MechChem Africa March-April 2023

MechChem MAR-APR 2023 AFRICA

Level. Switching. Pressure. Measurement technology and automated inventory monitoring for the chemical and petrochemical industry.

www.vega.com

This month: Direct water recycling: a solution to scarcity

Integrated solutions deliver plant efficiency

Reducing energy consumption for mine dewatering

Fluid engineering for better power security

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CONTENTS 30 Water, wastewater and pumping solutions 6 Water recycling: a solution to scarcity and quality challenges MechChem Africa talks to Louis Koen of Zutari about the advantages of adopting direct potable, water reuse to overcome water scarcity and quality challenges. 8 Reducing energy consumption and costs for mine dewatering and water transport 11 The dangers of non-OEM peristaltic hose 12 Hawk pump-nozzles unblock all 13 IPR now distributes Atlas Copco dewatering pumps 42

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.

Power transmission, bearings, bushes and seals 14 SEW-EURODRIVE set to support Africa’s growth From its extended facilities in Johannesburg,SEW-EURODRIVE SouthAfrica is strengthening its footprint by establishing new branches aroundAfrica. 17 Custom engineered drive services for mining and minerals processing

18 Machine strength defined by pivot joints 19 BI promotions showcase new online store Minerals processing and materials handling 20 Integrated solutions deliver plant efficiency

Through its Integrated Solutions approach, Weir Minerals Africa provides fast and effective assistance. 22 Another innovation for sugar production 23 Turnkey condensation and recovery solution optimises safety 24 First locally manufactured SmartPlant™ in Africa Hydraulic, pneumatic and automation solutions 26 Sailing the seven seas with Keller 21Y pressure sensors A Keller 21Y pressure sensor is at the heart of a hydraulic system powering the tilting keel of skipper Isabelle Joschke’s IMOCA sailing boat. 29 OMRON and Mamello Clinical Solutions deliver SA’s first HERO21 sanitisation robots PowerGen, PetroChem and sustainable energy management 30 Fluid engineering for better power security MechChem Africa talks to Jannie Botha of HYDAC Technology about HYDAC’s Fluid Engineering philosophy and the tailored fluid solutions that enable power generation plant operators to optimise energy efficiency, process reliability, and system availability. Environmental management, waste and cleaning technologies 36 SA chemical engineering wins Blue Sky Young Researchers award A 25-year-old SouthAfrican,Leane Naude,has won third place in the global 2022-2023 Blue SkyYoung Researchers InnovationAwards programme. 37 Boost for black-owned recycling Innovative engineering 42 Accelerating ABB’s Mission to Zero Graham Abrahams, senior vice president for the Electrification Products Division of ABB South Africa, talks about what is required to achieve net zero emissions by 2050. Regulars 2 Peter’s comment: The Faure direct water reuse scheme: another global benchmark 4 On the cover: VEGA Inventory System: the proactive supply chain solution 38 Products and industry news 44 Back page: Green future for former coal mines 33 Zest WEG gains traction in oil and gas 34 Rand-Air adds energy storage to hire fleet

Transparency You Can See Average circulation Oct to Dec 2022: 9 824 Printed by: Tandym Print, Cape Town

Front cover: VEGA Controls SA (Pty) Ltd

Contact: Clint Viviers Tel: +27 11 795 3249 clint.viviers@vega.com www.vega.com

March-April 2023 • MechChem Africa ¦ 1

The Faure direct water reuse scheme: another global benchmark

While putting tother this issue of MechChem Africa I learned from Louis Koen of Zutari about the Faure New Water Scheme (FNWS), which was initiated by the City of Cape Town immediately after the Day Zero scare in 2018. For Southern Africa, this scheme is set to become a second global benchmark in the direct treatment and reuse of domestic wastewater to supply a city’s drinking water. The first? The WINGOC (Windhoek Goreangab Operating Company) plant, which has now been processing wastewater – for the people of Windhoek to drink – for over 50 years. The original Goreangab drinking water reclama tion plant was able to treat 4.3-million litres of water per day, which was 10% of Windhoek’s potable water demand. In 2002, though, the New Goreangab reuse plant was completed, and included an upgraded purification process that can produce 21-million litres of high purity potable water every day, meet ing 25% of the water needs in Windhoek. This plant is globally recognised as the pioneer of direct water reuse technology. In its 50 year history, while having provided clean drinking water to more than 300 000 residents of Windhoek, neither the new WINGOC plant nor its predecessor have ever been responsible for any negative health issues as a result of the wastewater resource or the failure of its treatment processes. This is perhaps because of the sensitive nature of using domestic wastewater, which demands vigilant monitoring of the water quality before it can be re introduced into potable water reticulation systems. As a temporary emergency intervention in re sponse to the severe drought, The City of Cape Town operated a modern demonstration reuse plant from the Zandvliet WWTP from mid-2019 to the end of May 2021. While the water was never introduced into the potable water distribution network – the dam levels supplying the City of Cape Town recov ered before the emergency plant was commissioned – it was repurposed into a demonstration plant to validate water quality results and ensure that direct wastewater treatment really does produce water that is safe to drink. The strictest available standards for purified wastewater were used in the assess ments, including international standards prescribed by the WHO, the US, EPA and others. As a result of this research, along with years of rigorous economic and environmental studies, technical research and planning, the Faure scheme has been designed based on the newest purifica tion technologies, sophisticated online monitoring and control systems, and best-practice operating protocols. The design has been peer reviewed by international water reuse experts and follows the

