MechChem Africa May 2018

Mech Chem MAY 2018 AFRICA

SEW-EURODRIVE – DRN IEC electric motors Driving the world

This month: Risk management and proactive maintenance

Passive fire protection and modern industrial coatings

Principles for effective combustion control in fired heaters

A roadmap to premium electric mobility

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Plant maintenance, lubrication and filtration 8 Mario on maintenance: Risk management and proactive maintenance

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

In this issue’s Mario on maintenance column,Mario Kuisis deals with risk management and suggests that plant and industrial operators should look beyond survival and towards reducing operational uncertainty to minimum levels possible. 11 Innovative oil for the environment-friendly engine 12 The payback from efficient mill liners 13 Partnership supports emerging black entrepreneurs 15 Minerals processing and maintenance JV, a first for Africa Materials handling 16 Drive train solutions for cost-effective materials handling MechChem Africa talks to BI’s Ross Trevelyan about Cooper and FAG bearings and power pack components for materials handling equipment. 19 Feature-rich hoists for very wide cranes 20 Chute options for lowest possible TCO 21 Rugged scalping screen, the heaviest yet 23 Healthy orders for tough, reliable apron feeders Corrosion control and coatings 24 Passive fire protection and modern industrial coatings MechChem Africa talks to Kansai Plascon protective coatings’ specialist, Alvin Varaden about passive fire protection (PFP) and the modern trend towards fewer and thicker coatings. Heating, cooling, ventilation and air conditioning 26 Principles for effective combustion control in fired heaters Robbie Frank of Boksburg-based ElementalAnalytics talks about combustion monitoring and control in fired heating systems. 28 TLT MechCaL becomes composites centre of excellence 29 Adding value in the HVAC space Water and wastewater processing 30 Cloud seeding technology to maximise precipitation By making use of the latest advancements in rain-enhancing technology,Middelburg-basedWAS seeks to use cloud seeding to increase precipitation. 33 Is desalination the key to South Africa’s water future? 35 Recycling wastewater key to water security Innovative engineering 42 A roadmap to premium electric mobility Trevor Hill, head of Audi South Africa, outlines a roadmap towards competitive, premium electric vehicle solutions. REGULARS 2 Comment: Malaria: African solutions to an African scourge 4 On the cover: SEW-EURODRIVE IEC electric motors Norman Maleka talks about the gearbox specialist’s DRN electric motor range that fully meets IEC standards. 6 SAIChE News: Polymer research, community service and containing malaria 36 Product and industry news 44 Back page: Fully electric autonomous trucks by 2030

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 Editors: Peter Middleton e-mail: peterm@crown.co.za Glynnis Koch e-mail: glynnisk@crown.co.za Advertising: Brenda Karathanasis e-mail: brendak@crown.co.za Design: Darryl James Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Karen Smith 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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May 2018 • MechChem Africa ¦ 1

Peter Middleton Malaria: African solutions to an African scourge B efore talking toWalter Focke for the SAIChE IChemE member profile this month, my personal experience of malaria was limited to choosing the tablets to takewhen visiting

main reason why nearly 90% of the world’s malaria cases are in Africa. For people living inmalaria-susceptible areas, par- tial immunity is developed over years of exposure, and while it never provides complete protection, it does reduce the risk that the diseasewill be severe. For this reason, most malaria deaths in Africa occur in young children, whereas in areas with less transmission and low immunity, all age groups are at equal risk. Thework described by UP professorWalter Focke in this issue of MechChemAfrica is all about prevention and ‘vector control’, as key ways to reduce malaria transmission. WHO recommends two basic forms of vector control: insecticide-treatedmosquito nets and indoor residual spraying. It emphasises the need for long- lasting insecticidal nets (LLINs) provided freeof charge to ensure equal access for all, along with behaviour change to ensure that all people at risk sleep under a properly maintained LLIN every night. Indoor residual spraying (IRS) of insecticides, ac- cording the WHO, is also a powerful way to rapidly reduce malaria transmission; but only when at least 80% of the houses in targeted areas are sprayed. Currently available sprays can be effective for 3- to 6-months, depending on the insecticide formulation used and the type of surface on which it is sprayed. In South Africa, Focke works with a team from the University of Pretoria’s Institute for Sustainable Malaria Control, along with some 50 students, to develop African solutions for this African scourge. In particular, his polymer expertise is being applied to bed nets and other fabrics to enable insecticides to be trapped and stored in the polymer chains for slowand effective release over a longer time period. In addition, though, Homa Izada, a chemical en- gineering student at UP, has come up with a novel formulation for mosquito repellents and insecticides. Using a mixture of two carefully selected mosquito repellent substances, he hasmade a negative pseudo- azeotrope: amixture that, on evaporation, produces a lower vapour pressure than either of the parent com- pounds. This reduces the release rate of the repellent, also giving it a longer life. With the development of bed nets, anklets, brace- lets, socks and wall linings from carefully crafted polymers, along with Izada’s novel repellent formula- tions, UP’s Institute for Sustainable Malaria Control is contributing to saving thousands of lives in Africa, which is a truly inspiring African success story. q

