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Mining technology in South Africa: what is working and what is still a plan
Tech Intelligence
Emerging Technology Intelligence Plan: Mining Disruption & Opportunities – South Africa & Africa (2026–2036)
Technology adoption in African mining is real but uneven: the evidence rests mostly on single projects and supplier claims, and South African examples are early, with one battery-grade manganese plant being commissioned and one automated drill rig.
Executive Summary
African mining is adopting new technology unevenly, and most of the evidence in this report comes from single projects or supplier statements. South Africa has one battery-grade manganese sulphate plant being commissioned (MMC, 6,000 t/y at Mbombela). Giyani Metals has made the same chemical at a demonstration plant in Johannesburg, and its full-scale plant is planned for Botswana. Automation evidence in South Africa is early: one automated low-profile drill rig at a chrome mine (Mine Master FLP1410 at Dwarsrivier), while the battery-electric truck trial (Kansanshi) is in Zambia and the autonomous electric trucks (EACON) run at a mine in China. On AI, KoBold says its machine-learning approach can cut the time and cost of finding deposits and that its Mingomba copper project in Zambia has progressed from discovery to development in about five years, and Kal Tire says its AI tyre tools lower downtime by up to 20%, with no mine result published. Two digital twin examples cited are outside Africa (ERG in Kazakhstan, MMG in Australia). A Mining Weekly report on the tenth anniversary of the Mining Equipment Manufacturers of South Africa cluster says South African mining was not yet ready for AI at full scale. On power, the one mine solar-plus-battery baseload plant found is Kamoa Copper in the DRC (233 MWp solar, 526 MWh battery, commercial operation 12 August 2026). South African mine solar is real but mostly without batteries: Bolobedu (148 MW, Richards Bay Minerals) and Exxaro's 68 MW plant at Grootegeluk are operating, and Kumba's 63 MW Sishen plant expects first power in Q4 2027. Hydra in the Northern Cape (216 MW solar, 500 MWh battery) sells to Eskom. Sensible next steps are to design new mines so they can take autonomy where the business case holds, to price and test storage at your own site, and to ask suppliers for results on a named mine before relying on their figures. Some sources could not be retrieved and some figures are supplier claims.
What matters
Key Findings
Mechanization and automation are starting to move from niche applications toward wider use for safety and efficiency in deep and complex mines.
Real-time visibility through digital twins and connected ecosystems is being used to revive underperforming assets and optimize complex resource extraction.
AI and machine learning are being applied to try to reduce the 'time-to-discovery' for critical minerals required for the global energy transition.
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Research landscape
Landscape Overview
Aggregated themes and takeaways across all analysis sections.
Key Takeaways
Automated drilling is being tested and used at single sites, such as Sentinel in Zambia (holes drilled rose by over one-third in tests) and a chrome mine in South Africa, moving operators away from the rock face.
South Africa and the DRC have early beneficiation projects for battery-grade manganese and rare earths.
Mines are increasingly turning to self-generation (e.g., the 148 MW RBM solar plant, which is solar only) to reduce grid exposure; the solar-plus-battery example found is Kamoa in the DRC.
KoBold says its machine-learning approach can cut the time and cost of finding deposits and that its Zambian Mingomba project has progressed from discovery to development in about five years, and Kal Tire says its AI tyre tools lower downtime by up to 20%.
Digital twins and connected mining hubs (like AngloGold Ashanti's in Ghana) are being adopted for operational oversight.
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Key Themes
Technology Impact Matrix for Mining in South Africa & Africa
The African mining landscape is at a critical juncture where survival depends on the integration of disparate technology streams: green energy, digital oversight, and intelligent automation. The move toward 'Connected Mining' [28] acts as the central nervous system, enabling the efficient use o...
Priority Technology Profiles: Deep-Dive Assessments
The deep-dive assessment into priority technology profiles reveals an African mining sector at a critical juncture. The shift from extraction-only models to value-added chemical processing, particularly for battery-grade manganese and rare earths, is moving from theory toward pilot and demonstration...
Strategic Implications & Recommendations for Mining Leaders
The South African and regional mining industry is at a critical juncture where the convergence of digital technology, renewable energy, and chemical beneficiation is redefining the sector's strategic value. The primary driver is the global energy transition, which has accelerated the development of ...
