MechChem Africa July 2019

Mech Chem JULY 2019 AFRICA

This month: Gypsum reprocessing for a cleaner environment

Gravity concentration and SA’s spiral specialist

Artificial intelligence in industrial manufacturing

Digitalisation: unlocks door to predictive maintenance

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Power transmission, bearings, bushes and seals 8 Digitalisation: unlocking the door to predictive maintenance

P U B L I C A T I O N S CR O WN

“Digitalisation is progressing apace but putting it into practice requires a different way of working,” says Mattias Årstadius of SKF. Here, he outlines how bearing specialist SKF applies the technology to reduce downtime and improve machine performance. 11 Geared drives for applications from sewage to power 12 Using quality motors and gearboxes optimises screen economy 13 Multi-level E-house from Shaw Controls for oil & gas sector Hydraulic and pneumatic systems 14 Hytec Engineering invests in efficiency. Bosch Rexroth South Africa Group of Companies continues to invest in its production facilities, with Hytec Engineering the latest Group company to have optimised its manufacturing and repair operations.

Published monthly by Crown Publications cc 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 Assistant editor: Phila Mzamo e-mail: philam@crown.co.za Advertising: Brenda Karathanasis e-mail: brendak@crown.co.za Design: Darryl James 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. P U B L I C A T I O N S CR O WN P U B L I C A T I O N S CR O WN 2015/02/10 01:17:09PM

2015CROWN LOGO february.indd 1

16 Class 0 oil-free versus technically oil-free air 17 Digital solutions showcased at Automation Expo Automation, process control, instrumentation and CAE 18 Artificial intelligence in industrial manufacturing

Evert Janse van Vuuren from Omron Industrial Automation in Johannesburg, South Africa, talks about the implementation of artificial intelligence (AI) on production lines and unpacks the advantages of and the differences between cloud and edge computing. 20 Altair releases HyperWorks 2019 21 Start planning the i4.0 transition today 22 The future of automation with MOVI-C® system 23 MS2N Servo Motor breaks boundaries in the electric drives industry

Minerals processing and materials 24 Gravity concentration and SA’s spiral specialist.

MechChemAfrica visits the South African manufacturing facilities of Multotec’s Gravity Separation division and talks to the unit’s general manager, Wynand Erasmus, about spiral technology and the company’s latest product enhancements.

27 Solid support for mining entrepreneurs 28 Kwatani recognised for local manufacture 29 Bottom line benefits from composite mill liners Innovative engineering 32 Gypsum reprocessing for a cleaner environment.

Transparency You Can See Average circulation January-March 2019: 5 168 Printed by: Tandym Print, Cape Town

Since the late 1970s, OMV (Pty) Ltd has been reprocessing a waste gypsum dump created by a phosphate fertiliser plant in Potchefstroom. MechChem Africa visits this now modernised plant and talks to OMV mechanical engineer, Marinus van den Berg and the company’s MD, Oscar Goudriaan. Regulars 2 Peter’s comment: Ramaphosa’s Vision 2030 4 On the cover: The best-fit approach to compressed air Atlas Copco’s Wayne Jacobs and JC Lombard talk about the company’s fit-for-purpose air solutions. 6 SAIChE IChemE News: A love of research as the springboard for teaching MechChem Africa profiles current SAIChE IChemE president, David Lokhat. 30 Product and industry news 36 Back page: Ultra-heavy-duty bulk bag filler with integral conveyor

Front cover: Atlas Copco Contact: Wayne Jacobs wayne.jacobs@atlascopco.com +27 11 821 9891 www.atlascopco.co.za

Publisher of the Year 2018 (Trade Publications)

July 2019 • MechChem Africa ¦ 1

Ramaphosa’s Vision 2030 and transformation

I n the conclusion of his state-of-the-nation ad- dress, Cyril Ramaphosa presents a wonderful image of what he hopes SouthAfrica canbecome: a countrywherebullet trains pass through Johan- nesburg as they travel from Cape Town to Musina; a high-techeconomywhere advances ine-health, robot- ics and remotemedicine are applied throughNational Health Insurance; and a SouthAfrica that doesn’t sim- ply export its rawmaterials but is amanufacturing hub for key components used in electronics, automobiles and computers. “Wemust be a country that can feed itself and that harnesses the latest advances in smart agriculture. I dream of a South Africa where the first entirely new city built in the democratic era rises, with skyscrapers, schools, universities, hospitals and factories,” he said, before asking: “Has the time not arrived for us to be bold and reach beyond ourselves and do what may seem impossible?” He finished his talk by reading a piece by Nigerian poet and novelist Ben Okri. “ … You can’t remake the world without remaking yourself. Each new era begins within. It is an inward event with unsuspected pos- sibilities for inner liberation … ” reads one short piece of Okri’s poem. Transformation is a powerful word that has come to be a divisive one in our country, particularly when accompanied by the words ‘radical and ‘economic’. The phrase ‘radical economic transformation’ was not used by Ramaphosa. The word ‘radical’ was not used at all, while ‘economic’ appeared 21 times peppered throughout the speech. Heused theword ‘transforma- tion’ three times andonly once coupledwith economic transformation. Conceptually, transformation is about ‘becoming something brand new’, which should be a wonderful notion for everyone. Unfortunately however, all over theworld, we are stubbornly trapped into intransigent positions, whichwe defend to the hilt.We are not only resistant to transformation, we are terrified of it, un- less it directly relates to our narrow interests. This makes it easy for reactionaries to garner sup- port around single issue soundbites such as radical economic transformation; land expropriationwithout compensation; black economic empowerment; Brexit in the UK; and Donald Trump’s ‘crooked Hilary’ and ‘fake news’ catch phrases. The end result is a world of divided nationswith different vested interests pulling in different directions, or worse, simply disrupting any real progress. We find ourselves increasingly