Validation and Hazard Analysis and Critical Control Points (HACCP) approach used by the food and beverage industry. A five step treatment process has been adopted: • Ozonation uses the strong oxidising proper ties of ozone to destroy any disease-causing pathogens/germs and break down complex organic substances into simple biodegradable organic substances, which are consumed in the BAC filtration process of Step 2. Biologically Activated Carbon (BAC) Filtration removes particles and biodegradable organic substances. Granular Activated Carbon (GAC) Filtration removes non-biodegradable micro-organic substances through adsorption. Ultrafiltration removes particles, pollutants and pathogens/germs that are smaller than 10 μm (1 000 times thinner than the width of a human hair). An Advanced Oxidation Process with ultravio let lamps combines light and chemical energy to break down any remaining organic chains to their molecular building blocks – CO 2 and water. The FNWS plant’s 100 million litres per day of po table water will initially be blended with raw water from dams, with a maximum ratio of 20% reuse water to 80% dam water. The blended water will then pass through the conventional treatment processes of the existing Faure Water Treatment Plant, before being stored in the Faure Reservoir ready to be widely distributed across Cape Town. Water reuse is one of the most cost-effective new water resource options. According to the City of Cape Town’s ‘Water Reuse for Cape Town’ book let, direct reuse is estimated to cost about 60% of a typical desalination plant or a groundwater plant from the Cape Flats aquifer – and set up costs are only slightly more than the cost of groundwater from the Table Mountain Group aquifer. It also has less environmental impact than desalination and other surface water options. Wastewater, particularly in coastal areas such as Cape Town, is often discharged directly into the ocean. In the light of global warming, we cannot continue to rely on the natural water cycle to clean that water and bring it back to us as rain. Like the water we get via our natural water resources, direct reuse water must be appropri ately treated to make it 100% safe to drink. This technology is long proven though, as well as being very cost effective, less energy intensive and more environmentally friendly than other options such as seawater desalination. • • • •

Peter Middleton

Comment

MechChem Africa is endorsed by:

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March-April 2023 • MechChem Africa ¦ 3

VEGA Inventory System: the proactive supply chain solution Some years ago, VEGA Controls SA introduced the VEGA Inventory System (VIS), a Cloud-Based system designed to manage and optimise stock levels of liquids in tanks and/or bulk solids in silos, into South Africa. MechChem Africa talks to Product and Technical support Manager, Clint Viviers, about the system’s benefits for suppliers and customers. C lint Viviers’ responsibilities include all technical aspects within VEGA Controls SA, along with sales and service support, and the flow of It enables multiple users from across the sup ply chain to see live data and how to manage their future needs remotely, from anywhere, on a 24/7 basis,” he adds.

makes for a lot of room for error,” says Viviers. If, on the other hand, the supplier is using VEGA level measurement technology – such as our VEGAPULS 6X RADAR Level trans mitter – along with our Inventory system, the supplier and the chemicals/commodities customer can connect to each other via the Cloud. The levels in every tank are measured and uploaded to the VIS at specified time intervals. From there they can be viewed by anyone with access to the VIS portal. Suppliers can also alert their customers directly to the need for stock in one or any number of their tanks. Orders can automati cally be generated and dispatched on a just in-time basis, without the need for human intervention. “For full transparency, customer levels can also be made available to the supplier, creat ing the certainty needed for future planning,” he explains. “So the customer’s needs are automatically made known to the supplier, who enables suppliers to proactively respond and plan a delivery, which will arrive without the need for any action from the customer,” Clint Viviers tells MechChem Africa . Advantages for the supplier include: quick access to current and historical customer consumption data, enabling supplier stock ing levels to be optimised; cost-effective production and inventory management in its own facilities; increased efficiency of plan ning processes; cost savings through optimised logistics;

Describing the conventional way of replen ishing stocks, he says that stock levels of tanks have always been measured using some sort of level measuring technique or sensor. “We at VEGA are specialists in level measurement and have a number of measurement solutions that are used in countries all over the world, including South Africa. “Traditionally, a production facility at a chemical plant, for example, would have relied on an operator to take manual readings of the levels in all the tanks, which would then be manually entered into an Excel spreadsheet. The accuracy of this manual reporting has a direct impact on production planning and the efficient supply to end users or customers. “The customer order would be received and processed, and the supplier would need to confirm having the stock before a tanker could be arranged, filled, and sent across to the customer. It was, and for many people still is, a very manual and time-con suming process – and manual intervention

communication on sensors and approvals between South Africa and Germany. “I am also the radiation protection officer, so I have multiple roles to keep me awake and excited,” he begins. The VEGA Inventory System (VIS) is another reason for excitement: “VIS is our value-added product, complementing our main business line of Level and Pressure Instrumentation. It is a purpose built and ultra-modern Vendor Managed Inventory (VMI) system that uses the Industrial Internet of Things (IIoT) to couple advanced software with our latest VEGA level sensors. It closes the supply chain loop between customers and production facilities dependent on stocks of chemicals, fuels, food, beverages or any liquid or powdered commodity stored in a tank or silo with a level sensor,” he explains. Companies across the world, he says, are moving to cloud-based inventory control sys tems. “Our VIS is the equivalent of a remote monitoring system for stocking levels in tanks.

and improved customer relationships and long term customer loyalty. From a supplier

perspective VEGA’s Inventory System offers continuous, 24/7 remote inventory monitoring for a diverse range of liquids, including

water, chemicals, fuels, lubricants, additives and liquid gases; as well as bulk solids such as cement, grain, powders, granules and pel lets. “The advantages in terms of security of production and customer are considerable. And not only does VIS software draw on

Ideal for petrochemical industries, the VEGA Inventory System (VIS) is a Cloud-based system designed to automatically measure, manage and optimise stock levels of liquids in tanks and/or bulk solids in silos.