Technology landscape
Technologies (44)
Discovered technologies with maturity and adoption assessments.
Advanced Hydrometallurgy & Direct Extraction for Battery Minerals5
This research section comprehensively covers advanced hydrometallurgical and direct extraction technologies for battery minerals in South Africa and Africa during 2025–2026. Key technologies include Giyani Metals and MMC's modular hydrometallurgical production of high-purity manganese sulphate monohydrate (HPMSM) with demonstration and first-phase plants, enabling scalable, low-impact battery-grade manganese supply. Rainbow Rare Earths and Steenkampskraal's direct solvent extraction and continuous ion exchange pilot projects advance high-purity rare earth element (REE) recovery critical for battery and magnet supply chains, supported by local industrial development funding from South Africa's IDC. Integrated manganese beneficiation projects benefit from IDC funding, enhancing local skills, economic benefits, and downstream value addition. Emerging technologies include solvent extraction from ferromanganese smelter wastes and continuous modular hydrometallurgical circuits by AE Fuels, which reported 95-99% manganese recovery and battery-grade HPMSM crystal production in a CSIRO mini-pilot in Australia. These technologies emphasize modularity, energy and chemical efficiency, lower emissions, and alignment with local content policies and resource constraints such as power and water availability. The research preserves all pilot data, yields, vendor names, funding details, and regulatory context with high confidence and evidence quality.
Giyani Metals and MMC have advanced modular hydrometallurgical routes toward battery-grade HPMSM in South Africa, enabling scalable, low-impact supply for evolving battery chemistries.
Drivers
Growing demand for battery-grade manganese
Local industrial development support
Modular and scalable process design
Barriers
Capital investment for commercial scale
Regulatory and environmental compliance
Supply chain and off-taker qualification
Rainbow Rare Earths and Steenkampskraal pilots use continuous ion exchange and solvent extraction to produce high-purity REEs with smaller footprint and lower waste, critical for battery and magnet supply chains.
Drivers
Critical supply chain demand for high-purity REEs
Local industrial development funding and support
Barriers
Capital and operational costs for pilot to commercial scale
Regulatory approvals and environmental compliance
Giyani Metals and MMC benefit from South African IDC funding, enabling in-country beneficiation projects that enhance local skills, economic benefits, and downstream value addition.
Drivers
Government industrial policy
Local economic development priorities
Demand for local beneficiation
Barriers
Policy changes or funding shifts
Project execution risks
A mini-pilot solvent extraction campaign successfully recovered manganese from ferromanganese smelter waste, demonstrating potential for battery-grade manganese production from industrial waste streams.
Drivers
Environmental regulations
Resource efficiency and circular economy
Barriers
Scale-up challenges
Economic viability of waste recovery
AE Fuels reported 95-99% manganese recovery and battery-grade HPMSM crystal production in continuous mini-pilot tests run by CSIRO in Australia, showcasing effective purification under sustained conditions.
Drivers
Demand for scalable battery mineral processing
Efficiency and recovery improvements
Barriers
Scale-up risks
Capital investment for modular plants
Low-Carbon, Modular & Circular Processing Innovations1
This research section comprehensively profiles six key technologies and initiatives advancing low-carbon, modular, and circular processing innovations in battery minerals and metals processing in Africa, particularly South Africa and Botswana, during 2025-2026. The modular HPMSM production by MMC offers a phased, capital-efficient route to battery-grade manganese sulphate, supporting EV and grid storage supply chains. Relithia Energy says its proprietary Electro-Vacuummetallurgy recycling technology achieves an 80% energy reduction and 99%+ purity in battery and e-waste recycling, with plans for significant scale-up. Giyani Metals advances pilot-scale hydrometallurgical production of HPMSM and HPMO with solar integration, supported by South African IDC funding. Molecular Recognition Technology (MRT™) by Isondo Precious Metals and Sibanye-Stillwater enables green, closed-loop recycling of PGMs including iridium, critical for hydrogen economy components. Circular mining and urban mining initiatives across Africa integrate tailings reprocessing and e-waste recovery, supported by industrial parks and partnerships to secure critical battery metals sustainably. South Africa's policy incentives and investments accelerate local battery precursor and cathode material production, including manganese and vanadium electrolytes, fostering regional clean-tech growth and EV sector transition. All technologies are supported by recent, authoritative sources with detailed process descriptions, quantitative data, and identified adoption drivers and barriers, reflecting a robust and transformative innovation landscape in African battery minerals processing.