suspicious of the other side and lacking in the will to even try to engage on issues with any positive intent. Exacerbating the lack of trust is blatant graft and corruption, which becomes impossible to root out due to the widespread practice by those in power of awarding jobs and other advantages to their compro- mised or unqualified friends, family or like-minded faction members. I am amazed at how acceptable it is for Donald Trump’s unelected family members to be granted such powerful positions in one of the most democratic countries in the world. Several phrases inCyril Ramaphosa’s SONAspeech suggest he fully understands how these issues are holding South Africa back. “We are committed to building an ethical state in which there is no place for corruption, patronage, rent-seeking andplundering of public money. We want a corps of skilled and profes- sional public servants of the highest moral standards – and dedicated to the public good…” he said, adding “But there is still much more work to do.” Indeed! “If we are to achieve the South Africa we want, we need a new social compact,” said Ramaphosa. This is an amazingly old theory of philosophy that goes back to 18 th century Europe and the Age of Enlightenment. The social compact questions the legitimacy of state authority over the individual and asks why a rational individual would voluntarily consent to give up his or her natural freedom to obtain the benefits of political order. “We need to forge durable partnerships between government, business, labour, communities and civil society,” and “this places a responsibility on each of us and all of us,” and “Government must create an enablingenvironment, usepublic resourceswiselyand invest in developing the country’s human potential,” are some of the sentences Ramaphosa used to explain what he meant. In summary, hepointedout that this social compact requires a contribution fromeveryone and it will also need sacrifices and trade-offs. “It is upon the conduct of each that the fateof all depends. Asweenter the last decade of Vision 2030, let us evenmore clearly define the South Africa we want and agree on the concrete actions we need to achieve them.” Your sentiments, I support Mr President, but it’s not going to be easy. We will all need to help, first by transforming from within so as to enable us to see what is in everyone’s interests rather than remaining locked in divisiveness. q

Peter Middleton

MechChem Africa is endorsed by:

2 ¦ MechChem Africa • July 2019

Long renowned for high efficiency premium compressed air solutions, Atlas Copco Compressor Technique also supplies best-in-class air solutions to suit the full range of market needs, from economy to premium. MechChem Africa talks to business line managers JC Lombard of Oil-Free Air andWayne Jacobs of Industrial Air about the company’s fit-for-purpose solutions approach. The best-fit approach to compressed air

reliable, but because every decision is price sensitive in theirmarket, wehave aneconomy range of equipment specifically for them, such as Atlas Copco L-Series piston compres- sors. These compressors offer durable, high performance compressed air where reliable switch-on/switch off air is needed with ab- solute minimum maintenance. In addition, our Automan range is even suitable for DIY use, or for occasional use at autobody repair shops,” he adds. “Then, for more professional clients that are still looking for simplicity, but at the best efficiency they can afford, we have a more professional range of compressors and ancil- laries, such as theG-Series oil-injected screw compressors that will typically have simple controllers and industry benchmarked free- air delivery (FAD) for their power, making them efficiency leaders in this second tier affordability bracket,” he continues. Further up the scale, Jacobs points out Atlas Copco’s Industrial product range, which is designed to suit more sophisticated and established industries that are more running-cost conscious, so tend to prefer

digital controls and tracking, for example. “Users of our industrial range need techni- cally advanced and robust machines that are referenced against their peers with respect to aspects such as noise, control sophistica- tion, energy recovery opportunities and air quality. These machines typically have heavy duty gearboxes, strong transmissions and industrial digital controllers,” he says. “While at the top of the range, we still offer premium compressors, which use high- tech digital controllers and VSDs to give the highest efficiency solutions available in the world. These feature FAD values of 5 to 10% higher thanmany competitors and thehighest efficiency drive-train components available,” Jacobs assures, adding “but while high-end productscostmorebecausetheydelivermore, we know that these machines are not neces- sarily thebest-fit choice for every customer or application,” he tells MechChem Africa . Atlas Copco’s four different product tiers of compressors and ancillaries, which prog- ress in terms of sophistication fromrelatively simple to state-of the-art, are all market lead- ers in their respective segments. “Our bread and butter technologies are the G- and GX-series of oil injected screw compressors, for example, which suit profes- sional and industrial users,” Jacobs continues. “Although priced for affordability, these are legendary for their reliability and efficiency and are the preferred compressed air solu- tion for small and medium sized businesses,” he says. The more affordable options mostly come with analogue controls, but for more discerning users, versions are now also avail- able with basic digital controllers. “For industrial users, the fixed-speed GA unitswithdigital controllers tend tobe a good fit,” Jacobs continues. In spite of their afford- ability, these are more energy efficient than competing equivalents.

A s thehomeof industrial ideas, Atlas Copco has long prided itself on having some of the most efficient equipment availableon themarket. “Performance, reliability, energy efficiency and green credentials have always been part of our development mindset and we are con- tinually striving to get better. “What may get missed by the market however, is themessage that we cater for the entire market: not just the premium sector,” begins Jacobs. “Some of our customers need simple, user-friendly equipment that is effective and

Atlas Copco L-Series piston compressors offer durable, high performance compressed air where reliable switch-on/switch off air is needed.

