The video provides a comprehensive overview of the Gamsberg zinc mine in South Africa, tracing its 40‑year legacy from discovery to Vedanta’s 2011 acquisition and the partnership with TCE in 2013. It details the feasibility and optimization studies that defined a 4 Mtpa (Phase 1) operation, including a 50 % reduction in stripping ratio, contract mining, and the addition of lead concentrate production. The narrative highlights the project’s end‑to‑end digitalisation, use of 3D engineering platforms, automated laboratory with LIMS, emerging flotation technology, and innovative water‑sourcing and tailings‑dam cyclone deposition methods that together saved millions of dollars in CAPEX and OPEX. Capital investment reached US$400 million, creating 3,000 construction jobs and employing extensive local resources. Environmental stewardship is emphasized through a biodiversity offset agreement in the succulent karoo hotspot and careful water management. The commissioning milestones (first blast 2015, plant commissioning September 2018, first product December 2018) and high‑profile inauguration by Vedanta Chairman Anil Agarwal and President Cyril Ramaphosa are noted. Finally, the video outlines Phase 2 plans to double ore throughput to 8 Mtpa and a feasibility study for a downstream smelter‑refinery complex, positioning Gamsberg as a catalyst for regional industrial growth.
Chapters
Gamsberg is located at Ergenis, about 30 kilometers from Black Mountain Mining in the Northern Cape, South Africa. It exploits one of the largest known undeveloped zinc obodies in the world and comprises an open-pit mine and a dedicated processing plant. The project has its own legacy, discovered more than 40 years ago and held undeveloped in the asset portfolios of various mining companies. It was acquired from Anglo American by the Vedanta Group in 2011. TCE partnered with Vedanta in 2013 for Gamsberg endeavors and developed the project from concept to commissioning. Phase 1 of the project commissioned in September 2018 and first product is trucked on the 6th of December 2018. The deposit remained unexplored since discovery because of high manganese in ore. High stripping ratio for matching mine plan and capacity of concentrator, sourcing of water, and highly sensitive ecologically and biodiverse hotspots. A critical feature of Gamsberg's development is its approach to biodiversity. The project is developed in the ecologically sensitive succulent karoo biome, a designated biodiversity zone and one of just 35 biodiversity hotspots in the world, which has resulted in a unique biodiversity offset agreement alignment with key stakeholders. In the feasibility study stage, TCE marshaled experts from around the world keeping in mind the complexity of the project. TCE revealed that previous studies on this deposit were revolving around the size of the deposit and were trying to leverage on the scale of operation. First task taken up by TCE was to do detailed optimization study to arrive at an optimum production capacity with respect to capital and operating cost. Optimization of mining capacity resulted in reduction of stripping ratio by 50% and also introduced contract mining. TCE adopted off-campaign processing philosophy in line with the marketing strategy to produce 2 concentrates and introduced lead concentrate production process, which has around 5% impact on revenue. Definitive feasibility report was submitted in 2014 considering a 4 MTPA mine and concentrator plant, which established the viability of the project. Report was approved by Vedanta Board, and subsequently order for implementation of the project was placed with TCE as owner's engineers. Vedanta gave the project the go-ahead in 2014, and the first blast occurred in mid-2015. Good morning. Undoubtedly, this is a major economic boost for the Northern Cape, isn't it?
Good afternoon, Deveni. Yes, indeed, it is a major economic boost not only for the Northern Cape but also for South Africa and the mining industry. Earlier on, we witnessed first blast at the Gamsberg Zinc Mine here in Achenaze.
Gamsberg is one of the most digitally advanced mines in South Africa. From the feasibility stage, team's vision for Gamsberg was always that the project would be an end-to-end digitally enabled operation with that digitalization built in from the ground up. Accordingly, all provision is made in basic design. In execution phase of the project, TCE further re-engineered the project to optimize both CapEx and OpEx and selected a South African EPC contractor through a global tender to ensure maximum utilization of local resources. Flawless detail engineering is done by adopting 3D platforms, ensuring safety in design and construction. All structural fabrication done at factory. Introduction of emerging flotation technology, aged flotation reactor with the potential of OpEx saving of around $1 million per year. Fully automated robotic laboratory with LIMS for data management. The project is engineered to source water from 30 kilometers away. Introduction of intermediate booster pumping station resulted in CAPEX and OPEX reduction. Engineering of tailings dam adopting cyclone deposition method to raise height up to 50 meters resulted in reduction of life cycle cost by $10 million US dollars. 80 cyclones placed around a perimeter of 4 kilometers. The project has been delivered at a capital investment of $400 million and has enabled the employment of 3,000 people during construction. Approximate quantity of concrete is 24,358 cubic meters. IBR sheeting is 26,859 square meters. Structural is steel, 2,630 tons. Piping is 40 kilometer for for the process plant. TCE ensured day-to-day supervision of works according to bill of quantity, standards, specifications, and drawings. TCE design and PMC team worked closely with whole project team to successfully commission the plant in September 2018. Mechanical completion, pre-commissioning, commissioning, and ramp-up demanded combined effort and cooperation of the entire project team. TCE coordinated and formulated the overall commissioning procedure with inputs from the individual package suppliers. Maintaining the required safety conditions during commissioning of utmost importance. The entire commissioning team needed to keep safety at the forefront in all their activities. Vedanta Group Chairman, Mr. Anil Agarwal inaugurated the Gamsberg mine and guest of honor was His Excellency, President Cyril Ramaphosa. TCE was proud to be part of celebration and congratulated the chairman. Gamsberg has the potential to trigger a new wave of industrial and economic development in the Northern Cape. Gamsberg currently produces 4 million tons of ore from its open pit mine. The project's current reserve and resource is more than 200 million tons. Studies into Gamsberg Phase 2 completed by TCE, which will see ore mined increase to 8 million tons per annum. Vedanta is simultaneously engaged TCE for pursuing a feasibility study into the development and construction construction of a smelter refinery complex.
