Vulcan Mozambique stands stoically as its nation’s largest and most successful mining company, having established itself amongst the most well-renowned and prominent employers in the country. We dig deeper into its environmental initiatives and exceptional work at the Moatize coal mine with CEO, Dr. Mukesh Kumar.
PERFECTING THE PROCESS
Proudly shining as its nation’s largest business and the responsible operator of the impressive Moatize coal mine is Vulcan Mozambique (Vulcan), a fully-owned subsidiary of Vulcan International.
Like the mighty god of flames, patron of the fire of volcanoes, deserts, metalworking, and the forge in ancient Roman religion and myth, Vulcan, like its mythic namesake, has forged and sculpted an enviable reputation within the African mining sector, flying the flag proudly for Mozambique.
As a crucial part of this worldwide venture, Vulcan is not only a mining specialist but is committed to the growth and development of Mozambique, focusing on driving innovation, efficient production, and most importantly, valuing its people.
“Africa is a land of opportunities and has vast untapped potential. However, large exploration efforts are needed to map its obvious geological potential areas,” introduces CEO, Dr. Mukesh Kumar.
“Some of the world’s largest and best reserves of various metals like copper, aluminium, lithium, niobium, uranium, tantalum, vanadium, titanium, manganese, and graphite are all available in Africa,” he sets out.
Following its recent acquisition of the Moatize coal and corridor logistics operations, Vulcan is strategically positioned to achieve optimal production capacity in the near future. This is exemplified by its consistent monthly production of over one million tonnes (t) of coal since June 2022.
This impressive upward trajectory is attributable to astute investments in production and maintenance processes, coupled with favourable market prices across the industry. As a result, Vulcan has emerged as the leading exporter in the mining sector within the East African country.
Besides its exceptional coal mining industry, Mozambique is rich in natural resources, biologically and culturally diverse, and boasts a tropical climate.
Its extensive coastline fronts the Mozambique Channel, which separates mainland Africa from the island of Madagascar, and offers some of the continent’s best natural harbours.
These ports have afforded Mozambique an important role in the maritime economy of the Indian Ocean, while the nation’s gorgeous white sand beaches are a vital and vibrant attraction for the growing tourism industry.
Abundant, fertile soil in the northern and central areas of the country has yielded varied and abundant agriculture, whilst the mighty Zambezi River provides ample water for irrigation and the basis for a regionally important hydroelectric power industry.
SETTING NEW BENCHMARKS
Now existing as a truly global mining company, Vulcan demonstrates a strong commitment to sustainability and community well-being through its work at one of Africa’s largest coal mines.
The business leverages cutting-edge technology and efficient logistics for operational excellence, upholding recognised sustainability practices to reduce global warming and promote responsible environmental stewardship.
As a trailblazer in the vast African mining industry, the company aspires to set new benchmarks for excellence and responsible business practices, driven by its unwavering dedication to philanthropic initiatives that foster community development at the heart of the company’s core values.
Furthermore, Vulcan is not only a prominent mining company but is also well known for being the largest employer in Mozambique, creating hundreds of jobs annually, with a focus on opportunities for young people in technical, operational, and administrative roles.
Meanwhile, as an equal opportunities company, Vulcan prioritises diversity, inclusivity, and workplace safety to foster a successful professional career for all its people.
In this way, Vulcan’s employees are vital to its success, and the company values their energy and innovative ideas. This aligns with Vulcan’s company-wide goal to cultivate an engaged, talented, and motivated workforce that will drive the growth and success of the entire business, setting new industry standards for future generations.
“We believe in empowering our people so that our operations are self-driven and require the least intervention from management. No change is impossible if your team is standing with you, and I am proud of my team who show extreme ownership and dedication in every part of our activities,” Kumar excites.
“Our goal is to cultivate an engaged, talented, and motivated workforce that will drive the growth and success of the company, setting new industry benchmarks for future generations,” he continues.
“We feel proud to be part of the Mozambique growth story and are making efforts to increase our contribution further.”
MOATIZE COAL MINE
Moatize is the principal town and administrative centre of the Moatize District in Tete Province.
