MechChem Africa January-February 2025

MechChem JAN-FEB 2025 AFRICA

Precision instruments for sma ter mining

This month: World-leading process machinery services

Pulp and paper industry progress

Water hammer analysis for piping

Local screen media supply expanded

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Minerals processing and materials handling 6 SRP expands and localises screen media supply

MCA visits the Johannesburg facilities of Sandvik Rock Processing and talks to Riaan Steinmann and Phumi Motsamai about the company’s expanding local operation, which offers local customers a more agile and resilient service. 9 Gearless mill drives and CO 2 emissions

10 CHIETA honours for collaboration, innovation and impact 11 Mobile drum dumper for use in hazardous locations PowerGen, PetroChem and sustainable energy management 12 Boiler water treatment to ensure effective heat transfer 15 Renewable energy for Lebalelo’s water infrastructure 16 Innovative financing models driving solar transition 17 Supercapacitors and containerised energy solutions Water, wastewater and pumping solutions 18 Water hammer analysis for complex piping systems

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: mechchemafrica@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: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors.

Chris Paterson and Ray Lund ofAssociated Energy Services (AES) present the case for paying more attention to boiler water. 14 Allmech celebrates 30 years

Ben Keyser from Applied Flow Technologies (AFT) talks about water hammer in complex piping systems and describes how AFT Impulse surge analysis software can be used to minimise its impact.

21 Custom solutions for unplanned mine dewatering 22 Godwin HL150 for open pit mine dewatering 23 KSB ready to support hydrogen economy Hydraulics, pneumatics and automation systems 24 ECO2 design prioritises ecology, economy

Through environmentally friendly manufacturing, SEW-EURODRIVE’s ECO2 drive unit designs are free of coatings and make responsible use of raw materials, while ensuring no compromise in their performance. 25 State-of-the-art geared motor assembly centre opens in Johannesburg 27 Transforming utilities with AI Maintenance solutions and asset management 28 Fluid technology and filtration services BMG’s Susan Victor talks about the importance of adopting effective filtration to ensure dependable performance, while Taylor Black highlights the key features of a bespoke BMG lubrication and filtration solution for a ball mill’s journal and pinion bearings.

Transparency You Can See Average circulation Apr to Jun 2024: 10 721 Printed by: Tandym Print, Cape Town

30 SEW-EURODRIVE to open new service and repair centre 31 WearCheck launches advanced thermography course Localisation, local manufacturing and food processing 32 Bühler: localising world class processing

Front cover: VEGA Instruments SA Contact: Miguel Petersen Tel: +27 11 795 3249

MCA takes a tour of the manufacturing facilities of Bühler Southern Africa in Honeydew, Johannesburg, and talks to the company’s MD, Marco Sutter. 34 ACTOM’s local MV-switchgear solution Innovative engineering 38 ABB showcases pulp and paper industry progress As part of its global Real Progress sustainability programme, ABB is launching a series of sustainability-focused white papers to give customers technology insights and perspectives into the processing industries.This article introduces the first of three papers covering the pulp and paper industry. Regulars 2 Peter’s comment: Coal and the path to sustainability 4 On the cover: Mining with precision: VEGA’s instruments deliver: How plant operators are using VEGA’s level, pressure and density instruments. 36 Products and industry news 40 Back page: SSAB enters fossil-free steel collaboration

Email: info.za@vega.com Website: www.vega.com

January-February 2025 • MechChem Africa ¦ 1

During December 2024, FutureCoal Limited, a global alliance for sustainable coal, published a Roadmap for a Sustainable Coal Value Chain, which highlights the role of modern coal technologies in delivering global cli mate goals while continuing to foster socio-economic growth. A combination of advanced coal technologies, the report argues, can reduce up to 99% of the emis sions associated with its use, including CO 2 emissions, while continuing to support the growth aspirations of developing and emerging economies. Key report findings include: • Emission reductions from high-efficiency low emissions (HELE) coal plants with carbon capture and storage (CCS) technologies could reduce emissions from power plants by up to 1 412 Mt of CO 2 per year, equivalent to removing 310-560-million SUVs from global roads. • Replacing lower efficiency coal plants with ultra-supercritical plants could inject over US$1.5-trillion into the global economy. In contrast, replacing these with alternative and renewable energy plants would cost an additional $2.7-trillion due to shortfalls in output. • Coal remains essential to key sectors, including steel (70% dependent), cement (90%), and alu minium (60%), while also producing cost-effective hydrogen and providing critical minerals such as copper, cobalt and nickel for renewable energy and battery storage systems. “This report challenges outdated views of coal, remind ing us that it is a versatile resource vital to modern life, industrial development and economic progress. Given the high-value of applications, strategic investments in advanced coal technologies ensures economic solu tions worldwide,” argues Paul Baruya, FutureCoal’s director of strategy and sustainability. The report underscores coal's positive impact on global communities, including job creation and provid ing essential resources for food security and infrastruc ture. It also calls for increased collaboration across the coal value chain to realise these opportunities through innovation and technology transformation. It challenges the notion of prematurely phasing out coal in favour of renewables alone. Instead, it explores how advanced technologies can be a linchpin in our journey towards a net-zero future. FutureCoal is underpinned by three Sustainable Coal Stewardship (SCS) principles that are founda tions for a suite of innovative sustainable business opportunities for the coal value chain. These commit FutureCoal members to advancing environmental and socioeconomic progress via initia tives that work in harmony to drive meaningful and responsible change. SCS has a strong focus on abated coal innova Coal and the path to sustainability