4 ¦ MechChem Africa • March-April 2023

⎪ Cover story ⎪

current measurement data, but it also tracks and trends historical data gathered from ongoing consumption. This is a powerful tool for optimising production and supply chains,” Viviers notes. He cites a recent success with a local chemical producing company that supplies a large mix of industrial chemicals to customers and plants across South Africa. “We have now installed our VEGA Inventory System coupled to the RADAR Level monitoring sensors on this supplier’s storage tanks. Now, any of their longstanding customers – if granted permis sion – are able to log into the system, check stock availability and schedule a delivery. And this is as easy as doing an online order at a supermarket,” he tells MechChem Africa . The ultimate goal, though, is to close the loop by having the system installed on both ends of the supplier chain. This would enable automatic reordering of stock to replenish any tank or silo on the customer’s end that is becoming depleted. Because usage is continuously tracked, the supplier is able to predict and plan ahead to meet future needs. Also, when the delivery arrives, the correct chemicals and quantities needed are deliv ered, minimising the costs of errors related to logistics and route planning. “It often happens that when a delivery ar rives at the customer site the receiving tank is not as empty as expected, for example. This means the tanker cannot discharge its full load and it must then carry any excess back to the supplier. This is costly and wasteful – and can be eliminated if suppliers and their customers both adopt this simple and very cost-effective VIS solution,” he says. In terms of installation, Viviers confirms that many suppliers and end users are already using level sensors such as the VEGAPULS 6X to monitor stock levels. “The VEGAPULS 6X is the ideal radar sen sor for continuous level measurement of liquids and bulk solids. It offers particular advantages for liquids in small tanks with tight mounting spaces. The sensor’s very good signal focusing also enables it to be used in vessels with internal structures such The VEGAPULS 6X is the ideal radar sensor for continuous level measurement of liquids and bulk solids.

The VEGA Inventory System enables chemicals to be automatically ordered, and tank deliveries to be scheduled for just-in-time delivery.

as stirrers and heating spirals,” notes Viviers. These are HART sensors that transmit measured values from up to 15 tanks/silos to a single VEGASCAN 693 controller. Data can then be sent to the company’s PLC, which is controlling production processes, and sepa rately, via a LAN or GSM ethernet connection, to the cloud-based server hosting the VIS software. “Generally speaking, as long as the level sensors being used are HART compliant, the only hardware required to implement the VEGA Inventory System is one VEGASCAN 693 controller for every 15 measuring points on the site,” he tells MechChem Africa . “A typical client environment might have many over 15 tanks spread across a 500 m plot of land. You can imagine how dif ficult it could be to measure all the tank level values manually and get them into a spread sheet. With this system, we can collect and up date values as frequently as every 15 minutes, which can be accommodated by a relatively slow broadband connection,” he adds. Wherever process control is involved, Viviers says engineers prefer to steer clear of ‘The Cloud’ for fear of the plant being hacked. But because the VEGASCAN 693 controller is purely collecting and visualising data, there is a low risk. “Even so, the first question I get asked when introducing our VIS is about cybersecurity”. “VEGA’s Cloud-based VIS Portal is very well protected. With respect to cyber secu rity, we are audited and certified to IDW DS 951 SOC2, which is the highest cyber security level a commercial sys tem can have. This ensures that all embedded sys

in information and data encryption for signals being sent via the Internet, are in place. Cyber security is always going to be important, but we are on top of it. We can confidently assure existing and potential customers that the VEGA Inventory System cannot be hacked,” Viviers assures. “Overseas, use of inventory management systems such as VIS is already the norm. Many people in South Africa are also seeing the beauty of the system. The installation cost is almost negligible and for the VIS software sys tem, VEGA has adopted a hosting approach so that it is seen as an operational expense. “Given the operational cost savings that will quickly accrue due to supply chain effi ciency and production optimisation savings, this hosting fee will also come to be seen as negligible. The system has a proven return on investment and adds real value through clear visualisation and simplified representation of inventory in real time, which allows stocks to be replenished reliably, efficiently and far more cost effectively,” Clint Viviers concludes. www.vega.com/en-za The VIS software can draw on current and historical measurement data to track trends gathered from ongoing consumption.

tem security mea sures, such as log

March-April 2023 • MechChem Africa ¦ 5

Water recycling: a solution to scarcity and quality challenges MechChem Africa talks to Louis Koen, a Cape Town-based process engineer and technical director at Zutari (Pty) Ltd, about the advantages of adopting direct potable water reuse to overcome water scarcity and quality challenges.

