MechChem Africa June 2019

Mech Chem JUNE 2019 AFRICA

This month: Forging Valyrian steel A slurry product fit for every application Steel processing for automotive success Waste-to-energy for micro-generation

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Pump systems, pipes, valves and seals 8 A slurry product fit for every application

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

MechChem Africa talks to Marnus Koorts, product manager for the slurry product range at Weir Minerals Africa, about fit-for-application solutions and the role Weir Minerals can play in optimising the performance and life of processing plants by selecting the best possible component combination for every application. 10 Dry vacuum pumps for better food processing 13 EMVAfrica brings 360˚ product and service solutions 15 Modern pumping systems and residents’ associations 16 Multotec ceramic impellers boost uptime 17 VSD cost saving in pumping systems Petrochemical, oil and gas 18 Novo Energy launches state-of-the-art natural gas compression station MechChem Africa attends the launch of NOVO Energy’s natural gas compression (NGC) facility in eMalahleni, one of the most advanced in the world. 20 Eastern Cape oil and gas opportunities 21 Sappi and Borregaard celebrate 20 years of biorefinery investment Power generation, sustainable energy and energy management 22 Cummins introduces new technology NG generators Cummins’ debut of the HSK78G natural gas generator series represents a bold step that pushes new levels of efficiency, transient performance and gas variation. 23 New solar heating systems save millions 24 Better transformers for improved safety and efficiency 25 Hamon deal beefs up John Thompson’s offering Environmental, waste management and cleaning technologies 26 Re-imagining waste-to-energy for micro-generation Kate Stubbs, director: business development and marketing at Interwaste talks waste-to-energy for micro-generation. 28 Metso showcases metal recycling offering 29 Wolfen PET recycling team established Localisation, manufacturing, production and food processing 30 Optimised steel processing drives automotive success Allied Steelrode’s steel processing technology is driving optimised efficiencies within SouthAfrica’s automotive manufacturing sector. Allied Steelrode general manager for sales in the automotive sector, Lee-Ann Geyser, explains. 33 Preparing for Generation Z in the manufacturing sector Special report engineering 34 Provisional patents essential for robust IP Janusz Luterek of Hahn+Hahn talks about the importance of seeking a provisional patent for an innovation before undertak- ing any research into its market potential. Innovative 38 Forging Valyrian steel Does a real-life version of Valyrian steel have the potential to revolutionise automotive markets? REGULARS

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

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

Front cover: Festo Kershia Beharie +27 (0)11 971 5531 kershia.beharie@festo.com www.festo.co.za

2 Comment: Plastic waste, the circular economy and RDF 4 On the cover: Higher productivity through digitalisation

Adrian Bromfield, outlines some of the technologies making Industry 4.0 at Festo much more than hype. 6 SAIChE IChemE: National Order of Mapungubwe for Thokozani Majozi and other news. 35 Product and industry news 40 Back page: Highly fire-retardant biomaterials coating.

Publisher of the Year 2018 (Trade Publications)

June 2019 • MechChem Africa ¦ 1

Plastic waste, the circular economy and RDF

I remember attending a press event at Interwaste in Germiston back in 2016 for the launch of South Africa’s first refuse derived fuel (RDF) plant. RDF, according to Mike Nicholls speaking at that time, is dry industrial waste, which Interwaste sources locallyby sorting suitablewaste fromtargeted industries: furnituremanufacturers and generators of non-recyclable/single use plastic waste, for example. Interwaste had begun to manufacture two types of fuel fromthewaste collected from its partner custom- ers: a pelletised solid fuel from wood-based waste, extruded logs and cardboard; and a fuel called ‘fluff’ produced by shredding and baling the pre-sorted plastic waste. Our lead Environmental management article in this issue features another article from Interwaste, in which Kate Stubbs urges us to re-imagine waste for energy production. She talks of the circular economy, in which resource input, waste, emissions and energy leakage are minimised. “This means eliminating un- necessary wastage and waste generation that would eventually be disposed of at a landfill site,” she says, “… by optimising resource efficiency through sustainable product designs; recovery, re-use and recycling of products;orenergyproductionthroughthesystematic approach of the waste hierarchy.” Retired British long-distance solo-sailor, Dame Ellen MacArthur, has established a foundation ‘to ac- celerate the transition towards a circular economy’. Having tospendmonthsonayacht carryingeverything needed for survival gives a keen sense of maximising resource use – food, material and energy – and mini- mising waste. She argues that the current system is no longer working for businesses, people or the environment. “We take resources fromtheground tomakeproducts, which we use, and, when we no longer want them, throw them away. Take-make-waste. We call this a linear economy,” she says. “We must transform all the elements of the take- make-waste system: how we manage resources, how we make and use products, and what we do with the materials afterwards. Only then canwe create a thriv- ingeconomythatcanbenefiteveryonewithinthelimits of our planet,” MacArthur argues. She believes that waste and pollution are conse- quences of the way our products and systems are designed. By changing our mindset to view waste as a design flaw, we can harness new materials and technologies to ensure that waste and pollution are not created.

