MechChem Africa May-June 2024

MechChem MAY-JUN 2024 AFRICA

For optimised productivity, minimised downtime and reduced operational costs

This month: Industrial uptime as a core offering

Spiral separation for optimised recovery

Ventilation on demand: opportu nities and risks

Lubricant management using quality sensors

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Maintenance solutions and asset management 6 Industrial uptime: the core of BI’s offering MechChem Africa talks to the management team of BI about the company’s new go-to-market strategy, which now has industrial uptime as the principle underpinning all brand and service offerings. 8 Hytec Fluid Technology reopens Oil Analysis Laboratory 9 Tribology and lubrication engineering for improved asset reliability 10 SKF SA celebrates 110 years of optimising rotational assets Water, wastewater and pumping solutions 12 Mine water stewardship begins with effective water management WSP’s Nirvishee Juggath outlines the key management principles needed for mining companies to reduce their operational water consumption. 14 Climate-resilient solutions: a call to action 15 IPR pump rebuild solutions Minerals processing and materials handling 16 Spiral separation for optimised recovery Menzi Xulu of Multotec talks about spiral technology for the primary separation of chromite ores and mineral sands, and their use to extract additional value from PGM tailings. 18 MATO conveyor belt fasteners and cleaners for Botswana 19 FLSmidth’s eccentric roll crusher 21 Innomotics partners in world's first digital mine 22 Pneumatically conveying of wet, abrasive mica Heating, ventilation and air conditioning 24 Ventilation on demand: the opportunities and the risks Russell Hattingh, MD of BBE consulting, and specialist ventilation consultant, Hannes Potgieter, present their perspectives on ventilation on demand (VoD). PowerGen, PetroChem and sustainable energy management 26 WEG Africa’s new Cape Town premises Celebrating 30 years since its inception, WEG Africa’s Cape Town branch is marking this achievement from its larger and improved premises in Richmond Business Park. 27 Microgrids for remote energy requirements 29 SOOTAWAY for cleaner and more efficient power plants 31 IRP 2023 could reset SA Local manufacturing and food processing 32 Bell Equipment’s expanding European presence MechChem Africa visits the South African facilities of Bell Equipment in Richards Bay and talks to Stephen Jones about the company’s global expansion and the consequent need to expand its European manufacturing hub. 34 Quality gearboxes for centre pivot irrigation 35 Volkswagen announces R4-billion investment Hydraulics, Pneumatics and Automation 36 Navigating the complexities of electric actuators Navigating the complexities of selecting the right electric actuator can be daunting. This article outlines how to make informed choices. 37 Atlas Copco introduces world’s first battery-powered portable compressor Special report 38 Zutari receives international recognition for Wild Coast toll road Zutari has received global recognition for its involvement in the N2 Wild Coast toll road development. Innovative engineering 42 Enhance lubricant management with cutting-edge oil quality sensors ISO-Reliability has partnered with Yateks ® , a technological leader in the manufacture of industrial borescopes, oil condition monitoring sensors and laboratory equipment. Craig FitzGerald from ISO-Reliability Partners explains why. Regulars 2 Peter’s comment: A city-centred energy transition? 4 On the cover: BMG’s World of bearings:Wayne Holton unpacks BMG’s bearings range. 40 Products and industry news 44 Back page: Sappi granted feed safety assurance for pelletin

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 Oct to Dec 2023: 10 846 Printed by: Tandym Print, Cape Town

Front cover: BMG World Contact: Wayne Holton: GM Consumables Divisions. Tel: +27 11 620 1756 Email: wayneh@bmgworld.net www.bmgworld.net

May-June 2024 • MechChem Africa ¦ 1

A city-centred energy transition?

A new report from the International Energy Agency (IEA) is urging governments to adopt policies to help cities to manage their energy demand and reduce the impact of climate change. This as part of the UAE Consensus at COP28 in Dubai last year, where an agreement was signed signalling the “beginning of the end” of the fossil fuel era. Most notably, the world’s Governments agreed to double the annual rate of energy efficiency improvement by 2030 and, in the same timeframe, to triple the global deploy ment of renewable energy capacity, putting the principle of energy efficiency at the centre of policy making. Cities currently account for around three quarters of global energy consumption and 70% of greenhouse gas emissions, and their contribution is set to rise. Of the more than 100-million people liv ing in cities without access to electricity, more than 90% are located in sub-Saharan Africa which, the report points out, is the fastest-urbanising region of the world. Global urban growth by 2050 is estimated to be equivalent to adding the combined land area of Germany, Italy and Japan, posing even more chal lenges to these larger and more densely populated areas – particularly during heat waves. In the hottest regions, electricity consumption can double in warm months of the year, compared to milder ones, with cooling accounting for over 70% of peak electricity demand. This – in addition to the growing electrifica tion of energy as more people use technologies such as heat pumps and electric cars – will place increas ing strains on electricity distribution infrastructure. On a global net zero pathway, investment in electricity grids worldwide needs to more than double by 2030: to US$750-billion per annum. Approximately 75% of this spending would need to go towards expanding, strengthening and digitalis ing distribution grids, including in cities, to improve system efficiency and manage more complex flows of electricity and data. Also highlighted is the need for improved access to and use of data for decision making: to support faster and more targeted implementation of energy and climate goals and to help align city and power system planning. Digital solutions and systems can be particularly powerful in cities, where high-density environments create economies of scale and can op timise infrastructure and create new opportunities. The role of G7 countries in fostering innova tion through greater international collaboration is suggested, creating enabling environments at city level for scalable pilot projects, while integrated urban and power system planning – together with improved data sharing – are crucial to maintain

