MechChem Africa January-February 2024

MechChem JAN-FEB 2024 AFRICA Reliable motion

for a better tomorrow.

This month: Big energy-saving opportuni ties in comminution

The premium submersible for dense abrasive slurries

Energy efficiency and the food and beverage sector

Net-zero shipping via green LNG

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CONTENTS 30 Maintenance solutions and asset management 8 A brief history of lubrication

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Steven Lumley, technical manager for WearCheck, outlines the history of lubricants from the Stone Age up to, in this first part, the Age of Enlightenment. MechChem Africa presents a summary. 10 ISO-Reliability Partners announces strategic partnerships 11 SKF Maxilube optimises Moroccan mill Water, wastewater and pumping solutions 12 Goodwin: the premium submersible for dense abrasive slurries MechChem Africa talks to Rui Gomes of Goodwin Submersible Pumps Africa about the niche applications and benefits of Goodwin submersible slurry pumps, which are engineered in the UK to handle very dense and abrasive slurries.. 15 Why use submersibles for fluid handling 16 Simple pumps and solutions for hygienic, hazardous and demanding applications Minerals processing and materials handling 18 Weir highlights big energy-saving opportunities in comminution At a COP28 panel discussion in UAE in December, Paula Cousins, Chief Strategy and Sustainability Officer at Weir revealed the highlights of a comprehensive study into opportunities for reducing energy use and emissions in crushing and grinding operations. 21 Exploring the future of minerals processing 22 SA mine gets world-first planetary gearbox customisation 24 Sports Nutrition and Flexicon bulk handling lines Heating, ventilation and air conditioning 26 Metso launches upgraded Evaporative Cooling Tower Metso Corporation has released an upgraded and more efficient dry gas cleaning solution for furnace off-gas, which offers improved cooling efficiency and excellent process control. 27 Dual-purpose vent and hoist shaft for Platreef PowerGen, PetroChem and sustainable energy management 28 AES, energy efficiency and the food and beverage sector Associated Energy Services (AES), SouthAfrica’s leading operations and maintenance service provider to the steam and boiler sector, believes it can help food and beverage sector manufacturers deal with their many challenges. 30 Achieving the energy future Africa needs 31 Coal’s place in our energy mix Local manufacturing and food processing 32 Competitive localisation of RE manufacturing and services Mamiki Matlawa, Group Business Development Executive at ACTOM, argues that localisation of the renewable energy industry can position African manufacturers to effectively compete with foreign companies. 33 Advanced feed mixer improves dairy cattle health Hydraulics_Pneumatics and Automation 34 Optimising two-port pneumatic valve selection Automation, pneumatic components and system’s support provider, SMC Corporation SA, presents some important aspects to the selection of 2-port pneumatic valves. Innovative engineering 38 Net-zero shipping via green LNG An MoU signed between Pilbara Clean Fuels (PCF), Oceania Marine Energy (Oceania), and RINA Marine Consulting (RINA) is pursuing a collaborative effort to help meet the net zero-emissions on the iron ore export trade routes from Port Hedland in Western Australia.

Published bimonthly by Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: peterm@crown.co.za www.mechchemafricamagazine.co.za Editor: Peter Middleton e-mail: peterm@crown.co.za Advertising: Elmarie Stonell e-mail: mechchemafrica@crown.co.za Design: Katlego Montsho Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors.

Transparency You Can See Average circulation Jul to Sep 2023: 10 703 Printed by: Tandym Print, Cape Town

Front cover: Innomotics South Africa Contact: Tim Walwyn Tel: 011 652 2000 Email: LDAquotes.za@siemens.com Website: www.innomotics.co.za

Regulars 2

Peter’s comment: COP28 and industry’s transformational role

4 On the cover: Motion innovation for Africa’s mines: Innomotics delivers end-to-end green solutions and digital transformation. 36 Products and industry news 40 Back page: ABB and Gravitricity to collaborate on energy storage systems

January - February 2024 • MechChem Africa ¦ 1

COP28 and industry’s transformational role

In his closing address at the COP28 summit in Abu Dhabi during December last year, the executive sec retary of the United Nations Framework Convention on Climate Change (UNFCCC), Simon Stiell, said that COP28 needed to send a crystal clear signal: “a global green light signalling all systems go on renewables, climate justice and resilience”. He went on to suggest that COP28 “delivered some serious strides forward: a tripling of renewables; doubling of energy efficiency; operationalising the loss and damage fund; and making an initial down payment on a framework for the global goal on adaptation”. Many of the initiatives, he acknowledged, are climate-action lifelines, not the finish line. “What I'm focused on is seeing these pledges converted into outcomes in the real economy where the rub ber really hits the road on climate action,” he said. So after 28 annual COP conferences we now have a lifeline! It is hard to feel any relief. COP28, he continued, also signalled a “hard stop to humanity's core climate problem: fossil fuels. We didn't fully turn the page on the fossil fuel era in Dubai, but this is clearly the beginning of the end,” he assured. He applauded concerns from Samoa and other is land states that this latest consensus does not go far enough to protect their populations and the planet. He then slipped in that the world is currently still on track for a global temperature rise of nearly 3.0°. “If all countries don't take the most ambitious approach to implementing the text, loopholes leave us vulnerable to fossil-fuel vested interests, which could crush our ability to protect people everywhere against rising climate impacts,” he warns. “Transparency, and people holding their governments to account, will be vital in closing these loopholes,” he added. What I find heartening, though, is the progress being made by industry in providing some of the real-economy outcomes needed. We report in this issue, for example, on an emissions mitigation study by Weir Minerals that was presented at COP28. By replacing conventional crushing and grinding technology with innovative new solutions, this case study-based report found that energy use was cut by 40%, and CO 2 emissions due to comminution in mining were halved. And as well as promoting sustainability, Paula Cousins, Chief Strategy and Sustainability Officer at Weir Minerals revealed that the study also resulted in lower operating costs for the mine. “Metals such as copper, nickel and lithium are critical elements of the technologies that will power a low carbon future, and it is widely accepted that a substantial