Peter Middleton

tion and technologies. This encompasses a range of responsible practices, including emissions controls, efficiency gains and adopting or upgrading to more advanced technologies. Three key components of SCS have been identified: pre-combustion; combustion and post combustion opportunities. Pre-combustion abatement opportunities are avail able to the upstream sector in the coal value chain and include efficient mining practices, digitalisation, waste management, renewable power, methane control, and management of surface subsidence, land disturbance and rehabilitation, among others. The range of efficient combustion technologies identified by FutureCoal include combined support for power and heat utilities to abate and capture up to 99% of emissions from power and heat generation plants. These include modern high-efficiency and low emissions (HELE) plants, such as ultra-super critical (USC); combined heat and power (CHP); electricity production from coal gasification and integrated gas ification in combined cycle (IGCC) plants; and co-firing boilers using combinations of coal and biomass. To best mitigate against emissions, these tech nologies must be combined with emission mitigation technologies such as flue gas desulphurisation (FGD), particulate matter control through electrostatic precipitators (ESP) and/or bag filters; low NOx sys tems; and carbon capture and storage (CCS) or carbon capture, utilisation and storage (CCUS) systems. Beyond the combustion opportunities for the coal value chain are novel business opportunities that transform coal into high-value products: Coal-to Liquids (CTL), synthetic liquid hydrocarbons, hydrogen, methanol, and agrichemicals, for example. Additionally, FutureCoal highlights that coal and coal waste form an ecosystem, offering secondary resources for valuable construction materials, such as the use of coal ash for fillers, cement, grouts and building blocks; and critical advanced coal-based minerals for the digitised future, such as graphene and carbon fibre. Rather than phasing out fossil fuels, which is a virtually impossible task for countries in the global South such as South Africa, FutureCoal advocates for a systematic phasing down of fossil fuel use. The report also highlights the potential effectiveness of upgrading existing coal assets on brownfield sites as a strategy for immediate CO 2 reduction, especially when compared to the replacement of these assets with greenfield renewable plants. While continuing to expand our fleet of cleaner and/ or renewable technologies and reducing coal use, we must also strive to optimise every aspect of the coal value chain, to immediately, steadily and permanently reduce CO 2 emissions. Both the planet and the lives of people all over the world are at stake.

MechChem Africa is endorsed by:

2 ¦ MechChem Africa • January-February 2025

Mining with precision: VEGA’s instruments deliver

This article highlights how VEGA’s range of precision level, pressure and density measurement instruments can help mine and minerals processing plant operators to deliver success in Africa’s tough operating environments. A frica is rich in mineral resourc es, positioning it as one of the world's largest mining hubs. Mining operations across the are engineered with resilience and accuracy as top priorities, and are designed to with stand harsh conditions. With comprehen sive solutions that improve measurement reliability, VEGA enhances operational efficiency and supports safety measures across mining processes, from ore extrac tion and stockpile management to flotation and tailings management. VEGA is there every step of the way.

for various level measurement applications, with the VEGAPULS 6X setting a benchmark in accurate and continuous level measure ment for the mining industry. The VEGAPULS 6X non-contact radar sensor functions as a versatile solution that integrates multiple radar technologies. It is capable of handling both liquid and solid level measurements, making it applicable in settings such as tank storage, crushers and separation plants. The instrument features enhanced radar performance, providing high accuracy and reliable readings, even in challenging conditions characterised by foam, steam and condensation. This capabil ity helps minimise interference from sur rounding structures, which is beneficial for detecting material build-up and preventing interruptions due to blockages or overflows. The extensive versatility and advanced radar capabilities of the VEGAPULS 6X facilitate effective performance, allowing users to reduce the reliance on multiple sen sors across mining operations, streamlining processes and increasing efficiency. Additionally, the device is designed for maintenance-free operation, which can lead to reduced downtime and lower associated costs. Its robust signal focus makes it suit able for a wide range of level measurement applications. Pressure, safety and control Mining operations require effective man agement of pressurised fluids and gases, making pressure measurement a critical aspect of ensuring safety and operational efficiency. VEGA offers pressure measure ment solutions, such as the VEGABAR and VEGADIF series, designed to provide precise and stable readings in extreme conditions, which can enhance control and reduce safety risks. For over 40 years, VEGA has been developing and producing smart pressure transmitters. The VEGABAR 80 series of pressure transmitters can measure gauge, Level precision in tough environments: VEGA sensors deliver reliable measurement data in all areas of metal extraction and production.

continent face a multitude of challenges, however, that complicate the processes of extraction, processing and management. Harsh environmental conditions, in cluding extreme heat, humidity, dust and corrosive atmospheres threaten the lon gevity of equipment and the accuracy of measurements. Many mines are situated in remote areas with limited access to main tenance resources and technical expertise, while breakdowns can grind operations to a standstill, resulting in millions of dollars of lost revenue. These challenges highlight the necessity for robust, reliable and low maintenance instrumentation capable of enduring tough conditions while delivering precise, real-time data. VEGA instruments

Level precision in tough environments

Level measurement is an essential compo nent in mining sector processes, encom passing material storage, slurry manage ment and wastewater treatment. Inaccurate level measurements can disrupt operational continuity and lead to issues such as mate rial overflows or shortages. VEGA is known for offering precise and reliable solutions

Measurement technology from VEGA can be found in all metal production processes from mining ore to steelmaking and blast furnaces, charging and storage applications.