downstream potable water treatment plant abstracting water from the same source. This is referred to as de facto reuse. “An additional challenge is that most of our drinking water treatment plants are not designed to deal with contaminants of emerging concern (CECs), and we rely on the environmental buffer to reduce the impact of these contaminants via dilution,” says Koen. To remove the contaminants, advanced purification processes are required. Although technology to address these CECs is avail able and mature, it is too pricy to apply in a normal potable water treatment plant. The technologies are rather reserved for projects that specifically target potable water reuse. “Our federal water laws are also not really

designed to protect users from CECs, which include pharmaceuticals; herbicides and pesticides; hormones; endocrine disruptors; micro plastics; forever chemicals and many other chemicals in low concentrations that, if unaddressed, are likely to cause long-term health issues for whole communities. Very few of these chemicals are regulated by our drinking water guidelines and we must rely on internationally published guidelines,” Koen explains. “In the City of Cape Town catchment area, we are fortunate that our traditional raw water supply is sourced from high mountain catchment areas that are unaffected by wastewater discharge. Our raw water is thus pristine, but this is not the case for inland

T o address South Africa’s water challenges, Louis Koen says it is important to distinguish between the problems in coastal areas such as the Western and Eastern Cape and those inland around the mining and key industrial areas of South Africa. “I don't think water scarcity is the same everywhere. Some areas of our country have been blessed with an abundance of rain with frequent flooding oc curring in Gauteng, the north coast of KZN and inland from the Northern Cape to the Northwest Province. “In direct contrast to this, other areas of our country are extremely dry, such as the coastal areas in the Eastern Cape. I think global warming is largely responsible for the unusual weather patterns we are seeing. “Here, in the City of Cape Town, we have had good rains since 2018, but we know that there will again be years when the rains fail, and we must be better prepared for these years than we were in 2018,” Koen tells MechChem Africa . “We are already concerned that last year we had a lower rainfall than the previous year, so our dam levels are lower than we had hoped. If we have another low winter rainfall season in 2023, we could be back where we were a few years ago. Changing weather patterns due to global warming are a reality, but it is very difficult to predict how they will impact us,” he says. Another critical issue affecting future wa ter security is the power crisis. “It is challeng ing to operate water and wastewater treat ment plants with intermittent power. For the City of Cape Town, we are installing massive diesel generators to allow their wastewater treatment plants to continue running during a power outage, but this is expensive and not all municipalities can afford it,” says Koen. Without backup power, power outages affect the treatment efficiency of our already ailing wastewater plants. “Most wastewater treatment plants are unable to produce qual ity wastewater during a power outage and this affects the surface water discharged into our rivers and dams,” he says. This is a particular concern in inland ar eas where wastewater treatment plants discharge to a river or dam that feeds a

The control room at the end of the treatment process overlooks the UV-based advanced oxidation process (AOP) that breaks down any remaining organic chains into CO 2 and water.

A view of the ultrafiltration plant that removes any particles, pollutants and pathogens/germs smaller than 10 μm.

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⎪ Water, wastewater and pumping solutions ⎪

facilities that source water from a river or dam impacted by wastewater. This is where potable water reuse is critical, whether it is de facto reuse, direct potable reuse or indirect potable reuse. “Potable water reuse is not uncommon, and the pioneers are without doubt our neighbouring country Namibia, which has been running the internationally renowned WINGOC advanced water treatment plant for the past 50 years. The WINGOC plant has long proved the potential and safety of direct potable water reuse,” he adds. The Faure New Water Scheme The current flagship direct potable water reuse project – for Zutari and for South Africa – is the Faure New Water Scheme (FNWS). The City of Cape Town initiated this project after the Day Zero scare in 2018. The FNWS will treat wastewater from the Zandvliet WWTP (Wastewater Treatment Plant) to potable water quality. The FNWS plant will produce up to 100-million litres of clean drink ing water per day. Although the water quality would be drinkable, the intention is to blend the reclaimed water with surface water from local dams, with a maximum blending ratio of 20% reuse water and 80% natural freshwater. One of the reasons for the success of this scheme is that the wastewater feeding the Zandvliet WWTP does not contain any contaminants from heavy industry, which would make it more challenging to treat. The Zandvliet WWTW predominantly receives residential wastewater.

Koen tells MechChem Africa that the FNWS makes use of advanced purification tech nologies to remove all CECs and other con taminants identified in the wastewater. “The water quality produced will be of a very high standard, complying with international best practices,” he says. To ensure this, the City of Cape Town has appointed an International Advisory Panel (IAP) to review the FNWS design and provide guidance and recommen dations to the Zutari design team. “Direct water recycling plants are using advanced oxidation processes to remove complex organics, including the CESs. These can be in our water in concentrations of nano grams per litre. And they are now also being found in the seawater around Cape Town because screened sewage is still being dis charged into the oceans. So direct recycling, while delivering superior quality water, can also help to clean up our oceans,” Koen argues. He adds that the cost of producing high quality water through potable water reuse is significantly lower than any other treatment options available to the City of Cape Town. The ‘Water Reuse for Cape Town’ booklet (CCT_Water_Reuse_Booklet.pdf) reports that the estimated cost of direct potable water re use is 60% of the cost of – or 40% less expen sive than – seawater desalination. It also has fewer environmental impacts than seawater desalination and other surface water options. At a Water Reuse Symposium in San Diego in the USA about two years ago, Koen says the Environmental Protection Agency (EPA) announced it would no longer support any

large water diversion schemes where water is transferred from a source over hundreds of kilometres to where it is needed. “In almost all cases, it makes much more sense, in terms of cost and the environment, to invest in direct potable water reuse,” he points out. In addition to the FNWS in Cape Town, he says there are already other smaller direct wa ter reuse plants highlighting the viability and practicality of the technology. There is a small direct potable water reuse scheme in Beaufort West that has been operating for quite some time now, and in eThekwini (Durban), there is a pilot plant that combines wastewater treat ment and seawater desalination. “As a water scarce country facing a climate and power crisis, we need to protect every water source available to us, now more than ever before. We need to become shepherds of every drop of water we have. There are too many wastewater plants that are discharging poor quality water and polluting our fresh water sources,” says Koen. “Zutari is very proud of what we have achieved so far with the FNWS project, which is being seen as a global flagship project for direct potable water reuse. We are creating a state-of-the-art direct potable water reuse treatment plant that, while building on the local WINGOC legacy, takes water quality to a new high, without

having to resort to costly or energy intensive alternative technologies,” Louis Koen concludes. www.zutari.com

An aerial view of the Zutari-designed Faure New Water Scheme, a new flagship direct potable water reuse project.