electricity security and prioritise people in clean energy transitions. The report also explores the value of pilot projects administered by the United Nations Environment Programme (UNEP) in Brazil, Colombia, India and Morocco, which leverage advanced digital technologies to improve energy management, enhance affordability and manage grid flexibility. Cities, the report suggests, can leverage public procurement to create economies of scale and bring down costs of clean energy technologies. More than 60% of public investment occurs at the subnational level, of which nearly a third is channelled into trans port systems, underlying the importance of cities investing in green and resilient urban infrastructure. Cities can therefore be front runners in the energy transition, with the G7 recognising the ‘transformative power’ of cities. In addition, the G20 has identified the need to finance the infrastructure of the cities of tomorrow. This is critical because, based on existing stated policies, without further urgent action in cities and on grids, climate goals will be missed and economic growth could be affected. A people-first approach is recommended, ex emplified by community energy projects that not only promote environmental sustainability, but also stimulate local economies, reduce energy bills and foster public trust in the clean energy transition. Supporting city-level action has the potential to provide the greatest carbon mitigation return on investment and accelerate inclusive clean energy transitions. The evidence is that investing in infra structure and technology to decarbonise the energy sector can reduce greenhouse gas emissions by up to 75% by 2050 – as long as the right policies are in place. In South Africa, city residents, private businesses, industries and processing plants have all demon strated their willingness to invest in green energy generation solutions. Cities such as Cape Town have been proactive in encouraging the registration of rooftop solar PV systems through its rooftop PV programme, with these systems feeding into the lo cal electricity grid to reduce demand from ESKOM. Many other municipalities are following suit. Instead of obsessing over Eskom’s shortcomings, every city should be pushing to establish modern lo cal networks of green generation, transmission and distribution, with the digitalisation and controls to fully utilise every spare kW of generation from every connected rooftop or wind turbine. Perhaps it is time to see the world’s national grids as the backup supplier, with people’s and businesses’ day-to-day energy needs being met via sources as local to them as possible.

Peter Middleton

MechChem Africa is endorsed by:

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March-April 2024 • MechChem Africa ¦ 3

BMG’s World of bearings Wayne Holton, BMG’s GM for the Consumables Divisions – Bearings, Power Transmission, Seals and Gaskets, Fasteners, Tools & Equipment and Automotive – unpacks BMG’s bearings range and the company’s total solutions service offering to support industry in reducing downtime and optimising productivity.

B MG’s focus is on optimising pro ductivity to minimise downtime and reduce operational costs for companies in all sectors of industry, says Wayne Holton, BMG’s GM for the Con sumables Divisions. “This is realised through a total solutions service that starts with the selection of appropriate quality branded components and correct installation, and goes on to include comprehensive predictive maintenance services, which include condi tion monitoring and oil analysis,” he says. Bearings, he continues, are critical in all types of machinery. They are key components for the efficient and reliable operation of any rotating shaft or accurate positioner. “Bear ings are essential for reducing friction and for supporting loads wherever two connected parts of a machine are required to rotate or move relative to each other. They also main tain alignment and accuracy, and support the transmission of power,” he adds. BMG Bearings Division offers a com prehensive range of bearings throughout Wayne Holton, BMG’s GM for the Consumables Divisions – Bearings, Power Transmission, Seals and Gaskets, Fasteners, Tools & Equipment and Automotive.

Southern Africa, including ball, roller and linear bearings. These range in size from min iature to extremely large units. The company’s product offering is enhanced by technical expertise, including bearing selection to suit exact requirements, condition monitoring, re-classification and repairs, bearing modi fication, manufacturing of assemblies and bearing and housing interchanges. “Our Bearings team focuses on every customer’s specific process needs and the formulation of integrated product solutions to ensure high efficiency. Very often, an enquiry for a bearing translates into a comprehensive long-term solution for a machine, or provides a solution to an ongoing problem in that ma chine,” explains Holton. “By providing the correct components, we are able to improve machine performance, enhance reliability and extend maintenance intervals and service life. This approach to bearings reduces the total costs of owning and operating an asset, which translates into maximum return on investment for our customers,” he says. BMG has secured distribution and service agreements with some of the world’s most re spected manufacturers of bearings, including

BMG’s comprehensive range of bearings extends from precision miniature bearings used in machine tools and

electronics applications, to giant size bearings that meet the demands of steel and mining industries. NSK, NTN, Timken, IKO, TR, RegalRexnord, FSQ and Rollix. “Our extensive bearings portfolio is carefully selected in terms of consistent quality controls, compatibility, standardisation, reliability and extended ser vice life,” Holton explains. The most commonly used bearings in the BMG bearing range are deep groove ball bearings, where radial and axial loads can be applied in both directions. These versatile bearings are suitable for applications where high speeds are required, for example, electric motors, compressors, and idler rollers for conveyors. This range is available in open type variants or sealed with either steel shields or rubber seals assembled on one or both sides. Sealed bearings are pre-lubricated with grease and BMG can offer polyamide, steel or brass cage assemblies. Angular contact ball bearings are designed to accommodate combined radial and axial

Together with Timken’s local expertise, BMG’s Bearings Division offers a complete bearing re-manufacturing and repair service, where used large size bearings are reconditioned to original specifications for optimum performance and extended service life.