MMC's modular HPMSM plant enables phased, low-capital battery-grade manganese supply, supporting EV and grid storage manufacturing in Africa.
Drivers
Growing EV and grid storage demand
Local value-add and supply chain security
Barriers
Capital investment risk
Market volatility for battery precursors
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Strategic analysis
Insights (16)
Cross-cutting strategic insights derived from technology analysis.
Mechanization and automation are starting to move from niche applications toward wider use for safety and efficiency in deep and complex mines.
Real-time visibility through digital twins and connected ecosystems is being used to revive underperforming assets and optimize complex resource extraction.
AI and machine learning are being applied to try to reduce the 'time-to-discovery' for critical minerals required for the global energy transition.
Large-scale solar projects, and at one DRC mine a solar and battery baseload plant, are helping African mines reduce reliance on national grids and work toward decarbonization targets.
Local processing of manganese, rare earths, and PGM recycling is starting to position Southern Africa in the EV battery supply chain.
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From insight to action
Strategy Cascade
What the analysis means and what must be done.
Strategic Imperatives
Mining engineering teams should consider incorporating high-speed 5G/LTE connectivity and autonomous-friendly layouts (e.g., specific turning radii and charging bays) into feasibility studies.
Invest in large-scale battery energy storage systems (BESS) specifically to provide the clean, stable baseload required by sensitive AI and autonomous sensors, which are prone to damage or resets duri
Transition from selling manganese/chrome/vanadium ore to forming joint ventures for local processing into sulphates and battery-grade materials.
Miners should partner with South African universities to create specialized curriculums for AI in mining.
Miners should leverage current IDC and developmental funding to scale pilot projects into commercial-grade HPMSM and PGM-based chemical refineries.
Implications
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Imperatives
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Looking ahead
Forward Signals
Early Signals
8Pilot deployments of battery-electric haul trucks by tier-1 miners
Automated Equipment Emerging at Single Sites in African Mines
Increased orders for low-profile autonomous drill rigs
Automated Equipment Emerging at Single Sites in African Mines
Establishment of centralized 'Mission Control' centers by major miners
Digital Twins and Connected Mining Emerging for Efficiency
Partnerships between miners and IoT platform providers
Digital Twins and Connected Mining Emerging for Efficiency
Monitoring
8Number of autonomous units added to annual mine fleet reports
Automated Equipment Emerging at Single Sites in African Mines
Investment levels in local technician training programs
Automated Equipment Emerging at Single Sites in African Mines
Percentage of fleet connected to real-time monitoring systems
Digital Twins and Connected Mining Emerging for Efficiency
Reduction in unplanned maintenance events
Digital Twins and Connected Mining Emerging for Efficiency
Wild Cards
4Regulatory mandate for zero-personnel mining in high-risk zones
Automated Equipment Emerging at Single Sites in African Mines
Major cyber-attack halting production across a connected mine network
Digital Twins and Connected Mining Emerging for Efficiency
Discovery of a major battery metal deposit using 100% remote AI sensing
AI-Driven Exploration and Resource Characterization Accelerating Discovery
A zero-fatalities year for the South African mining industry attributed to AI safety tech
Predictive Maintenance and AI Safety Tools Improving Operational Continuity
Scenarios
8Best-case: Full fleet automation leads to 40% reduction in Opex.
Automated Equipment Emerging at Single Sites in African Mines
Worst-case: Connectivity issues in deep mines cause frequent autonomous system shutdowns.
Automated Equipment Emerging at Single Sites in African Mines
Most-likely: Widespread adoption of digital twins for critical equipment (crushers, mills) by 2028.
Digital Twins and Connected Mining Emerging for Efficiency
Best-case: Entire value chain from pit to port managed through a single digital twin.
Digital Twins and Connected Mining Emerging for Efficiency
Evidence base
Sources (74)
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