She sees the circular economy, as “a newway to de- sign, make anduse thingswithinplanetaryboundaries. Shifting the system involves everyone and everything: businesses, governments, and individuals; our cities, our products, and our jobs. By designing out waste and pollution, keeping products and materials in use and regenerating natural systems we can reinvent everything.” Exciting! Themindset shift is the key, though. I ama recycler of plastic and an avoider of single use non-recyclable plastic. But it is impossiblyhard tobuyevenbasic foods without accumulating volumes of single-use plastic waste.Ihavestartedtomake ‘plasticbricks’fromwaste plastic film, by stuffing it into two-litre plastic bottles for use in simple cement-displacing building projects. I amunconvinced this solves any environmental issues, but it does make one very aware of just how much wastewe are generating. It alsomakes burning it seem a least-bad option, particularly when factoring-in the effect of the plastic islands in our oceans. AshipfullofplasticwasteexportedfromtheUKhas recently been rejected for recycling by Malaysia. On its return it is likely to be incinerated because landfill is in very short supply. It must surely be a better idea to use its fuel-value to mitigate against some of the emissions? Kate Stubbs says that single-site producers sel- dom produce sufficient waste to justify developing a standalonewaste-to-energymicro-generationproject. Pooling non-recyclable refuse for derived fuel micro- generation, however, makes perfect sense. A ship load for example? Interwaste’s Germiston RDF plant, converts single-use plastic waste into ‘fluff’ for use as fuel, either alone or with a co-combustor such as coal. This repurposing ofwaste-to-fuel reduces both the volume of non-recyclable waste to landfill and the consump- tion of conventional fuels that are non-renewable and potentially environmentally harmful. Plastic ‘fluff’ is particularly well suited to the calcining process in cement kilns, because non-combustible particulate emissions from the plastic tend to be encapsulated in the end product, leaving almost no ash. Using plastic waste in this way is soon likely to make financial sense. Stubbs points out that the global waste-to-energy market is expected to grow fromUS$28.4-billion in 2017 to almost $43-billion in 2024, “representing a massive economic opportunity to establish new industries and/or revenue streams.” And Interwaste is “striving toensure thatwaste-to- energy opportunities can be realised locally.” q

Peter Middleton

MechChem Africa is endorsed by:

2 ¦ MechChem Africa • June 2019

“At Festo, Industry 4.0 is more than just hype,” says Adrian Bromfield, head of national sales, South Africa. In this article he outlines why he can make this claim and some of the technologies and initiatives that are being rolled out. Higher productivity through digitalisation

A s the world is at the brink of an- other industrial revolution, Festo has adopted several integrated approaches to grasp Industry 4.0 in theworldof production. These approaches incorporate the interaction between people, technology, training and education. Since the introduction of Industry 4.0, Festo has launched a variety of solutions and technolo- gies for the future. Festo uses these products and solutions to increase customer’s produc- tivity in theworkplace, create a positive shift in the economy aswell asmodifyworkplaces. “At Festo, Industry 4.0 is more than just hype as it is backed up by specific products and projects,” says Adrian Bromfield, head of national sales, South Africa. “Our Motion Terminal VTEM, the modular con-

trol system CPX-E, Bionic Learning Network solutions, and the Festo App World which inspire innovation indigitalisation, CP factory as well as Industry 4.0 courses offered by Festo all reflect that Industry 4.0 is already here and being implemented,” he adds. Digitised pneumatics The Festo Motion Terminal VTEM is open- ing radical new dimensions in the world of automation, as it is the world’s first valve to be controlled by applications. As the first product to truly earn the label ‘digitised pneumatics’, the VTEM offers a multitude of functions that currently require more than 50different components to realise. TheFesto Motion Terminal uses an integrated concept to ensure energy-efficient operation. In addition to apps for saving energy, low- energy piezo valves have been developed for controlling the main valve stages. These reduce the power consumption for the pilot control by up to 90%while using just a single valve variant to reduce process costs from the design to the modernisation stage. This is where the FestoMotion Terminal VTEM comes in: it digitises pneumatics, thereby speeding up processes and reducing costs.

Gripper DHEF, which was derived from the FlexShapeGripper. This gripper was in- spired by the chame- leon’s tongue, with its ability to grip differ- ent types of insects. Unlike the mechani- cal grippers currently available on the mar- ket that can only grip specific components, the adaptive shape

gripper is extremely flexible. It can pick components with freely formed shapes and roundgeometries.Theabsenceofsharpedges makes it ideal for gripping sensitive objects such as air nozzles or trim strips. In principle, the gripper can pick up several parts in one movement,forexample,nutsfromabowl.This means that it canbeused tohandle small parts in classic machine building, in the electronic or automotive industry and in supply units for packaging installations. Thanks to simple operability, position monitoringandspeechcontrolincombination with machine learning and artificial intel- ligence, humans and robots can cooperate intuitively and efficiently. The Festo App world The Festo App World app intends to drive digitalisation in software and support cus- tomers that are transitioning to Industry 4.0. This App will be the central online platform for purchasing and downloading paid apps and digital services. Festo, as an automation expert, will combine its extensive knowledge of industrial applications with the latest developments in information technology to realise online applications for industrial automation practice. Festo will use digital communication to support its customers throughout the digital customer journey. This Festo app will be released in South Africa in the upcoming months. Modular control systems The Festo CPX-E is a great Industry 4.0 ad- dition. This powerful system for factory and process automation has been designed as an

This process is nowsimpler and less expensive thanks to the VTEMauto- mation platformbecause, instead of individual proportion- al valves, the Festo

MotionTerminal re- quires only half as

many valve slices. With the Festo Motion Terminal, 16 independent pressure zones can be set up. The key here is

the digitalisation of the pneumatics: the dif- ferent functions of theFestoMotionTerminal VTEM can be set using software apps Bionic Learning Network to inspire digitalisation The nature-inspired and technology savvy Festo Bionic Learning Network products stimulate innovation in digitalisation. A key example of this is the Festo Adaptive

The adaptive shape gripper of Festo’s DHEF grips formless, round and sensitive objects just like the tongue of a chameleon.