March-April 2023 • MechChem Africa ¦ 7

In response to the ongoing power crisis in South Africa and the global need to reduce carbon emissions by improving energy efficiency, Integrated Pump Technology’s key accounts manager, Justin Bawden, talks to MechChem Africa about some easily implementable dewatering solutions that mine and process plant operators can adopt. Reducing energy consumption and costs for mine dewatering and water transport

I ntegrated Pump Technology offers a wide range of pumping so lutions for dewatering, sludge, slurry, wastewater, dredging and water transport/circulation and recycling applications on mines and minerals processing plants. “We specialise in Grindex submers ible pumps that can operate from a pond floor or suspended above the floor using one of many pump flotation devices. “We can also offer pump cages as a means of additional protec tion for pumps that operate in rugged environments and, apart from standard cast iron and aluminium pump units, we also offer stainless steel solutions for use with corrosive media,” begins Justin Bawden of Integrated Pump Technology. In addition to its electrically driven range, the company offers a range of diesel driven units and pumps mounted on skids or on trailers, for ease of mobility to site. “We can supply fixed and mobile installations and our diverse range enables us to customise a solution to match the needs of mine and plant operators,” he tells MechChem Africa. The pumps themselves are mostly Grindex submersible slurry

pumps from Sweden, which can be configured differently depending on the pumping media and the specific plant needs. “We also have Faggiolati pumps, which are an Italian brand that is better suited to raw water applications. They feature cutter impellers that can chop up solid or fibrous materials to enable them to be passed through the pump without clogging,” Bawden explains. Turning attention to the energy crisis in South Africa, he says many of our mines are now starting to produce their own energy in order to supply emergency demand during loadshedding. “Where energy capacity is a problem, we provide added assistance by supplying mobile diesel driven pumps. Some locations on mining sites don’t have an easy connection to power, so diesel driven pump units are the only option. In areas of the mine where there is a lack of power, the need for diesel driven pumps is critical, particularly when required for emergency use to prevent flooding or ground contamination “While energy saving is a priority, mine dewatering or plant water transport requirements place limits on how much can be done without sacrificing production targets or onsite safety. In most cases, pumping must carry on, regardless of the energy required. While meeting plant needs, though, it is still possible to adopt more energy efficient tech nologies and power management options,” he continues. Grindex pump units are designed to meet their duty requirements using the minimum amount of energy necessary. “These fully insulated, protected and submersible pumps raise the bar in terms of energy ef ficiency. Many competitor pumps require far more power to achieve the same duty as the Grindex pumps, which also offer better reliability,” says Bawden. The operational expense of running pumps is mostly related to the cost of the energy being used. This far outweighs the capital costs of buying the pump. “We did a case study for a mine in Rustenburg where we compared the total costs of buying and running one of our Grindex units to a couple of the units they were using on site. The difference was astonishing. The operator was shocked to see exactly how much the old pumps had been costing them to run. “Buying a more expensive but more efficient Grindex pump can save an operation a massive amount of energy and money over time – and the energy and cost savings start to accumulate from Day 1 of switch ing,” he says, adding that payback periods on the capital expense of an efficient pump can be as little one year. “In the long run, though, a high efficiency pump solution that is well matched to specific pumping requirements, can save a company an exorbitant amount of money.” The Grindex submersible range is also renowned for its plug and-pump capabilities through its SMART electrical surveillance system, which means there is no need for an external electrical start-up box for pumps units of 18 kW and below. The SMART system’s phase-failure guard protects against phase loss, a tem perature guard stops the pump if overheating is detected, and the unit automatically restarts pumping when a detected fault is cleared. Phase control also ensures that the impeller turns in the right direction. Integrated accessories such as the SMART surveillance unit, along with add-ons such as water level regulators, not only better protect the pump, but they are automatic, so they manage power use better,

A Grindex Bravo unit being installed in a slurry application.