By integrating these devices into a digital inventory management system, mines can implement a data-driven approach to process optimisation, supporting profitability and sustainability objectives.

4 ¦ MechChem Africa • January-February 2025

⎪ Cover story ⎪

Pressure, safety and control: VEGABAR 80 and VEGADIF 85 pressure sensors accurately monitor high-pressure processes, improving both operational control and safety.

the processing of ores and minerals, where maintaining the optimal slurry density is essential for effective separation and recovery. The SOLITRAC 31 provides a radiometric, non-contact solution for den sity measurement, making it particularly well-suited for mining operations where intrusive methods are not practical. Using gamma radiation, the SOLITRAC 31 detector delivers reliable density mea surements for slurry applications without direct contact with the medium. This non-intrusive approach makes the device suitable for use with abrasive materials for providing accurate, real-time data on slurry density—an essential factor for optimising separation processes and minimising losses. This density measurement instrument offers continuous measurement without the frequent need for shutting down for maintenance or recalibration. The SOLITRAC 31 offers several key advantages that make it an outstanding choice for a variety of applications. Its non-intrusive design ensures resilience in abrasive environments, contributing to its durability. In addition, the device delivers precise density readings without interrupt ing ongoing processes, facilitating smooth integration into operational workflows. Its construction also reduces wear, leading to lower maintenance requirements and less downtime, which ultimately enhances overall efficiency. Smarter mining The mining industry is moving towards digitalisation, and solutions such as the VEGA Inventory System are designed for integration into data-driven environments. This system enables operators to monitor devices remotely, providing critical data in sights that contribute to informed decision making and operational efficiency. Key advantages of the VEGA Inven tory System include its support for remote monitoring of assets, which allows users to

absolute or differential pressure reliably in all liquids, gases and viscous media. Spe cially designed ceramic CERTEC ® measuring cells and metallic measuring cells enable high-precision measurement. Additionally, VEGABAR’s diagnostic features support proactive maintenance and are commonly utilised for monitoring pressure in slurry lines, filtration systems and tailings dams. Their area of application ranges from -1 to 1 000 bar at process temperatures from -90 to +400 °C. VEGABAR 80 instruments provide sev eral advantages that make them suitable for various applications. They are resistant to both abrasion and chemical exposure, which contributes durability in challenging envi ronments. Advanced diagnostic capabilities offer insights for predictive maintenance, helping to identify potential issues ahead of time. The VEGABAR 80 enhances safety by delivering accurate and reliable pressure measurements, which support operational efficiency and safety. The VEGADIF 85 differential pressure transmitter is designed for precise control in applications such as flotation cells, where maintaining an optimal pressure differential is critical for process efficiency. Its compact design and robust construction make it ap propriate for use in abrasive environments, allowing for reliable readings that can assist in process optimisation and reduce downtime. Notable features of the VEGADIF 85 include its ability to provide accurate dif ferential pressure measurements under fluctuating conditions, which supports consistent performance. The compact and rugged design is well-suited for harsh en vironments where durability is important. Additionally, the VEGADIF 85 can enhance process control, potentially improving yield and efficiency across various applications.

oversee inventory from various locations. The system's capacity to facilitate proac tive adjustments based on real-time data ensures that necessary changes can be implemented promptly. Additionally, the insights gained from this data-driven ap proach contribute to enhanced safety and efficiency, optimising overall performance. Production optimisation The African mining industry encounters a range of operational challenges, includ ing remote locations and demanding environmental conditions, as well as a requirement for sustainable practices. VEGA’s instrumentation solutions aim to address these challenges by offering pre cise, reliable and low-maintenance options for level, pressure, and density measure ment. Instruments such as the VEGAPULS

series, VEGABAR, VEGADIF, and SOLITRAC 31 facilitate production optimisation with reduced downtime and enhanced safety in mining operations. By integrating these devices, mines can imple ment a data-driven approach to process optimisation, sup porting profitability and sus tainability objectives. As min ing companies in Africa adapt to shifting market demands and regulatory frameworks, the adoption of VEGA’s tech nology may provide a basis for improved operational resilience and growth. www.vega.com/en-za

Density and slurries: VEGA’s SOLITRAC 31 can monitor slurry density non-intrusively, achieving better recovery rates and reducing maintenance requirements.

Density and slurries Density measurement plays a key role in

January-February 2025 • MechChem Africa ¦ 5

Sandvik Rock Processing expands and localises screen media supply MCA visits the Johannesburg facilities of Sandvik Rock Processing and talks to Riaan Steinmann and Phumi Motsamai about the company’s expanding local operation, which offers local customers a more agile and resilient service.