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⎪ Cover story ⎪

loads. These are formed by combining two bearings as a ‘duplex pair’. Possible combi nations include face-to-face, which have the outer rings facing together, back-to

which are capable of supporting combined radial and axial loads in one direction, use cone shaped rollers guided by a backing rib on the cone, which runs against a mating outer race called a cup. If mounted as opposing pairs, axial loads in both directions can be achieved – and double-row and four-row tapered roller bearings are also available to cater for increas ingly high load capacities. For axial-only rotating applications, where one ring needs to rotate while in contact with another, thrust ball bearings, needle roller thrust bearings, spherical roller thrust bear ings, and slewing rings are recommended. Slewing ring bearings link two mechanical components on one axis of rotation and are capable of handling axial, radial and moment loads. Advantages over a traditional bearing arrangement include the requirement for a reduced number of rolling elements, less ma chining, quicker and easier assembly, weight and space saving, and thus lower capital investment and operating costs. Downtime for maintenance is also reduced. The introduction of a structured maintenance management programme, which can be imple mented in-house or partially outsourced to a professional organisation, is critical to maxi mising production efficiencies. The effects of friction and the resulting wear of moving components are significantly reduced by ef fective lubrication. Condition monitoring identifies lubrica tion problems, misalignment and vibration troubles and helps in identifying the causes of the damage so units can be fixed before further destruction occurs. This means re duced downtime, efficient production and substantial cost savings. BMG’s team of mobile technicians conducts breakdown and Maintenance management and lubrication

routine maintenance on site and carries out trouble shooting and advising on possible pro ductivity improvements to ensure the highest level of plant output and reliability. Specialist services include installation, adjustment, re placement and maintenance of components, shaft and pulley alignment, balancing, condi tion monitoring, oil sampling and analysis and critical equipment inspections and lubrication schedules. BMG’s Bearings Division, together with Timken’s local expertise, also offers a com plete bearing re-manufacturing and repair service, where used large size bearings are reconditioned to original specifications for optimum performance and extended service life. This repair service includes a customised assessment, analysis, re-manufacturing and preventative maintenance programme for the bearings and auxiliary components used in all industries. The value of re-manufacturing is enor mous in that it ensures substantial savings in downtime and reduced replacement costs. A reconditioned bearing can result in significant cost and time savings when compared with purchasing a new one. Efficient refurbishing options, using the most sophisticated processes and equip ment, are offered for all brands, types and sizes of bearings. BMG works closely with a customer’s maintenance team to analyse the condition of bearings and to assess when a bearing needs to be serviced. When preventa tive maintenance programmes complement reconditioning, bearings are capable of reach ing their full life potential. Technical training is delivered to all BMG staff to promote a culture of ongoing learning. This training is also available to BMG customers to assist them to understand their bearing products and to enhance their maintenance practices. www.bmgworld.net

back, or both front faces in the same direction. Typical applications include gearboxes, clutches, pumps, machine tools, steel mills and wind turbines.

Self-aligning ball bearings generate less friction than other types, which allows them to run at higher speeds without building up as much heat. Self-aligning ball bearings are designed with two raceways and the outer ring has a single spherical raceway. These bearings can accommodate minor angular misalignment of the shaft relative to the housing, which could be caused by machin ing or mounting errors. This type of bearing often has a tapered bore for mounting with an adapter sleeve. Cylindrical roller bearings offer high radial load capacity, because each cylindri cal roller is in line contact with its raceway. Different types are denoted by NU, NJ, NUP, N, NF for single-row bearings, and NNU, NN for double-row bearings, depending on the bearing design. A variant of the cylindrical roller bearing is the needle roller bearing, which contains many slim rollers with a length of 3 to 10 times their diameter. As a result, the ratio of the bearings’ outside diameter to the inscribed circle diameter is small, giving needle roller bearings a high radial load carrying capacity. Needle roller bearings offer a low-cost per kg of capacity and have an advantage where space is limited, making them particularly well-suited for use on automated assembly equipment. Another popular roller bearing variant is the spherical roller bearing, which has two rows of barrel-shaped rollers running in a single spherical raceway. Spherical roller bearings are self-guiding and can accom modate angular misalignment. They are especially well suited for use where there is heavy and/or impact loading. Split roller bearings have a split-to-shaft feature, which allows them to be fitted where access to the shaft ends is difficult or where the drive side is difficult or costly to disas semble. Using a split bearing allows the shaft to be raised and the split components to be assembled without having to remove other elements from the rotating shaft. Where high axial or thrust forces are re quired, BMG specialists recommend the use of tapered roller bearings. These bearings,

NSK's angular contact ball bearings feature a contact angle that sustains significant axial loads as well radial loads. They are usually used in pairs.