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⎪ Water, wastewater and pumping solutions ⎪

Left: A Grindex Bravo being tested at the company's in-house test facility to ensure it meets OEM specifications. Right: Grindex Maxi pump units being boxed for export to a mine in Africa.

giving pump users peace of mind with respect to protection and en ergy use. “The SMART surveillance unit embedded in Grindex pumps is also 100% compatible with generators. This ensures that, even during extended periods without mains, the pumps can continue to operate reliably and efficiently, preventing downtime or production loss,” Bawden adds. Describing the energy saving role of a pump level sensor, he says dewatering pumps can automatically be switched off when the water in a pond or sump reaches a safe level and, as soon as the level rises, the pumps will automatically switch on again. This improves reliability and minimises unnecessary energy use. Pumps that cannot access features such this will continue to pump regardless of the water level. Eventually, no water will be pumped, but the pump will continue to operate on the far left of its curve. Not only is this a waste of energy, but it will also cause the pump to overheat, potentially causing damage,” Bawden points out. Most important is that the pumps being used are well matched to the duty required by the application: primarily in terms of flow rates and pressure heads, but also in terms of the specific media being pumped and the surrounding environment. “We like to visit a site and analyse the pumping requirement before coming up with a solution. This allows us to make the best recommendation possible for match ing specific onsite needs and the duty, configuration, performance and efficiency required of the Grindex pumps. Our approach is to carefully consider the pump application and all the factors involved to see how they may affect the whole pumping system. “In many of the surveys we have conducted, there is large 45 kW pump, for example, operating in an application where 18 kW would be sufficient. The extra pumping power is just wasting energy and, over time, costing a fortune. In terms of safety factors, it is more efficient, more reliable and less expensive to buy a second standby pump than to install a pump that is twice the necessary size. “The most energy efficient solution will always be the one where the pump units meet the application duty at minimum consumption – and right-sized Grindex pumps can almost always outperform competitors,” Bawden notes, adding that right sizing pumps to operate at their best efficiency also maximises pump reliability and extends service intervals. Pumps do wear, however, so a planned maintenance programme is necessary to maintain pump efficiency. “If mostly pumping clean water, then service intervals can be longer, but abrasive slurries with stones and grit will cause impeller wear. Then a timely service programme is advisable to find out how much the pump duty and efficiency has been compromised and to restore it to its best possible condition.

“It is always good to check that a pump is still running as expected. At Integrated Pump Technology we have a fully operational service facil ity with testing equipment and a test bay where we can run a pump to make sure it is operating on its pump curve at best efficiency. If not, we offer a full range of repair services, from installing a basic repair kit to doing a full pump refurbishment to OEM specifications. “It is never worth taking shortcuts. A refurbished pump from Integrated Pump Technology looks and performs as if it were brand new,” concludes Justin Bawden. www.pump-technology.com

March-April 2023 • MechChem Africa ¦ 9

Ad: KSB Pumps and Valves

10 ¦ MechChem Africa • March-April 2023

⎪ Water, wastewater and pumping solutions ⎪

The dangers of non-OEM peristaltic hose

Reinhard Seidel of Verder Pumps SA talks about the dangerous and potentially expensive consequences of fitting that “cheap, yet surprisingly expensive,” non-OEM peristaltic hose.

I n any industrial setting, the balancing act between cost savings and profitability is a careful one. The mining industry for instance, driven by needs for profitability, efficiency, and yield maximisation, is one of the toughest industrialised working environments in which to achieve this balance. Too often in such a competitive arena, companies are driven to keep purchase costs as low as possible. So, they resort to fitting non-OEM aftermarket spare parts into so phisticated pieces of equipment. This approach undermines the company’s ability to keep up with tight production sched ules and ensure minimal downtime, as the non OEM aftermarket parts seldom stand up to the rigorous duty the OEM part was designed for and, ultimately, ends up impacting on uptime, resulting in production losses. In a recent case study at one of the largest copper producers in SADC, the hidden costs of buying a “cheap, yet surprisingly expensive,” peristaltic hose were realised. For commercial reasons the mining company chose to fit a non-OEM hose in a Verder peristaltic pump. Production bore the brunt of this com mercial decision, as the non-OEM hose failure rate was, on average, at three failures per week. This resulted in production stoppages and increased maintenance and manpower requirements. In response, Verder was asked to investigate the reason for the failures and present a solution. The remedy was simple: fit the OEM hose. The exercise of buying and fitting a slightly lower cost, non-OEM hose in an attempt to reduce inventory costs and minimise expendi ture proved to be an expensive choice. While non-OEM aftermarket hoses may cost less on initial purchase, using hoses with incorrect dimensions, and hoses of inferior construc tion, leads to frequent hose failures, which in turn leads to the unplanned stoppages, production losses and unavoidable mainte nance costs. Hose failures also result in other direct and unavoidable costs: the need to replace the hose lubricant; premature gearbox failure due to the ingress of the pumped media into the gearbox when the hose bursts; and the direct cost of fitting a replacement hose. Verder’s OEM hose was fitted to the DURA Pump experiencing these problems and run

under the same operating conditions. Records were kept over this time to monitor the hose conditions and the remaining life for avoiding a potential failure of the Verder hose. The results have been astonishing. The non-OEM hose had failed and been replaced, on average, three times a week. In comparison, the Verder OEM hose installed on 1 December 2021 is still in opera tion on the date of writing this article, without failure or loss of production throughput. The cost saving has far outweighed the cost dif ference between the cheaper non-OEM hose and Verder’s properly engineered OEM hose. Every Verderflex hose is manufactured to tight specifications for consistent wall thickness, to ensure that the fibre reinforcing is embedded centrally when the hose is constructed. With the precision manufacturing process, the need to carry out machining of the outside diameter is eliminated. Verder hose also has a signature textured finish, which enhances lubricant adhesion to the hose, thereby reducing surface friction between hose and shoe. Lower surface friction leads to lower temperatures and longer life. The importance of correct pulsation dampeners and other technicalities that af fect hose life cannot be understated. Even dimensional differences will have an influence on hose life, which leads to costs associated with unplanned stoppages. The construction of the OEM hose plays an integral part in

the life span of the hose. One must consider that the OEM is there for the long haul and that its hoses have undergone extensive test ing in its own equipment. For operators to be sure that an OEM hose is being fitted, they can check for the Verderflex hose’s clear colour-coded identifi cation stripe, along with the Verder branding along the length of the hose, which indicates the material of construction. “If the hose being fitted to your Verder peristaltic pump does not have these mark ings, you can be sure that while you may be saving upfront costs by buying cheap, you will most certainly be buying at least twice as many hoses and experiencing far more unplanned stoppages than necessary,” Seidel concludes. www.verderliquids.com/za The Verderflex Dura 55 is the class leader for this size of peristaltic pump, significantly outperforming its competitors in both continuous and intermittent duty applications.

