MechChem Africa May-June 2023

MechChem MAY-JUNE 2023 AFRICA

Total plant solutions for sugar

This month: Leveraging better wastewater treatment

Excess heat and the energy crisis

SA Foundry Industry goes to Düsseldorf

Water reuse and long-term supply solutions

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CONTENTS 30 Maintenance solutions and asset management 6 Integrated solutions from Circular Economy Centre The SKF Circular Economy Centre is securing new customers based on its ability to offer solutions that optimise operations, save costs and deliver environmental benefits. 7 Online condition monitoring improves diamond plant efficiency 8 thyssenkrupp Uhde extends life of ammonia tank 9 Reliability Partners champions predictive maintenance 10 How to find reliable lubrication solutions 11 WearCheck saves customers time and money Water, wastewater and pumping solutions 12 Leveraging better wastewater treatment Verder SA urges wastewater treatment plant designers to carefully consider modern options to determine the long-term viability of their solutions. 14 Biological trickle filtration systems supplied to Ghana 15 Dewatering plan saves the day at iron ore mine 16 Technology to achieve ‘Water for All’ 17 Use data to optimise municipal water management Minerals processing and materials handling 18 Degritting spiral reduces carbon costs for mining operations in West Africa The use of a modified Multotec SX4 spiral is achieving up to 95% removal of contaminants from the activated carbon used in gold processing. 19 FLSmidth’s comminution line-up leads the pack 21 Sandvik introduces industry-first carbide recycling 22 Weba chutes prove their worth at US power plants 23 Fast, optimal solutions underpin Africa growth Heating ventilation and air conditioning 24 Excess heat: a greener and safer route out of the energy crisis According to a Danfoss ImpactWhite Paper – Issue 2 – excess heat is the world’s largest untapped energy source. MechChem Africa extracts the highlights. PowerGen, PetroChem and sustainable energy management 26 The growing need for 10 MW-plus power plants South Africa-based Zest WEG is serving the need for larger power plants with a range of in-house solutions. 28 Energy optimisation and best practices keep industry turning 30 Why green hydrogen for SA? 33 Solar tax breaks offer a little, but not enough Local manufacturing and food processing 34 SA Foundry Industry goes to Düsseldorf MechChem Africa talks to NFTN Director Ndivhuho Raphulu about the National Foundry Technology Network’s decision to exhibit SA’s metal casting capabilities and investment opportunities at GMTN 2023 in Düsseldorf this June. 36 Gear business driven by sustainability Corrosion control and coatings 38 Why is stainless steel not the first choice for SA projects Sassda executive director, Michel Basson, questions why key local sectors in South Africa are not using more locally produced stainless steel. 39 Zinc supports clean energy technologies from solar to wind Hydraulic, pneumatic Automation systems 40 Green and efficient compressed air solutions Atlas Copco Compressor Technique highlights how the company’s Industrial Air team is meeting the growing appetite for green, solutions. 41 Omron’s EtherCAT capabilities and solutions Innovative engineering 46 Water reuse and long-term supply solutions MechChem Africa talks to Thys Els of Veolia Services Southern Africa, about water reuse and the innovations that could help us to overcome water scarcity. Regulars 2 Peter’s comment: Can SA become a green hydrogen fuel exporter? 4 On the Cover: Total plant maintenance for the sugar sector: BMG outlines the critical role it is playing in the sugar sector. 42 Products and industry news 48 Back page: Energy storage testbed to boost battery industry 46

Published bimonthly by Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: mechchemafrica@crown.co.za www.mechchemafricamagazine.co.za Editor: Peter Middleton e-mail: peterm@crown.co.za Advertising: Elmarie Stonell e-mail: mechchemafrica@crown.co.za Design: Katlego Montsho Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors.

Transparency You Can See Average circulation Jan to Mar 2023: 10 217 Printed by: Tandym Print, Cape Town

Front cover: BMG KZN Regional Services Centre Contact: Keith van Wyk, Tel: +27 31 534 4827 keithvw@bmgworld.net www.bmgworld.net

May-June 2023 • MechChem Africa ¦ 1

Can SA become a green hydrogen fuel exporter?

Governments are scrambling to meet ambitious carbon reduction targets towards net zero, initially to meet interim 2030 commitments but ultimately for 2050, by which time CO 2 levels in the Earth’s atmosphere are ‘scheduled’ to have stopped ris ing. That gives us less than 27 years to completely transform the global energy system away from using fossil-based fuels: coal, gas, petrol, diesel, aviation fuel, heavy oil, paraffin and many more. It is worth remembering how short a time 27 years really is: The first climate conference was held in Geneva in 1979. The final declaration at that conference was: ‘To foresee and prevent potential man-made changes in climate that might be adverse to the well-being of humanity’. That was 44 years ago! Then in 1997 in Kyoto, 26 years ago, the first declaration to reduce overall emissions of CO 2 and other greenhouse gases – by at least 5.0% – came into ‘force’. In South Africa, load shedding first started at the end of 2007, 16 years ago, but warnings of an im pending power crisis were first identified in a 1998 report by ‘analysts and experts in Eskom and the SA Government’. So, we in South Africa have been grap pling with this need to transform our power grid for 25 years. And it has never been more obvious, not only because of the climate crisis, that the South African energy grid must be completely transformed. My daughter will be 49 in 2050. Will she still be living with a climate crisis? Will South Africa still be facing load shedding? The transformation to a greener, net-zero world involves, first and foremost, the replacement of fossil-based power generation with renewable alternatives – wind, solar, hydroelectric, geother mal, etc – while focusing on the electrification of transport systems to displace demand for liquid fuels. These changes are happening, more rapidly in some countries than others, but renewable en ergy plants are now accepted as cost effective and adoption rates are accelerating. The International Energy Agency (IEA) anticipates that global renew able power capacity will have grown by 2 400 GW by 2027 and, in the UK, the proportion of new cars sold in April 2023 that were either fully electric or plug-in hybrid was 21.9%. But there are still some hard to decarbonise sectors in industries where direct electrification is difficult, such as metal and cement processing, and transportation for aviation, shipping and heavy on- and off-road vehicles. It is in these areas where renewable/green hydrogen is seen as playing an essential role in displacing carbon and supporting the