4 ¦ MechChem Africa • June 2019

⎪ Cover story ⎪

Industry 4.0 has become a keyword for industrial production, most shop floor workers have only a vague ideas of what Industry 4.0means andwhat impact itwill have on their working environments. This trainingprogramprovides comprehensive information on Industry 4.0 and creates understanding and acceptance for its implementation. As a result, companies will find it easier to introduce Industry 4.0 and to maintain the motivation of the workforce. The target group includes s hop floor workers and machine opera- tors. The course duration is one day. • Introduction to I4.0 for management: Industry 4.0 is an increasingly trending topic,andpeopleworkinginleadershippo- sitions encounter Industry 4.0more often thanmost; therefore, theymust be know­ ledgeable about its impacts. Managers need to have a basic understanding of the core elements, technologies, and how their interaction leads to Industry 4.0. Subsequently, they can develop new business models and specific strategies to imple- ment Industry 4.0 solutions in their companies. The target group for this one-day course includes upper management, decision-makers and executives. • Industry 4.0 - Applications in series of applications that previously could not be implemented or that could only be implemented through tedious manual labour. These applications can be used for plant operation, maintenance, planning and control, as well as for tracking orders and inspecting plant operation. During this training course, the participants will learn about ways to use these kinds of applicationswithin a complete production process, using the Festo Didactic CP Lab or the CP Factory as an example. This is a five day course that targets t eachers and trainers who want to work more closely with the technical contents of the CP Lab or CP Factory. This year Festo is showcasing all the listed solutions that place it at the forefront of Industry 4.0 at the Festo Automation Expo. The first Automation Expo in Johannesburg has been concluded and was a great success. If you missed the Johannesburg expo,there is still an opportunity to attend expos in Port Elizabeth on the 4 th July, Cape Town on the 19 th July and Durban on the 15 th August. Space is limited soRSVPonwww.festo.co.za/ expo2019. For more info about the Automation Expo, contact 08600 FESTO (33786) or email the marketing team at events.za@festo.com. practice: Industry 4.0 allows smart-factoryworkers tousea

Above: The Festo cyper-physical learning and research platform used by businesses, in industry and at educational facilities. Right: The Festo CPX-E combines servo and stepper motor technology for smooth mixed operation. EtherCATmaster controller and motion controller with protec- tiontoIP20.WithNE21-specific certifications, the CPX-E is fast becoming the central control system for handling technology.

learning fac- tory solution – a modular learning envi- ronment that can be used to

Several bus modules are available for the configuration as a compact and low- cost remote I/O. In addition to comprehensive PLC func- tions right up to multiple axis applications with interpolation, the CPX-E can be easily integrated into existing host systems. This is made possible by the EtherCAT master interface, the integrated PROFINET device interface or the EtherNet/IP slave interface. The OPC UA client and server functions ensure easy integration and interoperability in Industry 4.0 host environments with cloud anddigitalisation concepts. Inaddition to this, the Festo CPX-E features specific software functions that are tailored for products and solutionpackagesfromFestosuchasHandling technology and complete automation. Cyber-Physical Factory The Festo CP Factory (Cyber-Physical Factory) reflects this new Industry 4.0 pro- ductionparadigmbyofferingamodularSmart Factory system for teaching and research purposes. The CP Factory is part of a holistic

qualify personnel in the operation of a par- ticular production process or in a particular field of work, such as production technology. A variety of qualification modules can be added to the CP Factory: process-oriented training in thefields ofmechatronics, logistics and process optimisation as well as organ- isational and skills training in aspects such as interdisciplinary collaboration, learning capacity and adaptability. Industry 4.0 courses offered by Festo WhiletherearespeculationsthatIndustry4.0 machines might take people’s jobs in the industry, Festo believes that machines can never entirely replacehumans in the industry and that Industry 4.0 is only there to sim- plify people’s lives. This is why Festo offers Industry 4.0 courses to equip its customers with this change towards digitalisation. This year Festo is offering the following Industry 4.0 courses: • Introduction to Industry 4.0: Although

June 2019 • MechChem Africa ¦ 5

Professor Thokozani Majozi of the University of theWitwatersrand has been named as a recipient of the National Order of Mapungubwe. National Order of Mapungubwe for Thokozani Majozi