H aving acquired Kwatani vibrating screens and SP Mining’s screens and train loader businesses from Schenck in recent years, Sandvik Rock Processing has now integrated all these operations into its global structure. In terms of vibrating screens and screening media, the Kempton Park facility focuses on the fabrication of screen assemblies, while the company’s Crown Mines facility is han dling the manufacture of an ever expanding range of screening media. “Here at our Crown Mine facility, we manufacture for Europe, the Middle East and Africa, with local production of our screen panels supporting these markets. We use polyurethane and rubber for our screen ing media, with customised formulations and special designs to address screening challenges. We also produce wedge wire for dewatering screens,” says Riaan Steinmann, operation director for Screening Solutions for the EMEA region. “At our Crown Mines facility, we pro duce screen media panels for use in both new vibrating screens and for aftermarket applications across Africa,” adds Phumi Motsamai, Sandvik Rock Processing’s re gional manager for Screening Media and Wear Protection. In terms of a manufacturing strategy, Sandvik Rock Processing is aiming to reduce

transportation costs, improve screening efficiency, and so support sustainability for customers. This is all part of a strategic focus to be number one in screening, and to provide a world-class customer experi ence by bringing the company’s globally renowned product offerings closer to local customers. In support of this strategy, the local screen media manufacturing capacity from the Crown Mines facility in Johannesburg is being systematically expanded. “Investment in this facility builds on our screen media product offering and supports the local manufacture of our capital equipment, while ensuring we meet expanding aftermarket demand,” continues Motsamai. “Local manufacturing of screen media is a very exciting story for Sandvik Rock Processing, in that we don't just manufac ture for South Africa or for our own vibrat ing screens. We can design, customise and manufacture for the whole of Africa,” she says. “We supply into all the mining hubs of Africa, and our locally made panels are being shipped to Europe, the Middle East, as well as to India,” she says. “Before our recent acquisitions, Sandvik screen media was manufactured in Europe. We have now raised our local manufacturing capability and capacity to meet demand across the

African market, which is a fast growing market right now,” Motsamai explains. Hence the decision to invest, consolidate and expand manufacturing here in Africa: a truly exciting story for South African manufacturing! “Screen media panels are consumables, and the aftermarket is the fastest growing sector of our business, so we have spe cifically focused our efforts on being able to custom design media panels for any screen ing application,” Steinmann adds. This customisation capability has been achieved through investments, in the tool ing library and processing capability of Sandvik Rock Processing’s Crown Mines manufacturing plant. “Polyurethane (PU) is at the core of our offering, but we also offer specialty Sandvik Rock Processing rubber compound panels, specifically formulated to optimise screening performance and enhance resistance to impact and wear abrasiveness.” On the quality side, Motsamai assures that Sandvik Rock Processing’s locally manufactured screen media products are

Sandvik Rock Processing’s screen media manufacturing facility exemplifies the company’s dedication to producing reliable solutions for the mining and aggregate industries.

6 ¦ MechChem Africa • January-February 2025

⎪ Minerals processing and materials handling ⎪

Sandvik Rock Processing’s facility is a benchmark for precision and quality in screen media manufacturing.

aligned with Sandvik’s global standards with respect to raw material procurement. “Our screen media is a high-quality prod uct designed and manufactured to meet our customers´ demanding applications requirements. Being an important part of all vibrating equipment, our screen media panels are designed to achieve optimised screening results, maximum production performance and lowest possible total cost of ownership,” she assures. “As an OEM of both vibrating screens and screen media, we understand screen dynamics and the challenges experienced on mine sites. Without fit-for-purpose screen media, vibrating screens cannot function properly. The aperture size, shape and ri gidity/flexibility of each panel then plays a vital part in achieving optimal screening and preventing issues such as pegging, which will rapidly reduce screening efficiency,” she explains. Only once the media and the vibra tion parameters are properly matched can the full screening performance be realised,” argues Motsamai. Local supply, she continues, offers benefits such as shorter lead times, lower transportation costs and better collabora tion with local suppliers. “By increasing our local supply offering, Sandvik Rock Processing is supporting the local economy while reducing environmental impact due to shorter transportation routes. Localisation also overcomes the emerging risks of sup ply chain disruptions, longer lead times and increase transportation costs for imported screen media,” she adds. “Innovation is the cornerstone of our company,” says Steinmann. “Our R&D drives the development of the solutions we offer and our global team of R&D engineers are working on several projects which are in various stages of completion, which will be launched in due course,” he concludes. www.rockprocessing.sandvik

Sandvik Rock Processing’s screen media production is backed by rigorous quality control and innovative engineering, ensuring optimal performance in the field.

Every screen media product from Sandvik Rock Processing’s local manufacturing facility reflects the company’s commitment to superior craftsmanship and operational efficiency.

Sandvik Rock Processing’s screen media is designed and manufactured to meet customers´ applications requirements

January-February 2025 • MechChem Africa ¦ 7

Reliable measuring results for extreme process conditions

Whether level, limit level, density, interface or mass flow: Radiation-based process instrumentation delivers precise measuring results in industrial production and handling processes, and that even under the most di cult operating conditions. Flexibility through detector variety: You can choose between dierent types of detectors. Detector can thus be optimized for widely dierent applications becoming the specialist for your particular measuring task.