energy transition to net zero. This issue features an excellent article, by Karen Surridge of SANEDI, that unpacks why green hydro gen is ideal for SA. In it she cites South Africa’s well developed expertise in Fischer-Tropsch technology. South Africa has an abundance of the platinum group metals (PGMs) required for making the cata lysts for hydrogen fuel cells, as well as those for use in Sasol’s gas-to-liquid fuel reforming processes. Sasol’s Fischer-Tropsch technology relies on cata lysts to convert Syngas – a mixture of hydrogen (H 2 ) and carbon monoxide (CO) – into syncrude, which can then be refined to produce high quality liquid fuels and chemicals. While Sasol’s gas-to-liquids process is far from green at present, it isn’t hard to imagine the pro duction of its fuels becoming greener as part of an energy transition. Eventually we will have to stop burning carbon-based transport fuels, but in the interim, green hydrogen and renewable energy could help to decarbonise the production processes to some extent. And the quality of fuels produced via Sasol’s Fischer-Tropsch process makes them ideal for greener aviation fuel, which currently has few carbon-zero alternatives. Green hydrogen fuel is ideal for direct use in trucks and heavy on- and offroad vehicles, with hydrogen fuel cells producing onboard electricity to power electric drives. An alternative hydrogen-based green fuel is am monia (NH 3 ), which has a higher energy density per unit volume than hydrogen gas and it is easier to store and transport. Suitable for trucks and ships, ammonia can be used to fuel combustion engines or, again via hydrogen fuel cells, to power electric drives. Surridge cites our abundant sun- and wind-ener gy resources, along with the land on which we can establish industrial-scale renewable energy plants. Via electrolysers, these can be used to generate the hydrogen needed for next-generation green fuels. Launched late last year, the Infrastructure SA hydrogen economy pipeline of 19 green hydrogen projects is valued at more than R300-billion, while the IDC has secured €23-million (R478-million) in grant funds from the German government to sup port our green hydrogen economy. The troublesome Medupi and Kusili power stations have cost us that much already. Like Karen Surridge, I am excited and inspired by the goals of this programme. Wouldn’t it be fantastic for South Africa to become a green fuel exporter, while simultaneously creating a transformed, stable, reliable and clean energy network.

Peter Middleton

Comment

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2 ¦ MechChem Africa • May-June 2023

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May-June 2023 • MechChem Africa ¦ 3

Total plant maintenance for the sugar sector from BMG Through its Riverhorse Valley regional workshop, its regional distribution centre (RDC), and branches across the country, BMG plays a critical role in the sugar sector: providing engineering solutions for growers and millers; a comprehensive range of products that suit the industry’s intensive needs; and total plant maintenance capabilities. T he sugar industry – in South Africa and in neighbouring African coun tries – is an important area of growth for BMG, begins Hylton Doyle, the wall thickness between the bearing journals – which was where cracking had occurred. Because of the harsh operating conditions of the mill and the high torque load of these units, BMG specialists recommended replace ment of the carriers as the preferred option to repair and refurbishment.

operating efficiencies in the sugar sector,” says Doyle. BMG also supplies a wide range of robust cane carrier chain, the most critical of which is the reclaimer chain, which carries the bagasse for fuelling the boilers of the mill. Power transmission solutions “Through the provision, over decades, of power transmission solutions that ensure high productivity in cane fields and during processing and refinement, BMG boasts a depth of experience in the sugar sector,” says Gavin Kirstein, BMG’s Business Unit Manager for the Power Transmission division. “Our power transmission division supplies and supports a wide range of products, which are carefully selected for dependable perfor mance in demanding conditions of the sugar industry. These components include diffuser and mill gearboxes, carrier and diffuser chains, knife and shredder bearing housings, custom sprockets and gear couplings, as well as steam gaskets, heat exchangers and hydraulic tools. In addition, mill lubrication and hydraulic systems, form a critical part of our power transmission range. An important service to the sugar sector is BMG’s chain refurbishment facility in Durban, where chains are stripped, inspected and re-assembled, using new components where