T he prestigious National Orders rec- ognise South Africans and foreign nationals who have contributed towards the advancement of de- mocracy and made a significant impact on improving the lives of South Africans. As the highest awards that our country’s President, Cyril Ramaphosa bestows on citi- zens and eminent foreign nationals, the 2018 National Orderswere issued at an investiture ceremony held on 25 April 2019. They rec- ognise the contributions made by individuals who contributed and continue to contribute towards building a non-racial, non-sexist, democratic and prosperous South Africa as envisaged in our Constitution. Thokozani Majozi was awarded a Bronze Order of Mapungubwe, which recognises SouthAfricanswhohave accomplished excel- lenceandexceptionalachievementtotheben- efit of South Africa and beyond. He received the award for his outstanding contribution to science, particularly the development of Upcoming courses Root Cause Elimination Course 10 & 11 September 2019, Durban Elimination of root causes to problems is critical to enable continuous improvement of performance, and at the heart lies the success of Root Cause Analysis (RCA). KEPNER and FOURIE technology har- nesses divergent and convergent thinking processes in a structured manner enabling elimination of problem root causes. The course content includes structural prioriti- sation, root cause identificationand solution development. Licensed and presented by Thinking DimensionsGroup, the courseaccreditation as a Continuous Professional Activity is in the process of being renewed. All course brochures and registration forms are available from the Resolve website by clicking on Training followed by Scheduled events. Process Design Practices: Cilliers Kruger 04 to 08 November 2019, KOPANONG Hotel and Conference Centre in BENONI, Gauteng. According to a processmanager for amulti- national oil company: “This course is a must i

for all process support and process design engineers.” Cilliers Kruger has a lifetime experi- ence in process engineering ranging from operational support and troubleshooting, through process design, construction and manufacturing to commissioning and full production again. This course not only il- luminates the fundamentals and practical tricks-of-the-trade of process equipment design, it puts them within the context of real operational environments – unlocking the ability to troubleshoot and problem solve from a fundamental understanding of how equipment works. The course material collates compre- hensive process equipment knowledge and information focused at the design of new equipment as well as the optimisation, troubleshooting and problem solving of equipment in operation. “Great course from somebody with real life experience in design and plant op- erations and troubleshooting. You arenever too old to learn how stuff really works!” [Principal Process Engineer, 25 years experience, International Petrochemical Company] “This course cuts through all the fuzz universities taught us to give a practical a novel mathematical technique for near- zero-effluent batch chemical facilities, which enables the better re-use of wastewater. Majozi’s 2008 research paper on this topic highlights the advantages of reusing wastewater inbatchproductionplants, which can negate much of the effluent produced, thereby enabling a process to operate in an almost zero-effluent manner. The paper presents a mathematical technique for the simultaneous design and scheduling of batch operations to function with near-zero effluent discharge. The tech- nique determines the number and size of the processing vessels, while ensuring maximum water reuse in the production process. The principles were applied to an illustra- tive example and an 80% savings in waste- water was achieved, with a corresponding plant design that achieves the required production. “As a young scientist, more trailblazing is expected of him in the years ahead,” reads

overview of process engineering. I would recommend it to all young engineers as a starting point for their careers. It is life changing.” [Process Engineer, 2years experi- ence, Engineering Contracting Company] Lieberman Process Troubleshooting Seminar 02 to 06 December 2019, Southern Sun, Vanderbijlpark. This popular process troubleshooting seminar is conducted by the internation- ally acknowledged expert in his trade and author of several world renowned books. The presentation is interactive and would benefit all those working in the process engineering field from novice engineers to the most experienced. The full spectrum of troubleshooting methodology, practical approach as well as process fundamentals – including dis- tillation; reboiling and condensing; fired heaters; pumps, turbines and steam jets; ejectors and compressors – are addressed in a challenging, stimulating and enthusi- astic manner. It is eye opening, challenging and inspiring. The course is accredited with 5 CPD credits (SAIChE 349) www.resolvekzn.co.za A posthumous Gold award was also be- stowed on Edna Molewa for her exceptional contribution to the fight to save our planet from the effects of climate change “Through her tireless efforts, SouthAfrica is recognised as one of the global leaders in matters of environment of justice,” reads her citation. q the announcement by the Chancellor of the National Orders. Majozi is in very good company, with other National Order of Mapungubwe win- ners including: Silver Order awards forMalik Maaza for his outstanding contribution to the field of nanoscience and nanotechnol- ogy; and storyteller, poet and social scientist, Ari Sitas, for his excellent contribution to social science scholarships and progressive policy-making.

6 ¦ MechChem Africa • June 2019

⎪ SAIChE IChemE news ⎪

Registration is nowopen for theSouthAfrican Chemical Engineering Congress – SACEC 2020: EnteringTheAnthropocene –which takes placeatTheUniversityoftheWitswatersrand from 1-3 July next year. The Anthropocene, the current geologi- cal age, is viewed as the period during which human activity has been the dominant influ- ence on the climate and the environment. How can our engineers and scientists con- tinue to improve the lives of all, whilst being cognisant of and reducing our impact? At this event, attendees can explore, discuss and discover all the ways in which Chemical SACEC 2020 registration open

New SAIChE IChemE president

Engineering has the ability to change the future for the better. Topics already identified for discussion include: Chemical Engineering Education; Environmental Process Engineering; Fluorochemical Engineering Science; Metallurgical Process Engineering and Coal Technology; Process & Materials Synthesis; Reaction Engineering; and Separation Technologies, with emerging technologies and fields of thought also catered for. Online registration is now open online at the address below. sacec2020.co.za/user/register

The new SAIChE IChemE president, Dr David Lokhat (left) took over from past president, Prof Craig Sheridan (right) at the 2019 AGM in April. Lokhat is the Head of the Reactor Technology Research Group of the School of Engineering at the University of KwaZulu-Natal in Durban, South Africa. His research interests are in catalysis and reactor engineering, specifically process intensification, high temperature processes and applications in fluorochemistry.