Advantages ▪ Simple mounting and operation ▪ Maintenance-free operation ▪ Easy adjustment ▪ Self-monitoring and diagnosis ▪ Developed acc. to IEC 61508 ▪ Compact device with integrated inputs for temperature or belt speed

Electronics ▪ 4 … 20 mA/HART ▪ Profibus PA ▪ Foundation Fieldbus

High sensitivity NaI scintillator for density applications

Display and adjustment module ▪ PLICSCOM ▪ VEGACONNECT and DTM ▪ VEGA Tools app Housings ▪ Aluminium double chamber ▪ Stainless steel double chamber

PVT scintillator up to 3 m length

Flexible plastic scintillator up to 7 m length

www.vega.com

⎪ Minerals processing and materials handling ⎪

Gearless mill drives and CO 2 emissions

Martin van Zyl of ABB argues the case for switching to Gearless mill drives (GMDs) to simultaneously maximise productivity while still achieving efficiency and sustainability objectives.

processing plants. ABB’s latest white paper investigates how such issues are impacting the copper industry. Copper is vital for the energy transition and demand is predicted to double by 2050. Yet today, roughly only 0.5% of ore can be converted to copper, down from historical levels of 1%. To main tain the same levels of copper production, modern mines must process double the quantity of ore. However, increasing mining outputs without supporting sustainability initiatives could contribute more emissions than copper can negate. One way to help produce more critical minerals such as copper while also mini mising the environmental impact of mining operations is through the use of GMDs. GMDs have proven their value across industries for more than 50 years and have

demonstrated the potential to deliver a more environmentally friendly, efficient, and reliable grinding operation than would be possible with alternative technologies. GMDs are the system of choice for

mines looking to a more efficient and productive future. As GMDs have fewer mechanical parts, they have been found to be more energy efficient, more reliable and easier to maintain. These char acteristics mean it is less energy intensive while having more uptime, de

A chieving energy efficiency sav ings is highly important to the future of the mining industry. Humanity’s demand for critical minerals is growing thanks to the twin drivers of increasing digitalisation and the energy transition. Meanwhile, ore quality is declining, requiring more ore to be mined to produce the same amount of metal. This challenge is further compounded by grow ing pressure to reduce the environmental impact of mining. Addressing all challenges simultaneously is a challenge of enormous proportions. ABB has released an in-depth white paper detailing the vital role that gearless grinding technologies can play in driving productivity in mining while simultaneously reducing their carbon footprint. One of the key findings in the report, based upon exten sive testing of ABB’s current installed base of gearless mill drives (GMDs), is the high level of efficiency they provide. GMDs can be up to 3.6% more en ergy efficient than ring-geared mill drives (RMDs), reducing energy consumption and operational costs of the mine. This level of efficiency across ABB’s GMD installed base equates to 195 kt of CO 2 , the equivalent of 89 000 cars taken off the road. Even a conservative 2% of increased efficiency equates to 106 kt of CO 2 saved, or 49 000 cars taken off the road. Grinding operations at mines around the world are undergoing a transforma tion. Multiple marketplace pressures are driving mining owners to deploy technol ogy solutions that minimise energy use and maximise productivity while achieving sustainability objectives. Going gearless can meet mining business objectives by exceeding standard availabil ity targets in grinding operations. ABB’s GMD is the most powerful mill drive system on the market to power semi-autogenous (SAG), ball, and autogenous (AG) mills. This workhorse for grinding operations combines a robust, service-friendly, and fit-for-purpose design to provide highest throughput, reliability, and availability for

The full interactive White Paper can be accessed by scanning the QR code.

livering the twin benefits of a reduced car bon footprint and increased productivity. https://new.abb.com

An ABB GMD control room at a mining site.

Gearless Mill Drives (GMDs), GMDs can be up to 3.6% more energy efficient than Ring-Geared Mill Drives (RMDs), reducing energy consumption and operational costs.

January-February 2025 • MechChem Africa ¦ 9

CHIETA honours leaders driving collaboration, innovation and impact

The Chemical Industries Education and Training Authority (CHIETA) Chemical Industries Awards celebrated exceptional contributions from SA’s chemical companies to skills development, collaboration and innovation, while highlighting the industry’s efforts to drive impactful change.

workforce skills with cutting-edge digital training platforms.

In addition, two CEO Special Awards were given to: • PG Group (Glass Sector): Recognised for pioneering digital skills training and innovation in the chemical industry. • Afrox (Base Chemicals Sector): Honoured for its leadership in work force innovation and collaboration. The 2024 CHIETA Chemical Industries Awards underline CHIETA’s dedication to advancing collaboration and innovation as pillars of growth and competitiveness in South Africa’s chemical industries. CHIETA CEO, Yershen Pillay, highlighted this com mitment: “These awards celebrate the inno vative spirit and collaborative efforts of our industry partners. By working together and driving impactful solutions, we are shaping a sustainable and resilient future for South Africa’s chemical industry.” The evening concluded with a high energy performance by DJ Small Deep, group celebrations, and reflections on how the chemical industry can continue to in novate for impact. https://chieta.org.za

At the CHIETA Awards ceremony are, from left: CHIETA CEO, Yershen Pillay, CHIETA board chair, Wezi Khoza and CFO, Ncikazi Kabi.

H eld at the Venue at the Houghton Hotel in Johannesburg last year, the CHIETA Chemical Industries Awards brought together key stakeholders, industry leaders and innova tors committed to reshaping South Africa’s chemical industry through forward-thinking partnerships and innovative solutions. With renowned Programme Director, Lesly Musina, guiding the evening, the ceremony featured dynamic video show cases, top-tier musical performances by the Soulnote Band, and the recognition of those companies leading the way in industry innovation and impactful collaboration. Top levy payers recognised as pioneers in the chemical industry included: • Sasol South Africa Ltd (Petroleum Sector): Honoured for spearheading green hydrogen skills training initia tives, and setting a new standard for clean energy innovation. • Unilever South Africa (FMCG Sector): Celebrated for empowering women in STEM through scholarships and targeted training programmes. • Ardagh Glass Packaging (Glass Sector): Recognised for its sustainability-fo cused skills development programmes, advancing eco-conscious practices. • AECI Ltd (Specialty Chemicals Sector): Acknowledged for closing skills gaps