company’s engineering manager for KZN. BMG operates the Riverhorse Valley re gional service centre in KZN with specialist assembly, repair, maintenance and support, which offers combined technical expertise and value-added product solutions. “Our workshop’s specialist services to the sugar sector include bearing and gearbox inspec tion, bearing and chain refurbishment, and large-size bearing assembly, alignment and balancing. The team also works on shredder lube systems, juice heater door hydraulics, mill roll hydraulics, mill bearing lubrication, shred der hook bar removal systems, as well as many customised product designs,” says Doyle. “We strive to offer customers dependable service, repair and delivery solutions; central ised technical support; and easy accessibility to BMG’s comprehensive range of quality branded engineering components,” he says, adding that Dorstener planetary gearboxes, for example, have been used successfully in the sugar industry for many years: on dif fuser drives, mill drives and feeder tables, for example. The KZN service centre and the field service team have recently been involved in several projects during off-crop seasons, as well as dealing with urgent breakdowns in sugar mills and refineries. Doyle cites a re cently completed refurbishment, fabrication and replacement project on worn components of a gearbox in preparation for the high pro ductivity growing season. “In spite of tight time restrictions before the seasonal start-up of the mill, coupled with manufacturing challenges, BMG recently de signed, fabricated and installed new carriers for these gearboxes, reducing the normal 24 week delivery period for OEM replacements to only four weeks, with cost savings of about 7.5 times those of the OEM parts. Carriers, which connect the planet gears to the output shaft of a planetary gearbox, are normally manufactured from cast iron, which is extremely difficult to repair. In this case, there was the additional problem of bores positioned close together, with virtually no

The planet carriers were re-engineered and fabricated out of 355WA steel plate, which is not only stronger than the cast iron used in the original units, but also allowed BMG to manufacture them in a lead time of just three weeks. The team was on a tight deadline to have drawings and designs approved and to ensure highly accurate dimensions for a perfect fit with clearances to accommodate the gear mesh. Welding challenges to maintain the structural rigidity of the system were over come by machining interlocking tabs in the top and bottom main plates, as well as in the webs and side rings, to ensure a more precise assembly for welding, and less distortion. The webs and side plates were welded to the bottom ring and the entire assembly was then fitted onto the top ring. Slots were later filled with weld metal so that the webs formed an integral part of the structure. “This success exemplifies BMG’s total plant maintenance capabilities, which are geared to optimise productivity and enhance process plant reliability: making a real difference to

The BMG team works on a diffuser headshaft at the Riverhorse Valley regional workshop in KZN. The facility offers specialist inspection, assembly, refurbishment, alignment and balancing services to the sugar sector.

4 ¦ MechChem Africa • May-June 2023

⎪ Cover story ⎪

necessary. This refurbishment service is often carried out under strict time restrictions, which requires advanced planning. “Analysis of chain failures is also con ducted at this facility. BMG specialists are able to advise customers on the expected remaining wear life of a chain and on what improvements need to be introduced to their systems,” he adds. “Other specialist services include bear ing and gearbox inspection, bearing and chain refurbishment,

large size bearing as sembly, alignment and balancing, as well as customised product design. We also offer a troubleshooting and maintenance service, condi

BMG offers wide range of lubricants and additives including synthetic oils, lubricants and bespoke lubrication systems.

tion monitoring and training,” Kirstein says. Key sugar sector components from BMG’s power transmission division, such as Tsubaki high performance chains, are well-suited to the harsh conditions in sugar processing and production, offering enhanced strength and reliability, a cleaner environment and extended operating life. “BMG specialists are able to provide solu tions for any problems our customers face when using conveyor chain. We can adapt the materials used and even the heat treat ment of a chain’s components, to match the specific application and operating environ ment – whether in the sugarcane field, or in the mill or refinery,” explains Marthinus Janse van Rensburg, National Product Manager for Tsubaki at BMG. “We also offer a range of chains with stainless steel components to protect against corrosion, which is especially problematic on bagasse carriers and elevators. Stainless steel components can be heat treated to provide wear and corrosion resistance, as well as ad ditional strength. “And on the agricultural side, BMG’s Tsubaki cane harvester chains are manu factured at an ISO certified manufacturing facility in line with Tsubaki’s exacting speci fications. All components are shot-peened and the chain is also statically pre-loaded for enhanced wear life in the harsh conditions of cane fields,” Janse van Rensburg says, adding that BMG supplies a wide range of robust cane carrier chain that provides excellent du rability and wear resistance during operation in demanding conditions in sugar mills, the most critical of which is the bagasse reclaimer, which fuels the mill. High performance additives and lubricants For the sugar industry, BMG also offers wide range of lubricants and additives including synthetic oils, lubricants and bespoke lubrica

Cera Tec Ceramic additives improve reliability of industrial equipment, lower engine and transmission noise, minimise maintenance requirements and reduces downtime.

tion systems. “We often see operators in the local sugar sector facing ongoing difficulties, for example with transmission gearing in conveyor systems under arduous conditions,” explains Carlo Beukes, Business Development Manager for BMG’s Agricultural, Automotive and Lubrication divisions. “This results in accelerated wear and higher temperatures. Problems occur where dust accumulates in the transmission, thus increasing friction between the gears and other components, accelerating wear,” he adds. Another problem in the industry is high ambient temperatures, which increase the temperature of the oil in the transmission. The risk of inadequate lubrication and exces sive wear thus increases, adding the threat of failures and subsequent loss of production. The BMG team has received positive feedback since last year’s launch of the industrial wear protection additive called Liqui Moly Cera Tec, which is proving to be highly effective in protecting gears in sugar mills. Customers report there are now fewer operational problems, includ ing improved dust control, lower mainte

nance and replacement requirements and longer service life of critical components. “Cera Tec Ceramic additives – with excep tional resistance to high temperature and pressure – improve reliability of industrial equipment, lower engine and transmission noise, minimise maintenance requirements and reduce downtime. Other benefits include energy savings, reduced risk of contamina tion, lower pollutant emissions and more efficient operating costs,” notes Beukes. BMG’s Riverhorse Valley workshop, its field service teams, and branches across the country enable total plant maintenance solutions to be implemented for sugar mills and refineries in tight time frames by locally re-engineering and manufacturing replacement components or by incorporating BMG’s broad range of quality branded engineering components. This plant maintenance capability is sup ported by a team of engineering specialists and 24-hour technical support services from competent teams to ensure ongoing reliability, efficiency, extended life and energy savings at sugar mills and on sugarcane plantations. bmgworld.net