SAIChE IChemE

SAIChE IChemE Board members: President: D Lokhat Past president: C Sheridan Honorary treasurer: L van Dyk Honorary secretary: EMObwaka EXCOmember: MHughes EXCOmember: JJ Scholtz Council member: D van Vuuren Council member: MChetty  Council member: HMazema Council member: K Naidoo Council member: P Cairns Council member: MMabaso Council member: C Sandrock Council member: CMausse Member (co-opted): NN Coni Member (co-opted): MD Heydenrych Contact details SAIChE PO Box 2125, North Riding, 2162 South Africa

A waste-to-energy plant for generating electricity and/or heat from the primary treatment of waste. Engineers and scientists in the Anthropocene age will need to find more ways to improve the lives of all, whilst being cognisant of and reducing human impacts.

SAIChE IChemE Innovation Award nominations SAIChE ICHemE is seekingnominations for its Innovations Award, which is awarded to a practising chemical engineer or team of chemical engineers in recognition of outstanding innovative contributions to the profession or industry. The nominee needs to be:

nuity in implementing novel process technology. The level of achievement, innovation, origi- nality and chemical engineering content, the degree of practical implementation or implementation potential and evidence of direct or indirect economic or profes- sional value are the main criteria, with the emphasis on quality and creativity. Anyone who knows of worthy candi- date for the award is urged to contact Femmy Le Roux at the SAIChE IChemE SA Office. saiche@mweb.co.za

• A person who has developed a relevant novel idea: a theory, experimental de- sign or application. • A teamthat has inventedanddeveloped novel process technology for local application. • A person or team applying great inge-

Tel: +27 11 704 5915 Fax: +27 86 672 9430 email: saiche@mweb.co.za saiche@icheme.org website: www.saiche.co.za

June 2019 • MechChem Africa ¦ 7

MechChem Africa talks to Marnus Koorts, product manager for the slurry product range at Weir Minerals Africa, about fit-for-application solutions and the roleWeir Minerals can play in optimising the performance and life of processing plants by selecting the best possible component combination for every application. A slurry product fit for every

I n spite of ongoing constraints in the mining industry,Marnus Koorts believes that Weir Minerals Africa is well placed to support its customers. “In general, we are hedged against downturns by our excel- lent branch infrastructure and our focus on holistic solutions. Irrespective of whether the mining market is growing or not, main- tenance is an essential ongoing requirement and we are actively implementing strategies to help people manage the maintenance of their assets to extend wear life and reduce costs,” he says. In the mining industry, says Koorts, Weir Minerals has always strived to assess the mines’ entire processing circuit to maximise the uptime of the whole plant. “One has to look at a systemas a combination of essential components rather thanas a series of isolated ones,” he explains. “Every piece in the chain must be looked after: the mill feed passes into the mill pump, is pumped through pipes into a cyclone and onto a screen. By chang- ing any one of these circuit components, all of the others will be affected. Weir Minerals realised very early on that it could not offer customers lasting solutions without look- ing at the system as a whole,” Koorts tells MechChem Africa . The approach has driven acquisitions,

including crushing specialist, Trio ® , which ex- tendedthecompany’salreadycomprehensive mining offering. “This gives us a system-wide presence that enables us to install individual pieces of equipment that slot perfectly into a circuit without any negative effects on other parts of the process,” says Koorts. Describing how the approach works at a mine’sminerals processing plant, he says that every milling circuit is different. “Pumps are fundamental slurry handling components in minerals processing plants, but every pump in the circuit has to be designed, sized and optimised tomatch the mineral feed, mineral type and all of the other surrounding circuit components,” he points out. “While we have an unparalleled range of slurry pumps at our disposal, we no longer see ourselves as a pumps company. We offer system wide slurry handling solutions, from mill circuit pumps to cyclones, screens, valves, hoses, spools and liners. “At the end of the day, one can’t be a specialist in any of these products without understanding thewhole system. We service an extensive installed base handling different minerals at differentmines and as a result, we know and have learned where the problems and bottleneck areas are. “Many suppliers will only focus on manu-

facturing spares for pumps, or they specialise inone typeof pump: vertical spindlepumps or process pumps ormill pumps, for example. All types are important to ourmining customers, and if the understanding of the subtle differ- ences between pumps is lacking, customers may end up losing a lot of money,” Koorts suggests. Explaining further, he boasts that mill cir- cuit pumps such asWeirMinerals’ Warman ® MCR ® aredesigned tobe larger than compet- itors’ pumps, in order to turn a lot slower and reduce wear rates. On the other end of the spectrum, clearwater process pumps can be made smaller, which results in them having to turn a lot faster to do the same duty. This is beneficial from a capital cost point of view and does not have negative effects on wear as these are pumping less abrasive material. “On the large mill circuit pumps, mainte- nanceandelectricityarecritical–largepumps cancost tens ofmillions of Rands to run, which amounts tomore than the capital value of the pump. A larger pump, although more capital intensive up front, has a significantly lower operational cost, and is farmore cost effective in terms of R/ton costs,” he argues. “For every application, individual pump and every piece of connected equipment we focus on energy efficiency, product through-

A Cavex 500CVXT hydrocyclone cluster installed at a coal mine in Mpumalanga, South Africa.