May-June 2024 • MechChem Africa ¦ 5

Industrial uptime: the core of BI’s offering MechChem Africa meets the management team of BI at its Parkhaven office in Kempton Park to find out about the company’s new go-to-market strategy, which now has industrial uptime as the principle underpinning all brand and service offerings.

Calmeyer adds. So first and foremost: BI only represents the very best brands from around the world. “We rely on high quality products and are not interested in selling inferior brands at low prices. This ‘race to the bottom’ pricing approach does not support what we are trying to do in terms of industrial uptime and keeping customers in motion,” he explains. While BI still looks at component value in terms of price, availability and convenience, quality is the key driver, with availability following as a close second. In a sugar mill, Calmeyer argues, the cost of keeping the plant running and properly maintained using the most appropriate quality brands is abso lutely negligible compared to the value gained by producing at 100% capacity. “Looking at procuring at the cheapest prices and ignoring quality or off-the-shelf availability, demon strates a dangerously skewed focus,” he says. “Price obviously matters, but every aspect of our range is chosen based on reliability and fitness-for-purpose in the application in which it will be applied,” adds James Calmeyer. Summarising how BI has reorganised sales, Calmeyer introduces three new GMs: Robert Sillis, GM for Product Management; Christian Chipamaunga, GM for Segment Sales; and Charmaine Beukes, GM for Channel Sales. “Robert focuses on what it is that we are selling and our brand and product choices. He looks at what is in each of the baskets for different applications and what we need to have readily available. But he does not make these decisions on his own. He is informed by Christian, who looks at the different market segments. His job is to focus on the pain points of each key industry and what customers in these segments really need to keep their machines in mo tion. He translates the voice of our customer into a right-priced quality basket of products and packaged solutions for each segment. Restructured sales of the organisation

The BI team responsible for implementing the company’s new go-to-market strategy: Charmaine Beukes, GM for Channel Sales; Christian Chipamaunga, GM for Segment Sales; James Calmeyer, MD; and Robert Sillis, GM for Product Management.

“W e have changed from being a distributor of engineering products to being a provider of industrial uptime,” says James Calmeyer, the MD of the Hudaco Group company, BI. “We believe that selling a component to a customer is of no value unless it solves this critical, but simple, problem. Industrial customers invest in plant and equipment to do a job. So when any part of their plant is not running, a critical problem arises that needs a long-lasting solution. “That's why we have changed our catch phrase, which is now simply, ‘in motion’. This highlights that, as a company, we are moving forwards and that our core business is keep ing customers and their equipment in mo tion. When their processing equipment stops, profitability stops. We are here to keep industrial customers producing,” BI’s MD tells MechChem Africa. BI is targeting improved resil

enables those employees to feed their fami lies,” he says. Farmers, he adds, understand that there is a time for sowing and a time for reaping. But if they miss any time window because the necessary equipment is not working, then the annual harvest becomes worthless. Instead of profit, the farmer ends up in debt. “Farm equipment has to work when it is needed. So, we now look to find solutions for customers with a view to making sure that their plant and equipment can do what is needed at the time it is needed. “If any part of that mill is standing still, production is haemorrhaging. And if that problem is being caused by one poor quality part, then it really does make the

decision to use that part seem shortsighted,”

ience in South Africa’s fast grow ing industrial sectors: those contributing the most to the country’s GDP – industries such as mining, manufacturing and, within that, key sectors such as sugar, pulp and paper, petrochemical plants and steel mills. “We are also supporting the

“Then we have a third leg of the sales organisation, which is about geography; being in the right place at the right time. We now have 46 outlets and we are constantly ex panding. This is where Charmaine’s

growing FMCG and pharmaceuticals sectors that process our food and medicines and, fur ther downstream, the important agricultural sector responsible for feeding the nation. “Keeping all these industries in motion is as important now as it ever has been. Industry is important because it employs people and

I-MAK’s wide range of gearboxes and drive solutions are designed to address the most pressing challenges faced by the gearbox market, which makes the range ideally suited to the mining industry.

Channel Sales team comes in,” he continues. Their job is to find and talk to strategic cus tomers in each area identified by Segment

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⎪ Maintenance and asset management ⎪

Sales. The Channel Sales team then ensures that each local outlet has the right products on their shelves to match local industry needs in each segment. Combined, these three sales focus areas are absolutely intertwined to deliver the right products for the right type of customers, while also putting in place best possible levels of technical support from an appropriately trained local team. “We have a very good range of global prod ucts, but these have to be translated into local applications for them to be really useful and valuable. And that is what this team does. It puts the right product in the right place at the right time,” James Calmeyer adds. Robert Sillis continues: “BI is a highly specialised bearings, power transmission and electric motor supplier – offering everything required to transfer torque from one point to another. We use the expertise available to us in this area to achieve our core purpose, which is to provide uptime to industrial customers, in partnership with strategic global suppliers that have considerable experience garnered from all over the world,” he says. Exemplifying his role, Christian Chipamaunga cites a recent project launched for the mining sector. “Robert and his team, in conjunction with us in Segment Sales and Charmaine in Channel Sales, identified some target customers in the mining segment. We set up a high level engagement and identified a few tailored solutions – most notably for mill and conveyor drives – to take back for further development. We then put together some tailored solutions to present to selected local clients. After further meetings, we included some key condition monitoring technologies into the solution to keep an eye on machine health,