May-June 2023 • MechChem Africa ¦ 5

Integrated solutions from Circular Economy Centre The SKF Circular Economy Centre is securing new customers on the strength of its ability to combine deliverables that optimise operations and cost savings with environmental benefits.

Lourens Pretorius

metric, form and quality specifications as new SKF products. Remanufactured components carry a one-year conformance warranty, which is testament to the high quality and reliability of these products. Finally, Pretorius points to the fact that bearing remanufacture reduces material consumption; while bearings not eligible for remanufacture can be recycled to produce new bearings, effectively closing the reduce /reuse/recycle loop. SKF’s Mechanical Field Service team stepped in to ensure that the bearings were correctly fitted by using a selection of MaPro mounting tools including a bearing heater, hydraulic nuts and spanners; and a C-Spanner was purchased by the customer. In addition to providing a baseline vibra tion monitoring required by the customer to ensure that the equipment passes all the necessary requirements before commission ing, SKF’s Connected Technologies team was also able to provide baseline readings on other critical equipment. The complete SKF solution includes condi tion monitoring; vibration and temperature data is collected in real-time and is analysed to identify potential issues on the bearings. Alongside extending bearing life and increas ing mean time between failures (MTBF), con dition monitoring and data analytics can also identify potential bearing failures, enabling the unit to be removed timeously for repairs or replacement and thus reducing the risk of costly production stoppages. Pretorius sums up the sustainability ben efits of SKF’s turnkey solutions: “Benefits for our customers include increased service life, machine and equipment reliability and longer lifecycles, as well as operator safety and all the related cost savings. These fac tors are fundamental to ensuring sustainable operations. Furthermore, reduced material consumption, direct energy consumption and emissions because of our reman process also reduce impact on the environment.” Pretorius confirms that the work for the new customer is ongoing. “We have identified more areas where we can add further value for this customer and are bringing our other departments on board to lend their profes sional expertise.” www.skf.com

professional bearing fitment and a condition monitoring solution that called on the exper tise of SKF’s Mechanical Field Service and Connected Technologies team. “We remanufactured a total of 25 bear ings and replaced three bearings that did not pass our remanufacture assessment require ments,” explains Pretorius. “We also supplied eleven new units as well as local engineering components, including new bearing sleeves and lock nuts.” Pretorius weighs in on the value that SKF’s specialist Remanufacturing Centre adds. “In the true sense of what makes up a circular economy, our remanufacturing capabilities enable us to reduce, reuse and recycle. Instead of being replaced, remanufactured bearings are given a new lease of life and are reused. As remanufactured bearings are much more cost-effective than new bearings, we can keep costs down significantly for our customers.” “Moreover, the waiting period for certain large size bearings can be up to several months but as we are able to remanufacture bearings within three to five working days we sub stantially reduce the lead times, getting our customers fully operational within a few days.” Pretorius adds that SKF’s remanufactured bearings and units conform to the same geo

A ligning with SKF’s circular economy drive, the organisation continues to innovate its products, systems, and services. One of SKF’s greatest strengths is the development of new tech nologies and value-adding solutions to assist customers in achieving their economic and environmental sustainability goals. “This proud reputation prompted the cus tomer, who is a leading operator in the mining sector based in Gauteng, to approach us in August 2022 for a bearing remanufacturing solution,” says Lourens Pretorius, SKF Circular Economy Centre Manager. “The customer later called for a further eighteen additional gearbox bearings to be sent to SKF’s Reman Centre for assessment.” What initially started with a request for a site inspection of SRBs (spherical roller bear ings) – while still running on their respective shafts – to determine if they were suitable for remanufacturing, was followed by a fully integrated solution from the SKF Circular Economy Centre. This included the supply of new and refurbished bearings, mounting tools, and local engineering components as well as additional support services such as

SKF remanufactured a total of 25 bearings and replaced three bearings that did not pass remanufacture assessment requirements, explains Pretorius.

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⎪ Maintenance and asset management ⎪

Online condition monitoring improves diamond plant efficiency

A leading global diamond producer has raised plant efficiency by installing SKF automated machine health monitoring and surveillance systems, along with the @ptitude Observer (@O) software.