increase in the production of these metals is needed for the transition to net zero,” Cousins told COP28 delegates. The cover story in this issue of MCA comes from Innomotics, a newly formed company carved out of Siemens Large Drives. I find the story inspir ing in terms of green ambition, sustainability and transformation. Innomotics has been set up to deliver innovative green solutions through digital transformation, most notably in the energy intensive minerals, energy and cement sectors. Citing a recent success, Sven Demmig, the company’s global head of mining says that, in Peru, Innomotics has built a complete Greenfield mine using Siemens’ software and automation solutions: starting from the design phase, through the mine construction phase and up to operation. Closing the loop, the solution comes with a digital-twin of the entire mine, all based on state-of the art digitalisation capabilities for the mining environment. The benefits, on top of the environmental ones that accrue due to the use of best-efficiency equip ment, are the ability to optimise every aspect of operation so as to deliver better uptime, longer life, lower operating costs and much better productivity. The system has already saved the customer around US$70-million over a period of three years – through improved coordination across the value chain – and these savings where “a happy accident” discovered after full implementation. The initial and fully achieved intention was simply to harmonise the IT systems from the company’s many mining opera tions: to reduce licensing costs, server numbers and maintenance and support costs. And there is more: Our Innovative Engineering piece describes a multifaceted initiative to help meet the net zero-emission on dry-bulk minerals/ iron ore exports shipped out of Port Hedland in Western Australia. The solution has three prongs: an electrified low carbon footprint LNG plant in Port Hedland; an LNG re-fuelling concept based on ship-to-ship bunkering of vessels while at anchor; and a dry-bulk ship design with an innovative LNG marine fuel system involving pre-combustion carbon removal and hydrogen production. These are all vital initiatives targeting some of the world’s most challenging emissions problems. They also suggest that investing in cleaner, safer and more environmentally sustainable solutions can also deliver economic benefits. If, on the other hand, we fail to “take the most ambitious approach” and global warming reaches 3.0° or more by 2050, the consequences could be very costly indeed.

Peter Middleton

MechChem Africa is endorsed by:

2 ¦ MechChem Africa • January-February 2024

Motion innovation for Africa’s mines In advance of the Mining Indaba in Cape Town, MechChem Africa talks to Sven Demmig and Tim Walwyn of the newly formed Innomotics, a Siemens Business. Created from Siemens’ Large Drives and Low Voltage Motors businesses, Innomotics delivers end-to-end green solutions and digital transformation to the mining, cement, chemical and other sectors.

wants to emphasise its position as a world class solution provider for electrification, automation and digitalisation in the mining and associated industries. “Our market-leading products are com plemented by the expertise of Innomotics’ Solutions division in integrating these products to create complete solutions, most notably for the mining and cement industries,” says Demmig, adding that this is backed up by a globally active Service divi sion. “Because all the equipment involved are assets in critical applications, their reli ability is key for the long-term success and sustainability of any operation. “The first digital mine has been devel oped for a copper mine in Peru using our technology, starting from the design phase, through the mine construction phase and up to operation. Closing the loop, the solution comes with a digital-twin of the entire mine, all based on our state-of the art digitalisa tion capabilities for the mining environ ment,” says Demmig. This global customer now plans to use the same technology for its next Greenfield mine. “We see the Digital Mine by Innomotics as a triangle of technologies,” Walwyn fur ther explains. “We start with an engineering platform, which is basically a digital model of the mine represented in a single common database. Then we develop the automation systems needed to control and manage min ing and minerals processing sequences. And the third component is a simulation engine,

Left: Chief Executive Officer of Innomotics in South Africa. Right: Sven Demmig, Global Head of Minerals Solutions for Innomotics.

I nnomotics, according to Sven Demmig, Global Head of Minerals Solutions, is an independent new company that is whol ly owned by the Siemens Group. “With a trusted Siemens legacy of more than 150 years of engineering expertise, Innomotics has a portfolio of leading solutions in auto mation, digitalisation and electrification to deliver the digital transformation, first and foremost in mining, but also for the cement, chemical and other industries.” In reference to Innomotics’ long heritage of innovation in mining, Demmig cites the company’s gearless mill drive (GMD) tech nology as a key contributor to reliability and efficiency on the mine. Some of these GMDs are amongst the world’s biggest mills. At the Sentinel copper mine in Zambia, for example, two 28 MW GMD drives have been installed to run two 40-ft SAG mills

plus two 22 MW drives to run two 28-foot ball mills “These are reliable, high-efficiency mills that reduce total costs of ownership and deliver sustained high performance in meeting the production requirements of mining operations,” he notes. “We have a product-oriented focus on large and medium voltage (MV) drives and motors – and we are the world market leader in MV-drives. Everywhere in the world, these are critical components for reliable motion for industrial processes and infrastructure,” says Tim Walwyn, Chief Executive Officer of Innomotics in South Africa, adding that Innomotics has access to over 16 Siemens factories around the world that produce these motors and drives.