4 ¦ MechChem Africa • July 2019

⎪ Cover story ⎪

The oil-free range includes the ZR/ZT and ZE/ZA compressors, which can also be coupled to VSDs for premium performance. JCLombard’sOil-FreeBusinessUnit deals with the high-power end of the compres- sor market, from 90 kW all the way up to 3.0MW. In spite of the unit’s name, however, the range includes both oil-injected and oil free compressor options. “Larger machines mostlymeet industrial and premiumrequire- ments,” Lombard tells MechChem Africa . “On the oil-injected side, we have G, GX, GA and GA+ (VSD) options, while the equivalent oil-free range includes the ZR/ZT and ZE/ZA compressors, which can also be coupled to VSDs for premium performance,” he reveals. “Everyone likes to look at the top of the range blue efficiency-type models on the showroom floor, but these vehicles don’t work for everyone. Some people need a 1-ton bakkie. It is very important that we at Atlas Copco can offer compressor choices across this whole performance range. By focusing only onourworld-leading products, whichwe have always had, we lose out because people don’t see our excellent lower tier options,” Jacobs adds. Lombard agrees. “Our focus in the 90 kW and above range is the same. We strive to sell themost energyefficientmachinepossible for the particular applications we are looking at. That means that a Tier 2, G-series machine might be more appropriate than a GA or a GA+ machine. Rather than selling our best possibleproductatthehighestprice,westrive to offer the most cost appropriate option for our customer’s needs at the time.” Jacobs argues that, in comparing compres- sors, the free air delivery (FAD) requirement is a good starting point. “The FAD enables us to compare how much air one can get from a compressor. Two 20 kW compressors are never quite the same.What a user wants is as much air as possible fromthemachine and, by using FAD instead of kWto size the machine, it may be possible to buy a machine with a smaller motor and footprint that delivers the

Atlas Copco also offers a full range of medical air products, which meet the European Pharmacopia air quality standards.

system, leaving the companywithguaranteed compressed air reliability at all times. “Italldependsonpeople’spreferences,lev- els of sophistication and the criticality of the air they use,” Lombard tells MechChemAfrica . He adds that the number of compres- sors required also changes the equation. “Customersneedingoneortwomachinesmay be inclined towards G-series solutions, but if 10 or 15machines are needed, they are likely to prefer GAor GA+machines because of the efficiency benefits and the return on invest- ment opportunities available by reducing the net power draw,” he argues. “Needs also vary considerably. People need food-grade air, dry air and very high- quality laboratory air. All combinations can be accommodated according to the real needs of our different clients. We even have a full range of medical air products, which meet the European Pharmacopia air quality standards: oxygen and nitrogen generators; pressure swing adsorption systems; medical and surgical instrument air solutions; and medical oxygen,” says Lombard. “At the end of the day, we strive to offer compressed air solutions that least affect the end costs of our customers’ products and services. The more the cost of air influences the end costs of doing business, the more it will pay to invest as much as is affordable in an energy efficient compressed air solution,” Jacobs concludes. q

necessary volumes. The smallermotormeans a lower energydraw, whichmakes the specific energy – the amount of energy required per unit of air supply – more favourable and the compressor more efficient. “So before requesting a quote for a 20 kW compressor, look at the air volumes needed in terms of litres per second at 7.0 bar, for example. Some compressors may require 22 kW to produce the volume needed, while we at Atlas Copco may be able to do it us- ing an 18 kW compressor. Not only will the smaller compressor be less expensive, but the specific energy will be lower, making the compressormore energy efficient – an added bonus if efficiency is particularly high on the wish list,” he argues. “The smaller unit also impacts the cost of maintenance,” continues Lombard. “The size ofthebearings,thebasesize,theamountofoil used, the separators, filters and replacement parts can all be smaller and less expensive,” he adds. From the serviceability perspective, Lom­ bardaddsthatthesameapproachalsoapplies. “Economy customer canadopt simplepreven- tativemaintenance by buying service kits and repairing their own equipment if they prefer. Professionalandindustrialusersmaypreferto look at safer and more efficient maintenance options, such as service plans, while premium users often want total care packages, where Atlas Copco takes total control of the whole

July 2019 • MechChem Africa ¦ 5

MechChem Africa profiles SAIChE IChemE’s new president, David Lokhat, who is the academic leader for Chemical Engineering and head of the Reactor Technology Research Group at the University of KwaZulu-Natal (UKZN).With a BSc, MSc and PhD in chemical engineering, Lokhat is an active researcher in the field of chemical reactor design and optimisation; and chemical kinetics, with a focus on process intensification. A love of research as the springboard for teaching

D avid Lokhat was schooled at a smallcommunityschoolinDurban North, where he grew to love sci- ence and mathematics “I lost my father when I was very young andmymother did everything she could to ensure that I had a proper foundation. She instilled in me a fascination for the natural, physical, scientific and technological worlds. I was always taking machines apart to see how they operated,” he begins. “When it came tomymatric option choices in Grade 10, I decided on an S7 package that was available at our school, andwhich includ- ed maths and science as well as accountancy. I expected to follow in my sisters footsteps into chartered accountancy, but I had amuch

greater interest in maths and science than I did in accountancy, so I decided on taking up my hobbies as a career instead,” he recalls. Lokhat decided to apply for engineering at the University of Natal. “I had multi-disci- plinary interests, though. I enjoyed chemistry, electricity andmechanics, so I was tornwhen choosing an engineering discipline. The new central applications system required us to make three choices, with one being awarded based on available space. I chose the courses in alphabetical order: chemical; electrical and mechanical engineering, and I got into chemi- cal engineering, my first choice. “I regard this as the best choice I ever made,” Lokhat tells MechChem Africa . “The chemical engineering discipline is amassively broad one that