A diamond producer in Botswana was looking for an online condition monitoring system to align with its digital transformation strategy in a cost-effective way. In addition, the customer required support for its reliability strategy in a bid to reduce unplanned downtime at its mining operations. Owing to its proven world-class online condition monitoring systems and outstand ing service solutions, SKF was selected to be a long-term partner on the customer’s journey to full digitalisation at the client’s four mining sites. Kutsi Jaka, SKF Product Manager: Condition Monitoring (CoMo), explains that the mining company was already familiar with SKF having been an indirect customer for several years. “SKF South Africa has been supplying products and services including bearings, seals, MaPro, power transmission, training, as well as several other related services to the customer via distributors in Botswana. The customer has also been using the SKF Microlog hand-held vibration analys ers and @ptitude Analyst software.” Before building a proposal, the SKF team held several online meetings with the customer, building up to a scoping visit at the mine site, to understand and define the necessary requirements. SKF South Africa recommended the Enlight IMx-1 automated machine health monitoring system and Multilog IMx-8/16 surveillance systems complete with the @ptitude Observer (@O) software to monitor the customer’s critical and semi-critical assets. Satisfied with SKF’s proposal, the custom er gave the green light to implement the online condition monitoring project to monitor all its critical assets at the mine site. The critical assets monitored in real-time by the wired SKF IMx data acquisition devices include High Pressure Grinding Rolls (HPGRs), Gyratory Crushers and Conveyor Drives, whilst the semi-critical equipment is looked after by the wireless SKF Enlight Collect IMx-1. The SKF Enlight Collect IMx-1 system, comprising vibration and temperature sen sors and gateways, collects critical data on the health of machines and equipment. Both the Multilog IMx-8/16 surveillance and Enlight Collect IMx-1 systems provide data to the

customer’s historian (data store) for machine learning algorithms and analytics. The historian uses the SKF

functions. “The expert diagnostics and analyses functionality resident in @O provide unrivalled application insights to maximise rotating equipment performance (REP),” states Jaka. “This optimises safety, reliability and sustainability and allows the customer’s business to be more agile and deliver greater output.” By providing real time data on the condi tion of the customer’s assets and general plant health, SKF’s holistic online condition monitoring solutions contribute to optimised equipment performance, efficiency, reliability, and reduced life cycle costs. The subsequent optimised plant and machine availability en hances uptime and production at mine sites, for ultimate customer peace of mind. According to Jaka, based on the success of this project, SKF will be rolling out further online condition monitoring systems to the customer’s other three mines in due course. q SKF’s Enlight Collect IMx-1 is a scalable and easy to set up mesh sensor network for data collection from condition-based monitoring sensors.

@ptitude Observer suite (@O) data through the Phoenix API (Application Programming Interface) enabling the customer to access condition monitoring data onsite, saving significantly on possible PLC I/O card costs they would have had to invest in. The data is analysed by specialists based at the SKF Africa RDC in Johannesburg, and an overview and detailed asset health report is created periodically for the customer. The data store collects history data such as temperature, pressure, current, voltage, and any other type of operational data, from the SKF IMx range data acquisition devices. Each of these data sets or signals also has a time stamp assigned to it in order for the historian to simplify the most demanding data report ing and analysis requirements. Primarily developed to work with on-line condition monitoring systems, @O is a core platform in a family of reliability software applications that work together as the SKF @ptitude Monitoring Suite. The software offers an easy-to-use op erator interface and intelligent diagnostics

SKF Enlight IMx-16 automated machine health monitoring systems provide for early fault detection and improved reliability, availability, and performance of rotating equipment.

May-June 2023 • MechChem Africa ¦ 7

thyssenkrupp Uhde has reached the halfway mark in the inspection and refurbishment of an ammonia tank located at Richards Bay’s back-of-port facilities in South Africa’s KwaZulu-Natal Province. thyssenkrupp Uhde extends the life of ammonia tank

t hyssenkrupp Uhde designed and built two 19 034 m 3 anhydrous ammonia stor age tanks for a key customer in Richard’s Bay back in 1982. Ammonia (NH 3 ) is an inorganic compound of nitrogen and hydrogen. Ammonia gas is colourless and can either be easily compressed or cooled down to sub-zero temperatures to form a clear liquid. Liquid ammonia is stored in low pressure cryogenic tanks at harbour import facilities for distribution to various industries around the country. Ammonia is used in a host of ap plications that include the manufacturing of pesticides, fertilizers, plastics, textiles, dyes and other chemicals. Ammonia is also used as a refrigerant gas and to purify water supplies. Due to the highly corrosive properties of liquid ammonia, and to protect people and the environment, it is statutory to take stor age tanks out of commission every 20 years to allow for internal and external inspection. “By inspecting the integrity of the structure, we can identify possible weak areas and carry out all the necessary refurbishments. This helps to prevent potential ruptures and subsequent leakage, extend the tank service life and, importantly, also allows for continu ous safe operation of the facility,” says Yurisha Singh, HOD Sales & Proposals, at thyssenk rupp Uhde. thyssenkrupp Uhde was awarded the am monia tank revamp project in October 2022. “As the prime contractor, we deploy a full construction management team, including safety management, to site,” explains Singh. “We appoint sub-contractors to attend to the necessary construction work.” She says the thyssenkrupp Uhde site team is well-known to the customer as it was already in Richards Bay, having just completed a project. “So, the thyssenkrupp Uhde team and contrac tors simply ‘rolled over’ from their previous project to commence immediately with the necessary preparatory work required for the tank inspection and refurbishment process.” Before any inspection can commence, the tank’s interior environment must be made safe. This involves draining all the ammonia liquid, which is followed by purging of any residual gases from the tank using a non reactive gas such as nitrogen. Once the space is cleared from ammonia it is further vented with natural ambient air. Only then is it safe for a skilled thyssenkrupp Uhde technician to enter the tank without the need for a breath ing apparatus to commence with the inspec

thyssenkrupp Uhde is inspecting & refurbishing a 20-year-old ammonia storage tank for increased lifespan and continuous safe operation.