The digital mining approach At the 2024 Mining Indaba, Innomotics

Innomotics has a product-oriented focus on large and medium voltage (MV) drives and motors. The company is the world market leader in MV-drives.

4 ¦ MechChem Africa • January-February 2024

⎪ Cover story ⎪

which enables role players to interact with mining processes in a realistic way.” “We can use the mine simulation design, for example, to build operator training simu lators so the people that will be working in the mine can get a very good idea of what they will need to do in the real mine through engagement in a safe virtual environment.” “This Digital Twin enables any of the key process parameters in the real world to be modelled. Different scenarios can be explored within a whole process simulation to see if there are any more efficient options than those being achieved.” “And while we have been talking mostly about Greenfield mines, most of the demand for mine optimisation is for mines that are already in production, so Innomotics en ables the digitalisation of existing mines. We can already present examples where our suite of digital solutions is being used to optimise daily operations of fully opera tional mines,” adds Demmig. Walwyn points to a solution recently developed for a major iron ore producer in South America, collecting data to create a pit to port digital model of a complete min ing value chain. “This to enable companies to follow the value stream from the mine, though to stockpiling, blending, loading, and right across the rail network until it is loaded

onto ships and/or into processing plants. It delivers end-to-end visibility of every stage of the mineral extraction, beneficiation and transportation and logistics cycle,” he says. Through improved coordination across the value chain, the company has achieved savings of around US$70 million over a period of three years. By improving the efficiency of minerals processing, Innomotics’ leading solutions can also reduce energy consumption and improve the industry’s sustainabil ity. “Innomotics solutions enable mines to achieve highest-possible efficiencies from processes such as crushing and grinding. Our key digitalisation focus, though, is on plant reliability, availability, and optimised

productivity,” explains Walwyn. Innomotics will be showcasing its digi talisation competence with a live demon stration of how to optimise operations with the company’s pit-to-port solutions at the Mining Indaba from 05-08 February 2024. “In Cape Town we aim to build awareness of our new role and to highlight our mining capabilities,” he tells MechChem Africa . “In Africa, we see Innomotics as a key brand for transforming the mining industry. Innomotics looks forward to building and developing stronger partnerships with its customers on the continent, delivering ef ficient minerals extraction and processing solutions," ends Tim Walwyn. www.innomotics.co.za

Innomotics will be showcasing its digitalisation solutions at the Mining Indaba – from 05-08 February 2024 – with a live demonstration of how to optimise mining operations from pit-to-port.

Gearless mill drive (GMD) technology is a key contributor to reliability and efficiency on mines. “These are reliable, high-efficiency mills that reduce total costs of ownership and deliver sustained high performance in meeting the production requirements of mining operations,” says Sven Demmig.

January-February 2024 • MechChem Africa ¦ 5

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A brief history of lubrication In part one of a series called ‘Sliding though time’ being published in WearCheck’s Technical Bulletins, Steven Lumley, technical manager for WearCheck, outlines the history of lubricants from the Stone Age up to, in this first part, the Age of Enlightenment. MechChem Africa presents a summary. T he history of lubrication is a story that demonstrates how oil, a seem ingly simple substance, has pro pelled human progress, shaped in petroleum in ancient history were under taken by the Egyptians. There are Egyptian hieroglyphs that depict the use of bitumen as an embalming fluid, to grease chariot wheels and in the construction of monumental structures such as the pyramids. Egypt’s primary source of bitumen was the Dead Sea, which the Romans later named Palus Asphaltites (Asphalt Lake).

dustries and ushered in a world of smoother operations and optimised performance. Lubrication, in its simple form, has been in existence since at least the beginning of documented times. Ancient history 3500 – 476 BCE The oldest historical evidence of ancient oil use was discovered in archaeological records near the city of Hit in Mesopotamia, modern day Iraq, at the site of an oil seep known as The Fountains of Pitch. This petroleum-derived pitch (bitumen) had the advantage of being both adhesive and slippery, making it suitable for a variety of applications. Our Sumerian friends used pitch as a caulking agent for waterproofing ships, as a lubricant on wheeled carts, an adhesive to secure the handles of various tools, and even as a setting agent for jewels and mosaics. Some of the most widely known uses of

Steven Lumley, technical manager of WearCheck.

dragging the statue, with one man stand ing on a sledge pouring a mystery liquid on the ground, presumably to reduce friction between the two surfaces. Back to Mesopotamia, in around 1800 BCE, we find the Babylonian civilisa tion using bitumen to construct roads and bridges. Bitumen was applied to road surfac es to help bind gravel and create smoother, more durable roadways, not a million miles away from how we make roads today. More than a millennium later, the Greek historian Herodotus described how bitumen was used as mortar to construct the famous walls of Babylon, and the world’s first skyscraper – ‘Etemenanki’ or the ‘Tower of Babel’. Meanwhile in East Asia in 780s BCE, the Chinese discover the friction-reducing prop erties of a concoction made with vegetable

Archaeologists have discovered a greasy substance on a sled wheel dating back to 2600 BCE that belonged to an Egyptian pharaoh. Analysis later showed that this substance was a mixture of beef and sheep tallow – a rendered animal fat made up of triglycerides – mixed with lime powder. This discovery led to the conclusion that the ancient Egyptians used tallow as a lubricant for transporting materials such as wood and rocks. Paintings and hieroglyphics found in the tomb of Tehuti-Hetap,, in Egypt showed a giant statue of the man himself being moved with the aid of a liquid believed to be either water or oil. The painting, aptly known as ‘Colossus on a sledge’, depicts labourers

A timeline of tribology development: 3500 BCE to 1699 CE.

