• OPERATIONS
STABILITY, SUSTAINABILITY AND SKILLS FOR THE FUTURE
By Sharon Mdaka
Smelters and Refineries form part of an important mining ecosystem. These departments process raw, low-value earth minerals into immaculate, usable finished products. This is where the critical chemical and physical dedicated work begins, turning raw minerals into being commercially viable.
At the Palabora Mining Company( PMC), this department is headed by Brave Mushikita, who believes that stability, efficiency and sustainability must go hand in hand. Here, Smelter and Refinery are undertaking a quiet but important evolution, one that reflects the broader shift taking place across Africa’ s metallurgical operations.
“ Our key priorities are process stability, energy efficiency and environmental compliance. The smelter retrofit has allowed us to reduce sulphur dioxide emissions significantly while improving furnace energy consumption. Consistent feed quality, optimised furnace control, and safe operations remain central to efficiency and stability,” explains Mushikita. This move has aligned operations with tightening environmental standards.
Not without its fair share of challenges, like many other operators, PMC is also navigating an environment faced with energy insecurity, ageing infrastructure and regulatory pressures. Load-shedding continues to disrupt operations, forcing mines to rethink how they manage energy-intensive processes such as smelting. Global competitiveness requires continuous modernisation, and at Palabora, these challenges are addressed through technology upgrades, predictive maintenance and energy optimisation programmes.
The Smelter Retrofit marks a clear shift toward modern, cleaner and smarter operations. Advanced gas-cleaning systems and improved furnace control technologies have reduced both emissions and energy intensity. Meanwhile, automation and digital monitoring are improving consistency across the plant.
Predictive analytics makes it easier for the teams to anticipate equipment failures before they occur, reducing downtime and protecting productivity. As a result, digital tools have become increasingly central to the company’ s operational strategy.
“ We have integrated Distributed Control Systems( DCS), real-time monitoring and data-driven optimisation across the Smelter and Refinery operations. These tools have delivered measurable benefits: reduced downtime, improved metal recovery and enhanced safety performance,” he states. These integrations go well beyond efficiency; they are changing how decisions are made on the plant floor.
Energy remains a critical challenge for smelting operations in South Africa. Palabora’ s approach has been one that includes process optimisation, furnace efficiency improvements and operational scheduling to mitigate load-shedding impacts. The retrofit has already reduced specific energy consumption, strengthening reliability.
Beyond efficiency, the company is exploring solar integration and alternative energy sources to supplement the grid supply.“ These initiatives align with our broader sustainability goals, reducing carbon footprint and supporting South Africa’ s transition to cleaner energy.”
All images supplied by Palabora Mining Company
The smelter Retrofit marks a clear shift toward modern, cleaner and smarter operations.
One of the most strategic decisions facing any operation is whether to upgrade existing infrastructure or invest in entirely new systems. Their strategy has been one that balances retrofitting existing assets, such as upgrading refractory linings and cooling systems, with selective investment in new technologies.“ Retrofitting is cost-effective and minimises disruption, while new systems allow us to leapfrog to advanced solutions when justified,” says Mushikita.
“ Key considerations include capital intensity, operational disruption, regulatory compliance and long-term
22 • African Mining • June 2026 www. africanmining. co. za