the Kruger Park, while bemoaning the inconvenience and the cost – and, of course, takingmeasures to avoid mosquito bites; always a good idea. Focke tells of a much scarier and personal experi- ence, however, which nearly caused the death one of his relatives. This prompted him to join a community of committed scientists andengineers seeking sustain- able and longer-lasting ways of reducing the disease’s impact. According to the November 2017 World Malaria Report, there were 216-million cases of malaria in 2016, up from211-million cases in2015. The estimat- ednumber ofmalariadeaths stands at 445000, similar to the 2015number (446000). Children younger than 5-years oldaccount for 72%of the fatalities, while90% ofcasesand91%ofdeathsoccurinsub-SaharanAfrica. Although these numbers are horrific, deaths from the disease are falling. Since the year 2000, the num- bers cited above represent a 22% decrease in malaria cases and 50% fewer deaths. But according to the WHO, the disease is 100% preventable and curable. Malariaiscausedbyparasitesthataretransmittedto peoplethroughthebitesofinfectedfemalemosquitoes. In terms of treatment, early and accurate diagnosis is essential to prevent it becoming deadly, with the best availabletreatmentforthemostdangerous Plasmodium falciparum malaria being artemisinin-based combina- tion therapy (ACT). The artemisinin is fast-acting and combining it with other classes of drugs reduces the likelihood of the parasite developing resistance. Key outstanding problems with respect to treat- ment, however, include delivery and access to drugs at the point of need, and their cost. Hence the focus on reducing transmission and infections by seeking ways of preventingmosquitoes frombiting people and surviving to infect other people. Only female mosquitoes bite people and they do not feed on blood. They are looking for a ‘blood meal’ to nurture their eggs, which they lay in water, each species having its own preferred aquatic habitat. The rainy season in wet and warm climates, therefore, is the most dangerous. Transmission is also more intense in places where themosquito lifespan is longer; because this gives the parasites more time develop. The long lifespan and strong human-biting habit of African species is the

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2 ¦ MechChem Africa • May 2018

SEW-EURODRIVE IEC electric motors Direct from the gearbox specialist

An SEW-EURODRIVE DRN electric motor range that fully meets the IEC 60034 electric motor standard (IEC standards) was recently introduced into South Africa. Norman Maleka unravels what this means for plant operators and equipment specifiers and reminds customers that while SEW-EURODRIVE is better known for gearboxes, its geared motor range proves its technical expertise as an electric motor manufacturer.

“ W e are very well known as a supplier of gearboxes and gearedmotors, which we sell every day in every part of theworld. But for over 85 years, SEW- EURODRIVEhasalsobeenmanufacturingthe electric motors that are integrated into our geared motor product range. “Our customers, however, still tend to see us as a gearbox-only specialists, often specifying our gearboxes for usewith the IEC electric motors from other OEMs. While we are always happy to comply with customer- specific specification, we want them to know that there is an alternative. We have a new range of premium efficiency DRN electric motors that are built according to the global IEC standards, which makes them 100% in- terchangeable with any other electric motor built on this universal platform,” Maleka tells MechChem Africa . The new DRN IEC motor is a standalone electric motor that is relatively new to the SEW-EURODRIVErange.“Butthetechnology

used is the same as that incorporated intoour premium efficiency IE3 geared motor range. So the motor technology involved is far from new to us,” emphasises Maleka. “But we fear we may have confused the market with acronyms such as IEC and IE3 without taking the time

to unravel exactly what these terms mean and their advantages. So I would like toput a little context onto global developments of elec- tric motor standards,” Maleka says.

The standardisationof electricmotors and their associated efficiencies began in theUSA and its National Electrical Manufacturers’ Association (NEMA), which still remains the dominant standard in the USA. NEMA was founded back in 1926 in order to enable consumers to select from a range of safe, ef- fective, and compatible electrical products. More recently, however, efficiency has become the driving force behind innovation and NEMA was first to champion energy efficient electric motors. SEW-EURODRIVE quickly started offering its modular DR mo- tors in three efficiency levels: standard, high efficiency, and NEMA Premium ® efficiency. NEMA motor designs tend to be larg- er and heavier than modern European motors, though, so the IEC (International Electrotechnical Commission) electricmotor standard is fast taking over as the preferred option outside of the US. IEC-approved electric motors and controls tend to be less expensive, more compact, inherently safe and they react far more quickly to overloads. “The IEC 60034-30 electric motor stan- dard, therefore, caters more to the interna- tional markets, while NEMA, although avail- able elsewhere, applies mostly in the USA,” Maleka explains. Sowhat is an IECelectricmotor?Generally speaking, any electric motor that is designed according to the IEC standard is associated with a set of codes that specify the mechani- cal dimensions (frame sizes 63 to315), power ratings (0.37 to 375 kW), efficiency (high efficiency: IE2; premium efficiency: IE3; and super premium: IE4) as well as a host of

Ten SEW-Eurodrive DRN motors with MC-series gearboxes were recently chosen for the aerators at a Meyerton wastewater treatment plant.

