MechChem Africa July-August 2024

MechChem JUL-AUG 2024 AFRICA

Making agility count

This month: Managing and protecting SA's groundwater

Green hydrogen: Harnessing its full potential

Rotating Equipment Performance: easily accessible, everywhere

Industrial efficiency: towards circularity and decarbonisation

Consistent quality Reliable delivery

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CONTENTS 34 Water, wastewater and pumping solutions 6 Managing and protecting SA's groundwater Chetan Mistry of Xylem Africa talks about the importance of our groundwater resources and the Xylem solutions for protecting them. 8 Verder advances dosing product range 11 Inline pumps for space-saving applications Power transmission, bearings, bushes and seals 12 Optimised motors for maximum efficiency BMG’s electromechanical specialist Graeme Neilson talks about optimising electric motors for maximum energy efficiency and productivity. 13 Advanced drive tech for key automotive project 15 Food line SRBs: a new food safety benchmark 16 Prime gearbox solutions for pump applications Minerals processing and materials handling 14 EPC(M) solutions for efficient project execution Engineering company, thyssenkrupp Uhde South Africa, with the addition of procurement, construction and management capabilities to its portfolio in the 1970s, has become a full EPC(M) solutions provider for a diverse and extensive range of project types. 19 Leading N 2 O and NOX abatement 20 Measurement for enhanced efficiency and safety of distillation units 21 Sandvik builds local production of screening media 23 Multotec showcases its innovative sampling technologies Hydraulics, pneumatics and automation solutions 24 Zutari and 4Sight collaborate on sustainable smart infrastructure Since announcing a partnership in 2022, Zutari and AltX-listed 4Sight have refined their unique service offering by working on some of the largest and most complex mega projects. 26 New medium-pressure axial piston pump expands Hytec’s eOC platform 27 SMC ATEX products: embracing safety and efficiency PowerGen, PetroChem and sustainable energy management 28 Green hydrogen: Harnessing its full potential According to a new impact paper by Danfoss, green hydrogen, if produced efficiently, can be used to minimise the costs of production and demand for renewables. 29 City of Cape Town shores up sustainable energy distribution 30 Energy optimisation in SA’s pulp and paper sector 33 Rebranded WEG to make powerful debut at EMA Environmental management, waste and cleaning technologies 34 SA-first solution for converting paper sludge into bioethanol A pioneering South African-first solution has been demonstrated to convert cellulose fibre-rich waste from pulp and paper mill operations into ethanol. 35 Sappi signs milestone 175 GWh pa Power Purchase Agreement Maintenance and asset management 36 Rotating Equipment Performance: easily accessible, everywhere John Storm for the SKF Group in South Africa talks about the Rotating Equipment Performance Centre in Johannesburg, which extends the company’s diagnostic and proactive maintenance service offering. 38 Customised lubricant formulations for critical applications 41 Diagnostic online monitoring solutions Innovative engineering 46 Industrial efficiency: towards circularity and decarbonisation JulieWells previews the 2024 NCPC-SA Conference, which aims to equip industry to transition to a green, low carbon and circular economy. 38

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

Transparency You Can See Average circulation Jan to Mar 2024:10 795 Printed by: Tandym Print, Cape Town

Front cover: Rand Air Contact: Mpho Ngamlane Tel: +27 11 345 0700 Email: mpho.ngamlane@randair.com Website: www.randair.com

Regulars 2

Peter’s comment: Backcasting, net-zero and the resource efficient future 4 On the cover: Rand Air Temperature and the eight-ton boiler Edmund Haddad of Rand Air, talks about the company’s new steam boiler rental offering. 42 Products and industry news 48 Back page: BBE releases SCADA-compatible VUMA Live

July-August 2024 • MechChem Africa ¦ 1

Backcasting, net-zero and the resource efficient future

Peter Middleton

While putting together this issue of MCA, I received a fascinating opinion piece called “ Backcasting to the future ” by Johan Potgieter of Schneider Electric. Potgieter begins with the Grandfather Paradox hypothesis, where a time traveller goes back to change the past, and therefore changes the future. If the traveller killed his still-young grandfather, for example, the traveller himself may never have existed, which means he couldn’t have gone back to kill his grandfather. Hence the paradox. Backcasting, Potgieter explains, turns this sce nario on its head by defining a future vision and then reverse engineering the “requisite actions to achieve this future” – and unlike the Grandfather Paradox, backcasting is completely possible. “In essence, backcasting begins with the end goal and then works backwards. This is counterintuitive to traditional forecasting, which extrapolates from the past to predict the future,” he adds. He cites a 2014 talk by the futurist speaker, Thomas Frey, who described several backcasting scenarios: controlling a hurricane; people living past the age of 200; self-care healthcare; invisible wireless lightbulbs; gravity-reducing technology; and human controlled hurricanes. And already much closer to realisation, he cites flying drones that move like a flock of birds – now realised in spectacular drone light shows; 3D printing becom ing the industry standard –certainly the case in some niche applications ; and driverless car high ways. In each case, the ‘fanciful/visionary’ idea is mooted and, by working backwards, the technolo gies, policies and operational plans needed to bring the idea to reality are systematically identified and sequenced. I think the climate crisis brings this backcast ing approach into sharp focus, with survival of the planet as the key future goal. Arresting global warming and associated climate change by legis lating a pathway towards net-zero by 2050 is the more specific target. But this has been in place for decades now and we continue to struggle to come anywhere near the reduction targets required to prevent a climate crisis. Perhaps because our economies are so totally dependent on the fossil-based energy and fuel tech nologies of the past, any transition pathway is seen to result in unaffordable expenses and economic sacrifices. This along with the incessant bickering about who is most responsible and who should pay. Also though, I believe, net-zero, while necessary, is hardly an exciting future vision. Who is inspired by legislation? Our green and sustainable 2050