David Lokhat in Kyoto as an invited speaker for the 2015 International Congress on Chemical, Biological and Environmental Sciences (ICCBES).

has allowed me to regularly tap into classical engineering topics and other technological fields to bring solutions together, which was exactly what I was initially looking for,” he adds. Lokhat’s first few years at university were not easy. “I did OK in myfirst year, but the secondyearwas challengingand I had to repeat two subjects,” he says, adding that this opened up a lotmore time in the following year, which enabled him to help the department with tutoring and research assistant work. “I can honestly say that this changed my whole life. Doors opened that would not have opened and I discovered research, which becamemy first love,” he explains. “I came to realise that the first fewyears of engineering courses are foundational, going back to the fundamentals of physics and mathematics that are essential foundation blocks. I was a late bloomer however, who only really began to enjoy the degree in my third year when we started to be exposed to the professional courses in chemical engineering. My results got better and better and I started to achieve the highest marks in class,” he says. “As an academic, I have seen this happen time and time again with students at university. Students who have done well in school struggle initially but, once they find their interests, they start to excel,” he adds. Inhis final year of undergraduate studies, hewas approachedby Matthew Starzak, an associate professor in the area of optimisa- tion and chemical reaction engineering at that time, to participate in a Sasol-supported industry project as his first semester project. The project involved investigating metathesis (double decom- position) of 1-hexene, a chemical process involving the exchange of substituents in an unsaturated hydrocarbon resulting in the forma- tion of longer chain molecules. “Organic chemistry was previously a challenge to me and I really wanted to make it my own by taking my module knowledge and applying it. By passing 1-hexene over a solid catalyst in a fixed bed chemical reactor at a high temperature,

The Chemical Engineering laboratory at UKZN where David Lokhat is the Reactor Technology Research Group leader.

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⎪ SAIChE IChemE news ⎪

The reactor developed at UKZN for the gas- phase production of HFPO from the reaction of hexafluoropropylene with molecular oxygen (O 2 ) under mild reaction conditions. we were able to create 5-decene, a 10-chain hydrocarbon molecule that is used in the manufacture of surfactants,” Lokhat explains. “Through this project, I had the wonder- ful opportunity to work for a short time at the Technical University of Lodz in Poland in a highly sophisticated laboratory with advanced analytical equipment. After Lodz, I knew research was what I wanted to do. “Towards the end of the project, Prof Starzak came over to visit me in Poland and, whilehavingameal in thebeautiful oldcapital, Krakow, he invitedme to stay on todo anMSc with him after I graduated. I said yes immedi- ately,” he says. David Lokhat completed his BSc in chemi- cal engineering in 2006 and, after a short break, returned to start his MSc in April the following year. Still based on the initial metathesis of 1-hexene, he set out to look at the funda- mentals and reaction kinetics. “TheMSc took another 18months andhelpedme tohonemy research skills. We commissioned an entirely new bench scale reactor for the work andmy MSc was finally awarded cum laude in April 2009,” he recalls. Then, following the launch of the Fluoro­ chemical Expansion Initiative (FEI) and establishment of the South African Research Chair for Fluorine Process Engineering and SeparationTechnology under the directionof Professor Deresh Ramjugernath, Professors Starzak and Ramjugernath identified an in- dustry relevant PhD project for Lokhat: the production of hexafluoropropylene oxide (HFPO), a fluorochemical intermediate used to make ion exchange membranes for fuel cells. “I was tasked with developing a new cleaner and higher capacity process for the production of this chemical on a commercial scale,” Lokhat informs MechChem Africa .

A schematic diagram summarising the award winning process developed by Lokhat for his PhD.

ceptedthepostandbecameafulltimelecturer in 2013. I soon found I enjoyed teaching even more than research! There would be no re- searcherswithoutteachers–andIhavenothad to give up onmy research interests,” he says. Between 2013 and 2017, David Lokhat received numerous best lecturer and dis- tinguished teacher awards for his work in chemical engineeringatUKZN.He stillspends half his time on research focused on process intensification and chemical reaction engi- neering. “I strive to make process units that are more efficient, have a smaller footprint, use fewer resources and produce less waste. In the process, I also get to explore various alternative technologies, such as ultrasound, microwave energy, centrifugal fields and advanced materials,” he notes. Priorto2018,hehasbeencreditedwith25 journal papers and seven book chapters. He is rated as an emerging researcher (Y-rated) by the National Research Foundation and, in 2019, he became the academic leader for Chemical Engineering at UKZN. As the Institute’s new president he be- lieves that SAIChE IChemE has a critical role toplay, locally andglobally. “Interesting things arehappening in theworldandwe increasing- ly need strong technical and scientific voices. Global phenomena such as climate change, social cohesion and the 4th Industrial revo- lution are affecting the way things are done, who is doing them and their consequences. We as chemical engineers have a responsibil- itytobecomeinvolvedinidentifyingpathways through these challenges. “As an institution representing engineers in South Africa, SAICHe IChemE is in an ideal position to interact on behalf of our membership with broader global communi- ties: to mitigate against current challenges while continuing to secure our standards of living through advanced technologies,” he concludes. q