4 ¦ MechChem Africa • May 2018

⎪ Cover story ⎪

witha like-for-like equivalent faster thanever before,” he says. Fromawarrantyperspective,itisfareasier and cheaper for us and for the customerwhen a singlewarranty covers all of thedrive equip- ment. When a third-party motor is specified, separate contracts have to be drawn up and, whenaproblemarises,individualresponsibili- ties are not always obvious. “By choosing to couple ourDRNmotors to our IGgearboxes for newdrives, the customer can sign a single long-term contract dealing with the overall drive solution, which can re- duce the initial investment costs byup to10%. “More importantly, though, should a problem arise, we will take full responsibility for every component on the drive train. In addition, instead of simply replacing a failed component, we will seek to determine the exact cause of the failure so as to prevent a re-occurrence,” Maleka assures. Also, he continues, “those people already using our IG industrial gearboxes in multi- brand drive trains can now start to replace the IEC motors they are using with our DRN IE3 motors, which are 100% compatible and interchangeable. Over time, this will enable users to improve the energy efficiency of all their drive systemswhile alsobenefiting from our one-supplier drive service offering. “It is no longer necessary for customers to specify a third-party motor on any system that uses a gearbox,” Maleka says. “With access to our own motors, we can offer full turnkey power pack solutions for both new and retrofit drive systems that incorporate IEC motors of any brand – and our motors are particularly suited for use in systems that alreadyuseSEW-EURODRIVEgearboxes,” he concludes. q

SEW-EURODRIVE DRN motors are particularly suited for use in systems that already use SEW gearboxes. But they are also ideal for any drive train designed to meet IEC standards.

other technical specifications such as ingress protection (IP) and insulation class ratings (A to H). “So if a customer is using 45 kWIECmotor with a frame size of 225, any other brand of motorwith the same frame size, power rating and the same associated set of IEC codes will do exactly the same job and have the same footprintandmountingarrangement,”Maleka points out. “By choosing an IEC standardmo- tors, users are assured that identical replace- mentmotors are readily available andquickly interchangeable,” he adds. This makes the new DRN IEC range from SEW-EURODRIVE a universal electricmotor offering that can be incorporated into any IEC-based drive train with any SEWgearbox. “So while the majority of SEW-EURO­ DRIVE motors and brakemotors are pre- mounted in our own gearmotor units, the IECDRNoption gives us a stand-alonemotor options that can be incorporated into drive systems from any OEM. “More importantly, mining project houses, conveyor and fan manufacturers, waste- water treatment plant engineers, hoist designers and any plant operator in need of a universal IEC motor to drive one of our SEW-EURODRIVE gearboxes, no longer needs to specify a third-party electric motor. SEW-EURODRIVEhas an equivalent that can be perfectlymatched to the selected gearbox and supported by us,” Makeka suggests. “Technically, these motors are a German- engineered premium brand and carry the same quality guarantee associated with all of our other products. Also though, they are price competitive with any premium-brand equivalent. And if associated with one of our custom-engineered drive solutions, the total package can often be significantly cheaper thanoneput together usingunits fromseveral different suppliers,” he assures. Describing a recent success in thepulpand paper industry, Maleka says that a KwaZulu- Natal customer has recently standardised on the use of SEW-EURODRIVE products across its plant. “We are now supplying drive

solutions for the conveyors handling the raw materials arriving onto the site and all of the industrial gearboxes and gearmotors driving theplant equipment. Ourmost recent success was that the plant has chosen our premium efficiency DRN IEC motor range as its pre- ferred standalonemotor aswell,”Maleka tells MechChem Africa . “A significant benefit to the plant is the standardisationof itsmechanical drive equip- ment, which can be custom-engineered, sup- plied, installed, warranted and serviced from a single supplier: SEW-EURODRIVE. This gives the customer full confidence that, in the event of an issue arising, product, technical and service support is readily available on a 24/7 basis, across the full lifecycle of each of the individual drive systems. “In addition, by standardising on our pre- mium efficiency (IE3) IEC DRN motor range, the company can be assured of reduced oper- ating costs with respect to energy, alongwith high reliability and fast responsewith respect to downtime: the motors can be changed out

A 250 kW premium efficiency (IE3) IEC DRN electric motor was incorporated into the SEW-EURODRIVE drive train for a mill-drive at a chromiummine.

May 2018 • MechChem Africa ¦ 5

In this issue we profile SAIChE IChemE memberWalter Focke, who talks to MechChemAfrica about the link between chemical engineering and his passion for reducing the impact of malaria inAfrica. Polymer research , community service and containing malaria

“ W hen I was young, I didn’t have a home computer, but I did have my own chemistry lab. I was for- ever doing experiments, making rockets and firing them off, with only occasional mishaps. “I always wanted to become a vet, though. I grew up on a farm, and had visions of taking over the care of the cattle. But after some real farming experiences, and the realisation of how hard it would be to study veterinary science atOnderstepoort, I soon realised that life in the service of farm animals was not for me,” Focke tells MechChem Africa . After completing his matric at Hoërskool Brits in 1973, Walter Focke applied to study chemical engineering at the University of Pretoria (UP) where he graduated with a Bachelor’s degree, cum laude , in 1977. “After completing my military service, I then went to work at the CSIR, where I de- signed heat exchangers for the Sasol 2 and 3 plants thatwereerected inSecunda.Wewere