Located on the eastern side of the Zambezi River at the confluence of the Moatize and Revuboe Rivers, it is the second largest urban area by population in Western Mozambique.
The Moatize coal mine concession is located 17 kilometres (km) northwest of the provincial capital of Tete along the Zambezi River, 180km southwest of the Cahora Bassa reservoir and 80km south of the border with Malawi.
Today, the vast 25,000 hectare mine site is one of Vulcan’s main assets in the area and presents differentials that place it in a prominent position in the world market, with estimated resources of over 1.5 billion t.
“Vulcan is going to play a major role in the future of our industry, as the type of coal available in our mines is unique because of its low volatile matters and such coal is available in very limited countries,” Kumar acclaims.
An essential input for the transformation of iron ore into steel, the Moatize coal mine produces two types of coal – metallurgical and thermal.
The former, used in steel manufacture, is the focus of Vulcan’s operations and projects and the company’s main global export product.
Thermal coal, meanwhile, is also produced by Vulcan’s operations and is used to generate heat and power in thermoelectric plants.
The Moatize Coal Mine is a coking coal mining operation, which is required for making iron and steel. The annual global demand of steel is likely to increase from its present value of 1.9 billion to around 2.5 billion by 2030, out of which nearly 70 percent shall be made using coking coal.
“Thus, Vulcan is going to play a major role in time to come as the type of coal available in our Mines is unique because of its low volatile matters and such coal is available in very limited countries. As the ash in coking coal is a critical requirement, we have set up one of the most modern coals washery operations of about 50 million t per year in capacity and are further upgrading it to maintain our quality in our endeavour to be the most preferred supplier,” he acclaims.
EQUIPPED TO SUCCEED
Vulcan counts on state-of-the-art technology including equipment of various types and functions, namely excavators, off-highway trucks, wheel loaders, and auxiliary equipment such as crawler tractors, motor graders, drilling machines, and tanker trucks, among others.
Within this fleet, one of the company’s most trusted pieces of machinery is the CAT 797F, which is one of the largest off-highway trucks in the coal mining industry.
A trusted vehicle present at the Moatize coal mine, it has the capacity to carry up to 364t of nominal payload.
The truck uses the biggest tyre in the world at four metres in height, while its fuel tank has a standard capacity of 3,785 litres and 4,000 horsepower.
In addition to this, Vulcan utilises the abilities of the CAT 793D, Hitachi EH5000AC-3, and the Caterpillar 6090 FS, which is the largest hydraulic excavator in the world reaching a load of 93t in each bucket pass.
Finally, Vulcan’s main loading and transport equipment is supported by auxiliary mine infrastructure equipment such as bulldozers, motor graders, and water sprinkler trucks to keep the access routes humidified, thus greatly reducing remissions.
GROWING TOGETHER WITH THE MAMBAS
Vulcan is now proudly an official sponsor of the Mozambique national football team.
Under the inspiring slogan “Together to grow with the Mambas”, Vulcan and the Mozambican Football Federation (FMF) initiated a historic sponsorship agreement in April 2024, aimed at strengthening and promoting the development of football in the country.
What Vulcan has achieved here is not isolated, but rather another big step in favour of the growth of sport in the country. Indeed, the company has been carrying out various other initiatives, such as its Community Sports Project, which focuses on teenagers and young people, as well as supporting local teams with sports equipment.
CHANGING LIVES
Vulcan seeks to establish healthy and prosperous relationships that include a range of influential actors in society and works to build a network of partnerships with the aim of contributing to the development and economic sustainability of the communities where it operates, therefore generating long-term value for the entire production chain.
The company does this through the promotion of dialogue and understanding, engagement and relationships with communities, and restoring livelihoods to mitigate the impacts resulting from the Moatize coal mine.
Fostering income generation and social inclusion is another way of supporting local development and transforming lives, as is Vulcan’s Agriculture Support Programme.
At present, around 1,200 families benefit from training activities within the Fazenda Modelo, located in the Cateme locality in Moatize, where block production and horticultural techniques are taught in demonstration plots and home gardens. Certified seeds, technical assistance, production tools, and mechanised tillage are also provided by Vulcan.