which is 100% compatible with keeping cus tomers in motion. So we can now monitor and collect data from this solution that gives a warning of any harmful fault condition, which enables just-in-time predictive maintenance to be scheduled and unscheduled breakdowns to be avoided,” he explains. Charmaine Beukes goes on to describe an associated Channel Sales launch at local level, which involved the company’s new I-MAK brand of gearmotors and industrial gear units (IGUs). “The beauty of this brand is that it is interchangeable with other lead ing IGUs currently in use on our mines. It was initially introduced during Covid, but we ran a region by region relaunch in November last year to coincide with Christian’s Segment Sales initiative. “Sales teams from each regional outlet, along with the branch managers, attended an extensive training session built around the merits of the I-MAK brand. They were taken through all the technical data and mainte nance requirements and afterwards had to write a test to make sure their understanding was good enough to take the I-MAK brand to local customers. They were then asked to identify some target accounts that could benefit from an engagement with Robert’s Product Management specialists,” she informs MechChem Africa. “This shows how Product Management, Segment Sales and Channel Sales work to gether. My field sales teams need Robert's Product Team and Christian’s Segment Sales team to open the doors by developing holistic solutions based on real client priorities that convince customers of our technical expertise and the quality, availability and value of the products and solutions we sell,” Charmaine

Beukes explains. Chipamaunga adds that this approach also generates demand. “We need to understand and identify what customers need, what their pain points are and how best to use the prod ucts at our disposal to help them to develop value-based solutions,” he says. Sillis concludes: “Not only do we have the necessary technical skills sets; our global sup pliers help us to identify and implement best practice solutions for customers. With their help, we have a great proposition aimed at increasing production uptime for customers. “This global level of service can then be passed all the way down through our network to a local mine, plant operator, production plant, mill or farm in any community across South Africa,” he says. www.bearings.co.za

A Timken TNA bearing solution that offers bi-directional thrust and simple installation: “First and foremost, BI only represents the very best brands from around the world,” says James Calmeyer.

Rexnord load-resistant Roller Chain provides high static and dynamic loading capabilities, reliability, long wear life, high breaking loads and long fatigue life.

May-June 2024 • MechChem Africa ¦ 7

Hytec Fluid Technology reopens Oil Analysis Laboratory Owing to an increase in demand, Hytec Fluid Technology (HFT), a Bosch Rexroth Africa Group company, reopened its Oil Analysis Laboratory in Kempton Park, Johannesburg, on 3 January 2024, with a bolstered service offering.

Hytec’s reopened laboratory now offers oil analysis services, helping clients to achieve industry-required ISO standards.

T he state-of-the-art HFT Oil Analysis Laboratory caters to a range of industries where the reli ability and performance of hydrau lic fluids, glycols and related substances are crucial for manufacturing and industrial facilities, such as power generation and chemical processing plants. To further enhance the laboratory’s service offerings, it now features new technologies. These technologies include the CIX system, which assesses particle level contamination in hydraulic fluids, as sisting clients to achieve industry-required ISO 4406 levels of cleanliness in their oil. Another new technology includes the X-Ray Fluorescence (XRF) machine, which identifies chemical elements and provides detailed compositional breakdowns of

materials. “The reopening of the laboratory marks an impressive milestone for HFT and Bosch Rexroth Africa. It is equipped to assist clients to achieve optimal performance through advanced analysis techniques. The reopening re flects a continued commitment to resum ing full-scale operations and contributes to meeting the industry's demands for analysis of hydraulic fluids,” said Abigal Nel, Laboratory Analyst, HFT. A sample bottle with a minimum volume of 100 ml is required for accurate analysis, testing, and reporting. This ensures that crucial information is relayed to clients to protect their equipment, boosting produc tion and profitability. Services offered include: • ISO Cleanliness Analysis (CIX).

• XRF Technology for Elemental Analysis. • Crackle Tests. • Karl Fischer Moisture Content Analysis. • Total Acid Number (TAN) Analysis. • Wear Metals Analysis. • Viscosity Measurement. • Refractometer for Water to Ethylene Mix (Brix ratio). • Membrane Patch Colorimetry Tests for Varnish Potential Analysis. HFT provides total fluid management solutions to the industrial and mobile equipment markets, helping companies extend service intervals, maximise uptime and reduce the total cost of ownership of their hydraulic machinery. https://boschrexroth.africa/

Improve food safety at every step of production SKF Food line spherical roller bearings for demanding food and beverage applications

SKF is the first to introduce a range of spherical roller bearings specifically designed for the food and beverage industry. Our new bearings come with food grade seals and food grade grease to enhance food safety. You can also count on these bearings for an average of three times longer service life compared to open bearings, resulting in more efficient production and less maintenance.