8 ¦ MechChem Africa • January-February 2024

⎪ Maintenance and asset management ⎪

oil and lead, the first historical record of a compound lubricant. And when the Olympic Games were held in Olympia in Greece in 680 BCE, four-horse chariot racing was added to the event, with a requirement for high-speed wheel-axle lubrication in the form of animal fat, the first historical record of a racing lubricant. The pax Romana era: up to 200 CE 879 years later and during the Roman Empire – also known as Pax Romana (Roman peace) – we find a multitude of olive oil-based lubricants in everyday use. Experimentation led to the use of more so phisticated lubricants, including those from olive oil and other vegetable derivatives. The Romans discovered that some of these more viscous liquids not only dissipated heat better than tallow, but also allowed mechanisms to move more freely. Writings by the Roman senator and historian, Cato the Elder recommended that wagon axles be lubricated with the boiled, viscous by products of olive oil production. Greases made from calcium salts and olive oil (basically calcium grease) were used to lubricate axles in horse-drawn chariots used for travel and warfare, and different oils were used in various metalworking process es to lubricate moving parts in water clocks and to keep door hinges from squeaking in temples. It was even rumoured that Caligula, the 3 rd Roman emperor, had his engineers make up a concoction of beeswax and olive oil to lubricate the bronze bearings on the rotating platform of his palatial pleasure barge on Lake Nemi. These early experimentations marked the dawn of machinery lubrication. The medieval period: 475 CE to 1400 CE Between the fall of the Western Roman Empire and the beginning of the Renaissance, this period was characterised by economic, intellectual, and cultural stagnation with feudalism, Viking raids and the bubonic plague thrown in. During this dark time, tallow was used predominantly as a lubricant in Northern Europe to lubricate mechanisms such as pivots and bearings. Tallow was often thick ened with agents like clay or lime to form greases that were used to lubricate vertical watermills and post mills, for opening the gates of castles and on carriage wheel axles. During the late 7 th century, warfare took a nasty turn with the invention of a devastat ing incendiary weapon called Greek fire – the medieval equivalent of napalm – which was invented by Callinicus of Heliopolis during the reign of Byzantine Emperor, Constantine IV. The recipe was a closely

that could treat anything from rheumatism to toothache.

guarded secret, but many historians believe it was composed of liquid petroleum, bitu men, and quicklime. Viking warriors were considered the quintessential shipwrights of the 8 th century and built longships called Drakkars – a term derived from the Old Norse words ‘dreki’ and ‘kar’ meaning ‘dragon ship’. These ancient mariners are believed to have used whale oil to lubricate the sail-hinge supports, rowlocks and the rudder axes. This incredible period in human history was full of cultural, artistic and intellectual development with origins in Bel Paese: oth erwise known as Italy. Some of the greatest revolutionary minds developed inventions and mechanical tools such as the printing press, microscope, and the barometer, to name but a few and the period was blessed with an ensemble of overachievers: Nicolaus Copernicus, Galileo Galilei, Johannes Gutenberg, Christopher Columbus, Dante, Andreas Vesalius, Michelangelo, and Leonardo da Vinci. Animal fats and primitive oily compounds were in use throughout the world at the time, but the father of invention, Leonardo da Vinci, made significant observations about friction and lubrication. He was the first to suggest that the friction force is proportional to the applied load or weight acting between the surfaces being moved. He also developed the concept of reducing friction by using a layer of lubricant between moving surfaces. He went on to create a self-oiling lubrication system for wheel axles, using bearings that he lubricated with animal fat and opium oil. Da Vinci’s mechanical inventions and designs laid the groundwork for many ad vancements in mechanical engineering and lubrication techniques that followed in the centuries to come. “The noblest pleasure is the joy of understanding,” he said. As iron and brass replaced wooden machine parts in the 1600s, animal fat fell short of our lubrication requirements. As a result, people in Europe began experimenting with mixtures of vegetable oil, including castor, peanut, rapeseed, and canola oil. Whale oil, however, saw continued use throughout this century, not only as a lubricant, but also as a fuel in lamps and for manufacturing of candles.Meanwhile in the new world, we find Seneca Indians in North America using crude oil to waterproof baskets and wigwams, as a glue to make arrowheads, but mainly for medicinal purposes to cure a va riety of ills. Seneca Oil, as it became known, was traded by the Senaca tribe to European settlers as a tonic, insect repellent and salve The Renaissance: 1400 to 1600 CE

The Age of Enlightenment/Reason The Age of Enlightenment was an intellec tual and philosophical movement between the late 17 th century and the 18 th century that emphasised reason, individualism and the pursuit of knowledge and human rights. It played a crucial role in shaping modern thought, including political and scientific developments. Notable progress included René Descartes’s first principle of ‘I think therefore I am,’ and the inventions of the steam engine, telegraph, lightning rod, the mechanical calculator, and the hot air balloon. Sir Isaac Newton was an intellectu al giant of this time. His most famous work, Philosophiæ Naturalis Principia Mathematica, was published in 1687 and in it he outlined his laws of motion and uni versal gravitation, providing a mathematical structure for understanding the physical world. He also formulated the mathemati cal framework for understanding viscosity and its relationship to the flow of fluids. While he did not provide a comprehensive theory of viscosity or use the term itself, his contributions to the mathematical descrip tion of fluid motion and forces within fluids were foundational for later developments in fluid mechanics and our understanding of viscosity in the modern sense. In the late 16 th century, a self-taught French physicist and engineer called Guillaume Amontons presented a paper to the Royal Academy of Sciences in Paris, entitled De la résistance causée dans les machines – On the Resistance Encountered in Machines. Expanding on the earlier works of Leonardo da Vinci, Amontons’ paper explored the frictional forces that occur when surfaces come into contact with each other. This groundbreaking research laid the foundation for the study of friction and the laws governing it, namely Amontons’ first and second laws of friction. • The friction force is independent of the nominal or apparent area of the surfaces in sliding contact. • The friction force F is proportional to the normal force N between two bod ies in sliding contact, ie, F= µN.