Verderflex Dura pumps offer fast and easy hose changes because of their unique connection system.

March-April 2023 • MechChem Africa ¦ 11

Hawk pump-nozzles unblock all

Gavin Pote, director at Hawk Pumps, unpacks his company’s range of nozzles – which are designed to overcome any blockage – and explains why choosing the right nozzle is key. H awk Pumps is a Durban based company that specialises in the production of high-pressure cleaning equipment and acces sories, offering a wide range of heavy duty drain, tube, and sewer nozzles. clean tubes in heat exchangers, such as in boiler tubes. Where there is scale

Flat nozzles are most often used for removing sand from storm water drains.

build-up in these systems, the heat transfer becomes inefficient, which can lead to higher energy use and poor performance. The spin ner nozzles are effective at removing scale from the interior of pipes, as the barrel of the nozzle spins at a high velocity, pumping water from sideways, backwards, and facing holes. This washes the debris backwards. Spinning nozzles come in many variations, each suited to a different heat exchanger system. A wide range for any need One of the key advantages of Hawk Pumps’ nozzles is their versatility. The nozzles can be used to clean a wide range of drains, including kitchen sinks, toilets and sewers. They can also be used to remove blockages and debris in pipes and other drain systems. In addition to drain and tube cleaning, Hawk has a range of nozzles for different high-pressure cleaning applications, such as cleaning surfaces and equipment, as well as graffiti removal.

Gavin Pote, director at Hawk Pumps, explains that the nozzles are specifically de signed for use in drain cleaning applications, using high-pressure water flow and power ful cleaning capabilities. “The nozzles are available in a range of sizes and models, with different flow rates and pressure levels to suit different drain cleaning needs – but knowing which nozzle to use for your blockage is key”. Static (bomb) nozzles Static or ‘bomb’ nozzles are best used when cleaning and clearing blockages, and greasy deposits lining drain and sewer pipes. They are egg-shaped, giving them their moniker of ‘bomb’ nozzles. A hose is attached to the back end, and a solid stream jet fitted to the front. Three to six solid stream jets surround the hose, facing backwards and outwards, in a cone pattern. Bomb nozzles are used in pipes from 40 mm diameter domestic pipes (using 15 ℓ /min pumps) to 900 mm storm water ones (200+ ℓ /min) at pressures up to 200 bar. The reaction of the rear jets pulls the hose through the blocked pipe, while the front jet cuts into any blockage, allowing the bomb to pass through. Once through, the rear jets force the offending material to disintegrate and wash out of the pipe. At the same time, the rear jets wash greasy deposits from the interior walls of the pipe, as is typically the case in hotels, restaurants and hospitals. The bomb nozzles have been used with good success in many cases, including for eThekwini Municipality in clearing storm water drains and blockages. Flat (wedge) nozzles Flat nozzles are most often used for remov ing sand from storm water drains. They have a row of solid stream jets in the rear, which push the nozzle along the bottom of the drain until it reaches the sand blockage. The wedge shape rides up the sand, allowing the rear jets to fluidise the sand and wash it backwards.

Hawk is a manufac turer of industrial high-pressure pumping and cleaning equipment and spray ing solutions, industrial nozzles and eyewash and safety showers. “One of our biggest strengths is that we have the capacity to custom design and manufacture machines tailored to specific customer needs,” says Gavin Pote. “We serve a wide range of customers from virtually every industrial sector, including processing plants, factories, workshops, contract cleaners, drain and sewer cleaners, car, truck and bus washers, mines, agricultural infrastructure and more,” he concludes. hawkpumps.co.za

Spinning nozzles are most commonly used to clean tubes in heat exchangers, such as in boiler tubes.

Spinning nozzles Spinning nozzles are most commonly used to

12 ¦ MechChem Africa • March-April 2023

⎪ Water, wastewater and pumping solutions ⎪

IPR now distributes Atlas Copco dewatering pumps

Previously known as Integrated Pump Rental, local pump and dredging specialist, IPR, recently rebranded to reflect its expanded market offering. The company will now also sell and rent Atlas Copco’s diesel-driven and submersible pump range.

