MechChem Africa May-June 2025

MechChem MAY-JUN 2025 AFRICA

NORD MAXXDRIVE from BMG: the powerful drive for mixers and agitators

This month: Tailings storage seen as valuable resources

Study for enhanced water supply for Buffalo City

Innovative asset integrity management

Converting forestry emissions into green plastics

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CONTENTS 12

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MINERALS PROCESSING AND MATERIALS HANDLING 6

The evolving landscape of tailings storage facilities Lili Nupen of NSDV Law talks about the regulatory reforms driving the view that tailings storage facilities (TSFs) are valuable resources demanding careful stewardship. 9 ABB to deliver world’s largest mine hoist 10 Pioneering Tru-Trac intelligent belt scale

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: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors.

11 Mill liners designed with 3D scanning technology and DEM POWERGEN, PETROCHEM AND SUSTAINABLE ENERGY MANAGEMENT 12 MEPS regulation and the motor-efficiency revolution

WEG Africa’s Rodrigo Cetenareski outlines the reasons and benefits for the mandatory change to the IE3 motor efficiency standard. 14 Boiler selection for optimal thermal energy performance 15 SPS solar project first for Darling Estate 17 From steam to scrap – the effects of poor boiler maintenance WATER, WASTEWATER AND PUMPING SOLUTIONS 18 Collaborative effort to improve Buffalo City water A comprehensive pre-feasibility study is underway to enhance the water supply system for the residents of Buffalo City in the Eastern Cape, spearheaded by the Municipality, the German Federal Ministry for the Environment and local engineering firm, GIBB. 20 The water supply battle in SA’s cities

21 Dry prime pumps chosen for gas project vessel 23 Preparing pump systems for adverse conditions HYDRAULICS, PNEUMATICS AND AUTOMATION SYSTEMS 24 Electromagnetic stirrer enhances EAF efficiency in Türkiye

An ABB ArcSave ® electromagnetic stirrer will be integrated into the world’s largest electric arc furnace (EAF) in Turkey. 25 PACE Compressors for agriculture

MAINTENANCE SOLUTIONS AND ASSET MANAGEMENT 26 Chempute adds Cenosco IMS suite to portfolio

Transparency You Can See Average circulation Jan to Mar 2025: 10 636 Printed by: Tandym Print, Cape Town

MCA talks to Omar Rugebani from Cenosco, and Andrew Taylor, MD of Chempute, about Cenosco IMS, an innovative asset integrity management system purpose-built to support high-risk plants. 28 Revolutionary microfine filtration extends equipment life 29 Galvanizers association steels SOEs for the future HEATING, COOLING AND VENTILATION 30 Mine ventilation and cooling: efficiency vs health and safety BBE Group CEO,Wynand Marx, talks about modern mine ventilation and cooling solutions and the balance between energy efficiency and health and safety. 31 HVAC performance and equipment uptime LOCAL MANUFACTURING AND FOOD PROCESSING 32 Malben Engineering: over fifty years of manufacturing excellence Customer- and people-centric is how operational director Luca Smargiasso describes automotive component manufacturer, Malben Engineering, which is celebrating its 50 th anniversary this year. INNOVATIVE ENGINEERING 38 Converting forestry CO 2 emissions into green plastics VTT Technical research centre of Finland and LUT University have completed a research project on carbon capture and utilisa tion, which investigated producing raw materials for renewable plastic from CO 2 and green hydrogen. REGULARS 2 Peter’s comment: Mitigating our uncertain future 4 On the cover: Modular industrial drives for mixing and agitating: Johan Stoltz of BMG unpacks Nord modular drives for mixing and agitating applications. 32 Products and industry news 40 Back page: A space programme that never leaves Earth

Front cover: BMG Contact: Johan Stoltz, specialist for Nord drives Tel: +27 11 620 1558