His final PhD details a continuous process forproducingHPFOundermildreactioncondi- tions (lower temperatures) that substantially reduce waste and are associated with a much smallerenvironmentalfootprint.Aswellasbe- ing accepted for his PhD, thework culminated in several journal articles, a patent and the commissioning of a 5.0 t/a onsite pilot facility at the DST fundedMultipurpose Fluorination Pilot Plant (MFPP) at NECSA in Pelindaba. The process? “HFPOused to be batch pro- ducedusing a chemical solvent as theoxidiser. Unfortunately, this is not a selective process, somany other products are formed alongside HFPO,allofthemunwantedandsomeofthem dangerously toxic. “We developed a gas-phase production system that involved the reaction of hexa- fluoropropylene with molecular oxygen (O 2 ), which eliminated the solvent and most of the by-products. The key problem we had to overcomewas the high temperatures needed to activate this reaction, but by running the process under tightly controlled conditions and initially coating the inner surface of the reactor with a polymeric by-product (an oligomer) to catalyse the reaction, we were able to lower the temperature and make the process continuous,” he explains. In addition the few gas-phase by-products produced are much more easily separated out. The process Lokhat developed won him, together with co-investigators, the SAIChE Innovation Award in 2013 and is being com- mercialised through the DST for use by some multinational chemical producers. “In 2012, I was among the first doctoral graduates to emerge from the FEI programme and the research has since lead to the development of a whole new portfolio of products and processes,” he adds. Lokhat was then offered a lecturing post at UKZN.“Thiswasabigdecisionforme,because of my love of research, but I eventually ac-

July 2019 • MechChem Africa ¦ 7

“Digitalisation is moving on apace but putting it into practice requires a different way of working,” says MattiasÅrstadius of SKF. Here he outlines how bearing specialist SKF is applying the technology to reduce downtime and improve machine performance. Digitalisation: unlocking the door to predictive maintenance

T here has been much conversation about the Industrial Internet of Things and Industry 4.0, but the focus has generally been about the concept and the technology surrounding this revolution, rather than about the ways it can be put into practice. Here we look at why delivering customer value is so important and how digitalisation is beginning to transform business models and industrial partnerships. Recent improvements inconnectivity, con- trol and analytical capabilities have unlocked the potential for significant improvements in the cost, quality and productivity of indus- trial operations. However the secret to truly successful digitalisation for manufacturing and production companies lies in putting the technology touse in suchaway that it delivers real and measurable customer value. The mistake that is often made is to focus on developing a system solution, rather than looking at the customer’s specific needs. Digitalisation shouldbe about improving cus- tomer performance. So, thefirst stepneeds to determine what value means to that specific company and what they consider to be their key performance indicators (KPIs). For example, a key performance indica- tor for many operators is to improve output. In the past, SKF has begun the customisa- tion process by talking about maintenance contracts and consultancy agreements. However what customers really want is to add to performance byminimising unplanned downtime – for many companies each hour of downtime can cost many hundreds or thousands of Euros. With this inmind, the discussion shouldn’t be centred on maintenance schedules but on maximising asset performance and avail- ability for long-term resilience. It requires deep knowledge of the application condi- tions under which the company is operating. This knowledge then unlocks the door to a far more analytical approach to predictive maintenance and to the potential value that digitalisation of processes can create.

SKF’s IMx Multilog On-line System for early fault detection now has the ability to monitor eight signals or sensors (down from 32).

its KPI’s – operational efficiency. To mitigate against high levels of unplanned stoppages, condition monitoring was introduced. Not only has thismove to predictivemain- tenance saved the papermill several hundred thousand Euros in terms of downtime reduc- tion, but the monitoring system is delivering real-time noise, temperature and vibration data to allow SKF to not only solve present issues but avoid future ones. Thanks to the introduction of 4G and 5G real-time connectivity, the door is beginning to be opened to the next stage in predictive maintenance – the bigger picture. Although SKF’s focus is on rotating shafts andbearings, thanks to digitalisation these data readings are increasingly being connected to those of air, pressure and other parameters, showing the health of the machine as a whole, rather than just its individual parts. Real-time data is also opening the door to far greater integration across the supply chain. For example, in the very near future, component manufacturers will be able to ac- cess customer machine data so that they can manufacture replacement wear parts before the asset actually needs the replacement. How digitalisation is transforming business models Through condition monitoring and the digi-

talisation of industrial processes, traditional transactional models are increasingly being replacedbyperformance- and function-based contracts. SKF is beginning to see this shift, with more companies choosing one of these contract models. The former is a base fee paid monthly, with a bonus performance payment added at longer intervals should the customer’s KPI’s be achieved. Function-based agreements, however, commit the provider to deliver in terms of functionality for anagreed fee. There are real advantages for both sides to these models and SKF believes they will continue to increase in popularity, as more companies begin to exploit the potential of digitalisation to create different ways of financing opera- tional performance. Acase inpoint is amining operationwhere SKF has placed 8 000 sensors on the produc- tion lines tomonitor 2400 critical assets such as pumps, fans, gearboxes and large rotating grinding mills. A continuous service agree- ment is in place with the mine owners and as a result of digitalisation, SKF has been able to document that the predictive maintenance measures being carried out are saving the company almost €8-million per year. As mobile computing devices become smaller and more cost-effective, the ability to place sensors on minor as well as major

The digitalisation of predictive maintenance

SKF has been working with a large pulp & paper company in Sweden to deliver one of