using one of the early CDC supercomputers at that time, and programming was done in Fortran.We chargedonlyR100per individual heat transfer design and perhaps up to R300 for a big layout, which seems incredibly little by today’s standards,” he recalls. After several years at the CSIR, dur- ing which time he completed a Diploma in Datametrics at UNISA, followedby aMasters degree in chemical engineering at UP, Focke decided to read for a PhD in polymers with the department of Material Science and Engineering at Massachusetts Institute of Technology in the USA, which he completed in 1987 with a theses entitled: ‘Conduction mechanisms in polyaniline’. Polyaniline (PANI) is an advanced polymer that, due to its con- ductivity, can be used for applications such as muscle tissue regeneration. Following his PhD studies, Focke returned to the CSIR to join the polymer programme, a divisionthatwasknownasMATEKatthetime. “In 1990, I started a small business in the

polymer industry called Xyris Technology, which manufactures custom additives and masterbatches for the plastic industry. Our product lines include flame-retardants, vola- tile corrosion inhibitors, barrier additives and purging compounds. We are unique in South Africa for in-house formulation development that focuses on specific customer require- ments, such as flame, retardant compounds for deep underground mining applications; andour vapour phase corrosion inhibitor sys- tem(VCI) formild steel (Xyro-SorbVCI 39E),” he tells MechChem Africa . Amajor research focus for Focke andXyris is the development of plastics from renew- able resources such as starch. “We anticipate that these materials may well become cost- effectivealternatives toconventional plastics. We have also worked on technology for the controlledphoto-degradationofpolyethylene and polypropylene,” he explains. Walter Focke joined the department of Chemical Engineering at UP in 1997 and has been there ever since. “In June this year, I will be celebrating my 21 st year with the University,” he says, proudly. His teaching responsibilities include the Thermodynamics courses for undergradu- ates as well as Polymer Processing; Additive Technology; and Chemical Engineering for graduates as well as delivering short courses on Surfactant Technology; Polymer Additives and Polymers in Chemical Product Design – and he is also the director of the Institute of Applied Materials within the Chemical Engineering department. Out of the community service responsibility, which is part and parcel of his role as a UP professor, Focke has developed a particular passion for mitigating against malaria, one of Africa’s deadliest diseases. “I developed a particular interestwhenone ofmy familywas hit by cerebral malaria. He was ill for eight months and the doctors told us that if we had brought him in just a fewhours later, hewould have died,” Focke recalls. This personal experience led Focke to start research into the spread of the disease as a community service issue: with consider- able success. “We are now developing and testing a range of products through research Malaria research and community service

Bongs Sibanda installing a polymer wall lining impregnated with slow release repellent/insecticide. Inset: the installed lining.

6 ¦ MechChem Africa • May 2018

⎪ SAIChE IChemE news ⎪

months and survive many washes. This means that, even if a mosquito gets though the net and bites you, she is not likely to survive long enough to bite or infect anyone else,” Focke explains. One particular polymer design consists of bi-component fibres with a core and a semi-permeable sheath. The liquid repellent/insecticide is trapped in the hollow core, and it leaks slowly to the surface through the containing sheath. “The fibre dimensions can be manipulated in order to control the permeability and therefore the rate of release. This is one of our solutions that is currently being commercialised,” notes Focke, adding that the possibility of knitting socks impregnated with repellent is also being looked at; “with a 20washes and six month active repellent life.” Another repellent-based solution has been developed based on filling polymermaterialswith slowrelease liq- uid repellents. “There is amuch greater risk of being bitten by amosquitowhile sitting or walking outside. To reduce this risk, we have developed a microporous polymer matrix that can contain a large amount of repellent. So instead of a bangle or anklet that can protect for a day or two, ours should be effective for several months. “Sincemosquitoes tend to bite near to the ground, feet areparticularly susceptiblewhen walking, hence the anklet. But for people sleeping in huts near or on the ground, we have also used this fibre to produce wall lin- ings, which can be 100% effective when im- pregnatedwith repellent or insecticide for up to five years. Traditional commercial surface insecticides, such asDDT spray, degradewith time, but ours, originallydevelopedas a repel- lent, not only lasts, but is also significantly more effective,” he points out. OneofWalterFocke’sPhDstudents,Homa Izadi, has also come up with a very promising new mosquito repellent formulation, which is already proving far more effective and long lasting that the commercially available DEET-based versions (diethyl- m -toluamide). The idea was to reduce the apparent vapour pressure and, therefore, the rate of mass loss of the repellent toproduce a longer- lasting effect, without reducing it to the point where the amount of repellent vapour is insufficient to provide adequate protection. Focke and Izadi came up with the idea of applying the concept of using negative pseu- do-azeotropes. These are mixtures of two or more substances that, together, produce a lower vapour pressure than the parent com- pounds at aparticular azeotrope composition. The reduced vapour pressure translates into slower repellent release.

“By luck, the two repellent substances chosen by Homa to make the azeotrope also proved to have a mortality effect. So this product is nontoxic and contains a food grade mosquito repellent forming an insecticide that outperforms all those currently on the market,” suggests Focke. At the University of Pretoria a large team is involved in this work, including multi- disciplinary staff members of the Institute for SustainableMalaria Control and some 50 students studying the disease from all sorts of different angles. “This is one of the things I like most about chemical engineering. It is a very diverse field that engages engineers of almost all disci- plines aswell the full suite of scientists: chem- ists, bio chemists, entomologists; doctors, climatologists, cartographers andmanymore. There is nothing limiting about being a chemi- cal engineer,” Walter Focke concludes. q