AWarman MCR 450 pump installed in the secondary mill discharge circuit of a platinummine.

8 ¦ MechChem Africa • June 2019

⎪ Pump systems, pipes, valves and seals ⎪

application

Other valves for different parts of a processing circuit: pinch valves, pneumatic valves, auto-ball and butterfly valves also formpartoftheoffering.“Ourauto-ballvalves are required whenever a standby pump is installed. This valve sits between two pump outlets in a Y-configuration with the valve outlet connecting into the process pipeline. The valveball blocks theoutlet of the standby pump.When thepumps are switchedover, the ball is pushedoff its seat by thefluidflowfrom the standby, blocking the outlet of the other pump instead,” he explains. “A right-sized ball valve with comparable wear characteristics to the pump is necessary wherever a standby is installed toavoida total shutdown of the feedline should the duty pump break down,” Koorts adds. “The choice of liners and design for each component choice depends on a host of dif- ferent factors, the nature of the ore, the pH of the slurry, and particle size. Large particles from a primary mill for example, will cause more impact wear, which makes rubber lining preferable because it can absorb a significant percentage of the impact energy. Our Warman MCR mill circuit pumps – rub- ber lined with Linatex premium rubber – are therefore widely preferred for primary mill discharge duty,” he says. “For every specific application, however, it is important to look for the specific pump or valve or cyclone that will perform best. At WeirMineralswe have a huge range of equip- ment, material and construction types, which enables us to supply whole solutions that are more reliable and less costly tooperate. In the end,thisapproachleadsto thelowestpossible overall costs per tonand, therefore,maximum profitability,” Koorts concludes. q

Themetal-on-metal seals lastwell in these applications because tough and corrosion- resistantmaterials, suchasduplex steels, have been chosen for the knife seat and sealing components. “The pressure under which these valve seals operate means that they can split any rock in theirway and still ensure the integrity of the seal. Additionally, from a maintenance perspective, the only component needing any attention is the knife itself,” says Koorts. Going back to the pumps needed for leach and thickener applications, he says that Warman ® AH ® pumps with stainless steel and other wet-end impellers and bushes are widelyused. “Thesepumps are typicallymuch smaller than mill discharge pumps and they can run faster because they transfer semi- processed materials at lower volumes. In terms of wear, acidity and corrosion are the problems rather than abrasion, so materials are needed to cater for this,” he says. “Underneath a thickener, we typically use our Warman AHF pumps to cater for thickened underflow or the froth that over- flows from flotation cells. The latter usually contains the high value concentrate but the froth is full of air, whichmakes it very difficult to pump. Our AHF ® pumps have self-inducing vanes that draw in the froth and compress it to remove the air volume, which makes it easier to pump. “Inaddition,weofferanadd-ontechnology calledAHFCARS (continuous air removal sys- tem) which further helps to remove air with- out extracting any high value liquids, creating the liquid concentrate streamneeded further down the line,” he says. “Removing the air also reduces the volume, so a much smaller pump can be used,” he adds.

put, the cost of maintenance and the reduc- tion of downtime,” he says, adding “efficiency, longevity and the reduction of spares, is the game we are in.” The same approach applies to the com- pany’s valves offering, Koorts continues: “Every valve choice must match the applica- tion requirements, but the importance of this is understated in mining circles. Valves are treated as commodities. We regularly see ‘valve graveyards’ with heaps of used valves, because it is acceptable practice to remove and replace a valve as soon as it leaks. “We believe valves should help thewhole system to run more safely and for longer pe- riods between shutdowns, which is why our valves are maintainable. Our Isogate knife gate valves, for example, are designed for a longer knife and seal life, and we can quickly replace the rubber seals, which typically last for over a year. This is a lot more cost effec- tive than installing a commodity valve and replacing it every three to six months. Once again, life of mine and total cost of owner- ship come into play and we urge operators to adopt our approach instead of feeling trapped into routine replacement cycles,” he says. Koorts also points toWeirMinerals’ Delta Industrial™ severe duty knife gate valves, which use a metal-to-metal seal. “These are used in very aggressive environments such as acid leach slurries, and operators do not want these to leak because the concentrate contains valuable product,” he informs MechChem Africa .

Isogate knife gate valves installed in a coal operation.