through innovative apprenticeship models in chemical manufacturing. • Adcock Ingram: Awarded for compre hensive skills development initiatives, and increasing access to artisan and technical training for underprivileged communities. • African Explosives Limited (AEL): Honoured for its trailblazing safety training modules, setting a new bench mark in workplace safety education. • Kansai Plascon: Acknowledged for mentorship programmes fostering di versity and inclusion in the workforce. NECSA (South African Nuclear Energy Corporation): Recognised for excel lence in nuclear-specific training and impactful youth development initiatives. • Omnia Group: Honoured for its invest ment in advanced agricultural chemical skills programmes, promoting sustain able food security solutions. Recognised medium and small enterprises (SMEs) in the chemical sector included: • Creighton Products CC (FMCG Sector): Acknowledged for fostering entrepre neurial growth and supporting small scale producers through collaborative efforts. • Buckman Laboratories Pty Ltd (FMCG Sector): Celebrated for advancing •

Afrox’s Sebastian Sachtleben (right) receives the most innovative CEO award from CHIETA CEO, Yershen Pillay.

NECSA (South African Nuclear Energy Corporation) was recognised for excellence in nuclear-specific training and impactful youth development initiatives.

10 ¦ MechChem Africa • January-February 2025

⎪ Minerals processing and materials handling ⎪

Mobile drum dumper for use in hazardous locations Flexicon has launched a sealed Mobile Drum Dumper for dust-free volumetric feeding that is ideally suited for use in hazardous locations.

Flexicon’s TIP-TITE ® Mobile Drum Dumper allows dust-free volumetric feeding of bulk material from drums into downstream processes with minimal operator intervention.

F lexicon’s TIP-TITE ® Mobile Drum Dumper with integral flexible screw conveyor is designed for use in hazardous locations. It allows dust-free volumetric feeding of bulk mate rial from drums into downstream processes with minimal operator intervention. The system is mounted on a mobile frame with quick-action floor jacks for stable operation anywhere in the plant. The hydraulic power unit used to lift, seal and tip the drums is activated pneumatically, eliminating the risk of potential sparks from electrical or other equipment that might otherwise be used to actuate the hydraulics. As an additional safeguard, the controls for the flexible screw conveyor are mounted on extended support brackets, placing them outside the hazardous zone.

the screw and the tube wall to eliminate or minimise grinding. The drive motor is located beyond the point at which the mate rial exits the conveyor, preventing contact with bearings or seals. It can be rolled into storage when not in use, or to a designated area for cleaning during material changeovers. The system is available constructed of carbon steel with durable industrial finishes, with material contact surfaces of stainless steel, or in all-stainless steel finished to food, dairy or pharmaceutical standards. A broad range of screws with specialised geometries is available to handle free- and non-free-flowing materials, including prod ucts that pack, cake or smear in other types of conveyors. www.flexicon.com

The unit accommodates drums from 115 to 200 , measuring 91 to 122 cm in height. After the drum is placed in the lifting carriage, the carriage is raised against a rubber gasket mounted inside the discharge cone, creating a dust tight seal. The entire apparatus is then tipped, with a motion-dampening feature stopping the process when the pre-determined dump angle is reached. The material exits the discharge cone and into the charging adapter of the flex ible screw conveyor. Fully enclosed inside polymer or steel tubing, the inner screw of the conveyor is the only moving part contacting material, resulting in reduced maintenance and increased reliability. As the screw rotates, it self-centres within the tube, providing ample clearance between

January-February 2025 • MechChem Africa ¦ 11

Boiler water treatment to ensure effective heat transfer Poor boiler water treatment is the primary cause of poor boiler performance. Chris Paterson, MD of Associated Energy Services (AES), and operations director, Ray Lund present the case for paying more attention. N ot all water is created equal and there is a lot more to water treatment than ensuring that it appears clean, says Chris going into a boiler has two direct impacts: the first on the life of the boiler and the second on its heat transfer capacity and efficiency, which both affect overall energy plant management.

properties. Hardness levels – how much calcium and magnesium is in the water – and total dissolved solids (TDS) need to be considered. When using borehole water, the iron and silica content need to be checked. Furthermore, boiler water should be thor oughly tested over time to see what is in it and to check the variability of the various contaminants, so that one can design and install appropriate treatment equipment and technology,” Paterson advises. According to Lund, the quality of water

Paterson, managing director of special ist operations and maintenance service provider to the steam and boiler sector, Associated Energy Services (AES). Yet, this is where many companies are tempted to cut costs. Because correctly treated boiler water is integral to preventative maintenance and essential to ensuring boiler safety, effective operation and energy efficiency, this is one of the first and most critical issues that AES addresses when taking over the operations and maintenance of a client’s boilers and energy plant. Poor infrastructure has reduced mu nicipal water quality, while the increased cost of municipal water has persuaded many companies to switch to alternative sources, such as borehole water and stored rainwater. This is creating a whole new set of challenges, says AES Operations Director Ray Lund. “Each of these streams has different

Corrosive water damages internal boiler surfaces, Lund explains: “It can cause pitting of the surface material. This often results in boilers either having to be downgraded to operate at lower pressures because the material has been compromised, and the boiler may eventually have to be scrapped.”