SAIChE IChemE

Testing the effectiveness of new mosquito repellent formulations. funded by the Medical Research Council, the Bill &Melinda Gates Foundation and the Deutsche Forschungsgemeinschaft (DFG),” he says, adding that due to global warming, the spread of malaria, which thrives in hot climates with a lot of moisture, is likely to get worse inmany places on the continent and in South Africa. Malaria is a vector-bornedisease, explains Focke, which means that it is transmitted from one individual to another. When a mosquito bites an infected individual, it is infected by the parasite. After a short incuba- tion time, it spreads the disease to the next individual it bites. So to better control the spread of malaria, mosquito populations must either be con- trolled or theymust be prevented frombiting people and surviving to bite other people. Traditional solutions, therefore, include in- secticides, repellents, andbarrier bednetting. Combiningpolymer technology for netting withan insecticide, for example, Focke andhis teamhavemanaged to impregnate a physical bed net with insecticide. “Common bed nets aremade frompolymer fibre, most commonly PET,butpolypropylene(PP),andpolyethylene (PE) are also used. “The trick we developed is to modify the structureofpolymerfibressothattheimpreg- nated insecticide or repellents are released in a controlled fashion. The difference here is that, instead of an insecticide simply sitting on the surface of the net to be washed off in- stantly, our systemenables the slowmigration of insecticide to the surface over time – and the insecticidewill remain active over several

SAIChE Board members: President: C Sheridan Imm. Past President D van Vuuren Honorary Treasurer L van Dyk + Vice President: Honorary Secretary: EMObwaka Vice President: D Lokhat Council member: JJ Scholtz Council member: AB Hlatshwayo Council member: K Harding Council Member: M Low Council member: BK Ferreira Council Member: HMazema Council Member: MChetty Council Member: A de Bondt Council Member: MMabaso Council Member NN Coni Member (co-opted): MD Heydenrych Chair Gauteng: C Sandrock Chair KZN: D Lokhat Chair Western Cape: HMazema Contact details SAIChE PO Box 2125, North Riding, 2162 South Africa

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

May 2018 • MechChem Africa ¦ 7

Mario on maintenance

Risk management and proactive maintenance

In this issue’s Mario on Maintenance column Mario Kuisis deals with risk management and suggests that, as we slowly return to normal business practices following several years of unpredictability, plant and industrial operators should look beyond survival and towards reducing operational uncertainty to minimum levels possible.

F or many South African businesses, if not most, the main focus of the past year or two has been about survival in an uncertain economic and politi- cal environment. There has therefore neces- sarilybeengreat attentiondevoted to cost re- duction.Wehavediscussedmanyexamples of howproactivemaintenance canmake a great contribution here. However, as indications of a return to normal business strengthen, it is time to start examining some other business

fundamentals that were relegated to a back seat. One of the more important of these is organisational risk management. Whilst concentrating on assuring survival, other business risks have not gone away. If anything, many have increased. So let’s take a look at how, in particular, proactive main- tenance can make a useful contribution to managing organisational risk in asset inten- sive organisations. Bydefinition, risk is theeffect of uncertain-

ty on business objectives. All organisations have a natural aversion to risk as it renders the future unpredictable and thereforemore difficult tomanage. Trust and confidenceof all stakeholders is enhancedwhen the degree of uncertainty is contained to acceptable levels, at reasonable cost. The radically revised and recently pub- lished ISO31000RiskManagement standard sets out excellent guidelines for organisa- tional risk management. It is intended for

The ISO 31000 Risk Management standard is intended for those people who create and protect value in organisations. The general approach is to apply a set of basic principles in a structured framework that is coordinated with a defined process.

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⎪ Plant maintenance, lubrication and filtration ⎪

those people who create and protect value in organisations. The general approach is to apply a set of basic principles in a structured framework that is coordinatedwith a defined process. The relationship between these is detailed in the standard and illustrated dia- grammatically by the figures opposite. There are of course different types of risk that an organisation must consider (strategic, compliance, operational, financial, reputational, etc). There are also a host of potential origins, both external and internal and including environmental, human and cultural influences. Some examples are natural disasters, health and safety incidents associated with products or services used or supplied, influence of industrial action in and outside the organisation, security threats, rawmaterial and utility supply interruptions, OEM support for key production equipment, adversemarket trends, economic headwinds, legislative policy changes, etc. Most of these risks are not pertinent to this discussion. Our interest iswherever physical assets come into the picture, as this iswhere value canoftenbe found by applying the principles of proactive maintenance. Note we are not talking about typical op- erational reliability issues. Nor is it about Risk BasedMaintenance (RBM). That is a perfectly valid proactive maintenance approach, but for these purposes that is considered to be a part of normal business and having an impact on the cost of doing normal business. It is not the subject of this discussion. We are dealing withmatters of governance and leadership at the top level of the organisation. Our concern here is with the materialisa- tion of an incident, situation or event that may be in isolation, trigger a cascade or be a catalyst toothers that individuallyor together threatenorganisational objectives or sustain- ability or possibly even survival. The riskmay be in the form of a sudden safety incident, environmental disaster or mission critical asset failure. In the case of physical assets the impact on the organisation is typically in the form of extended business interruptions affectingall ormajor parts of theorganisation. It may also be a more insidious situation. For example, where critical assets are unknow- inglydeteriorating faster thanprojected, with consequent inadequatefinancial provision for timeous capital replacement. As is evident fromthe principles, topman-