SKF South Africa (Pty) Limited 6 Marlin Road, Jet Park Tel: 011 821 3500 Email: sales.za@skf.com

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⎪ Maintenance and asset management ⎪

Tribology, the study of interaction between moving surfaces, most notably, friction reduction and increase, has applications in engineering, medicine and daily life, whether it’s related to a hip replacement or a gearbox. For Lubrication Engineers (LE) South Africa, it is a subject dealt with every day. Tribology and lubrication engineering for improved asset reliability

L E South Africa MD, Colin Ford, says that 90% of his company’s work involves reducing friction, rather than increasing it, and that a good understanding of tribology is key to this. “It is a very interesting subject,” he says. “The South African Institute of Tribology offers courses that relate mainly to the mechanical and machinery aspects. Internationally, there’s the Society of Tribologists and Lubrication Engineers (STLE), a professional technical so ciety that offers a range of technical research, education and professional development resources.” Science and innovation in lubrication Ford says that much of LE South Africa’s work involves assisting customers with asset reli ability solutions. Rather than merely supply an oil or grease, LE works to help customers protect their equipment, optimise its effi ciency and extend its lifespan. “Lubrication has come along in leaps and bounds over the past decades with the devel opment of new and specialist additives,” he says. “We can now drastically reduce friction in everything from motor vehicle gearboxes to wire ropes. We work with a lot of old-school engineers who really know their way around machinery, but it’s our job to keep up with the latest science and innovations in lubrication, and to assist them by demonstrating what next generation products can do.” This is why training and development is a key focus at LE South Africa – both for

its workforce and for customers. “We train our sales staff and technicians, and we offer in-house customer training. In fact, we’re busy upgrading our training facilities so we can physically demonstrate things such as the latest wire rope lubrication technology. For example, we have a portable steel-wire rope inspection solution that enables 100% accurate non-destructive inspection of wire ropes, something that’s fairly new in the lo cal market.” Asset reliability life cycle While many lubrication manufacturers and resellers focus on selling products to match applications, Ford says it’s important to take the full asset reliability life cycle into account. This incorporates lubrication methodology, storage, application, monitoring and analysis. “I liken it to taking care of yourself,” says Ford. “It’s basically the difference between putting good habits (that keep you healthy) into practice – such as eating well, exercising, and doing preventative check-ups – versus having to go to the emergency room when something goes wrong. If you look after ma chinery by selecting the best lubricant, paying attention to keeping it free of contaminants and ensuring the lubrication application schedules and methods are correct, you’re likely to have much healthier equipment that lasts much longer. And you experience less downtime and costly repairs.” Thankfully, Ford says, young engineers en tering the workplace tend to understand the

LE South Africa MD, Colin Ford.

importance of leveraging expert suppliers and taking a holistic approach, which he believes is due to education institutions working to impart communication skills and an apprecia tion of technical innovation. “Of course, we’ve also developed long standing relationships with customers who have been in business for many years, where we’ve been able to show that not only do we stock high-quality products that will outper form their competitors, but we’re willing to go the extra mile to ensure the best possible outcome,” he concludes. Lubrication Engineers (LE) South Africa represents the global LE brand in South Africa, Botswana, Namibia, Mozambique, Zimbabwe and Zambia, providing high performance, heavy-duty, quality lubricants for virtually ev ery industry and application, as well as expert technical back-up and support. www.lubricationengineers.co.za

Left: Tribology is the study of interacting surfaces in relative motion. This causes friction and wear, which can both be substantially reduced using advanced lubrication formulations. Right: Rather than merely supply an oil or grease, LE works to help customers protect their equipment, optimise its efficiency and extend its lifespan.

May-June 2024 • MechChem Africa ¦ 9

Established in 1914 by Swedish Holding Company, SKF AB, SKF South Africa is proudly celebrating its rich 110 year heritage of delivering premium value solutions to customers across South and Southern Africa. SKF SA celebrates 110 years of optimising rotational assets

SKF Jet Park JHB head office where the Remanufacturing and TBU Centres are housed.

T he first SKF subsidiary on the African continent, then known as SKEFKO (South Africa) Ball Bearing Company Limited, was established in Pritchard Street, Johannesburg in 1914. It has since evolved from a bearings and engineering services supplier into a developer of innova tive products and advanced technologies that seamlessly integrate with the digital era to meet the rigorous demands of modern day industry. Today, SKF SA leads the South and Southern African market as an OEM supplier of bearings, seals, power transmission and lu brication products, supported by professional mechanical engineering and remanufacturing services. These state-of-the-art product and technology solutions are widely used within around 40 market sectors across the region, including mining, materials handling, auto motive (passenger and commercial vehicles), solar and wind energy, railways, machine tools, medical, food & beverage and the paper industries. Several important developments and mile stones during SKF South Africa’s distinguished 110-year history include: • The relocation in 2019 of its Jet Park, Johannesburg headquarters to larger, purpose-built premises to accommodate future development and growth. The design of the new building, also situated in Johannesburg’s prominent Jet Park industrial area, aligns with SKF’s net