8 ¦ MechChem Africa • July 2019

⎪ Power transmission, bearings, bushes and seals ⎪

assets is also increasing. In fact SKF’s IMx Multilog On-line System for early fault de- tection now has the ability to monitor eight signals or sensors (down from 32) – and even more cost-effective next generation versions will see many more single assets being monitored. This however means the creation of vast amounts of data. To accommodate this, the company has turned to using intelligent data analysis patterns to enable engineers towork with big data and deal with critical alerts in a timelymanner. This is one of the reasons why systems such as SKF’s Enlight data capture and knowledge solution, are increasingly proving their worth. As everyday operations increasingly become digitalised, connectivity is also happening at a supply chain level. End users, OEMs and suppliers such as SKF are beginning to work in even closer partnerships to take out costs, increase efficiencies and add more value. At present, SKF isworkingwitha rangeofOEMs, helping them to incorporate SKF algorithms intomonitoring tools, tohelp themworkmore closely with their customers. In the coming years, the impact of digi- talisationon industrialmanufacturing and the benefits it can deliver will depend in part on the level of trust that is developed along the How digitalisation is transforming industrial partnerships

Systems such as SKF’s Enlight data capture and knowledge solution, are increasingly proving their worth. supply chain. The companies that will benefit most from the digitalisation process will be the ones who are prepared to go into long term relationships and are willing to rethink how they work together. The technology is already there and will

only keepon getting better. The critical factor will be companies’ willingness to share data andknowledge in an increasingly competitive global environment. q

BI launches Bauer multi-mount terminal boxes Traditional cast iron electric motors only cater for top-mounted terminal boxes. This is nowset to changewith the industry’s first multi-mount terminal box for cast iron motors available from leading supplier, BI. The latest cast-iron Bauer elec- tricmotor range fromBI can accom- modate the terminal box on the top, left-hand or right-hand side. The major benefit for customers is that it reduces duplicate stockholding to accommodate different terminal box positions. BI Bauer Electric Motors product manager, Lewis Hiepner.

robust, and therefore ideal for the arduous operating conditions of mining operations. “We have received significant interest in the new Bauer multi-mount range, combined with its energy-saving potential,” Hiepner says. BI, a member of the Hudaco Group, is a leading distributor of bearings and power transmission products in Southern Africa. With its customer-focused approach, the company is committed to delivering value to all its stakeholders, while offering quality solu- tions that make a real difference to optimising plant availability and turnaround time. “With over 60 years in the

bearings and power transmis- sion industry, BI puts its experi- ence to good use by going great

Traditionally, cast iron electric motors are available in a wide power range from 0.37 kW up to 400 kW, with BI only catering for top-mounted terminal boxes. “Someplants either have top, left-hand or right-hand terminal boxes,making it a complex and costlyexercise to stock all three,” explains BI Bauer Electric Motors product man- ager, LewisHiepner. BI itself orderedwhichever variantwas required ex-factory, with a normal lead time of about 14 weeks. TheBauermotor range fromBI is also available in various energy efficiency ratings, from IE1 as standard and IE2 high efficiency, all the way through to IE3 and even IE4. “We are standardising on IE1 motors, with the possibility of being able to offer IE2 as a standard option as well, although this is still in the pipeline,” Hiepner reveals. The multi-mount motor range, being cast iron, is particularly

lengths to ensure their product range and ser- vicesmeetthechanging needs of clients, indus-

try and busi- ness,” Hiepner concludes. q

The latest cast-iron Bauer electric motor range from BI can accommodate the terminal box on the top, left-hand or right-hand side.

July 2019 • MechChem Africa ¦ 9

⎪ Power transmission, bearings, bushes and seals ⎪

Deon Crous, BMG’s national product specialist for NORD Drive Systems talks about ideal solutions for sewage treatment, while Kelly MacIver, BMG’s Gears Business Unit manager talks about the Varvel Brand and its new worm drive solution for the PV Solar industry. Geared drives for applications from sewage to power

B MG’s electromechanical drive tech- nicians, with extensive experience in gearing, offer technical advisory and support services, which are tailored to meet the precise specifications of contractors, designers and the end-user. These include brands such as NORD and Varvel, amongst others, which all have niche applications. “NORD drives, which consist of Unicase helical shaft-mounted geared motors, have special features to meet the requirements of water treatment applications,” says Deon Crous, national product specialist for NORD Drive Systems at BMG. “These drives consist ofgears,motorsandbrakesthatareprotected against corrosion. Special covers for the hollow shaft and motor also ensure that the drive is entirely resistant to spray from tanks and the humid and aggressive conditions to which the units are exposed in sewage treat- ment plants.” Explosion-proofmotorswithelectricaland mechanical speed control are fittedwith anti- condensation heaters for stand-still periods and reinforced bearings for extended life are standard. Special vent plugs, lubricants and a valve-type oil drainage facility also enhance performanceinthesedemandingapplications. Driveswithhelical flange-mountedgeared motors have theflexibility tofit into restricted and awkwardly shaped areas below tank de-sludgers. The traversing platform of this system is equipped with four-wheel drive to preventwheels fromslipping, evenunder load and in unfavourable wind conditions. Drives for revolvingde-sludgers (helical bevel geared motors) and propeller-type agitators and aerator drives (flange-mountedhelical geared motors) can comfortably handle continuous operation 24 hours a day. Foot mounted heli- calgearedmotorsarerecommendedinpaddle mixer drives and, despite heavy loads, design life can exceed 100 000 hours. A unique feature of these drives is the Unicase gearbox that accommodates all bearing seats within a rigid one-piece cast- ing – no bearing seats are located on bolt-on flanges or covers. Sealing surfaces are not subjected to torque stress or overhung loads and hardened wheel bodies with specially treated teeth ensure smooth and quiet op-