The next instalment of this Sliding Through Time se ries will be published in Technical Bulletin 89, where we will brave the age of revolution and the events that spawned the modern petroleum industry. www.wearcheck.co.za

Scan the QR code to access full version of this article in Wearcheck’s Technical Bulletin 88.

January-February 2024 • MechChem Africa ¦ 9

ISO-Reliability announces strategic partnerships Leading provider of reliability and lubrication solutions, ISO-Reliability Partners, has capped off a highly successful 2023 with a landmark five-year tender to supply Royal Purple premium lubricants to Transnet Engineering for lubrication of high speed traction motor bearings. “I n the mining industry, we add considerable value to milling and processing plants. We have grown our market share in the open gear Performance Lubricants (Pty) Ltd. As a result of this acquisition, the company now con trols distribution of both the industrial and consumer range of Royal Purple’s energy saving premium lubricants.

ISO-Reliability's Royal Purple range offers substantial improvements to asset protection.

to address this by offering innovative tech nologies to improve efficiency and reduce electricity wastage. Its collaboration with Royal Purple of the US, which has developed energy-saving lubricants capable of signifi cantly lowering electricity consumption, is testament to this commitment. “Dynamometer tests reveal an increase in engine output of around 12% gained by reduced frictional losses through the engine and drivetrain,” FitzGerald points out. Friction accounts for 15% of all energy usage worldwide. Therefore, Royal Purple has developed energy-saving lubricants for a range of industrial equipment. It is capable of lowering electricity consumption by 4% to 18%, while achieving the same production output. “A commonsense approach to fric tion reduction results in considerable cost reductions,” argues FitzGerald. Looking to 2024, FitzGerald says his outlook remains positive. ISO-Reliability Partners fosters an environment of inclu sion and positivity, with focus-driven goals to grow its valued client base and range of cost-reducing technologies. “Our employees are the heart of the business. As such, a large effort is made in terms of technical and managerial training to raise the skill levels of our employees and add value to the service we offer our clients,” he says. ISO-Reliability Partners has consolidated knowledge and expertise in the fields of fil tration, lubrication and tribology, providing industry with substantial and quantifiable improvements to plant and asset protection. “The well-being of the environment is of key concern but is often overshadowed by business needs. Through the more efficient use and handling of commodities such as fuel and lubricants, we reduce pollution through lower usage and disposal of lubricants, conserve electricity usage while achieving higher production outputs and better asset protection. Not only is this better for the environ ment, but it also lowers the lowest cost of ownership for plant and machine operators,” concludes Craig FitzGerald. www.iso-reliability.com

lubrication field by onboarding new custom ers looking to improve production output while lowering operating costs,” notes Craig FitzGerald of ISO-Reliability Partners. In addition, the company showcased its expertise by demonstrating the enhanced compressor performance achieved by Sasol Synfuels when it adopted Royal Purple Synfilm GT, resulting in improved protection and reduced energy consumption. “Our success has come with challenges,” continues FitzGerald. The company had to address attempts by unscrupulous competi tors to replicate its pioneering Filter Focus branded micro fine filtration technology, for example. Despite copied products re sembling the original, these underperform significantly. ISO-Reliability’s strategy for 2024 involves continued education efforts to inform customers about these imitations and emphasise the superior performance of authentic Filter Focus products. Another milestone goal for next year is establishing a predictive maintenance platform powered by Artificial Intelligence (AI), in partnership with a leading German AI technology firm. FitzGerald expects to announce these partnerships early next year, with the aim of delivering substantial cost-saving initiatives to its client base. To extend its offering and break into the consumer and retail markets for premium motor vehicle lubricants, ISO-Reliability Partners has acquired 100% of Power

In terms of latest trends, FitzGerald says AI “is undoubtedly one of the biggest trends that our industry will see for many decades to come.” The company anticipates leverag ing AI for real-time equipment monitoring, providing early insights into potential issues and enhancing safety through reduced hu man interaction with equipment. Condition monitoring requires regular analysis performed at predetermined intervals to evaluate changes in machine vibration, wear particle analysis of lubri cating oils, and temperature increases through thermographic inspections. Most importantly, it requires human interaction and the use of off-site laboratories, with results often only available up to three days after a site visit. AI, on the other hand, can continuously monitor equipment in real-time at a fraction of the cost. It can provide early insights into potential machine issues months before the techniques used at present. “AI will dramatically reduce the costs as sociated with condition monitoring, with the added value of safety by eliminating human interactions with equipment. Our solutions provide automated fault reporting with root cause identification and recommendations for fault repair,” notes FitzGerald. He highlights the industry’s concern about the availability and security of elec tricity in South Africa. The company aims

“AI will dramatically reduce the costs associated with condition monitoring,” notes Craig FitzGerald of ISO Reliability.

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⎪ Maintenance and asset management ⎪

SKF Maxilube optimises Moroccan mill A complete Maxilube lubrication system from SKF has enhanced personnel safety, increased machine reliability, boosted uptime and delivered substantial time and cost savings for a leading paper mill in Morocco.