targets need to capture our imaginations in some way, so that any sacrifices we make now will seem worthwhile. In our innovative feature in this issue Julie Wells, of the National Cleaner Production Centre SA (NCPC-SA), previews the 2024 NCPC-SA Conference to be held at the CSIR on September 11 and 12. In term of a holistic and visionary approach to climate change, I think the NCPC-SA and the UN’s Global Network for Resource Efficient and Cleaner Production (RECPnet) have created an excellent platform for navigating a future that goes way beyond minimising carbon emissions. This is epitomised by the work already being done via the Global Eco Industrial Parks pro gramme, which was launched in South African back in 2010. “An industrial park is like a microcosm economy. It has an energy and a water supply, roads and street lights. Tenants working in differ ent industries share the space and the idea is to get them to share resources as well. No one should be sending a waste material out of one gate while someone else is bringing in the same new material via another. And why have six different delivery vehicles employed by six different companies that are idle for most of a day?” asks Wells. Working better together can massively reduce everyone’s environmental footprint, while also making each business more efficient and more economically sustainable. And from a community perspective, more jobs can be created and the sur rounding community can be better integrated into the local economy. This is a comprehensive vision of a new way of handling global production needs. An efficient, sus tainable, equitable and environmentally friendly way and a win-win solution to global warming. Achieved by simply ‘feeding off each other’ to make much better use of the Earth’s available resources. Energy efficiency, the renewable energy transi tion, the vehicle and fuel technology changes, the circular economy, smart solutions and every aspect of the changes required to meet the 2050 emissions reduction targets can be encapsulated into this multi faceted approach. In addition, though, it offers a view of a more exciting and better world. We are living with crises that often seem com pletely beyond our control. Putting backcasting to widespread use to re-imagine our futures – as the NCPC-SA and RECPnet seems to be doing – might be a better way to steer out of our current difficulties. Let’s all get behind this future vision and stop try ing to fix the past.

Comment

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2 ¦ MechChem Africa • July-August 2024

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Rand Air Temperature and the eight-ton boiler Edmund Haddad, the recently appointed business development manager for Temperature at Rand Air, talks about the company’s new steam boiler rental offering and the peace of mind it offers for meeting local manufacturing and processing needs. E dmund Haddad is a mechanical en gineer with extensive experience in design, research and development, manufacturing, mining and minerals Namibia. “We conducted studies into the fea sibility of extracting lithium from the orebody; the process design, capital cost, operational expenses and most importantly, the return on investment. So I understand manufacturing, mining and how to implement engineering projects, which, I think, stands me in good stead for this new business development role at Rand Air,” says Edmund Haddad. The 8t containerise boiler offering. On May 8 th this year, Rand Air part of Atlas Copco Speciality Rental, had a launch for its new Temperature offering. “We have been running a soft launch since earlier this year, and have already done a few projects us ing our 3 t boilers. We have now also taken delivery of two new German-built 8 t steam boilers, though, which is very exciting,” Had dad continues.

processing projects. “I started out in manu facturing in a copper foundry, specialising in simulations to optimise how molten metal flows into moulds. After several great years, I decided to join a startup foundry to recreate the successes already achieved and to move away from the specialist role,” he begins. “I joined the steel startup foundry in Springs just before Covid hit, so I had to de velop a lot of business skills in a short time, implementing workarounds to keep the busi ness running on a shoestring budget,” Haddad tells MechChem Africa . He then moved into a study manager role at a technology metals mining company in

“I have an engineering mindset, so I also un derstand what customers want from a rental company. When in Namibia, the mine was looking to expand the existing plant without a large upfront capital investment. So, we came to Rand Air for the compressors we needed. The rental option enabled us to get what we needed immediately while paying for it out of increased production. It proved to be a far better option in terms of cash flow, and it en abled the expansion project to be completed far more quickly, without adding a long-term financial burden,” he relates.