June 2019 • MechChem Africa ¦ 9

Integrated Pump Technology’s Scott Gordon talks to MechChemAfrica about the Leybold Vacuum product line and the advantages of two recent additions: the Leybold NovaDry vacuum pump for food processing and packaging; and ScrollVac, a low power state-of-the art vacuum system for demanding applications. Dry vacuum pumps for better food processing

S cott Gordon has a long history in South Africa’s vacuum pump in- dustry, having spent over 27 years working for a local manufacturer of liquid ring vacuum pumps. “Integrated Pump Rental, however, is a local agent for Leybold Vacuum, which has taken the stra- tegic decision to focus on dry-type vacuum systems, so liquid ring vacuum systems are not included in the Leybold range,” Gordon tells MechChem Africa . Vacuum applications can be slotted into four categories: rough, medium, high and ultra-high vacuum. “Rough vacuum is con- sidered to be anywhere below atmospheric pressure and above 1.0 mbar; medium vac- uum sits between 1.0 mbar to 0.001 mbar; high vacuum takes the pressure down to 0.0000001 mbar and ultra-high vacuum can go well below that,” explains Gordon, adding that high and ultra-high vacuum can gener- ally only be generated using combinations of technologies, such as a sliding vane pump connected to a roots pump and then to a dif- fusion pump, for example. Cryogenic systems and coldheads andother equipmentmay also be applied. Cologne-basedLeyboldVacuum,apioneer of vacuum systems for nearly 170 years, has vacuum equipment to meet all four of these vacuum levels. The company offers 13 main

rotary vane pumps to ultra-high vacuum diffusion and cryogenic pump technologies. Why the focus on dry systems? “Dry vacuumtechnologies tend tobeable tohandle a wider range of gases, for example SO 2 from anacidplant. If usingaswet system, suchas an oil-flooded sliding vanepump, acidic fume can mix with the oil and break it down. Such con- tamination is not an issue if usingadry system. BrandnewtoLeybold’s product range is its dry screw-type vacuum pump, the NovaDry, which was launched in May at the interna- tional trade fair for the meat industry (IFFA) in Frankfurt. This newly developed, oil-free screw vacuum pump ensures significantly greater safetyandefficiency in foodandpack- aging processes. “With five sizes available to deliver from 65 m 3 /h to 200 m 3 /h evacuation rates and absolute vacuum pressures down to 0.1 mbar, these pumps fit into the medium vacuum category and are designed to meet FDA requirements without the need for ad- ditional filtration,” says Gordon. “Leybold’sNovaDrypumpsoffertheshort- est pump-down times in the industry, which means they can evacuate enclosed spaces faster than any similarly specified pump on the market. In addition: • They have a compact design, whichmakes themeasytoincorporateintofoodpackag- ing machines and modular systems. • Noise levels have been reduced for amore comfortable working environment. • The air is 100% oil free, which leads to a

more sanitary environment required for food related applications. “Oil flooded vacuum pumps produce an oil mist in the discharge stream, whichwould have to be taken out by filters before being allowed to enter the atmosphere. The Nova Dry pumps do not contaminate the air in any way, so they do not require such systems,” Gordon explains. • The pumps can alsohandle lowconcentra- tions of food particles in the air such as marinade and sauces, which would con- taminate the oil used in non-dry systems. • These systems are air-cooled, so they require no additional cooling water. “This 100%oil-free vacuumpump is a first for the food industry and is set to revolutionise themarket. Oil-sealed rotary vane pumps are the norm, but they pose contamination risks. The NovaDry avoids these risks and ensures food quality and freshness is maintained,” Gordon notes, adding that this pump is set to become an industry benchmark. Globally, Leyold’s NovaDry oil-free vacu- umpumps are replacing the company’s legacy range of oil-flooded Sogevac sliding vane pumps, which remainavailable and supported in South Africa through Integrated Pump Technology. Also recently added to the local offering is the new Leybold ScrollVac pump. “These systems use two mating scrolls rotating against each other to create compressed air pockets that create the vacuum. All vacuum equipment works by compressing the gas, whichcreateslowpressurevoidsdownstream of the compression point. If the downstream space is isolated from the atmosphere, then the pressure in the space reduces continu- ously asmore andmore air is compressed and evacuated,” Gordon explains. “These machines require very high preci- sion machining to minimise slippage, which is the industry term for the amount of gas that bypasses the internal components of a vacuum pump. Slippage limits the degree of vacuum possible from a particular pump technology. The better design of the ScrollVac’s tip seals leads to much less slip and, therefore, better vacuum retention on the high end of

categories of vacuum prod- ucts to achieve this: from relatively simple oil-sealed

The new Leybold NovaDry dry screw-type vacuum pump can evacuate enclosed spaces faster than any similarly specified pump on the market.

10 ¦ MechChem Africa • June 2019

⎪ Pump systems, pipes, valves and seals ⎪

themediumvacuumrange –0.1mbar. This, in turn, leads to much better energy efficiency and reliability. “In spite of the ScrollVac’s sophistication, the unit is designed to be simple to maintain, with service kits available to enable them to be serviced in the field,” says Gordon. For additional energy efficiency, the Leybold ScrollVac vacuum pump is supplied withanintegratedVSD,whichvariesthescroll speed according to the level of vacuum re- quired. “This is also important in maintaining an accurate vacuum,” Gordon adds. “To hold a vacuum, the pump speed can be controlled to maintain theexact level required.Withafixed speed pump, on the other hand, the pump would generally run at full speed to maintain the vacuum.” On service support and maintenance, he says that excellent Leybold pump and spares stocking leads to quick response times on repairs and short lead times on purchases. “We receiveweekly deliveries fromGermany and no order is too small for us. If a customer needs a single special nutwith a 0.5mmbleed hole or a right-size O-ring, we will take these very small orders and make the delivery as fast as possible,” he assures. “Whenwellmaintainedbyroutinelychang- ingfiltersandoil,vacuumsystemscanperform for seven to ten years between rebuilds. Then