Commissioning will take place under the di rection of experts who have been especially assigned to the project, in collaboration with operations staff from the customer. Project commissioning and expected completion date is scheduled for June 2023. thyssenkrupp Uhde’s professional inspec tion and value-adding refurbishment capa bilities are supported by project management, procurement and engineering specialists who are based at the company’s head office in Rivonia, Gauteng. “Our ability to draw from a global com petency pool coupled with decades of local knowledge and experience, enable us to deliver turnkey plant and project solutions to our customers across Sub-Saharan Africa,” concludes Singh. About the company The local subsidiary of thyssenkrupp Uhde, was established in South Africa in 1959. It is a leading partner in the engineering, con struction and service of industrial plants and systems. The company’s solutions encompass the entire range of services for Fertilizers, Petrochemical, Oil & Gas, and others. Its expe rience spans 100 years and over six decades in Africa with an impressive reference list that extends throughout sub-Saharan Africa. www.uhde.co.za

tion procedures. More than 1822 Non-Destructive Tests (NDTs) are performed to detect any potential faults. As the tank is manufactured from cold duty carbon steel, a Magnetic Test (MT), which is designed for only this type of material, is conducted. “For stainless steel tanks we would carry out Penetrant Tests (PT),” notes Singh. Further tests conducted on the am monia tank during the inspection process include a material thickness test as well as a Radiographic Test (RT). “We also conduct ultrasonic tests on all the weld joints to de termine whether the quality is within param eters. Any problem areas are then flagged for re-welding.” Once all the revamp work has been com pleted, the thyssenkrupp Uhde team conducts further NDTs to ensure that the tank is compli ant with all necessary standards. thyssenkrupp Uhde directs its innovation prowess towards construction methods, opti mising schedules and costs, as well as mitigat ing worker safety risks and weather hazards. Although this is not a genuine ‘green’ project, Singh confirms that some of the identified re vamp scope will help to reduce environmental impact. “For example, improved insulation will help to cut down on energy loss.” Full refurbishment of the ammonia tank will be completed by thyssenkrupp Uhde.

8 ¦ MechChem Africa • May-June 2023

Clients looking for improved reliability and availability of industrial equipment have a new partner in ISO-Reliability Partners. “Our expertise combines the sciences of lubrication, filtration and tribology. We offer unique and dramatic cost-reduction solutions for our customers,” says Craig FitzGerald. Reliability Partners champions predictive maintenance ⎪ Maintenance and asset management ⎪

erating cost and, ultimately, the equipment’s productivity. “Significant performance improvements can be achieved when lubricants are treated as assets,” FitzGerald asserts. To bolster the company’s solutions, it holds distribution rights for premium US lubrication brands Bel-Ray and Royal Purple. “Both are phenomenal lubricant grades that significantly improve energy ef ficiency on large equipment,” he says. Another USA manufactured product it distributes is Seal Saver, a breakthrough in preventative maintenance tools for hydraulic cylin ders. ISO-Reliability Partners is the sole exclusive distributor of Seal Saver hydraulic cylinder protection solutions. Numerous companies trust the company with lubrication of open gear systems. For example, at Sibanye Stillwater, Reliability Partners holds the open gear lubrication contract, a critical application in the mining industry in terms of productivity and efficiency. “To be charged with lubricating the most important components at Sibanye’s opera tions is quite a feather in our cap,” he adds, as it reflects the client’s trust in the products it distributes and the associated thermal analysis services on offer. “The engineering team now also has the opportunity of evergreen time to address any potential issues well in advance, whereas previ ously the maintenance regime was largely reactive,” FitzGerald says. Another major reference is Rand Refinery, which had a history of equipment breakdowns and unplanned stoppages prior to using the company’s products. The largest integrated single-site precious met als refining and smelting complex in the world, Rand Refinery went from 80% red indicators on problem machines to 98% green and available, with zero breakdowns to date. “The engineering team now also has the opportunity of evergreen time to address any potential issues well in advance, whereas previously the maintenance regime was largely reactive,” FitzGerald says. As for the future, he concludes that ISO-Reliability Partners will continue to champion the advan tages of reducing energy consumptions through lubricants and make inroads into its existing industrial and mining markets as well as new ones. www.iso-reliability.com

I SO-Reliability Partners analyses oil samples and implements pro active measures to counter machine wear while plant machinery is in operation, which is the essence of predictive maintenance,” says Craig FitzGerald. The company’s reputation and success span 25 years, with it owning and managing the iconic Filter Focus brand, and FitzGerald having incorporated all his intellectual property into the new company. ISO-Reliability Partners is an own emblem manufacturer (OEM) of class-leading micro fine oil filtration solutions, vacuum dehydra tion systems, automated water removal for compressed air and high efficiency industrial air scrubbing. “The majority of our clients are manufacturing facilities, general industry and mining. Our products are suited to any large-scale user of industrial equipment, gearboxes or mobile machinery,” he explains. “Our solutions excel in high speed, extreme load, high temperature and high contamination applications.” ISO-Reliability Partners eliminates equipment failures and dramatically improves operating efficiencies. Energy efficiency through premium lubrication A trend in industry is to chase after price when considering lubricant purchases. The resulting inability of the lubricant to eliminate metal to-metal contact has adverse effects on equipment performance, op Industrial clients have a new predictive maintenance partner in ISO Reliability Partners.