The geographical area of the mine, including Moatize and Cateme, is the focus of the project, which involves hiring agricultural companies to provide inputs, technical assistance, offtake agreements, and geographical mapping to farmers.
“We are working in many areas including schools, roads, airports, connectivity, mobile connection, health, and more, where we believe in sharing the benefits of a project with the community so that inclusive growth can be ensured,” Kumar explains.
GOING FURTHER
Vulcan’s objectives in Mozambique include creating job opportunities and supporting tax collection efforts. The company collaborates closely with local suppliers through training programmes and visits to the Moatize coal mine while also monitoring and supporting the development of national suppliers.
Additionally, Vulcan continues to recognise the crucial role of women in the development of the community. In this sense, its community programmes aim to encourage the continuity of girls’ studies in secondary school and reduce the rate of dropouts through training in vocational courses such as microfinance, entrepreneurship, cooking, cutting, and sewing.
With the support of this initiative, which currently covers about 300 girls living in Moatize and Cateme, many who had dropped out of school have now returned with the ongoing support of Vulcan.
The project also educates girls about entrepreneurship and menstrual health, alongside distributing reusable menstrual kits with the aim of promoting re-integration into secondary school.
Similarly, to train young Tete residents in interpersonal and technical skills, Vulcan is implementing the Programme for Preparation for the Labour Market (PPMT).
“We want the communities around us to be in a position where their lives have improved significantly in terms of health, wellbeing, and livelihoods,” confirms Kumar.
A CONCEPT BEYOND PROFIT
In order for Vulcan to ensure sustainability across its entire business, it is necessary to balance the environmental, social, and economic aspects of its operations.
This entails protecting and preserving the natural environment, promoting social equity and inclusivity, and fostering economic growth that is equitable and beneficial for all stakeholders.
By striking a synergistic equilibrium among these three pillars, Vulcan aims to create a sustainable future for both current and future generations, where environmental stewardship, social well-being, and economic prosperity can coexist and thrive in harmony.
As such, flora and fauna are a huge concern for the company, and in this sense, Vulcan employs its Biotic Environment Management Programme, where actions and activities are carried out to mitigate and control the impacts on the biotic environment in which the company operates.
This includes the systematic collection of the largest possible number of seeds from the areas to be mined, and the monitoring of periphytic algae and aquatic macrophytes, and more.
In addition to this, Vulcan has a robust environmental recovery plan that includes a plant nursery with a production capacity of around 60,000 seedlings per year, with the aim of recovering the mined areas and restoring the natural ecosystems and landscape in the medium and long term.
Alongside numerous examples of native species, fruit trees and shade trees are also being produced by Vulcan for educational institutions, government, and civil society that operate in Moatize and Tete for urban afforestation.
For Vulcan, environmental education is understood as the processes by which individuals and collectives build social values, knowledge, skills, attitudes, and competencies towards environmental conservation, which is essential to a healthy and sustainable quality of life.
At Vulcan, this programme aims to continue to raise awareness, educate, and empower communities and employees about the need to preserve the environment and change behaviours.
AIR AND NOISE POLUTION
Another key area of environmental stewardship that Vulcan is contending with is the management of air quality and atmospheric emissions.
To control the level of emissions from the open pit mining process, among other stages of coal processing, and comply with current legislation, Vulcan has an atmospheric emissions mitigation control system composed of water trucks and sprinkler systems.
Vulcan also has Mozambique’s only automated air quality monitoring network, which is certified by European Union (EU) and US Environmental Protection Agency (EPA) standards and monitors particles, gases, and weather conditions.
In addition to preventive equipment maintenance and noise and vibration monitoring, Vulcan also prioritises environmental sustainability in its mining operations. Through careful planning and the implementation of best practices, the company strives to minimise the negative effects of mining on local ecosystems.
Finally, through regular monitoring and the assessment of noise levels and seismic vibrations, as well as taking corrective measures to reduce any potential impacts, Vulcan is proactively managing these factors and aims to ensure responsible mining practices that prioritise environmental protection and sustainability.
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