When it comes to risk assessment, the team needs to identify and describe existing threats and emerging risks with relevant, current and accurate information that also clearly conveys limitations of knowledge, reliability of data and time related influences.

agementisresponsibleforensuringthatriskis properly andeffectivelymanaged. Thiswould be translated into a policy that defines needs andexpectations,responsibilityandauthority. Practically, execution relies on persons with the requisite skills, experience and resources tooversee riskmanagement andgiveeffect to the policy. Inclusivity requires that engineer- ing and maintenance teams take care of risks in their sphere of the organisation. They will be expected to demonstrate leadership and commitment by ensuring that risks are prop- erly consideredandunderstood, withsystems implemented to effectively manage the risk. Remnant risk must be appropriate and there must be clear communication of the risks and their management. When it comes to risk assessment, the team needs to identify and describe existing threats and emerging risks with relevant, current and accurate information that also clearly conveys limitations of knowledge, reliability of data and time related influ- ences. Factors to consider for meaningful risk analyses include likelihood of the event, consequences in nature and magnitude, complexity, stability and influence of time, effectiveness and confidence level associated with existing controls. Clearly this is a difficult requirement at the best of times, but even more so when the stakes are high. Many of these tasks rely on informationandinsightsthatarehardtocome by. This is where the principles of condition assessment and condition monitoring can make a meaningful difference. Guesswork, subjective judgement based on visual inspections, empirical evidence and hearsay can be replaced with objective data. The fact that this option exists may not be obvious to those concernedwith riskmanage- ment, as they will not necessarily be exposed to the techniques and technologies that will be evident to those who work with themon a routine basis. The aim of this discussion is to promote awareness and encourage internal dissemination of knowledge for the applica- tion of non-destructive testing, condition

assessment and conditionmonitoringbeyond the realm of routine maintenance. Examples include silo, flue-gas stack, bridge, reservoir, dam wall, cooling tower, pipeline, power boiler and other civil struc- tures. The likes of mills, fans, pumps, com- pressors, turbines, conveyor lines, valves, pipe networks, pressure and storage vessels are generally well covered by predictive maintenance – and statutory inspection and tests in some instances – which ensures that most risks are well covered. However, if any of these are mission critical in a single streamprocess then it is essential to conduct a more in-depth risk analysis to consider potential abnormal modes of failure and consequences. Similarly, in the electrical world it may be transmission lines, pylons, poles, power transformers, highvoltage cables, generators, motors or switchgear. Much can be achieved with periodic assessments that are not pos- sible or practical on a routine basis to look for evidence of slowdeveloping but catastrophic failure modes. Most importantly, routinemethodsmaybe insufficient for some of the assets and failure modes. Experts may need to be called in pe- riodically to conduct assessments employing specialist technologies togain insightwhere it is not possible to do so otherwise. In this way the task of organisational risk management can be rendered simpler, more effective and more reliable to the benefit of all stakehold- ers. In the case of physical assets it enables the guideline requirements of ISO 31000 to be applied fully and properly. Interestingly, many insurance underwrit- ers who provide cover for the burden of remnant risk will recognise the benefits of such proactive measures through reduced premiums. The simultaneous reduction of organisational risk andoperatingexpenditure makes this an attractive option for any lead- ing business. I suggest this is certainly worth consider- ation in thenormal business environment that we are all looking forward to. q

May 2018 • MechChem Africa ¦ 9

⎪ Plant maintenance, lubrication and filtration ⎪

A new top-tier heavy-duty engine oil that meets the latest American Petroleum Institute (API) CK-4 and European Automobile Manufacturers’ Association (ACEA) E9-2016 requirements has been launched locally by Blue Chip Lubricants, the sole licensed manufacturer in South Africa. Innovative oil for the environment-friendly engine

Q 8 Formula Truck 7000 15W-40 is a high-performance synthetic heavy-duty engine oil designed specifically for the lubrication of the latest environment-friendly engines, ac- cording to Johan Le Roux, lubricant support engineer at Blue Chip Lubricants. Customer benefits include added engine protection, oxidation and shear stability, and piston cleanliness. API CK-4 oils are especially effective at sustaining emission control systemdurability where particulate filters and other advanced after treatment systems are used. API CK-4 oils aredesigned toprovide enhancedprotec- tion against oil oxidation, viscosity loss due to shear, and oil aeration. They also offer protection against cata- lyst poisoning, particulate filter blocking, engine wear, piston deposits, degradation of low- and high-temperature properties, and soot-related viscosity increase. API CK-4 oils exceed the performance criteria of API CJ-4, CI-4PLUS, CI-4, andCH-4, andcaneffectively lubricate engines calling for thoseAPI Service Categories. ACEA E9 describes stable, stay-in-grade oils providing effective control with respect to piston cleanliness and bore polishing. It further provides excellent wear control, soot handling and lubricant stability. It is recommended for highly-rateddiesel engines meeting Euro I, Euro II, Euro III, Euro IV, Euro V, and Euro VI emission requirements and running under severe conditions, such as extended oil-drain intervals according to the manufacturer’s recommendations. It is suitable for engines with or without particulate filters, and for most exhaust gas recirculation (EGR) engines and engines fit- ted with selective catalytic NOX reduction systems. ACEA E9 oils are strongly recom- mended for engines fitted with particulate filters, and are designed for use in combina- tion with low-sulphur diesel fuel. The newly launched Q8 Formula Truck 7000 15W-40 exceeds the require- ments of Volvo VDS-4.5, Renault RLD-4, and Mack EO-S 4.5, MB 228.31, Detroit Diesel DFS93K222,MTUType2.1,DeutzDQCIII-10 LA,CumminsCES20086,CatECF-3,CatECF- 2, FordWSS-M2C171-F1, and JASODH-2.