Integrated Pump Technology’s legacy range of oil-flooded Sogevac sliding vane pumps, remains available and supported in South Africa. we can do the rebuilds onsite here in Jet Park using standard maintenance kits available to us from Leybold. We are also in the process of building up a loan range to enable us to offer replacement units to further minimise customer downtime,” Gordon says. “For everything we sell, our support and maintenance teams are trained to the highest international standards by Leyboldpersonnel fromGermany, whichwebelieve is essential if we want to keep up with emerging technolo- gies in South Africa,” he concludes. q

A good parts stockholding underpins the service support offering from Integrated Pump Technology.

June 2019 • MechChem Africa ¦ 11

⎪ Pump systems, pipes, valves and seals ⎪

Energy Engineered Products, Multi Alloys and E-Metals Cape have joined forces to create a powerful new brand, EMVAfrica, which has leveraged and streamlined each of the founding company’s strengths, expertise and experience. EMVAfrica brings 360˚ product and service solutions

E MVAfrica is a new company repre- sented by three heavyweights in the stainless steel, special alloy and valve industrynamelyENERGYMet- als, ENERGYValves and associated company, Multi Alloys. Through these companies, the team ismaking one of Africa’smost proficient one-stop stainless steel, special alloy and valve solution providers. Under the innovative one-stop solution provider EMVAfrica, thedivisions and subsid- iaries are well positioned to cater to custom- ers’ needs in Africa and deliver their strategy of product, service and stock solutions. “Our 360˚ approach in solving customers’ needs is what differentiates the business,” says Graham Whitty, director of EMVAfrica. “We see ourselves as Africans, we see our market as Africa and we wish to engage the world as Africans. As specialists, our capabili- ties include sourcing the best products from around the world and creating packages for local and international projects.” The ENERGYValves division, established primarily to complement the process materi- als offering, plays apivotal role as oneof three powerful brands within EMVAfrica and has earned its reputation as a leading supplier of premium quality stainless steel and special- alloy valves and supporting services. With stainless steel forming thebulkof the valves range, the division also offers valves in duplex stainless steel, titanium, 904L, zirco- nium, nickel alloys as well as numerous other high-performance alloys. The company’s comprehensive valves portfolio includes a rangeof ball, knife gate, wedge gate, butterfly,

EMVAfrica Warehouse.

check, needle, and pressure relief valves. “In addition to stainless steel, ENERGYValves supplies valves in lower steel grades such as carbon steels. The division also holds exten- sive stock of the most commonly used valves in corrosion resisting alloys.” In more recent times the valves division has expanded its offering to include a range of pneumatic actuators. The extensive technical expertiseinspecialalloysprovidesanin-depth understanding of their performance in corro- sive and challenging industrial environments. “As part of the dynamic EMVAfrica group, ENERGYValves is positioned as more than a supplier of valves; we offer complete solutions,” says Whitty. “Our valves are well- accepted in a range of industries including mining, construction and engineering. We remain committed to providing the finest quality products coupledwith unrivalled ser- vice excellence toour customers, irrespective of the application.” ENERGYValves is ISO9001: 2015 certi- fied. The range of stainless-steel valves is sourced from reputable and highly certified manufacturers and suppliers with proven track records. “The division is focused on establishing long-term relationships with suppliers. It regularly audits its quality stan- dards andprovidesmaterial andpressure test certificates with all valve products.” The ENERGYMetals division imports, stocks and distributes premium quality industrial stainless steel. The company of- fers process materials such as pipe, fittings, flanges, fasteners and heat exchanger tubes, aswell as engineeringmaterials suchas round

bar, angleandflat bar, andpolisheddecorative tube. The company supplies fromstock or ex- mill for larger products. “Over the years, ENERGYMetals has as- sembled an industry-leading teamof special- ists enablingus tooffer unrivalledexpertise in allaspectsofourproductrange,”notesWhitty. “As part of EMVAfrica, ENERGYMetals is perfectly positioned to offer customers its comprehensive product and service suite, to ensurethatwemeetourcustomers’individual requirements.” Turning to service, Ken Perel, founder of Multi Alloys, affirms that EMVAfrica mirrors its extensive product expertise in its service and after-sales service offerings. “The com- pany’s ongoing commitment to adding value through decades of experience has earned us the reputationof oneof SouthAfrica’s leading purveyors of special alloys,” says Perel. “The company’s product portfolio consists of nickel alloys, duplex and super duplex stain- less steels, high performance copper alloys and other niche products which are sourced from certified manufacturers.” Combining excellent product knowledge with outstanding international logistics ca- pabilities, Multi Alloys’ professional team of- fers solutions from its industry-leading stock rangeaswell as through sourcinghard-to-find items internationally. “Multi Alloys is proud to be part of EMVAfrica. The quality of our products and services is of primary importance, sowemade sure that it retained its pivotal rolewithin the new business,” Perel concludes. q

June 2019 • MechChem Africa ¦ 13