Ray Clear Gear from ISO-Reliability Partners provides superior lubrication for open gear drive systems.

May-June 2023 • MechChem Africa ¦ 9

How to find reliable lubrication solutions for coastal environments Llewellyn Owen, national sales manager at Lubrication Engineers (LE) talks about the need to work with clients to understand their challenges and find the right lubrication solutions for their specific needs, particularly in coastal areas.

while these assets ‘breathe’. Where storage tanks and working assets are subjected to continuous temperature changes and large fluctuations in humidity, it is critical to in vestigate preventative measures to combat potential problems and implement them. ARS tools can play an important role in this regard. Owen adds that different industrial and agricultural applications require lubrication that will help get the best out of equipment and get the best returns for clients on the lifespan of their machinery. “Every industry has its own troublesome or problematic ma chine or component,” he says. Having the right lubrication partner gives maintenance teams access to expert advice, skills, and technology to help them solve any challenges that arise. For example, marine application lubrication can be particularly tricky – on fishing boats and boat trailers, for example. LE has developed a range of products specifically designed for these applications. For instance, LE 1498/9 is a waterproof grease that is suitable for marine use as it is not affected by saltwater. In the coastal agricultural industry, equip ment such as crop sprayers require a lubricant in the gearbox that can handle not only the environmental issues, but also constant water ingress. “In these instances, you need to have a high-quality lubricant that can separate from water easily, yet still protect the moving parts. LE’s high quality multi-viscosity EP gearbox oils outlast the majority of other lubricants offered in this market,” says Owen. “We like to think of ourselves as a head ache tablet. Regardless of the difficulty a client might be experiencing, whether it be a lubricant solution problem or a heat problem, we are able to assist our clients in solving or greatly reducing their downtime and improv ing their productivity,” he concludes. www.lubricationengineers.co.za The more we can help a client to protect and extend the life of its assets, the better the client’s business does.

Oxidation, rust, corrosion and water exposure can be significantly higher along South Africa’s coastal belt than inland. So much so that coastal conditions are often classified as ‘extreme condition environments’.

O xidation, rust, corrosion, and water exposure can be signifi cantly higher along South Africa’s coastal belt than inland. So much so that coastal conditions are often classified as ‘extreme condition environments’. This does not have to mean, however, that components operating in coastal plants will always have a shorter lifespan or run less efficiently than their inland equivalents. The key to extending the life of any piece of equipment is to protect it by using the right lubrication products in the correct quantities and at the appropriate frequency. Lubrication Engineers (LE) South Africa has long-standing relationships with clients in many different industries in South Africa’s coastal areas and has seen immense improve ments in its clients’ equipment lifespans and performance where the right lubrication is applied, and preventative maintenance devices are used. Llewellyn Owen, National Sales Manager at LE, explains that it is essen tial to work with clients to understand their challenges and find the right solution for their specific needs. This is particularly important in coastal areas where clients have to factor in the environmental impact on wear and tear, and contamination. Beginning with an onsite equipment as sessment, a trained lubrication consultant should be able to recommend lubricants, application methods, usage amounts, and drain or lube intervals to ensure effective maintenance.

Protecting coastal equipment Preventative maintenance and LE’s aftermar ket reliability solutions (ARS) form an impor tant part of this approach. “The better we can help a client in protecting and extending the life of its assets, the better the client’s business does, and the more money the client makes, because there are no continuous issues with downtime. Clients can achieve their targets as far as asset life is concerned. We find that the predictions set out are often exceeded by implementing these systems when running a high-spec, appropriate lubricant,” explains Owen. One example of this is enclosed gear boxes. Owen says that many imported en closed gearboxes do not have adequate level monitors or sight glasses, or the sight glasses get contaminated over time and it becomes difficult for operators to see what is happening inside the gearbox. LE’s Duolec ® Industrial Gear Oil solutions have proved to be an excellent and extremely reliable solution for enclosed gearboxes in coastal applications. “We have cases where we have gearboxes using Duolec ® lubrication that have been running for more than 22 years. The way that the Duolec ® Industrial Gear Oil product keeps oxidation from metal parts and gears is mindboggling,” Owen adds. Preventative devices, such as LE’s High Humidity Desiccant Breathers, can also be helpful air recovery system (ARS) tools when installed on gearboxes, pumps, transformers, and lubricant reservoirs. They help to exclude large amounts of airborne contamination

10 ¦ MechChem Africa • March-April 2023

⎪ Maintenance and asset management ⎪

WearCheck saves customers time and money Ensuring industrial machinery operates at peak performance with reduced maintenance costs – this is the expertise of condition monitoring specialist company, WearCheck.