The quality and technology involved is remarkable, he says citing the European CE standard mark and design details. “This is the Rolls Royce of packaged boilers, 72-hours unmanned, low emissions, fuel efficient, with little details such as the mounted steel badge indicating the nose levels.” A fire-tube packaged boiler with a deliv ery capacity of 7 800 kg/h of steam at 14.5 barg, the new 8 t dual-fuel boiler runs on any light liquid fuel, such as diesel or natural gas. Compared to standard coal-fired boilers in the

As part of its Temperature offering, Rand Air has now taken delivery of two new German-built 8 t steam boilers.

4 ¦ MechChem Africa • July-August 2024

⎪ Cover story ⎪

South African market, these are much cleaner and environmentally friendly, helping to re duce emissions and promote a greener future. The unit is packaged to meet the needs of the rental industry. Built into the container is the boiler unit, a feedwater tank, along with all the filtration and water treatment systems needed. A simple easy to assemble chimney stack slides into the back of the unit during transport. Inside the doors you will find the control panel and Scada system with all the embedded connectivity and data collection features of a modern IIoT-ready plant. “Rental boilers in South Africa are synony mous with older technology, coal fired boilers with multiple parts coupling to the plant. Our Rand Air 8 t steam boiler is an elegantly de signed package. Everything needed to deliver steam to a plant fits neatly into the container, and with a mass of just 28.7 t, it can be loaded onto the back of a road trailer for transporta tion to site,” he asserts. Plug and Steam Connecting a boiler is not as simple as install ing a compressor, he warns. “At Rand Air, we treat every installation with an engineering project mindset. We come to site to inspect and assess the customer’s needs, where the water is coming from and at what quality, how the steam needs to be connected into the system and where we will be placing the boiler unit,” continues Haddad. He points out that every boiler is a pres sure vessel that is subject to the Pressure Equipment Regulation (PER) of the South African Department of Labour’s Occupa tional Health and Safety Act. Specific safety features are required, and an independent authorised person (AIA) needs to inspect and formally sign off on the operational safety of the installation before it can be used. “We are working with local partners to see how we can streamline that process to get instal lation and commissioning done as quickly as possible,” he says. “As we see more and more customer, we are developing smarter processes, fittings and adapters to make the process of connecting up a boiler as simple and seamless as possible,” Haddad adds. Rand Air is calling this approach ‘Plug and Steam’. It involves “working smarter in our goal of getting the customer’s plant up and running in the shortest period”. With its partners, Rand Air can offer three rental options: • Short term rental, typically for plant breakdowns and the mandatory yearly and three yearly AIA inspections. Longer term rentals, typically for new boiler installations and major plant expansions. Outsourced steam plants. With this offering, the customer is hands-off and • •

Rand Air’s 8 t steam boiler is an elegantly designed package with everything needed to deliver steam to a plant fitting neatly into a container. With a mass 28.7 t the whole system can be loaded onto the back of a road trailer for transportation to site.

Rand Air is developing smarter processes, fittings and adapters to make the complex process of connecting up a boiler as simple and seamless as possible. The company is calling this approach ‘Plug and Steam’.

which is also available for steam boiler users, is outcomes based pricing. The steam user is not involved in any of the boiler operation or management activities. “The boiler is fenced off and our operators run it. The customer only pays based on metered steam usage, just as you would pay for electricity and water from a utility,” Haddad explains. “This is an appealing option for customers trying to move away from coal without the headache of having to invest in a new plant and boiler operators. We are already engaging with customers who are interested in this op tion, but for now, it is a future vision,” he says. “The future is likely to be a uncertain for the next few years. This is why rental is a great solution for South Africa. Rand Air can provide customers with the Temperature equipment they need, for steam and cooling, without them having to commit capital outlay. They can rent the equipment on a month-to month basis while Rand Air takes care of any maintenance requirements. “With uptime guaranteed, our customers get the full benefit of high quality products that are energy efficient and clean. In addi tion, when a better one comes along, there is no need to ‘sweat the asset’ of older technol ogy. We will happily bring the latest model to replace any of our older units,” Edmund Haddad concludes. www.randair.co.za

only pays for what is used. On these projects Rand Air supplies the steam hardware and partners with local sup pliers to run the operations. “On all these options we offer boiler supervi sion and water treatment services; along with training and support for existing personnel to ensure efficient running of the packaged boiler plant,” Haddad assures. By law, steam boilers need to be inspected by an authorised inspection authority once a year, with a major inspection once every three years. During these inspections, any wear to the boiler will be detected and repaired, resulting in downtime of between one week and a whole month. Plants typically schedule these shuts during the Christmas break, while demand is low, to minimise production losses. This approach results in businesses com peting for boiler inspection and repair re sources over the December period. “Renting a standby boiler to maintain steam production during a shutdown frees up the maintenance calendar and ensures adequate time for work to be done properly,” Haddad explains. Outcomes based pricing: ‘Steam over the fence’ Another innovative offering from Rand Air, Scheduled boiler inspection at any time of the year