B efore the SKF intervention, a paper mill in Morocco had little control over the lubrication of bearings on one of its paper machines. Extremely restricted safety procedures prohibited any approach to the running machine. The customer’s only solution therefore was to grease the bearings on the wet end when the machine was standing still during scheduled stoppages. As lubrication could only be performed on the bearings every 35 to 60 days, lu brication was insufficient and, when the machine’s runningtimeincreased,thiscausedthebearingsto overheat and ultimately fail prematurely. The customer subsequently requested SKF to supply and install a lubrication system on the wet end of the paper machine. Following numerous meetings and discussions with the SKF Morocco team,thecustomerchosetheMaxilubemonitored dual line solution. As the installation had to take place during the planned machine downtime, when all maintenance operations were carried out, SKF only had a five-day window in which to install the entire lubrication system and was the only supplier who was willing to accept this tight deadline. When the customer postponed the project for approximately four years, SKF faced new challenges. The customer contacted SKF in August 2023, requesting that the team again commence work on the lubrication solution. The complete lubrication system had to be installed before the

time. Extremely satisfied with the SKF Morocco team’s efficiency and professionalism, the cus tomer immediately requested a proposal from SKF for a Flowline oil recirculation system for 110 bearings, to potentially replace an existing system. www.skf.com/africa/en

end of October 2023 to take advantage of the scheduled five-day machine shutdown. Challenge accepted! Thanks to the support from SKF’s Muurame factory as well as the efforts of all the commercial colleagues at Customer Service, SKF managed to get the equipment three days prior to the start of the customer’s technical shutdown, which greatly assisted the team with the necessary preparation work. The monitored Maxilube lubrication system is connected to a Dualset unit with two MPB pumps for automatic drum changing when one of the drums is empty. The lubrication solution includes SGA distributors with cycle and alarm manufactured from AISI 316 stainless steel to ensure lasting reliability. The flexible system also has the potential to connect alarms to the customer’s DCS going forward. The SKF team completed the project within ten days of equipment delivery, assembly and testing to final commis sioning and hand over. This included only five days during which the machine was shut down. According to the Moroccan paper mill, SKF achieved the best score of all the other projects that were running on the machine at the same life of assemblies. Cera Tec also improves reli ability of industrial equipment, lowers engine and transmission noise, minimises maintenance requirements and reduces downtime. Other benefits include energy savings, reduced risk of contamination, lower pollutant emissions and more efficient operating costs. “The graphite like structure of resilient ceramic particles, with high mechanical and thermal stability, fill in the roughness in the metal of oil lubricated engines, transmissions, pumps and compressors, thereby preventing direct metal-on-metal contact. An ac tive chemical uses the existing friction energy to ensure a smooth-running effect that reduces fuel consumption in gasoline and diesel engines. The < 0.5 µm particle size guarantees optimum filter flow properties and protects against depositing of solid lubricant particles. Cera Tec is miscible with all industrial oils,” explains Beukes. According to BMG specialists, local operators face continued difficulties with transmissions, for example, with the gearing in conveyor systems. Problems occur sensors installed on the distributors to monitor the efficiency of lubrica tion operations. All components are

SKF’s Maxilube dual line lubrication solution was chosen for a paper mill in Morocco.

High performance additives for industrial transmissions The BMG team works closely with key players in diverse sectors to enhance production efficien cies, minimise downtime and extend the service life of power transmission systems and industrial equipment.

largely in applications where dust accumulates in the transmission, increasing friction between the gears and other components, which acceler ates wear. Another troublesome factor is the high ambient temperature, which increases the temperature of the oil in the transmission. Experts have proven that with the inclusion of Cera Tec additives in transmission oil, the temperature of the transmission oil decreases by up to 15 °C. This solution offers better protection formachines,andreducestheriskofmalfunctions and lowers maintenance costs. Lubrication cools internal components and protects metal from corrosion, which reduces wear of the system. Through BMG’s wide range of energy efficient products, which include synthetic oils, lubricants and bespoke lubrication systems along with technical support from a competent team, the company can ensure efficient maintenance, extended life of components and energy savings at any plant. www.bmgworld.com

“A recent development has been the addition of high-performance additive, Cera Tec, which has exceptional resistance to high temperature andpressure,”saysCarloBeukes,BMG’sBusiness Development Manager for the Agricultural, Automotive and Lubrication divisions, BMG. “This is proving to be highly effective in protecting gears in industrial transmissions in many sectors, including sugar mills, mining, chemical plants, manufacturing and general engineering,” he adds. Cera Tec – developed by Liqui Moly, a global leader in additives, motor transmissions and hydraulic oils – is a micro-ceramic solid lubricant suspension based on hexagonal boron nitride (BN) in selected base oils. This product reduces friction and protects the engine and transmis sion against wear, thus extending the service

January-February 2024 • MechChem Africa ¦ 11

Goodwin: the premium submersible for dense abrasive slurries MechChem Africa talks to Rui Gomes of Goodwin Submersible Pumps Africa about the niche applications and benefits of Goodwin submersible slurry pumps, which are engineered in the UK to handle very dense and abrasive slurries.

