

Innovation in action

Another example of increased focus on sustainable technology is energy-efficient machinery and the introduction of renewable energy sources at mines – an area where TDS itself is active.

TDS has been extensively involved in introducing battery-powered mining vehicles in underground mining operations. Supported by solar installations and charging infrastructure, its projects have helped mining companies to meet environmental targets, while addressing concerns surrounding energy security, emissions, and noise pollution, improving underground working conditions.

The company’s work at the Venetia diamond mine further demonstrates how local engineers are tackling complex challenges with tailored, creative solutions. When tasked with installing an underground water door, its experts had to account for natural ground movements, varying pressures, temperature fluctuations, and moisture levels, all while managing the installation in a confined space with limited access and active mining operations with high underground traffic.

Innovative planning and rigging practices were implemented to ensure that the work was done safely and on schedule. Despite the challenges, they successfully completed the project within record time, relative to all earlier water door installation projects at Venetia.

Adapting for South African needs

Although South African engineers follow and implement global best practices, they’re increasingly modifying designs to match unique local requirements, adapting them to account for specific geological complexities or even worker expectations.

“For example, we often place emphasis on simplifying the design of equipment and structures to decrease the number of potential failure points. We also look to simplify production processes to eliminate any unnecessary steps that could pose a risk to workers.”

He notes that the South African engineering sector is heading in the right direction overall, and has shown remarkable resilience in the midst of mounting local social and economic pressures.

“In fact, pressures such as energy constraints have made South Africa a testing ground for innovations and responses that could set new global benchmarks. We have the technical capabilities – the only question remaining is companies’ willingness to invest and evolve.

“Ultimately, engineers’ ability to rise to the challenge, and deliver practical, cost-effective solutions, will be essential in closing the innovation gap, and ensuring the mining industry’s long-term viability,” he concludes.