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Using the digital economy as a blueprint for a safer South African workforce

Recognising this pressing need, the Department of Science and Innovation (DSI) through investing in companies like Stone Three is working hard to drive innovation that leverages the power of data driven analytics and Artificial Intelligence (AI) to transform how South African industries and companies approach workplace safety, wellbeing and health.

By facilitating the adoption of these cutting-edge technologies, organisations can significantly enhance their hazard detection capabilities, mitigate risks and create safer working environments across core sectors such as mining and health.

Revolutionising workplace safety with the Internet of Things (IoT) and AI

The Internet of Things (IoT) is ushering in a new era of data driven safety. Innovations such as smart sensors and cameras can now vigilantly monitor workspaces, instantly alerting supervisors when an employee isn't wearing proper safety gear. This real-time analysis is significantly reducing accidents in high-risk industries.

The concept of the "connected worker" is gaining traction, with employees donning wearable devices like smart helmets and tracking bands. These devices do more than just monitor; they actively contribute to worker safety.

By leveraging real-time data, AI systems can provide data driven personalised safety advice, creating a proactive approach to accident prevention.

These technological advancements are not just improving safety statistics; they're changing the very culture of workplace safety.

As these innovations continue to evolve, they promise to create a safer, more productive economy that can compete on the global stage. Source

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Futureproofing South Africa's mining industry with AI and digital innovation

South Africa's mining industry, a cornerstone of the national economy, is facing complex challenges that are reshaping the sector globally.

The global energy transition is at the forefront, with investors calling for sustainable practices and heightened accountability. In this context, data driven digital transformation is essential for building a resilient, durable and sustainable mining sector in South Africa.

The mining industry is also facing a chronic labour shortage, adding to its challenges. With 86% of mining executives globally finding it increasingly difficult to recruit and retain necessary talent, this issue is likely to impact South Africa's mining sector as well.

Amidst these complexities, South African mining companies are striving to balance productivity and profitability with purpose. The Department of Science and Innovation (DSI) is supporting this effort by promoting the adoption of cloud-based platforms, the Internet of Things (IoT), mixed reality and more recently, generative AI.

Accelerating digital transformation in South African mining

South African mining companies are increasingly adopting data driven digital technologies to enable business agility, drive efficiency and accelerate innovation across the entire mining value chain.

Current trends emphasise broader goals such as corporate environmental, social and governance (ESG) targets and the transition to net-zero emissions.

The Department of Science and Innovation (DSI) is facilitating this transformation by investing and promoting solutions like advanced data platforms, which provide a single, flexible platform for databases, analytics, AI and data governance.

These tools are crucial for South African mining companies looking to enhance their digital capabilities and compete on a global scale. Source

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Stone Three: revolutionising African workplace health, safety and productivity through AI

Stone Three, an industrial 4.0 IoT company, is at the forefront of leveraging machine learning and AI to transform workplace productivity, health and safety across Africa.

Dirk Wagener, General Manager of People Productivity and Health at Stone Three, encapsulates their mission:

"Creating technology and services that not only matter to organisations but are able to make an actual difference is a big driving factor behind our success."

Innovative solutions for complex African environments

Stone Three specialises in addressing unique challenges faced by certain South African industries and the public sector:

Operational productivity:

• AI-augmented smart sensors for minerals processing, crucial for South Africa's mining sector
• Remote monitoring and diagnostics through SmartROCs, enabling efficient management of geographically dispersed operations
• Advanced Process Control (APC) for crushing, grinding, and flotation, optimizing processes in Africa's resource-rich mining industry

Health and safety:

• Telehealth solutions with app enabled technology for healthcare professionals to monitor the cardio and pulmonary health of employees, improving healthcare access in remote African locations
• Video Safety Analytics (VSA) and Digital Twins for employee monitoring, enhancing safety in high-risk African industrial environments
• Absenteeism and fatigue monitoring systems, addressing key challenges in workforce management

Pan-African and global impact

While Stone Three's solutions are implemented worldwide, they have a particular focus on addressing African challenges.

By specialising in industrial health and operational productivity in the mining sector, a vital sector for the South African economy, the company has developed deep domain expertise to address client-specific challenges across the country and continent.

The power of machine learning in the African context

By combining expert services with data driven machine learning, Stone Three aims to create safer, healthier and more productive work environments tailored to African needs.

Their AI-enabled, data driven machine vision systems solve complex real-time measurement problems unique to African industries, while their remote monitoring services provide crucial insights for operational optimisation in challenging African settings.

Stone Three's approach not only enhances productivity but also supports the industry's goal of Zero Harm, demonstrating how technology can significantly improve workplace conditions and efficiency when applied strategically to certain industrial challenges.

Wagener emphasises the importance of this approach in the African context:

"Africa is a booming continent; I consider it a privilege to be part of such a vibrant culture and economy. Our partners globally all face different problems based on location and/or infrastructure.

In today's 'digitally transformed' world, what can we do for our clients to ensure they remain productive even when the world throws pandemic-sized curveballs? Technology can change the game if being utilised in the correct way." Source

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Turning plastic waste into sustainable energy: a game-changer for South Africa

While the idea of burning plastic might seem counterintuitive, recent innovations have revealed its potential as a sustainable fuel source. Plastic waste, with its high content of hydrogen and carbon, possesses an energy content comparable to refined fossil fuels like diesel.

