Table of Contents
Executive Overview Strategic Summary Technical Methodology Project Deliverables Implementation Timeline Compliance & QA Investment Analysis Next Steps

Coal Stockpile Profiling & Quality Modeling

Advanced Digital Management System for SASOL Mining Secunda

Comprehensive 3D modeling and machine learning solution for strategic coal stockpile quality management and synthetic fuels production optimization.

6 Historical Stockpiles
3D Interactive Modeling
ML Digital Twin System
AI Predictive Analytics

RFQ: 6003408713

Proposal Date: May 27, 2025

Deadline: June 9, 2025

Executive Summary

Strategic overview of our comprehensive coal stockpile profiling and quality modeling solution

Project Overview

USK Consulting Africa proposes a comprehensive coal stockpile profiling and quality modeling solution for SASOL Mining Secunda. Our approach combines advanced drilling techniques, SANAS-accredited laboratory analysis, and cutting-edge 3D visualization to create a dynamic digital management system for your strategic coal stockpiles.

Strategic Value

This solution will provide real-time quality assessment capabilities, enabling optimized blending strategies for synthetic fuels production, reducing quality variability, and enhancing operational efficiency through predictive analytics and automated stockpile monitoring.

Innovation

Our machine learning-powered digital twin will continuously learn from new data inputs, automatically updating quality predictions as coal is added or removed, providing unprecedented insight into stockpile dynamics and quality evolution.

Technical Methodology

Advanced technical approach combining industry-leading equipment and methodologies

1. Drilling & Sampling Protocol

Equipment Specifications

  • Rubber-tracked drill rig with 152mm diameter Auger Continuous Tube Sampling System
  • Maximum particle size capability: 125mm PSD
  • ASTM D4916-04 compliant sampling methodology
  • Class D Method for compacted stockpiles

Sampling Grid Strategy

  • Stockpiles <3m height: 5m × 5m grid pattern
  • Stockpiles ≥3m height: 10m × 10m grid pattern
  • Depth intervals: 1m vertical sampling
  • Sample increments: ~73 per stockpile (45,000 Mg lots)

2. Laboratory Analysis

Proximate Analysis

  • Moisture Content
  • Ash Content
  • Volatile Matter
  • Fixed Carbon

Ultimate Analysis

  • Carbon Content
  • Hydrogen Content
  • Sulfur Content
  • Nitrogen & Oxygen

Specialized Testing

  • Calorific Value (Gross & Net)
  • Ash Fusion Temperature
  • Trace Elements (Hg, Cl)
  • SANAS Accreditation

3. 3D Modeling & Visualization

C-Tec EVS Platform

Interactive 3D visualization with multi-layered quality parameter display including calorific value, sulfur content, ash content, and moisture distribution mapping.

Quality Interpolation

Advanced geostatistical modeling using kriging and inverse distance weighting for accurate spatial quality prediction between sample points.

Dynamic Updates

Real-time model updates as new analytical data becomes available, maintaining current stockpile quality representations.

4. Digital Twin & Machine Learning

Predictive Analytics

Machine learning algorithms trained on historical and real-time data to predict quality variations and optimize blending strategies for synthetic fuels production.

Automated Integration

Seamless integration with SASOL's operational systems for automatic data ingestion and quality model updates as coal sources are added or removed.

Decision Support

Advanced analytics dashboard providing actionable insights for stockpile management, quality control, and production planning optimization.

Project Deliverables

Comprehensive suite of deliverables ensuring complete project success

1

Comprehensive Sampling Report

  • Detailed grid maps and depth profiles
  • Sample increment summaries
  • Quality assurance documentation
  • Compliance verification reports
2

Laboratory Analysis Results

  • SANAS-accredited analytical data
  • Tabulated quality parameters per stockpile
  • Statistical analysis and quality distributions
  • Uncertainty assessments
3

3D Visualization Model

  • Interactive C-Tec EVS platform
  • Multi-layered quality metric visualization
  • Spatial interpolation models
  • User training and documentation
4

Digital Management System

  • Machine learning quality prediction models
  • Digital twin implementation
  • User interface for data input and visualization
  • Integration protocols and APIs

Project Timeline

Structured implementation approach ensuring timely delivery

Project Initiation & Planning

Site preparation, equipment mobilization, and detailed sampling plan finalization based on SASOL stockpile drawings.

Weeks 1-2

Field Sampling Campaign

Systematic drilling and sampling of all six stockpiles following ASTM D4916-04 protocols with real-time quality control.

Weeks 3-5

Laboratory Analysis

SANAS-accredited testing of all samples with comprehensive quality parameter determination and data validation.

Weeks 4-7

3D Model Development

C-Tec EVS model construction, quality interpolation, and interactive visualization platform development.

Weeks 6-10

Digital Twin Implementation

Machine learning model training, digital management system development, and integration with SASOL systems.

Weeks 8-12

Compliance & Quality Assurance

Rigorous adherence to international standards and best practices

International Standards

  • ASTM D4916-04 sampling methodology
  • ISO 9001:2015 quality management
  • SANAS accredited laboratory analysis
  • SASOL safety and operational protocols

Quality Control

  • Duplicate sampling at 10% frequency
  • Certified reference materials
  • Chain of custody documentation
  • Independent QA/QC verification

Data Security

  • Encrypted data transmission
  • Secure cloud storage infrastructure
  • Access control and audit trails
  • SASOL data governance compliance

Investment Breakdown

Transparent and detailed cost analysis for informed decision-making

Drilling & Sampling Operations

Equipment & Personnel (480 hours @ R850/hr) R 408,000
Travel & Mobilization (2,400 km @ R18/km) R 43,200
Site Preparation & Safety R 25,000

Laboratory Analysis

SANAS Accredited Testing (440 samples @ R650/sample) R 286,000
Specialized Analysis (Ash Fusion, Trace Elements) R 45,000

3D Modeling & Digital Systems

C-Tec EVS Software Licensing & Development R 185,000
Machine Learning Model Development R 125,000
Digital Twin Implementation R 95,000
User Training & Documentation R 35,000
Subtotal R 1,247,200
VAT (15%) R 187,080
R 1,434,280

Total Investment

Ready to Transform Your Coal Quality Management?

This proposal is valid until June 9, 2025. Project commencement available within 5 working days with completion scheduled for delivery by June 15, 2025.

Accept Proposal

Next Steps

Your trusted partners for advanced coal quality management solutions

Project Contacts

Project Director: Steve Kalule

Technical Lead: Nhlanhla Mazibuko

Email: proposals@uskconsulting.co.za

Phone: +27 11 234 5678

Implementation Timeline

Proposal Validity: Until June 9, 2025

Project Commencement: Within 5 working days of acceptance

Completion Date: June 15, 2025

Contact Person: Thabo Kgase (072 525 4477)