that can match us when it comes to pumping dense slurries. The ANZE range can handle slurry densities of up to 2.8 kg/l, with a solids content by weight of up to 65%,” says Gomes. Describing a typical application, he cites tailings recovery for mining operations as key. “Tailings dams are typically loaded at an SG of between 1.6 and 1.65. The fines then settle, and the water is recovered. The remaining product is what we typically get involved with,” he says. He cites a four-year project undertaken in Lydenburg in Limpopo to recover the chro mium from the tailings of a platinum opera tion. “This is known as minerals recovery or hydro mining, and we are negotiating doing something similar in the Rustenburg area. After a tailings dam has been left to settle, there is often an opportunity to recover sec ondary minerals, such as chrome in this case, which were not initially targeted. This is often the case at platinum production plants. To recover the chrome, the tailings need to be transported back into a different process plant. This can either be done using front-end loaders and trucks or we can pump it back as a dense slurry,” Gomes explains. In Lydenburg, this was done over a four year period using Goodwin’s largest 112 kW,

high density slurries. For this, world leading expertise in large castings and the technol ogy that goes into abrasion and corrosion resistant materials has been developed and incorporated into Goodwin’s pump designs. While the most common material used for wear resistance of centrifugal slurry pumps is hard chrome, Gomes says that Goodwin has developed its own range of casting materi als with market leading abrasion resistance. For the 200 mm 112 kW Goodwin ANZE ® submersible slurry pump, for example, the company’s proprietary NiHard composition is used for the casings, while the impellers and wear plates use a tungsten carbide-coated NiHard formulation to deliver application spe cific abrasion and the wear resistance needed. “The global submersible market is massive, going from smaller 2.2 kW submersibles all the way to 300 kW pumps. Our smallest unit is a 30 kW submersible, and at the moment we go up to 112 kW in South Africa. In terms of motor power this is typically mid-range, but we are in the upper echelon when it comes to the ability of these pumps to handle heavy density slurries,” Gomes notes. This is the differentiator for Goodwin sub mersible slurry pumps. “There are very few OEMs in the world with submersible pumps

“G oodwin PLC, our holding company, has manufactured engineering components in the UK for some 140 years, for the power generation and nuclear in dustries; for petrochemical projects; and for safety critical structural solutions,” begins Rui Gomes, operations and marketing director of Goodwin Submersible Pumps Africa. On the pump side, the company specialises in submersible slurry pumps with the abrasion and corrosion resistance needed for pumping Goodwin submersible slurry pumps are purpose-built to deal with the abrasion and corrosion resistance needed for pumping high density slurries.

For application specific abrasion and wear resistance, the 200 mm 112 kW Goodwin ANZE® submersible slurry pump uses Goodwin’s NiHard composition for the casings, while the impellers and wear plates use a tungsten carbide-coated NiHard formulation.

12 ¦ MechChem Africa • January-February 2024

⎪ Water, wastewater and pumping solutions ⎪

200 mm discharge ANZE submersible slurry pump. “Each of these units weighs in at about 2.3 t and they each transported between 720 to 780 m 3 of slurry every hour: for 24 hours a day over a four-year period. Being able to do this made the operation exceptionally cost effective, with a return on investment on each pump of about five weeks per unit,” Rui Gomes tells MechChem Africa. At the project’s peak, he adds, the operation, which ran from 2017 to 2021, had four Goodwin submersible units operating simultaneously. In terms of service support, Goodwin Submersible Pumps Africa was also re sponsible for regular refurbishments as the wet-end components wore down. “Similar to centrifugal slurry pumps, the impellers, wear plate and casings of Goodwin submersibles must be replaced at regular intervals to re store performance as the pumps wear. The longest running time for one of our pumps on this project was nine months, but in general, we had to replace the impeller and the wear plate at four-to-five-month intervals, while changing the casing on every second service,” he says. Gomes highlights some of the standout features of the Goodwin submersible pump design: “One of the key reasons for the ex ceptional reliability of these pumps, particu larly of the bearings, is the electrical design. The electric motor and the bearings are in a completely sealed unit in the pump-motor housing, which is fully submerged in hydraulic oil to lubricate and cool the drive components. A double mechanical seal at the pressure end of the pump and a ceramic sealing layer around the electrical cable gland at the top fully isolates this motor unit, so we seldom see electrical, seal or bearing failures,” he notes. “This also makes it possible to replace the whole of the wet end, in-situ, without af fecting or compromising the electrical-end, bearings, or the sealing arrangement. This is not normal for a submersible slurry pump,” Gomes asserts. The sealed electrical unit sits symmetri cally in the split pump volute, which reduces vibration and allows the process flow to continuously cool the hydraulic oil inside. “Even during dry-running, air is kept circulat ing around the motor unit to prevent rapid overheating. From real dry running test of our units, we can comfortably claim that these pumps can be run dry for extended periods of time without consequence,” he says. In addition, on the inlet on the bottom of the pump, an inducer has been incorporated onto an extended impeller shaft as a standard on all pumps. This is designed to send hydro dynamic shockwaves into the dense slurry, which re-suspends settled solids on the pond floor to improve pumping efficiency. The open vane impellers used also ensure that large

particles can be accommodated, typically 25 mm ‘stones’ on the smallest 100 mm, 22 kW NZE submersible slurry pump and small rocks of up to 76 mm on the 200 mm 112 kW ANZE. “The 30 kW 100 mm Goodwin submers ible, our smallest, is an ideal substitute for vertical spindle pumps in typical sump ap plications. Traditional vertical spindle pumps are often dotted all over minerals processing plants, to remove accumulated waste slurry from bunded areas beneath the likes of flota tion plants or thickeners for example,” he says. “While the key reason our submersibles are becoming a preferred option is their den sity handling capability, which is far superior to vertical spindle pumps, the reliability of the Goodwin ANZE is a significant second. If the sump is deeper than a metre or so, then a ver tical spindle pump will require a longer shaft. This increases the risk of excessive vibration, which can negatively affect bearing reliability. Vertical spindle pumps are typically pulley driven and pulley drives fail often, which obvi ously results in time consuming maintenance and replacement costs. A Goodwin submers ible has none of these inherent problems and will overshoot vertical spindle maintenance intervals by a long way,” Gomes says. “And if for any reason there is no slurry being pumped and this is not noticed immedi ately by an operator, a vertical spindle’s bear