This characteristic, combined with the abundance and constant production of plastic waste, positions it as a reliable and potentially inexhaustible energy source.

What makes this approach particularly appealing is its versatility – all forms of plastic waste, from grocery bags and food containers to bottles and cling film, can be utilised as fuel. This presents a significant opportunity for countries like South Africa, where excess plastic waste often ends up in landfills.

The potential for a thriving plastic circular economy in South Africa is substantial. Despite boasting some of the highest recycling rates globally, the country still grapples with an abundance of plastic litter.

By collecting and recovering this waste for energy production, South Africa can address two pressing issues simultaneously: sustainable energy generation and job creation.

This represents an opportunity to innovate, create new revenue streams and contribute to solving a critical environmental challenge.

By investing in plastic-to-energy technologies, companies can position themselves at the forefront of sustainable practices while potentially tapping into new markets and government incentives, source.

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Understanding the plastic-to-fuel process: a technological overview

To fully grasp the potential of plastic-to-fuel technology, it's essential to understand the process. Here's a breakdown of the key stages:

1. Collection and sorting: The process begins with the collection of plastic waste from various sources such as households, industries and recycling centres. This material is then meticulously sorted to remove any non-plastic contaminants.
2. Shredding and pre-treatment: The sorted plastic is shredded into small pieces to increase surface area and improve process efficiency. Additional pre-treatment steps, such as washing or drying, may be employed to remove contaminants like dirt or moisture.
3. Pyrolysis: This is the core of the process. The shredded plastic undergoes thermal decomposition at high temperatures (typically 300°-500°C) in an oxygen-free environment. This breaks down the plastic into simpler hydrocarbon molecules.
4. Vaporisation and condensation: The vapours produced during pyrolysis are cooled and condensed into a liquid containing various hydrocarbon compounds and impurities.
5. Refining: The condensed liquid undergoes further processing, including fractional distillation and hydro-processing, to separate and purify different hydrocarbon fractions. This results in usable fuels such as gasoline, diesel and kerosene.
6. By-product handling: Any by-products generated during the process, such as char or residue, are treated through additional processes like hydro-cracking, or are recycled or disposed of appropriately.
7. Gasification: An alternative to pyrolysis, gasification involves reacting plastic waste with a gasifying agent (steam, oxygen or air) at high temperatures (500°–1300°C). This produces synthesis gas, or syngas, which can be used to generate electricity through fuel cells.

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The compelling advantages of converting plastic waste into fuel

The excitement surrounding plastic-to-fuel technology is well-founded, with many envisioning landfills as the oil fields of the future. The advantages of this technology are numerous and significant:

• Environmental benefits: The fuels produced through this process have properties of clean fuel, resulting in a lower carbon footprint compared to coal, oil and natural gas when burned.
• Circular resource utilisation: By using existing carbon and hydrogen molecules, this process reduces the need for new carbon extraction, aligning with circular economy principles.
• Reduced incineration: Converting plastic to fuel decreases the amount of plastic incinerated, thereby reducing associated carbon emissions.
• Landfill diversion: This technology prevents hard-to-recycle or non-recyclable materials from ending up in landfills, addressing a critical waste management challenge in South Africa.
• Versatility: There's potential to expand this method to include other waste materials, including those that may not be easily recyclable, such as metal waste.
• Industrial application: The chemical compounds produced can replace fossil fuel-based alternatives in existing production lines, offering a more sustainable option for various industries.
• Cost-effectiveness: Once the initial plant setup is complete, the operational costs are relatively low, making it an attractive long-term investment.
• Reduced methane pollution: By decreasing reliance on traditional oil and gas production, which is associated with significant methane pollution, this technology contributes to reducing greenhouse gas emissions.

These advantages represent not just environmental benefits, but also potential competitive edges in an increasingly sustainability-focused global market, source.

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UNISA's disruptive technologies: pioneering solutions for environmental challenges

The University of South Africa (UNISA) is at the forefront of developing innovative solutions to address societal challenges while protecting the environment. Their work in plastic waste management and energy generation is particularly noteworthy.

The University of South Africa (UNISA) has developed an energy-generating system that utilises polyethylene plastics to produce synthesis gas (syngas). What sets this system apart is its anaerobic gasification process, which eliminates the need for oxygen and removes the air separation step.

This innovation significantly lowers energy costs compared to conventional gasification systems.

Key features of the University of South Africa’s (UNISA) system include:

• Anaerobic gasification: This unique approach simplifies the process and reduces energy requirements.
• Latent heat recovery: The system can recover a portion of the latent heat of water, leading to improved energy production compared to conventional designs.
• Polyethylene plastic feedstock: By using this common plastic waste as feedstock, the system addresses a major environmental concern.

The benefits of this system are substantial:

• Higher energy production: The simplified gasification process and heat recovery lead to increased energy output.
• Low energy costs: The elimination of the air separation step results in significant energy savings.
• Efficient plastic waste disposal: The system provides an effective method for disposing of plastic waste while generating valuable energy.

The University of South Africa’s (UNISA) innovation presents opportunities for collaboration, technology transfer, and potential commercialisation, source.

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