July-August 2024 • MechChem Africa ¦ 5

Managing and protecting SA's groundwater Chetan Mistry, Strategy and Marketing Manager at Xylem Africa, talks about the importance of managing and protecting our groundwater resources, and the Xylem solutions making this possible.

buckling wastewater treatment sites. In addition, heavy metals and other pollutants from mining, farming, and industrial sources are leaching into our groundwater systems. These incidents are still a minority, but that they exist at all is reason to be concerned." Hence the need for urgent action. Xylem’s Lewara borehole pump brand, which offers premium efficiency and longer life in this challenging pumping environment. With more water being extracted, it is quickly becoming necessary to monitor and control how much water is being extricated and how this impacts the water level in each aquifer. To access groundwater from a borehole, a deep – often 60 to 80 m – and narrow well needs to be dug. A high-head submersible pump is then dropped into the well. As well as being energy efficient, reliability is essential, so Mistry recom mends using a premium quality borehole pump, such as Xylem’s Lewara borehole pump brand, which offers premium efficiency and longer life in this challenging pumping environment. "Anyone operating pumps to extract ground water will benefit from greater control and measurements. Not only is it likely that govern ments will start enforcing more oversight to ensure aquifers remain stable and healthy, but it makes sense from a sustainability perspective to measure what you use. Doing so will help man age the health of an aquifer – which can take decades to recharge if depleted – and ensure that water-heavy operations are not wasteful." Xylem will soon be introducing a solar-pow ered range of borehole pumps geared particu larly to markets where access to electricity is an issue. Here, the controllers can help operators carefully manage when and how much water is pumped every day. Monitoring water quality From a monitoring perspective, however, the bigger issue is water quality. Contaminated water can seep into the groundwater, which means that wells will be contaminated as well. The solution, Mistry suggests, is twofold: Managing groundwater levels

Groundwater supplies are not infinite. It is possible to exhaust and even pollute them, and recharging underground aquifers can take years, even decades," warn Chetan Mistry of Xylem Africa.

“A t the moment, many mines, farms, communities, industries and wastewater treatment plants discharge polluted water into our water systems, which causes massive issues for water security and puts pressure on SA's groundwater resources,” says Chetan Mistry, strategy and marketing manager for Xylem South Africa. From an organisational perspective, the management of quality water is an intrinsic part of the new ESG protocols now being used to measure how responsible brands and com panies are. But water security should also be a priority for governments and municipalities, and the resource underpins the success of the United Nations' Sustainable Development Goals (SDGs). “If you look at the Sustainable Development Goals, poor water quality affects pretty much all of them. In rural communities, women often walk for several kilometres every day in search of access to clean water (SDG6), which impacts directly on gender equality (SDG5), and their ability to secure decent work (SDG8), and it impacts on poverty, hunger and good health (SDGs 1, 2 and 3, respectively),” notes Mistry. Similar arguments can be made for every one of the seventeen SDGs, he continues, because access to water of suitable quality is fundamental to everyone's survival. Water impacts corporate sustainability and public sector service delivery. Governments can enforce water-protection policies, municipali ties can reduce water wastage and theft, and individuals can use water smartly and report water abuse, such as pollution.

Groundwater: our reserve supply The borehole has long been a South African staple, most notably for farmers accessing groundwater from underground aquifers for irrigating crops and watering livestock. South Africa, says Mistry, has relatively abundant supplies of groundwater. However, "ground water supplies are not infinite. It is possible to exhaust and even pollute them, and recharging underground aquifers can take years, even decades," he warns. Groundwater is our backup, but there is already substantial and growing use of this resource. Agriculture is still the main con sumer, accounting for two-thirds of current groundwater consumption, but, according to a 2019 report by the CSIR, ‘ Groundwater: The Impact of climate change on South Africa's future groundwater availability’ , mining and residential users are responsible for around 15% of current groundwater consumption. In most places on the planet, groundwater is crucial. According to the Groundwater Project, it supports nearly half of Earth's population and three-quarters of its irrigation needs. While South Africa is still largely dependent on surface water, this is changing quickly: growing popula tions and shifting climates are increasing the demand for groundwater, with rural communi ties often dependent on groundwater for safe drinking water. “Traditionally, we assume that the water pumped from underground sources is clean and ready for consumption. Yet researchers testing groundwater at boreholes are discovering con cerning levels of harmful bacterial life, such as E. coli-contamination, probably coming from SA's