This multi-fleet motor oil is aimed at a wide range of commercial and industrial ap- plications, including transport, mining, con- struction, quarrying and agriculture. “With the current influx of diesel engines into the South African market requiring this type of technology, now is the ideal time to introduce Q8 Formula Truck 7000 15W-40. The launch supports our expansion strategy, since the diversification allows us access to all diesel- engine operators,” Le Roux says. The latest launch means that Blue Chip Lubricants is at the forefront of the latest developments in the industry. “We are now able to offer the latest top-tier heavy-duty engine oil technology that offers several im- provements in terms of engine performance and protection. Operators may now use one motor oil for all their diesel engines, since Q8 Formula Truck 7000 15W-40 is also suit- able for older model engines,” Le Roux notes. The new product will be blended at Blue Chip Lubricants’ state-of-the-art blending plant in Kya Sands, Johannesburg, based on the same formulation, base oils, and additives usedbyQ8Oils globally. BlueChip Lubricants secured an agreement toblend anddistribute lubricants fromQ8Oils in 2015. Q8 is a subsidiaryof theKuwait Petroleum Corporation (KPC), one of theworld’s largest oil producers. Formula Truck 7000 15W‑40

Johan le roux, lubricant support engineer at Blue Chip Lubricants. was developed at the Q8 Research & Technology facilities in The Netherlands, the largest research-and-development facility of its kind in Europe. “With the substantial resources of KPC on tap, we have the people, products, and proficiency to keep the wheels of industry turning,” Le Roux concludes. Blue Chip Lubricants was established in 1983, buying and selling grease as its core business. It soon established its own blending site, and began manufacturing grease and oil formines across SouthAfrica. As the company grew, so did its target market. It now supplies various industries from the automotive, min- ing, engineering, agricultural, industrial, and commercial markets. With over 30 years’ industry experience and technical expertise, BlueChip Lubricants is a trusted South African partner, manufac- turer, and distributor to some of the world’s best oil brands. With its very own state- of-the-art manufacturing plant and testing laboratory, the company is able to cater for all types of lubricant needs, from blending to repackaging and distribution for both large corporationsandindividualendconsumers. q

Blue Chip Lubricants blends and distributes lubricants from Q8 oils of Kuwait.

May 2018 • MechChem Africa ¦ 11

The payback from efficient mill liners

According to Sam Hearn, global sales and business development manager at Multotec Rubber, there is a misconception that mill liners are expensive purchases. In this article he explains that the liners only cost between 10 to 20% of the operating cost of a mill, and that the cost of power is far greater. In addition, the efficiency of the mill liner relates directly to recovery efficiency of the downstream equipment.

One of the major costs associated with operating a minerals processing plant is the specific cost of power in kWh/t and this is significant becausewhen the efficiency of the closed-circuit mill is reduced, the material is essentiallybeing treatedmore thanonce. This is amajor additional cost factor, but oftenone that is not apparent. Sam Hearn, global sales and business development manager at Multotec Rubber says that a hurdle that needs to be jumped is the misconception that the mill liner is an expensive purchase. “Once we have engaged with the plant engineers and drawn to their attention that the liners only cost between 10 to 20% of the operating cost of a mill, and that the cost of power is far greater, we then have their attention,” Hearn says.” Power is a monthly expenditure for a plant and in most cases is not directly allocated to the mill’s operating costs, yet power accounts for about 60% of the total operating cost for that mill.” He says that if it is accepted that thepower cost is 60%and the liner cost is 10%, then the balance of the mill’s operating costs can be attributed to the grinding media. “This is an area which can be adversely affected by liner profile and charge trajectory, so Multotec takes special care to ensure the design is cor- rect,” he explains. Worn liners allow more slippage of the charge and this results in an acceleration of

“ T he correct time to change mill liners is when the efficiency of the mill drops and not when the lining is completelyworn.” This is according to Spike Taylor, managing director of Multotec Rubber, who goes on to explain that the efficiency of the mill liner relates directly to recovery efficiency of the down- stream equipment, and that plant operators need to adopt a far more proactive approach in this regard. “A further ramification of waiting too long to change out the mill lining is that the fresh feedratewilldecreasesignificantlybecauseof thehigherrecirculatingload,and thiswill have an obvious impact on production throughput of the plant,” Taylor says. Spike Taylor, managing director of Multotec Rubber, and Samuel Hearn, the company’s business development manager.