ings will typically fail within minutes, while our submersibles will grant at least a few hours of safe running before any consequences are likely to occur. Goodwin Submersible Pumps Africa’s South African head office in Edenvale has an extensive workshop for supporting, repairing, and refurbishing its pump range. “We carry spares to enable us to support our installed base for at least four to six months, and that changes as our success grows. We also market the Goodwin Pumps brand across the whole of the African continent, so we tend to make special logistics provisions for customers in countries such a Senegal, Guinea, or Mali to make sure we can get support for the pumps they are using. “Within South Africa, we have got seven sales engineers that are strategically placed in key mining areas, and in Zambia we have a small workshop that carries spares, re placement units and service support staff. In September this year, we opened a similar workshop in Tema, Ghana, which is a port town just outside the capital, Accra. “We only established Goodwin Submersible Pumps Africa in 2016, so we have not really caught up with whole of the market. But we are waving the Goodwin flag to make sure everyone knows we are on their doorstep,” Gomes concludes. www.goodwininternationalpumps.com

Goodwin Submersible Pumps Africa’s South African head office in Edenvale has an extensive workshop for supporting, repairing, and refurbishing its pump range.

Goodwin Submersible Pumps Africa also has a rental fleet to meet the project and short-term needs of plants across Africa.

January-February 2024 • MechChem Africa ¦ 13

⎪ Water, wastewater and pumping solutions ⎪

Why use submersibles for fluid handling Ruaan Venter, Rental Development Manager at IPR outlines the benefits of submersible pumps when compared to vertical spindle pumps and presents a compelling argument for their widespread adoption across various sectors.

quieter operational experience. Their under water functioning naturally dampens sound and curtails vibrations, offering a noise-free solution,” he continues. Moreover, submers ible pumps are stalwarts when it comes to reliability, even in challenging environments. Their underwater operation shields them from many external factors, ensuring they last longer and operate with unwavering reliability, even when conditions turn hostile. But what if the fluid isn't clear water? Submersible pumps have got that covered too. They are adept at processing an array of fluids, even those riddled with abrasive solids. This versatility makes them an excellent choice for varied tasks, be it sewage or other wastewater pumping applications or dewatering in intri cate mining operations or sumps in buildings or other structures. Safety is paramount, and submersible pumps do not disappoint in this aspect either. Their positioning underwater diminishes risks linked with rotating parts and potential leaks, issues that are often more glaring with above ground pumps. In today's age, where environmental consciousness is key, submersible pumps rise to the occasion. Many can be customised to avert fluid leaks, ensuring they operate with minimal environmental impact, adhering to contemporary ecological regulations and sustainability goals. Lastly, their design boasts flexibility. Depending on the depth requirements, these pumps can be adapted, ensuring a fluid han dling system that aligns perfectly with specific operational demands. "The decision between submersible pumps and vertical spindle pumps really comes down to the unique demands of the application in question but, given the vast array of benefits submersibles bring to the table – from energy efficiency to environmental safety – they un deniably present a compelling argument for their widespread adoption across various sectors,” Venter concludes. IPR is the master distributor for the full range of Atlas Copco submersible dewatering pumps, as well as the Toyo range of heavy-duty slurry pumps. The company has an extensive reference base and offers its pumps for out right purchase or on a rental basis. Its skilled team can assess an individual application and propose the most appropriate solution that will ensure the lowest total operating cost for a customer. www.pumprental.co.za

Submersible pumps have long been a staple in the world of fluid handling and pumping.

S ubmersible pumps have long been a staple in the world of fluid handling and pumping, with their presence becoming more pronounced, espe cially in applications such as sump pumping, wastewater management and numerous industrial processes. Ruaan Venter, Rental Development Manager at IPR, says that while engineers have various solutions at their fingertips, submersible pumps often stand out, particularly when compared to vertical spindle pumps. So, what gives these submers ible devices their edge?

“First and foremost, submersible pumps are known for their superior energy effi ciency,” Venter says. “This elevated efficiency not only makes them outperform their verti cal spindle counterparts, but it also leads to significant cost savings in the long run.” Space is often at a premium in dewatering setups, and this is where submersible pumps have the upper hand. Their direct placement for fluid handling applications means there is no need for extended piping or additional external infrastructure. This innate compact ness becomes a boon, especially in locations where space is tight. Maintenance is also a recurring concern in any wastewater, mining or industrial envi ronments and Venter says that submersibles come out on top here as well. With fewer moving parts than vertical spindle pumps, which often require above-ground mechani cal setups, submersible pumps are less prone to wear. This reduced wear translates into more dependable performance, ensuring a smoother operational experience. Fluid handling is the core of any pump, and submersible pumps excel in this do main. Venter explains that due to their fully submerged operation, these pumps are es sentially immune to issues such as cavitation or airlocks, which sometimes plague vertical spindle pumps. This submerged state ensures a consistent and smooth pumping process, of fering significantly enhanced reliability. “But it is not just about efficiency and reliability. Submersible pumps also promise a

Space is often at a premium in dewatering setups, and this is where submersible pumps have the upper hand.

January-February 2024 • MechChem Africa ¦ 15