6 ¦ MechChem Africa • July-August 2024

⎪ Water, wastewater and pumping solutions ⎪

“We need to ensure that any water discharged into the natural environment meets minimum discharge quality levels. To protect those that dependant on borehole water, the quality of extracted water should be routinely monitored and tracked to en sure the water is safe for its intended use,” he says, adding that Xylem offers a whole range of environmental quality monitors from its Italy-based Xylem YSI brand, which can pick up pH, turbidity, bacterial and heavy metal contamination, and more. If the water is contaminated, Xylem can help with a targeted treatment so lution, because the treatment process will change depending on the source of the contamination and the condi tion of the water. Simple filtration and disinfection may be enough, but Xylem offers a full suite of water treatment solutions, from bio digesters and clarifiers to ozone and UV disinfection. water treatment,” he says. Far more important than treating extracted groundwater, though, is to find the source of the contamination and to treat the discharge water. Chetan Mistry cites tailing dams as an example. “Instead of having a tailings dam that simply tries to store mine-affected water, which often seeps into the groundwater if the dam floor is compromised, there is an opportunity to set up a treatment plant and a fresh water reservoir that could enable the water to be safely discharged. Even better, the water can be reused on the site. Most wastewater can be brought back to a reusable quality standard and the investment will deliver savings and positive financial returns,” he says. “Many companies are reluctant to invest in water treatment. But between the rising scarcity of water, which is leading to more quota restrictions, and the impact of polluted water on surrounding communities, there is a good busi ness case to invest in wastewater processing. The community that works around a mine will typically be the worst affected by poor quality discharge water. Lowering pollution and even "We have also recently acquired Evoqua, an ad vanced water treatment services company that adds fluoridation and several other ultrapure treatment processes to our portfolio, mainly suited to utility scale

offering water to those communities can sup port development and cooperation. The same principles apply to biowaste contamination in agriculture, where flush and washdown water can easily be treated to water crops, for example. The role of smart technologies Key to overcoming water contamination issues is using smart monitoring, ICT and analytics to make specific problems as transparent as possible and quickly identify how to respond before significant harm is done. Mistry says that Xylem recently partnered with Idrica to bring together Xylem’s portfolio of digital solutions. The partnership offers an integrated software and analytics platform – Xylem Vue powered by GoAigua – that enables water and wastewater utilities to connect and manage their digital assets and streamline operations in a simple, secure and holistic view. The extended use of these and other smart technologies, if incorporated into both policy and ongoing water management procedures, can be used in just-in-time response procedures to act on poor water quality issues. “While the trend is very concerning, we can secure our groundwater sources. Legislation

and enforcement policies, coupled with greater investment in smart systems, will provide bet ter water management insight and efficiency, enabling water authorities and users to respond quickly to prevent contaminated water enter ing our rivers and aquifers. “Water is our most neglected resource, not just locally but also globally. But that also means it is full of opportunities for savings, development, and collaboration.

Taking care of water today is a last ing investment. And groundwater is the canary in the mine. If our groundwater sources are depleted or polluted, it means the situation on the surface is dire. “With the right attitude, partnerships and technology, however, we

can preserve water for gen erations,” concludes Chetan Mistry. www.xylem.com/en-za

Xylem YSI digital sampling systems are handheld multi-parameter water quality meters for providing accurate measurements of dissolved oxygen, turbidity, conductivity, salinity, TDS, pH, ammonia, nitrate, chloride and temperature along with depth.

The modern variable speed pump drive is taking pumping to a new level of flexibility and efficiency.

July-August 2024 • MechChem Africa ¦ 7

Verder advances dosing product range

Darryl MacDougall, MD of Verder Pumps South Africa, talks to MCA about the latest advancement to the company’s dosing, metering and transfer duty products range, which includes the Verderflex Dura 80; the ITC and Microdos range of dosing pumps; Vantage 5000 and Ds500 digital and IoT-enabled dosing and dispensing pumps; and the PACKO range of rotary lobe pumps.

H aving released the Dura 65 into South Africa a few years ago, Verder has now also introduced its Verderflex Dura 80 hose pump which, like the Dura 65, is an upgrade of the VF 80 from the VF series of hose pumps. “With the same basic construction and footprint, the new geometry of the Dura 80 delivers a higher swept volume from the same set of hoses used in the VF 80, making it a better than ever option for applications such as metering and transfer duties of sludges and dense and abrasive slurries,” says Verder’s Darryl MacDougall. In terms of flow rate, this peristaltic hose pump can now deliver up to 42 000 l/h or 42 m 3 /hr, and a maximum discharge pressure of 16 bar – and particle sizes of up to 20 mm can be accommodated. “This has been achieved by rearranging the geometry of the casing to make the shoe stay in contact with the peristaltic hose over a longer sweep length,” MacDougall explains. On the other end of the dosing spectrum, Verder's acquisition strategy, led by Verder Group CEO Andries Verder, diaphragm mechanism, comple ments the existing Microdos offerings, enhancing Verder's capability in delivering precision dosing solutions. The ITC brand's capability to dose up to 3 200 ℓ per hour, extendable to 7 000 ℓ per hour with a double-headed pump configuration, positions it as an ideal solution for applications requiring precise dosing, such as fertigation and water treatment,” he says. “For fertigation, a liquid fertiliser must be accurately dosed into has brought the innovative ITC dos ing pump into its product range. The ITC pump, characterised by its stepper motor and variable speed drive (VSD) controlled

The ITC precision dosing pump is characterised by its stepper motor and variable speed drive (VSD) controlled diaphragm mechanism. It is ideal for dosing in fertigation and water treatment applications.

an irrigation line to maximise crop yields,” says MacDougall, adding that the latest development using this technology is a world-first inte grated dosing pump that combines the ITC dosing system into an irrigation controller to enable pH and a whole suit lot of other data to be monitored, with dosing accuracy continuously monitored and automatically regulated,” he explains.