T aking another step upward as a lead ing dewatering pump and dredging specialist, Jet Park-based IPR has been awarded the master distributor ship for the Atlas Copco pump range in the Southern African region. According to Lee Vine, managing director of IPR – previously called Integrated Pump Rental – the new arrangement will further enhance IPR’s offering to customers. Over the past eight years, the company has built a significant presence in mining, construction, agriculture and other industrial sectors. “Representing a leading global brand like Atlas Copco reinforces IPR’s commitment to our customers, which combines the best quality equipment with our superior service levels,” says Vine. “Our extensive network in the region ensures we are close to customers, and the Atlas Copco range adds further to our capability to meet their site specific needs.” The new range includes wet prime and dry prime diesel driven pumps, as well as submers ible pumps for the three key pumping catego ries – dewatering, sludge and slurry. The diesel driven pumps range in capacity from a 30 m to 150 m head, with flow rates from 50 to 1 500 m 3 /h. The submersible range of Atlas Copco pumps extends from 0.4 kW to 54 kW power. “IPR has developed an unsurpassed depth of technical expertise and market knowledge since we launched in 2015,” he says. “Our skills base and connection to

customers have made this collaboration with Atlas Copco a perfect fit for us – adding considerable value for our customers.” As IPR product manager for the Atlas Copco range, Steve du Toit highlights that a substantial stockholding is in place at IPR’s Johannesburg head office to meet demand. The company’s well-equipped and professionally staffed service centre is always on hand to support the market. “The Atlas Copco brand boasts a high level of quality with robust materials of construc tion for strong performance and rugged wear,” says du Toit. “Features like high chrome impel lers and mechanical seal flushing all contribute to optimal reliability and uptime.” The pumps have also been designed with the user in mind, he explains – including the

ease of access to internal components, and a compact modular design. They are versatile and mobile and can be trailer-based or skid based. Just as IPR has evolved from a primarily rental company to selling increasing volumes of its pumps, so the Atlas Copco range will be available for either purchase or rental. “By having both a sales and rental option, IPR can help customers to optimise the cost of ownership for their particular conditions,” he says. After a sustained period of growth, IPR has recently moved into new, larger premises in Hughes, Jet Park. The expanded facilities will facilitate the necessary stockholding, as well as workshop space and offices for design, engineering, sales and administration. www.pumprental.co.za

The pumps are versatile and mobile and can be trailer-based or skid-based.

The diesel driven pumps range in capacity from a 30 m to a 150 m head, with flow rates from 50 to 1 500 m 3 /h.

March-April 2023 • MechChem Africa ¦ 13

SEW-EURODRIVE set to support Africa’s growth Africa’s industries are on the move and SEW-EURODRIVE is geared for steady expansion across the continent. From its extended facilities in Johannesburg, SEW-EURODRIVE South Africa is strengthening its footprint by establishing new branches around Africa.This strategy, says managing director Raymond Obermeyer, serves customers best and builds local economies. D espite the travails of the global economy and uncertainty in many countries, Africa will be the place to do business in the “The new headquarters – worth around R500-million in infrastructure and stock – was a carefully considered investment in our future growth,” he explains. “It has also enabled a three-fold increase in our stockholding, which is vital to ensuring that customers get what they need, when they need it.”

coming years. So says Raymond Obermeyer, managing director of SEW-EURODRIVE South Africa, whose company has worked successfully around southern, central and east Africa for decades. The company’s expansion efforts are now ramping up, as SEW-EURODRIVE has embarked on a progressive branch es tablishment strategy. “Customers around Africa know our brand well and respect the precision German engineering that underlies all our products,” says Obermeyer. “They also rely on our strong service ethic, which is based on our culture of responsiveness and under standing customer needs.” A key aspect of the company’s high levels of customer support derives from its infra structure and capability – as well as having a presence close to customers’ sites. Ready availability of stock, and quick turnaround times for designed solutions, are ensured by SEW-EURODRIVE’s newly built and expanded facility in Aeroton, Johannesburg.

greater, there is more control over factors like service quality and performance. By appointing and training its own staff, SEW EURODRIVE is ensuring that customers get a uniformly high standard of support, irrespective of their location. “This strategy aligns with the growing trend in Africa towards localisation,” he points out. “Countries are wanting to see more local benefit from economic growth, and a move away from relying on foreign companies and expatriate workers.” Building on the experience of running its own strong branch network in South Africa, SEW-EURODRIVE is excited about the prospect of building capacity around Africa. This includes more formal training and mentorship of local staff in African branches – to service the continent’s al ready large population of SEW-EURODRIVE motors, gearboxes, geared motors and other equipment. “Our equipment is to be found in a wide range of industries around Africa – from food and beverage to cement, mining and pharmaceutical,” says Obermeyer. “Our hands-on approach to our work means we understand operating conditions in each country, and we have developed the expertise to deliver the way our customers require.” He emphasises that casual observers tend to underestimate the recent growth – and potential – in most African countries. It is being driven by considerable invest ment in world class industrial facilities that demand high-tech equipment supported by qualified and experienced experts. “This is where SEW-EURODRIVE is po sitioned,” he concludes. “We are leveraging our experience in these markets to deliver the best quality equipment and components – supported by unsurpassed service and commitment to customers.” www.sew-eurodrive.co.za

In addition to serving branches in Nelspruit, Durban, Cape Town and Gqeberha, this state-of-the-art facility sup ports over 23 more countries in Africa. It is this proven branch model that the company is now rolling out. Moving gradually away from the distributor model of product sales and support, he explains that four countries are strategically being targeted each year for a branch establishment. “Taking a phased approach to our growth strategy, we began establishing branches in our key growth areas of Zambia, the Democratic Republic of Congo (DRC), Kenya and Tanzania in 2022,” he says. “In the years to come, we aim to target around four coun tries a year in which to put a branch in place.” The model, emphasises Obermeyer, has benefits not only to customers but also to the host countries. While the investment is

Construction of SEW-EURODRIVE's new headquarters enabled the company to increase its stockholding three-fold.

14 ¦ MechChem Africa • March-April 2023