Plants with very high TDS levels might require the installation of a reverse osmosis (RO) plant, which can be a very effective energy-saver, as it requires fewer blow-downs of the boiler to clean it out.

Correctly treated boiler water is integral to preventative maintenance and essential to ensuring boiler safety, effective operation and energy efficiency.

12 ¦ MechChem Africa • January-February 2025

⎪ PowerGen,PetroChem and Sustainable energy management ⎪

Using the analogy of a domestic kettle, Lund explains that compounds such as calcium and magnesium form a hard scale that ad heres to surfaces. This limits the transfer of heat from the fire side of the boiler to the water side, making the boiler inefficient when it comes to the production of steam. This does not happen immediately, how ever, Paterson warns: “Poor water treat ment damages boilers over long periods. Water does not go off specification in one day. Therefore, water treatment needs to be done correctly and consistently, every single day. Unfortunately, this is what many manu facturing and processing facilities miss.” Lund notes that the relationship be tween on-site boiler operators and water treatment companies forms a strong foundation for a watertight boiler water treatment strategy: “We partner with water treatment companies to train boiler operators in the importance and practice of testing feedwater daily. If any elements are out of specification, they raise that with the regional AES team, and we escalate this to our water treatment partners.” At the beginning of the boiler water treatment process, solids are removed via different forms of filtration. Plants with very high TDS levels might require the installa tion of a reverse osmosis (RO) plant, which

age when reaching a pipe bend. “This foaming also disrupts the measure ment of water levels to the point where, despite indications that these are correct, there may be very little to no water in a boiler, causing it to overheat or even to explode,” he explains. According to Lund, when scale has built up to the point where the equipment is at risk and efficiencies are compromised, clients have two options: using an on-line descalant; or a difficult and expensive off line acid wash, to ‘pickles the boiler’. In this case, in addition to lost production time, it can take up to four days to acid wash a boiler. The cost of the chemicals, as well as neutralising and disposing of the result ing acid effluent can have a very negative financial impact. Boilers requiring repairs after this acid wash process will further add to the overall cost. “Years of poor boiler water treatment can really add up, with negative operational and financial consequences. With this in mind – and aligned with our performance guarantee to clients – we do as much as we can to ensure that clients are aware of water quality concerns and the related risks, al lowing for timeous preventative action to be taken when required,” Paterson concludes. https://www.aes-africa.com

can be a very effective energy-saver, as it requires fewer blow-downs of the boiler to clean it out. “Typically with municipal water supply, the TDS is low, so we proceed directly to a softener. However, there are some areas in the country where the water is very hard. We look at various technologies to identify the most cost-effective way in which to manage that over the long term,” says Lund. PH control is always critical, and must remain within the right parameters to fa cilitate the formation of a protective layer to protect the internal surfaces of the boiler. Lund adds that oxygenates should also not be overlooked: “It is important to re move as much oxygen as possible before water goes into a boiler to prevent the oxygen causing pitting corrosion, especially when boilers have economisers, as there will be oxygen left in the water that will cause pitting and increase the risk of equipment failures.” Another consequence of poor water treatment is foaming. This results in liquids, instead of hot gas, being carried from the boiler into the steam piping network and flowing through the system. This can cause a condition known as ‘water hammer’. Pockets of water travel at the same velocity as the heated gas, potentially causing severe dam

January-February 2025 • MechChem Africa ¦ 13

Allmech celebrates 30 years Established as a closed corporation in 1995, Allmech has grown into a leading South African manufacturer of boilers, and supplier of water treatment components.

W hile 2024 has brought its share of challenges, Allmech MD Lionel Maasdorp says it’s been a good year overall and the company is positioned well for 2025, which will mark 30 years in the business. “With the 2024 national election came hope for change, and change did happen,” he says. “It hasn’t been in all places as expected, but for us the best is the fact that we have not had loadshedding. Maasdorp says one of the focuses for 2024 was to expand into new indus tries and sales representative, Lynette Morrey, who headed up this initiative made significant progress, exceeding expectations in growing the client base. “We also had several firsts as a business, including importing new Runxin valves,” he says. As the only authorised South African agent for Runxin valves, Allmech was invited to visit the global Wenzhou Runxin Manufacturing Machine Co, headquartered in China, to expe rience the latest technological developments

and decide which new products to bring to the local market. They have since begun to stock an automatic pool filtration valve, an irrigation valve with rain sensor, and a leak detection shutoff valve. “Material shortages for manufacturing of some of the valves have delayed our imports from China by as much as five months, but we’ve been able to expand our client base in the water treatment division. Certain new industries have found some of our unique Runxin vales a great addition to their product offering, such as pool shops and pump supply companies.” Allmech has also managed to increase awareness of its range in areas including Namibia, the Western Cape, Free State and Mpumalanga, where previously its main focus was in Gauteng and KZN. “Our Runxin range now covers over 150 products,” says Maasdorp. This includes: • Water softener valves: to remove water hardness. • Filter control valves: for managing the flow

and filtration. • Electronic ceramic 2-way and 3-way ball valves for precise and complex flow control. • Electronic and manual ceramic ball valves. • Runxin repair and maintenance spares. • Irrigation valves for controlling flow to dif ferent zones of irrigation systems. • Leak detection valves. • Disk filters for removing impurities. • Domestic reverse osmosis (RO) systems for home use. Maasdorp says that as the company prepares to celebrate its 30 th anniversary, Allmech is embark ing on an expansion plan for 2025, which includes stocking an even wider range of the Runxin valves. “Who knows – it might even end up with us secur ingnewpremisestoaccommodateallofusandthe stock under one roof!” he says. www.allmech.co.za