Competing products, he says, have relied on venturi-based dosing, which is not as ac curate because dosing volumes are directly linked to main line flow-rates, while the ITC pump enables these two variables to be separately controlled. The new ITC pump range has enhanced the dosing product range on the bottom end of dosing flow rates and at the higher end of line pressure. “We have also always had a pump called the Vantage 5000, which is a smart digitally controlled peristaltic tube pump that can de liver precision dosing and data monitoring. This pump is used for dosing of hydrogen peroxide (<35%) and sodium hydroxide at water purification plants, for example. Our R&D department has now brought out a second smart pump called the Ds500 for dosing at lower pressures, up to 4.0 bar with a flow of 500 l/h. Also, for water treatment, this pump is ideally suited for dosing reagents into low pressure lines or tanks. The Verderflex Ds500 is IoT-enabled and uses stepper motors with IP66 ingress protection. Addressing the critical need for com patibility in chemical processing, Verder has a Pure product range of diaphragm pumps for those needing to re move any possibility of a re action between the product being pumped and materials used. “The Pure range is made out of

The new Verderflex Dura 80 delivers a higher swept volume from the same set of hoses used in the VF 80, making it a better than ever option for metering and transfer duties of sludges and dense and abrasive slurries.

8 ¦ MechChem Africa • July-August 2024

⎪ Water, wastewater and pumping solutions ⎪

standards before discharge.” he explains. “Verder's innovations and market strategies are underpinned by a strong commitment to ESG standards. The conversation around access to water and the quality of discharge water is gaining momentum across industries. Verder recognises the critical importance of sus tainable water management practices, especially in the mining sector, where adherence to environmental regulations is closely linked to operational licensing. The company's efforts extend to improving municipal wastewater treatment plants, many of which are in dire need of upgrades to meet current and future envi ronmental challenges.,” concludes Darryl MacDougall. Verder's advancements in dosing prod uct technology, strategic acquisitions, and integration of innovative solutions underscore its commitment to providing comprehensive, high-quality, and environ mentally responsible pumping solutions. By expanding its product range to include the Verderflex Dura 80, ITC and Microdos dosing pumps, IoT-enabled Vantage 5000 and Ds500 pumps, and the PACKO series of rotary lobe pumps, Verder is set to meet the diverse needs of industries around the globe. Furthermore, the company's focus on addressing water treatment challenges and its adherence to ESG standards reflect its dedication to sustainability and environ mental stewardship. As Verder continues to innovate and expand its offerings, its contributions to the pump technology sec tor and environmental sustainability efforts will undoubtedly remain significant. www.verderliquids.com/za/en

Left: Verder’s Ds500 smart pump for dosing at lower pressure – up to 4.0 bar with a flow of 500 l/h – is ideally suited for dosing reagents into low pressure lines or tanks. Right: PACKO lobe pumps are widely used on liquid tankers as they are suitable for a wide range of pumped products.

pure polypropylene (PP) or pure PTFE and we have brought out an electric drive ver sion of this to complement our air-operated range,” says MacDougall. Verder’s Pure range is ideal for the chemical industry, particularly for abra sive chemical applications such as pump ing raw chemicals into a pharmaceutical plant, where no contamination from the material of the pump is permitted. “When using PTFE, we can also accommodate temperatures of up to 85 °C, and we supply over-moulded diaphragms. This provides up to five times the standard diaphragm life, because it prevents abrasive materials being trapped between the actuating plate and the actual diaphragm membrane,” he explains. Another Verder development for dia phragm pumps is the new flapper valve, which replaces ball-type non-return valves inside the pump. This means they run very quietly and can also better accommodate abrasive solids, which can pass more easily through the new valves rather than being restricted when flowing around a ball. They

deliver higher flow velocity because the effective apertures are wider, which also reduces the shearing effect on the product passing through the valve area. Following another of Andries Verder’s acquisitions, Verder has now extended its PACKO rotary lobe range of pumps. Lobe pumps are ideal for pumping shear sensitive liquids that are prone to separation. PACKO lobe pumps are widely used on liquid tank ers as they are suitable for a wide range of pumped products. “This is another product that is helping us to grow our market on the food and beverage side,” he says. “In South Africa, Verder is poised to capi talise on the growing demand for advanced water treatment dosing technologies. The introduction of the ITC dosing pumps, and the continued success of peristaltic tube pumps are central to Verder's strategy to address the needs of larger water treatment facilities. These facilities, which often deal with mine-affected water, require precise pH control and the addition of flocculants and lime to meet stringent water quality

July-August 2024 • MechChem Africa ¦ 9

XYLEM SOLAR SOLUTIONS High-efficiency solar powered pumps

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⎪ Water, wastewater and pumping solutions ⎪

Inline pumps for space-saving applications Pump manufacturer KSB Pumps and Valves South Africa has introduced its latest EtaLine range of inline pumps, which includes the advanced EtaLine Pro for diverse applications such as HVAC, industrial recirculation and heating systems.