O perating an extensive network of 16 world-class laboratories in nine countries across Africa, Dubai and India, WearCheck is recognised as a leader in the preventive maintenance field, servicing a wide range of industries with an array of different monitoring techniques. The company has clients in industrial sectors ranging from power generation and renewable energy to mining, fleet management, aviation, maritime and more. WearCheck’s core business is the scien tific analysis of used oil, fuel and other fluids, whereby samples are analysed in the laboratory for trace particles which indicate which com ponent is suffering unusual wear patterns. This information is assessed by a team of specialised diagnosticians, who make recommendations on the required remedial action for the component in question. Additional predictive maintenance tech niques offered by WearCheck – which are employed depending on the type of machinery being monitored – include asset reliability care

Left: Laboratory assistant Zamaswazi Dlamini operates the dielectric tester at WearCheck’s Durban transformer laboratory to validate the insulation properties of the transformer oil. Right: Nomusa Chamane, laboratory assistant at WearCheck’s Durban-based oil analysis laboratory, operates a Dosimat titrator used for determining the TAN (Total Acid Number) of an oil sample.

(ARC) services, water analysis, transformer chemistry services and advanced field services (AFS) such as non-destructive testing, technical compliance and rope condition assessment. The company also offers lubrication enabled reli ability (LER), providing clients with bespoke so lutions to ensure that their lubrication systems are well managed, efficient and cost effective. WearCheck MD, Neil Robinson, outlines the concept of proactive maintenance, “By monitor ing a component’s condition regularly over time, our scientific techniques provide reliable data which enables our diagnosticians to accurately

predict whether and when that component will potentially fail.” “We identify a potential failure before it oc curs and recommend a remedy. This way, cata strophic failure is avoided, thereby enhancing machine availability and performance. “Unplanned component failure can be extremely costly and preferably avoided. With forewarning about potential component failure, our customers dodge unnecessary maintenance costs and maintain efficiency by upholding op timum production levels,” Robinson concludes. www.wearcheck.co.za

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May-June 2023 • MechChem Africa ¦ 11

Reinhard Seidel, sales engineer for Verder South Africa, talks about the need for wastewater treatment plant designers to carefully consider pump requirements and modern options, using both CAPEX and OPEX studies to determine the long-term viability and suitable of their choices. Leveraging better wastewater treatment

F or water to be utilised without harm it needs to be clean and, the fact is, fresh water is not an infinite resource. In addition, increasing urbanisation places strain on water resources and infrastructure networks across Southern Africa. Fresh water used in industrial and process applications that is not remediated properly before being discharged back into local sewerage systems is also a significant contributor to water pollution, placing further pressure on treatment plants. All this is being further exacerbated by climate change and extreme weather events, most particularly the devastating impacts of drought cycles. This was plain to see in 2018, when following a three-year record drought (2015–2017) in the southwest of South Africa (SSA) and precipitated by the last El Niño, Cape Town came within days of Day Zero – becoming the first city in the world to run out of water. Startlingly, the latest monthly Seasonal Climate Watch issued by the South African Weather Service makes tentative predic tions extending until August, which currently indicate that another El Niño looms for South

Africa from mid-year, which could mean further droughts for the Western Cape with consequent water shortages. Wastewater encompasses a broad spec trum, including drainage from households, commercial establishments, hospitals, and industries. It also includes stormwater and urban runoff, along with agricultural, horti cultural, and aquaculture effluent. Untreated, dirty water gets released into natural water reservoirs, where it wreaks havoc on fish, animals, and crops. As it currently stands, however, waste water treatment is not being fully leveraged. According to the UN, approximately 80% of wastewater is released into the environment without being recycled or adequately treated. This increases the risk of contamination to potable and drinking water. Furthermore, failing to fully utilise efficient wastewater treatment has a deleterious impact on socioeconomic issues, impeding sustainable economic development. Effectively utilising wastewater is not only essential to environmental conservation and a smart way to address water shortages, but also potentially a resource, from which water,

energy, nutrients and a variety of recover able materials can be garnered. According to the UN Environmental Programme, and the Global Wastewater Initiative, there is 330 km 3 of municipal wastewater being gen erated globally each year. If this wastewater could be managed effectively, the resources embedded in the water could be used to irri gate and fertilise millions of hectares of crops, as well as produce biogas that could supply energy for millions of households. One of the reasons given why wastewater isn’t treated to its full capacity is the cost associated with upgrading wastewater treat ment systems. However, the Environmental Protection Agency in the US notes that this can be mitigated, as plant upgrades can pay for themselves and/or end up saving a plant money. Wastewater treatment plant design en gineers have a huge responsibility and stake in the management of diminishing water re sources. When designing new, and upgrading existing infrastructure, they should be very careful of false economy when setting the standard for their pump requirements. Many factors should influence the selec tion decisions for plant equipment, but with budgetary constraints, many of these factors are often overlooked. CAPEX versus OPEX studies should be extensive in the planning and implementation of new treatment fa cilities, as well as in managing and operating existing treatment facilities. For instance, when upgrading aging infra structure, new and improved technologies should be explored and considered instead of just replacing equipment like-for-like. The process should constantly be assessed and viewed in its entirety, and ultimately developed, refined and improved by adopting modern and more economical solutions to better the overall plant efficiency and efficacy. There are technological developments that can help reduce costs associated with maintenance and improve plant uptime, such as peristaltic dosing pumps, which are efficient and cost-effective. Over time, this technology has evolved from familiar lower pressure, low-flow medical devices into heavy duty, medium pressure industrial pumping

The Verderflex Ds500 metering and dosing pump has been designed specifically to challenge traditional technological solutions to chemical dosing in municipal and industrial pumping applications.

12 ¦ MechChem Africa • May-June 2023