eration at maximum load capacity. The NORD range is designed by German precision engineers and assembled locally by BMG according to stringent local and in- ternational quality specifications. The range has earned recognition throughout theworld for reliability, efficiency, low noise levels, ex- tended life and reduced maintenance. BMG has extended its range of Varvel gear- boxes and variators for small and medium power applications to include customised worm gearboxes for installation in photovol- taic (PV) solar tracking systems. “We work in conjunction with Varvel specialists and South African PV compo- nent manufacturers to design sustainable solutions,” says Kelly MacIver, BMG’s Gears Business Unit manager. “Through close col- laboration, BMG, Varvel and South African solar tracking manufacturers, PiA Solar SA, have re-designed mechanical drive compo- nents for solar tracking systems to enhance cost-efficiency, increase installation speed and optimise the performance of PV tracking installations. “Customised Varvel worm gearboxes – designed to minimise efficiency losses – are incorporated into PiA Solar’s ContouR+ single-axis trackers. These compact gear- boxes,whicharemaintenance-freeandsealed for the life of the unit, maximise efficiency by ensuringsolarpanelsarealwaysintheoptimal A solar tracking solutions from Varvel

BMG’s NORD drives, which consist of Unicase helical shaft-mounted geared motors, have special features to meet the requirements imposed during water treatment procedures. generation position relative to the sun.” Versatile Varvel RT worm gearboxes have numerous advantages for PV installations, including an ingress protection rating of IP66 – certified by specialist laboratories – to guarantee resistance todust andwater.Other significant features include a high ratio of 1 120:1 and the non-back driveability design for locking the solar panels in place, which prevents external forces from moving the panels off their optimal position. The Varvel range, which is designed for flexibility and interchangeability with other leading gearboxes, as well as easy mounting and quick lead times, enables BMG to offer customised power transmission solutions to users of gearboxes in diverse sectors. Apart from PV applications, Varvel gear- boxes and variators are used for pumps, mixers, conveyors and cranes, scrapers, screw feeders, apron feeders, automotive equipment,liftingcontrolandpipeprocessing. “What’s important is that each Varvel system can be custom-designed for specific requirements,” concludes MacIver. q

BMG’s customised Varvel worm gearboxes are incorporated in PiA Solar’s ContouR+ single-axis solar trackers.

July 2019 • MechChem Africa ¦ 11

Harsh operating conditions on vibrating screens demand high quality engineering and the strictest tolerances for unbalanced motors and gearboxes, or they simply will not last. This is why Kwatani designs its own range of motors and locally manufactures gearboxes for its vibrating screens with a zero-tolerance approach to quality. Using quality motors and gearboxes optimises screen economy

A ccording to Kenny Mayhew- Ridgers, chief operating officer at Kwatani, local design and manu- facture to the highest standard is non-negotiable for Kwatani and its products. The company designs its own range ofmotors and locallymanufactures thegearboxes for its vibrating screens. “We design our own motors with local

conditions inmind, giving the customer a high performance and long-lasting product,” says Mayhew-Ridgers, adding that optimal sealing arrangementsmust beconsidered for keeping electrical components dry and clean. “Power cables, for instance, must always enter from the underside to prevent water ingress,” he says. “Thedesignmust consider various orien- tations of the motor, depending on the angle of installation.” Dusty conditions on

Unbalanced motors engineered to internal technical specifications and manufactured exclusively for the company in partnership with one of the world’s leading motor manufacturers in Europe. ment for the lid, which includes a gasket.” Kwatani’s gearboxes are locallymanufac- tured, with only the high-quality bearings im- ported direct from leading global producers. Gearboxes comprise two shafts, eachwith its own set of unbalancedweights linked to each other by a gear to achieve synchronised mo- tion. Gears and shafts are locally fabricated by selected suppliers, while the housing is cast by a local foundry and machined to

mines also present a challenge. “Dust ingress can compromise the sealing configuration of the lid. Our design is therefore like a top-hat, so theO-ring is not on a flat surface but rather on a cylindrical, vertical surface. There is even a double-sealingarrange-

Exciter gearboxes are engineered and manufactured in-house to the most stringent quality standards.

The cost effective variable speed drive option Grant Robertson, managing director of Vert Energy, talks about the company’s Leroy-Somer LSK direct current (dc) motors, a cost-effective solution for variable speed applications.

“ L eroy-Somer has a depth of experi- encewith ac anddc variable speed drive systems and designs its standardmotors to withstand the new demands being imposed by frequency converters and variable speed operation,” says Grant Robertson, managing director of Vert Energy, the exclusive distributor for Leroy-Somer in Southern Africa. “Motors are thus able to withstand frequent speed or torque changes and reversals, running at overspeed of up to 6 000 rpm for the stan- dard four polemachine, and at lower speeds with full torque, without drawbacks such as overheating,looseningofstatorwindingsand damage to rotors or bearings. “The major advantage of direct current motors is the ease of effecting accurate speed control and LSK’s advanced technol- ogy enables motors to respond to electronic controllerswhichplacegreatdemandsonthe performance of DCmotors. Smooth running