zero drive: the building’s 383 kWp solar system delivers approximately 30% more than the company’s average electricity needs, with the warehouse, workshops, offices, logistics, and more, essentially operating completely off-grid from 08h30 to around 16h30. Being a grid-tied system, energy is not stored in batteries onsite. However, SKF ensures that the excess electricity is not going to waste by feeding it back to the Municipality – free of charge. • 2023 Earmarked the launch of SKF’s Circular Economy Centre – previously known as the SKF Solutions Factory – as well as the TBU Bearing Refurbishment Centre. With the deliberate intention of making a meaningful contribution to sustainability, the Circular Economy Centre comprises an organic collection of SKF services. The Centre houses a combination of quality circular economy products and service solutions, including SKF’s Bearing Remanufacturing Centre, Project Engineering, seal manufacturing services, RecondOil and a range of Onsite Services. • Machine efficiency and reliability are sustainability game changers. Through the provision of innovative designs, superior quality products, advanced technologies, connected lubrication systems, state-of-the-art condition monitoring, data analytics and machine

learning, SKF engineers increase mean time between failures (MTBF), extend machine longevity and lower energy consumption for customers. • Reducing, reusing and recycling are key elements of sustainability and here too SKF South Africa leads the market. Pivotal here is SKF’s specialist Bearing Remanufacturing Centre which, estab lished in 2008, gives high-value bear ings a second, third and even fourth life. Reusing rather than replacing keeps customers’ costs down, and reduces lead times and material consumption. Moreover, bearings not eligible for re manufacture can be recycled to produce new bearings, effectively closing the loop. SKF’s remanufactured bearings and units conform to the same quality specifica tions as new SKF bearings and units. • SKF South Africa now has a competitive edge when it comes to its comprehensive product portfolio of bearings and bear ing units, axle boxes, bearing mounting/ dismounting equipment, lubrication, and condition monitoring solutions for the rail segment. The establishment of the TBU Centre further elevates SKF’s value chain and unlocks the tremendous poten tial presented by this important transport sector on the African continent. Along with premium quality product and service solutions, steadfast customers, a dedi cated distributor network and a committed

10 ¦ MechChem Africa • May-June 2024

⎪ Maintenance and asset management ⎪

With the technological advancements of ag ricultural equipment to meet the increasing demands for higher efficiencies, performance and reliability, as well as reduced emissions, tolerances are becoming ever finer. This can lead to increased component wear so main taining a proper lubricant film is essential to reliability. SKF has developed a sophisticated range of lubricants and application systems that address these requirements by delivering a maximum machine and equipment life cycle and reduced costs of operation. Agricultural machines and equipment are subjected to extremely stringent conditions, working in an environment where the ingress of dust, dirt, stones, mud, plant material and water cause excessive wear and tear on critical components. This can potentially lead to equipment failure. Farmers have a very limited window for planting and harvesting, and unexpected breakdowns in the field can result in reduced or poor yields. “Taking into account that 56% of bearing failures are caused by contamination and inadequate lubrication, the importance of farm machinery lubrication can never be un derestimated,” says Charl Engelbrecht, SKF’s key accounts manager for Agriculture. “Add to this the fact that, while lubricants amount to between 2 and 3% of running costs in agri cultural machines, 40 to 60% of maintenance costs are a result of poor lubrication.” A correctly executed proactive mainte nance strategy can help prevent breakdowns, reduce downtime, optimise performance, reliability and efficiencies, extend equipment lifecycle, lower maintenance costs, enhance safety, and meet environmental compliance. SKF invests in long-term customer part nerships, delivering ever more advanced and energy efficient solutions that support the company’s strong narrative of optimising the performance, life, reliability and efficiency of customers’ rotating assets. Not only defined by the quality of its products and services, the company’s core values – empowerment; high ethics; diversity and inclusion – and team work drive SKF employees’ decision-making SKF team of employees continue to drive the SKF success story. Since the appointment of its first distributor in 1970, SKF South Africa has gone on to develop a strategic network of authorised independent industrial distributors –along with lubrication, commercial vehicle and agricultural distributors – in South Africa and neighbouring countries in a bid to deliver engineering, product and service solutions to customers’ doorsteps.

Left: SKF South Africa, originally founded in 2014, is proudly celebrating its rich 110 year heritage. Right: SKF South Africa is an OEM leader in bearings and rotating equipment technologies in South and Southern Africa.

processes and interactions both internally and with customers and distributors. With an unblemished reputation for excellence in products and services SKF South Africa looks to the future, keeping in step with market trends and requirements, ready to unpack the African continent’s vast potential, and continuing to hone its products, technologies,

each lubrication point on every machine can negatively impact schedules, maintenance costs and running time performance. For this reason we recommend automatic lubrica tion of agri equipment as farmers will benefit from increased equipment availability and improved uptime.” Adding further value to its lubrication portfolio, SKF has developed two apps: SKF LubeSelect accesses a knowledge base to as sist farmers with selecting an appropriate lu bricant for a particular application. SKF eLube enables users to determine lubricant levels and pump functions remotely. SKF’s lubrica tion solutions are bolstered by professional service and after-sales support delivered by a team of highly trained product specialists. SKF builds long-term partnerships, engaging with farmers to determine the best, tailored lubrication solution for each agri application. “Smart lubrication management that incor porates SKF products, systems and lubricants, is an essential part of agri equipment opera tion and maintenance and can make a signifi cant contribution to farming sustainability and profitability,” concludes Engelbrecht. www.skf.com services, experience, knowledge, capabilities and competencies. In so doing, SKF ensures that it continues to deliver the right solu tions that are aligned with a dynamic, rapidly developing industrial and digital landscape to future proof customers’ competitiveness and business sustainability. www.skf.com