14 ¦ MechChem Africa • January-February 2025

⎪ PowerGen,PetroChem and Sustainable energy management ⎪

Renewable energy for Lebalelo’s transformative water infrastructure

SPS’ solar photovoltaic (PV) and Battery Energy Storage System (BESS) solution will provide power to key infrastructure for the first stage of a vital water infrastructure development programme in Limpopo, known as the Olifants Management Model Programme (OMMP). T he OMMP, being implemented by the Lebalelo Water User Association (LWUA), is a public-private collabora tion between institutional members of

As part of the contract for Phase 2B & 2B+ of the OMMP, SPS will employ leading-edge solar and battery

Government;andcommercialmembersinthepri vatesector,includingminingcompaniesandindus trial users. The programme involves constructing 200kmofbulkrawwaterpipelinesand675kmof potable water pipelines, along with several pump stations, reservoirs and water treatment works. Rolled out in phases, the programme fast-tracks bulk raw and potable water supply infrastructure for communities and commercial users, including mines and industrial users, in Sekhukhune and Mogalakwena. It also optimises existing infrastruc ture and water supply of the De Hoop and Flag Boshielo Dams in the Middle Olifants catchment, and enhances water supply to the Polokwane Local Municipality, which currently faces a 30 M / day water shortfall. Renewable energy-powered water supply As part of the contract for Phase 2B & 2B+ of the OMMP, SPS will employ leading-edge solar and battery technologies to power key infrastructure for a duration of 25 years. These two phases of the OMMP programme includes a new pipeline that will transport bulk raw water from the Flag Boshielo Dam to reservoirs acrosstheNorthernLimboftheBushveldIgneous Complex. From there, 40% of the water will supply mines, and 60% will be treated at water treatment plants in Mokopane and Sekuruwe to provide potable water to 140 000 community members to addressing Mokopane’s water shortfall. The solar energy capacity will start at 16 MWp for phase one, increasing over two further phases over the next 10 years to 23 MWp in the final phase. In addition, a BESS with a capacity of 13.3 MWh will ensure a reli able and sustainable power supply for the three pump stations under construction, each to be equippedwithtwo3.5MWpumps.Therenewable energy system (RES) will provide all operational and auxiliary power to the three pump stations, as their current locations prevent connection to the utility grid. Phase 2B and 2B+, which includes the RES and the construction of the bulk raw water pipelines, pump stations, reservoirs and two water treat ment works in the Northern Limb, is expected

technologies to power key

infrastructure for a duration of 25 years.

to be completed within 28 months following the final contracting. Valued at R800-million in its initial invest ment, SPS’ contract is an integral part of the largerOMMP,whichisoptimisingandaccelerating the completion of the Government-conceived Olifants River Water Resources Development Project (ORWRDP) and expanding its scope to include potable water infrastructure. LWUA, with more than two decades of experience, already serves communities in Sekhukhune through its bulk raw water supply to the Department of Water and Sanitation’s (DWS) infrastructure, and commercial users, including platinum and chrome mining operations. The steady water supply provided by the OMMP will be crucial for current and future mining processes in the areas tobeserved,improvingbothproductionefficiency, operational reliability and expansion possibilities, while contributing to local economic growth. Says Bertus Bierman, CEO of Lebalelo Water User Association: “SPS emerged as the successful bidder in a competitive tender process, showcas ing their extensive expertise, flexibility and ability to tailor funding solutions. Their innovative ap proach to integrating renewable technologies and sustainable practices positions them uniquely to meet the energy needs of the Association’s expan sion into the Northern Limb through the OMMP.” “This project is an exciting pivot for SPS,” says Paul Rosenbrock, Business Developer at SPS. “We are leveraging our renewable energy expertise to make a tangible difference in communities that need it most. By supplying a renewable energy solution that will pump bulk raw water into areas currently lacking access, we are not only support

ingtheminingsectorbutfundamentallyimproving the quality of life for thousands of people.” TheRESwillalsohaveaprofoundenvironmen tal impact, reducing over 13 million kilograms of carbonemissionsannuallybyeliminatingtheneed for diesel generators. Social and economic development Inaccordancewithtenderrequirements,1%ofthe project value will be allocated to socio-economic development (SED) initiatives. This will ensure that local communities benefit directly from the investment through potable water, enterprise development, education and connectivity. A key SED initiative that forms part of the OMMP is the School Upgrade Programme, which provides essential infrastructure to schools across Limpopo to foster educational advancement. Beyond water security, the programme will fuel industrial development and regional growth in Sekhukhune, Mogalakwena and Polokwane. The impact is far reaching as the full OMMP is expected to create around 42 000 jobs, direct, indirect and induced, thus bolstering the local economy. “Winning this contract is a testament to our team's commitment,” says Anja Visagie, Head of Project Development at SPS. “SPS is not just enhancing water security but we’re also contrib uting long-term economic growth, job creation and community empowerment. “Furthermore, this kind of renewable energy solution can be replicated for other industries that don’t have access to the grid, offering reliable power at competitive rates compared to utility connec tions,” she concludes. https://sps.africa

January-February 2025 • MechChem Africa ¦ 15