The correct time to change mill liners is when the efficiency of the mill drops and not when one thinks the lining is completely worn. lifespanof the liner and the point atwhich the mill will become inefficient. The automatic measurement and display of the charge level is valuable in confirming that the operation of themill is correct and this value is essential in calculating the trajectory. Highly skilled technicians take thedata ac- quiredbyMultoScan and leverageMultotec’s Hawkeyeproprietaryprogramme to interpret and analyse the data. Significantly there is no time lag on the information analysis, which makes the level of responsiveness possible unprecedented, and allows customers imme- diate feedback on the condition of the liners and any immediate issues can be addressed on the spot. Multotec Rubber has a sound reputa- tion with its customers where the use of its MultoScan system has been implemented. Using the MultoScan measurements and the SCADA data that the company receives from customers, it is possible to generate an accurate report on the performance of the mill. This enables Multotec’s technical team to engage with the mill operator directly in terms of mill performance and costs. “In many instances, it is possible to make recommendationsbasedon thisdatamotivat- ing for an earlier mill liner change out as this can dramatically reduce operating costs and increase overall plant efficiency,” Hearn ex- plains.What ismost important in this scenario isMultotec’s ability touse the data generated to accurately determine the actual payback period for the new lining. q

the wear rate, which can lead to the pre- dicted life not being achieved. Sudden re- placement require- ments mean that more frequent liner measurements need to be taken as the lin- ers near the end of their lives. The introduction of MultoScan several years agomade it pos- sible for plants to ac- curatelymeasuremill liner profiles. Using this information, end users can easily and accuratelypredict the

Highly skilled technicians take the data acquired by MultoScan and leverage Multotec’s Hawkeye propriety programme to interpret and analyse the data.

12 ¦ MechChem Africa • May 2018

⎪ Plant maintenance, lubrication and filtration ⎪

Engen calls the former emergent black entrepreneur and current Easigas-Reatile Gaz chairman, Simphiwe Mehlomakulu “one of its biggest business success stories”. Now their partnership, forged in 2010 and expanded to take in Easigas five years later, aims to change the face of gas provision for the country’s poor. Partnership supports emerging black entrepreneurs

U nseating his prime competitor to becomeSouthAfrica’snumberone LPGmarket leadermakes Easigas- Reatile Gaz chairman Simphiwe Mehlomakulu extremely proud. But arguably more proud are his partners at Engen, whom Mehlomakulu credits with helping to position his black-owned andman- aged company as a key player in southern Africa’s energy sector. Mehlomakulu startedReatileGaz in 2006 with just three staffmembers. By 2010, there were 11 and by the time of the merger an impressive 90 people. In the past six years he has grown profitability 14 times and boosted eightfoldhissalesvolumesofliquidpetroleum gas (LPG). SincethemergerwithEasigas,thepartner- ship has built six depots around South Africa – two each in Cape Town and Gauteng, and one each in Port Elizabeth and Durban – and 200 people are currently employed. Unathi Njokweni-Magida, Engen’s head of TransformationandStakeholderEngagement, says this “growth and sustainability of black entrepreneurs is what will ultimately turn our economy around, ensure equitable profit

the company the traction to grow. The partnership also boosted his inter- national standing following the merger with Easigas, a companywithFrench roots, accord- ing toNjokweni-Magida. “That gavehimexpo- sure toglobal practice, so it’s not onlya caseof growing the South African business through Engen, but also positioning Mehlomakulu to workwith global players, as part of the Engen group of companies,” she explains. Already Easigas-Reatile Gaz operates in four other southern African countries, including Lesotho, Botswana, Swaziland and Zimbabwe, and Mehlomakulu has his sights set on further expansion to take in Mozambique, Zambia, Malawi and Tanzania. Closer to home, however, he is focused on supplying smaller andmoreeconomical 5.0kg gas canisters specifically aimed at poorer communities in a bid to make the use of gas a more attractive option. MehlomakuluandNjokweni-Magidaagree their companies are equally committed to a customer-centric approach, which in the case of the smaller gas canisters means bringing cheaper, safe energy to the poor. “Offering a diverse range of gas packag-

ing to suit all our customers’ requirements is a critical part of our company strategy of catering to local needs of all South Africans,” Njokweni-Magida says. It also dovetailed with Engen’s com- mitment to environmental responsibility, because broader use of gas would improve safety, especially in informal settlements constantly threatened by fires. Mehlomakulu credits Engenas anexample of the responsibility of big business in trans- forming South Africa’s economic landscape, by supporting incubator companies to grow, and to become global players. In his case, his company focused on areas considered “too small” for Engen, ultimately forging a partnership that was extremely profitable for both parties. “We need support for other entrepre- neurs like me. It’s a win-win situation that is definitelyeconomically sound, but alsoboosts vital job creation,” says Mehlomakulu. Engen and Reatile Gaz have a 40%-60% partnership, and together the two compa- nies have a 40% share in Easigas. The other 60% of Easigas is owned by Rubis Energie (France). q

sharing, and help lift people out of poverty. And Engen continues to build similarly successfulpartnershipsacross the spectrum,” she adds. “When Reatile Gaz cre- ates so many new jobs, it’s also important to remember that it’s about so much more than only job creation at face value. Each breadwinner is supporting an average five other people. If you look at it like that, then youbegin to see how that kind of job creation is good for our entire country.” MehlomakulusaysEngen’s crucial role in his success story included that the part- nership afforded his small, emerging company critical credibility in themarketplace, but also secured a constant volume supply, helped with credit lines, which gave

The Engen Refinery in Durban, South Africa, manufactures a quality range of petroleum-based products including LPG.

May 2018 • MechChem Africa ¦ 13