Left: The EtaLine Pro pump with built-in VSD offers impressive efficiency, delivering reliable performance without the need for balancing valves. Right: Space saving EtaLine pumps are ideal for industrial application in confined spaces.

T he new single-stage volute cas ing KSB EtaLine pump requires a smaller footprint while maintain ing high outputs, as required in tight industrial applications where space is at a premium. The standard range of dry installed EtaLine pumps varies in output from 1 400 l/min to 3 000 l/min making them suitable for numerous applications in tight quarters where performance and reliability are key. KSB EtaLine pumps are engineered to excel in air conditioning, heating systems, water supply, heat recovery, industrial re circulation and cleaning circuits, with key features most notably including a space

EtaLine pumps represent the pinnacle of fluid management technology,” says KSB Pumps and Valves market area manager, Dylan Mitchell. “With their innovative design and advanced features, our pumps offer unparalleled performance, flexibility and efficiency for applications in industrial pumping.” In addition to the cutting-edge design of our standard EtaLine pumps, the EtaLine Pro pump incorporates advanced intelligence features, including a VSD with remote capabilities and our user-friendly flow manager App. These features enable users to have greater control over their pumping systems, simplifying operation and maintenance processes from remote locations if required. Available Intelligent settings allow the pumps to adapt to the conditions for op timal performance, regardless of demand and flow rates, and allow vastly enhanced efficiency as a result. “These pumps are designed for efficien cy and longevity from the bottom up, and contribute to sustainable manufacturing practices by reducing material usage and weight, aligning with global efforts to mini mise environmental impacts. Their Carbon Neutral production process reflects KSB's commitment to sustainability and corpo rate responsibility,” says Mitchell. “With a focus on local manufacturing, we at KSB aim to expand our market share and solidify our position as an industry leader in fluid management solutions,” he concludes. www.ksb.com/en-za

saving inline design that allows for vertical or horizontal installation, and is ideal for environments with limited space such as roofs or attics. Unlike traditional long coupled pumps, EtaLine pumps eliminate unnecessary space requirements while maintaining exceptional performance. Despite their compact design, the EtaLine pumps boast impressive effi ciency, delivering reliable performance without the need for balancing valves. This efficiency is further enhanced by the integration of a variable speed drive (VSD) in the EtaLine Pro model, which is produced in Germany and offers users un matched control and energy savings. “Our

The EtaLine Pro pump incorporates advanced intelligence features that can simplify operation and maintenance processes from remote locations.

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Optimised motors for maximum efficiency According to BMG electromechanical specialist Graeme Neilson, the electric motor is known as the workhorse in the mining industry and plays a critical role in ensuring optimum productivity at every plant. But a major problem associated with electric motors is that they are mostly not optimised for maximum efficiency.

“I t is estimated that almost two thirds of the power consumed by the mining sector is associated with electric motors, particularly those used for pumps, fans and conveyors,” says Graeme Neilson, business unit manager for electric motors at BMG. “This is a concern for the mining sector – particularly at a time when the country’s power crisis is deepening. “At BMG, we work closely with our cus tomers to meet their needs for continuous operation and high productivity in arduous mining conditions through the development of energy efficient electric motors. Our team of electric motor designers and engineers has collaborated with global electric motor spe cialists to develop Synergy IE3electric motors that meet stringent quality standards and set the benchmark locally for arduous duty, high efficiency motors. “Apart from critical energy saving features, BMG’s Synergy IE3 motors have important advantages over other electric motors on the market. These benefits include lower cost of operation, suitability for voltage variation applications, reduced temperature rise and minimal maintenance requirements. Synergy motors also offer greater reliability, reduced noise and vibration levels, more flexibility and longer service life. “The BMG range of Synergy IE3 mo tors – developed specially for harsh mining conditions in Africa – have standard features that include IP66 protection against dust and water in gress and Class H insulation, with a Class B temperature rise. This means that

The Synergy range is ideal for use in many industries, including mining and metallurgy, pumps and water treatment, petroleum, chemical, cement and sugar and paper milling.