has been achieved by the introduction of an advanced frame design, incorporating the largest dimensioned shaft.” LSK square laminated frame dc motors, which have been designed by Leroy-Somer to the latest European standards for indus- trial requirements, have ratings from 2.0 to 750 kW. Leroy-Somer also produces non- standardmotors, providing a range of power from 0.06 kW to 18.5 kW. Vert Energy’s LSK dc range includes en- closed permanent magnet motors, enclosed wound motors, drip-proof wound motors and drip-proof, force-cooled wound mo- tors. These can be foot, flange or foot and flange mounted. Flanges are incorporated into the steel stator castings, giving a robust construction that eliminates vibrations. Four removable plates allowdirect access to brushes for easy replacement, thus simplify- ing maintenance. Leroy Somer’s advanced design of the

dc motor incorporates cooling and ventila- tion systems that reduce wear and tear on the brush gear, by the elimination of dirty particles. These motors, with a Class H insulation system, can operate at ambient tempera- tures of between +5.0 °C and +40 °C and are protectedwitha rangeof surface treatments that withstand harsh environments. The qualityof thewinding, insulationand impreg- nation guarantees optimum performance, even in arduous conditions. Optional features includeflange adapters that enable the easy modification of motors to all types of situations, without the need

12 ¦ MechChem Africa • July 2019

⎪ Power transmission, bearings, bushes and seals ⎪

forcostlyandtime-consumingadjustments. Pressure switches monitor air flow to de- tect if the ventilation motor has stopped working.Where there is littlevertical space for installing a motor, a connection kit can be used tomount a standard forced cooling unit in an axial position. Transparent doors can also be fitted to facilitatemaintenance procedures such as brush inspection, without having to remove inspectiondoors. Leroy-Somer has developed an on- line configurator to assist in the selec- tion of motors, brake motors or geared motors, combined with variable speed drives. A link to this energy savings web- site can be found at http://acim.nidec. com/motors/leroy-somer/services/ calculate-your-energy-savings The modular concept of this range enables a continuous production line for the entire LS product range, thus reducing delivery times. Lead times for adaptedmo- tors are also significantly shortened. Vert Energy also offers a maintenance programme which ensures optimum per- formance of dc motors and significantly extends service life. q “If there is the slightest imperfection in the flat surface of the join, this can cause costly damage to the drive and the screen,” says Mayhew-Ridgers. “This is why OEMs such as Kwatani havedetailed installationprocedures for issues suchas torqueingof bolts. Installers and maintenance teams need to stick closely to these specifications.” q exacting specifications. Mayhew-Ridgers notes that Kwatani has spent a great deal of effort on the sealing configuration, to ensure no oil leaks, stating that the company is probably the only OEM that services its own gearboxes. “This ensures adherence to strict toler- ances, so that units have sustained perfor- mance and longevity,” Mayhew-Ridgers tells MechChem Africa . He also highlights themassive centripetal forces that are exerted on the screening ma- chine by the unbalanced motor and gearbox, making it vital to secure them well to the screen. “To achieve this, we specify our own fabri- catedbolts, nuts andwashers. If sub-standard fasteners are used, components can come loose and cause extensive damage.” Unbalanced motors usually have to be installed at an angle. Taking account of the weight of these components, thereare rigging points all around the housing to manipulate the angleof installation. The feet arenormally larger than those of competitors, for a better contact surface.

Multi-level e-house from Shaw Controls for oil & gas sector A multi-level E-house, designed, engineered and manufactured by Shaw Controls, has been supplied as a fit-for-purpose solution at a major South African Port. S hawControls,amemberoftheZest WEG Group, has designed, engi- neered,manufacturedandsupplied a fit-for-purpose E-house solution into an oil and gas sector application at a major South African port. before transportation to site. Other important aspects of this E-house design include its fire rating, fire detection systems and HVAC systems for heating, cooling and ventilation. Rock wool mineral insulationbetween the cladding segregates themodules andprovides a two-hour struc- tural fire rating. Climate control systems will ensure that the coastal temperatures and humidity of KwaZulu-Natal do not disrupt smooth operations. q

Bevan Richards, managing director of Shaw Controls, explains that, using a draft concept supplied by the customer, the company has taken its E-house design and manufacturing capabilities to newheights. “Shaw Controls was responsible for the complete mechanical and electrical design as well as manufacture of this E-house solution, which comprises five modules,” says Richards. “Probably in a ‘first’ for SouthAfrica and accommodating space constraints on site, the design is amulti-level construction that will be fitted onto the available footprint.” This E-house solution comprises three modules at ground level with two above. The substantial structure, including all electrical substation equipment, weighs approximately 90 tonnes. A section of the groundfloorhousesamediumvoltage(MV) switchroom with a dry-type transformer for enhanced safety, and a module fitted with three 450 kW MV variable speed drives (VSDs). The thirdmodule contains a1MVAgen- erator set, sourced fromZestWEGGroup’s dedicated genset manufacturing facility in Cape Town, for backup power. The first floor comprises one module with a low voltage motor control centre (MCC) and four freestanding low voltage (LV) VSD panels, and a second module for control and automation. An additional E-house comprising onemodule for a sepa- rate (LV) substation has also been supplied. “Ourexpertiseandexperienceindesign- ing appropriate mechanical and electrical solutions using 3D modelling software makes this kind of innovation possible,” says Richards. Using a turnkey approach allows Shaw Controls to efficiently construct the full solution at its dedicated E-house facil- ity in Heidelberg, saving customers the complexity of managing multiple contrac- tors on site. At this facility, the modules are trial-fitted, assembled and tested

A view of the E-house module assembly at Shaw Controls showing both ground floor, which houses MV switchgear module and MV VSD module, and upper floor comprising MCC module and DCS/ESD module.

A view inside the LV MCC room of the E-house.

The MV VSD room of the H-house.

July 2019 • MechChem Africa ¦ 13