Smart lubrication management solutions from SKF It involves the systematic application and control of lubricants to reduce friction, heat and wear between moving parts, ultimately reducing the risk of failures and subsequent costly downtime. SKF offers holistic lubrica tion solutions for tractors, implements, trail ers, combine harvesters, special harvesting machines, balers, sprayers, slurry tankers, and more. The product range includes lubrication delivery products and systems as well as a selection of high quality lubricants.

“It starts with the correct choice of lu bricant because this carries as much impor tance as applying the correct lubrication methods,” stresses Engelbrecht. With years of experience with bearings, lubricants and applications as well as through continuous research, field-testing and validation, SKF has developed the right lubricants specifi cally suited for agri equipment. The special formulation of SKF LGGB 2 biodegradable, low toxicity, synthetic ester oil based grease, using a lithium-calcium thickener, makes it most suitable for agri applications where en vironmental contamination is commonplace. “Our LFFM 100 high-performance synthetic chain oil is specially formulated for the lu brication of chains operating in agriculture industries,” adds Engelbrecht. SKF offers manual, semi- and fully automated lubrica tion delivery systems that assist farmers with correct and accurate lubrication. Products include compact electric cartridge pumps, grease nipples, grease guns, lubricant hoses, progressive metering devices as well as a range of accessories. Engelbrecht explains that proper manual lubrication usually takes about 15 to 20 minutes per machine and main tenance cycle. “Failure to properly lubricate

SKF offers holistic lubrication solutions for enhanced agricultural equipment reliability.

May-June 2024 • MechChem Africa ¦ 11

Mine water stewardship begins with effective water management Nirvishee Juggath, Director of Water Management for WSP, outlines the key management principles that need to be put in place for mining companies to reduce

their operational water consumption. A considerable challenge facing the African continent is the decline of the availability of fresh water to meet basic human and ecological needs. This is putting significant pressure on industry to reduce its operational water consumption, pressure that will likely increase in the years ahead. Looking at South Africa, for example, this pressure is already evident. A growing population and rapid urbanisation, which lead to deforestation and increased demand for water, is putting strain on the country’s supply. When operational water requirements from mining and industry are included in the mix, the need for responsible water steward ship starts to become clear. It’s worth noting that South Africa is classified as a semi-arid country, and that this demand on an already limited water supply contributes to a growing water shortage crisis in the country. Considering that mining is an essential part of the national economy – according to Boston Consulting Group, it contributes about 8% of GDP and provides direct employment to approximately half a million people – it is imperative it can operate optimally. Though mining uses less than 3% of the national wa ter supply, it is one of the country’s largest industries and therefore in a position to make a powerful impact if it prioritises responsible water usage.

management has far-reaching impacts on the environment and surrounding communities. On a practical business level, it also has a negative impact on a company's image and will have a deleterious effect on its environmental, social and governance (ESG) reporting. Failing to implement effective water man agement and become a responsible water steward also has financial implications. Mining companies must demonstrate responsible wa ter management to access the funds required to develop new projects and expand existing operations. Furthermore, most investors are environmentally conscious and often require that the companies they invest in share their values. Therefore, mines must investigate and implement measures that enable them to reduce their dependence on external water sources, while still maintaining their opera tions for the short- and long-term. A key component of becoming a respon sible water steward is committing to effective water management. This can be broken down using the five key principles of an effective water management strategy: 1. Quantification of volumes Having a well thought out monitoring network and a central repository for the data is the first step in effectively managing water resources, which allows for the quantification of the cur rent water status of a mine. Flow monitoring onsite is often primarily focused on streams that a mine is required to pay for or that are

linked to a regulatory requirement: a munici pal water supply, river abstraction, etc. While internal reuse, recycle and inter transfer streams are frequently not mea sured – since there is no regulatory or cost implication to these – we recommend that these be included for a complete view of flow monitoring and more accurate data for better informed reporting, planning and decisioning. 2. Knowing your status The key to an effective water management strategy is knowing your water status. Mines should keep track of trends and gain an un derstanding of how water is being lost from a system, where, and what volume of water is being used. These metrics can then be used to identify areas for improvements. Water conservation and management initia tives can only be implemented if there is a clear understanding of water use. This can be accomplished by understanding the sources of water, how much water a mine consumes and exactly how this water is being consumed. 3. Modelling the site water management With the recommended flow monitoring network established, a mine should invest in a functional and dynamic water and salt balance model. This is a key recommendation and will allow for the quantification of the inputs, out puts and storage of water within the system over a specified time period. It provides an un derstanding of the key hydrological processes (climate, runoff, etc), the prediction of water

Accounting for the pressure to reduce Water is a basic human need. Poor water

12 ¦ MechChem Africa • May-June 2024