sures the starting sequence is efficiently man aged. Standard motors operate at fixed speed, regardless of the actual output required, while Synergy motors can operate efficiently, with out cogging at low speed, in conjunction with a variable speed drive (VSD) to reduce energy consumption by over 50%. VSDs are designed to manipulate power from a constant 3-phase 50/60 Hz supply, converting it to variable frequency. This enables the speed of the motor to be con trolled to achieve maximum efficiency at the required load. Synergy IE3 motors have been surface treated to ensure extended service life in

harsh mining conditions. For maximum flex ibility during installation, both integrated and removable feet are available. Solid motor feet provide a more resistant structure against vibration, while removing the feet enables the motor to be placed in different positions on the motor frame. The latest design also allows the terminal box to be mounted top, right or left and the cable entry to be rotated by 360°, without disassembling the motor. This minimises modification time and reduces stockholding. On these critical assets, BMG specialists recommend installing an SPM bearing moni toring device for continuous monitoring of the bearing condition. Synergy has also developed aluminium housing motors, with cast iron end shields, for frame sizes from 56 to 180. Advantages of this design include a robust structure and reduced noise. While BMG offers a full range of Synergy IE3 mo tors ex stock, it can also supply IE4 and IE5 units from the factory to meet specific requirements on every mine. All Synergy 3-phase asynchronous cast iron motors encom pass the latest technology in electric motor design and are used in many industries, including mining and metallurgy, pumps and water treatment, petroleum, chemical, cement and sugar and paper milling. BMG’s electromechanical team offers a technical advisory and support service throughout the entire Southern African region. wwww.bmgworld.net

the insulation can handle much greater heat than the motor’s op erating temperature at full load. An important performance feature is that Synergy motors are most efficient when run ning between 75% and 100% of full load. “These motors have a rated voltage of 400 V and 525 V and rated frequency of 50 Hz. The efficiency and power factor values make these

motors cost-effective, offering an invest ment return in efficiency gains of between three and five years,” says Neilson. An electronic soft starter – which controls parameters such as current and voltage – en

BMG’s designers and engineers have collaborated with global electric motor specialists to develop the Synergy IE3 range of arduous duty, high efficiency electric motors.

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⎪ Power transmission, bearings, bushes and seals ⎪ Advanced drive tech for key automotive project

SEW-EURODRIVE is set to enhance a US-based vehicle manufacturing plant with its cutting-edge decentralised drive technology, specifically from its Generation C range.This advanced technology will be incorporated into a brand-new storage and retrieval system at the automotive manufacturing facility. D ecentralised drive technology from SEW-EURODRIVE’s Generation C range is to be incorporated into a brand-new storage and retrieval to the US, while others are directed to the company’s facility in Gqeberha. “We have strategically planned our deliver ies in phases, tailored to the project’s require ments. Project completion is scheduled for September 2024,” adds Steyn.

system at a US-based automotive manufac turing facility. The primary objective is to streamline the supply of vehicle bodies to the existing manufacturing unit in a bid to meet the soaring demand for vehicles and to bolster the plant's production capacity. Highlighting the significance of securing the order, Phillip Steyn, SEW-EURODRIVE South Africa Gqeberha Branch Manager, says the company has a solid track record in supplying drive technology solutions to the automotive industry. “We have consistently demonstrated our commitment to innovation, and our drive technology solutions continue to play a pivotal role in enhancing the efficiency, precision and reliability of manufacturing processes within the automotive sector,” he says. “Whether it's providing advanced gearmotors, precision control systems or customised automation solutions, we contribute significantly to the industry's ability to meet the demands of an ever-evolving market.” Steyn points out the strong global support network of SEW-EURODRIVE, which offers unparalleled logistical flexibility. This ensures optimal shipping strategies including some drives being shipped directly from Germany

Phillip Steyn, SEW-EURODRIVE South Africa Gqeberha Branch Manager.

“It is noteworthy that this particular vehicle manufacturer relies consistently on SEW-EURODRIVE's drive technology for all its global facilities. Specifically for this project, over 300 units from the Generation C range will be incorporated and the decentralised technology will facilitate independent and collaborative operations of the drives, either positioned on or near the motor in the field,” he explains. “These units have been meticulously de signed to resonate with the fast-paced dynam ics of the automotive sector, ensuring a seam less process flow and top-tier production ef ficiency,” Steyn says. The decentralised drives will be integrated with SEW-EURODRIVE's Digital Data Interface (DDI) platform and state-of-the-art servo technology for peak energy efficiency. He elaborates on the advantages of decentralised tech over its centralised coun terpart, underscoring its sustainability and consistency. “All products in our decentralised range share a uniform controller and interface, enhancing user experience and flexibility, with reduced spare parts inventory.” The end-users

stand to gain significantly as well. They can expect quicker and cost effective installa tions, faster maintenance response times and minimal disruptions, paving the way for uninterrupted productivity. www.sew-eurodrive.co.za SEW-EURODRIVE South Africa has a solid track record in supplying drive technology solutions to the automotive industry.

Left: The decentralised drives will be integrated with SEW-EURODRIVE's Digital Data Interface (DDI) platform and state-of-the-art servo technology for peak energy efficiency. Right: Specifically for this project, over 300 units from the SEW Generation C range will be incorporated and the decentralised technology will facilitate independent and collaborative operations of the drives.

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