Email: johans@bmgworld.net Website: www.bmgworld.net

May-June 2025 • MechChem Africa ¦ 1

Based on data released in the World Economic Forum’s (WEF) Global Risks Report 2025, which captured the perspectives of more than 10 000 global business leaders through an executive opinion survey (EOS), PwC’s global strategy consulting team, Strategy&, has released a South African Economic Outlook report for 2025. WEF’s EOS asked company executives to identify the five risks most likely to pose the biggest threat to their country in the next two years (2025 to 2026). South Africa’s respondents identified Energy supply shortage; Unemployment/lack of economic opportunity; Water supply shortage; Poverty and inequality; and Economic downturn as their top five risks. From a global perspective, the biggest risks identi fied were state-based armed conflict, extreme weather events and geoeconomic confrontation. PwC’s South African Economic Outlook Report analy ses three of the key local risks and the mitigating company action required: Energy disruptions and the pressure on electricity, jet fuel, and gas; Water shortages and strate gies, given that nearly half of South Africa’s water systems (46%) are performing poorly or are in critical condition; and the increasing risk of extreme weather events, includ ing droughts, floods and wildfires. Despite the suspension of load-shedding a year ago, findings suggest that SA’s business leaders still viewed energy supply shortages as a major risk for 2025-2026. Beyond electricity, however, energy concerns extend to jet fuel and gas shortages, with increased dependency on imports. “Disruptions caused by these diverse energy supply challenges highlight the need for robust energy strategies and action plans to ensure business resilience,” reads the findings summary for energy disruptions. On South Africa’s water shortages, the report advises that businesses can recover, recapture, and reuse water; implement backup systems and harvest rainwater and greywater to mitigate water supply risks. Nearly half of all water supply systems (WSSs) across the country are performing poorly or at a critical level. Even though the key challenge to maintaining water infrastructure is money: non-revenue water increased from 42% in 2014-2015 to above 46% in 2021-2023. This means that almost half of all clean and treated water intended for consumers does not generate revenue – whether due to physical losses such as leaks, apparent losses such as meter inaccuracies or illegal connections, or authorised but unbilled consumptions, such as free basic water. “Conducting a water risk and usage baseline as sessment is crucial for developing a water strategy. Collaborating with the public sector can address infra structure and related service delivery challenges, while improved natural capital management could result in Mitigating our uncertain future

Peter Middleton

water and biodiversity making a larger contribution to the country’s labour productivity.” On extreme weather events, the report highlights that South Africa has experienced droughts, most notably in the Western Cape from 2015-2018, which led to the ‘Day Zero’ water crisis, and in the Eastern Cape from 2018 2021; recurring severe floods in KwaZulu-Natal (2017, 2019, 2022 and 2023); unseasonal hailstorms in Gauteng (2020 and 2024); snowstorms in the Free State (2021); +40 °C heatwaves in Limpopo (2020), North West (2020) and the Northern Cape (2021 and 2024); and wildfires in Mpumalanga (2020 and 2024), to name but a few. These have caused significant economic disruptions in recent years, impacting businesses across all industries by reducing water supply, damaging infrastructure and increasing operational costs. Risk identification and adaptation plans to mitigate these effects and ensure resilience are sure to be necessary. PwC is working with South African industry to de velop specific action plans. For companies facing electric ity disruptions and gas shortages, the suggested starting point is to implement energy efficiency measures, before investing in renewable energy solutions such as solar and/or wind. In addition, using power generators with alternative fuel sources; conducting energy audits to identify opportunities for efficiency and cost savings; and reducing reliance on public sector-supplied power and imported hydrocarbons, PwC suggests, are all crucial. On the water side, as well as maximising water recovery and reuse opportunities, collaborating with municipalities can also help to address infrastructure and related service delivery challenges. Extreme weather mitigation involves identifying the physical and transition risks across climate change scenarios, evaluating exposure and the sensitivity of assets and operations and putting comprehensive plans in place that consider a combination of technological, nature-based and behavioural solutions. Every country in the world seems to be facing its own ‘perfect-storm’ combination of challenges: climate change, poverty, unemployment, food insecurity, migra tion, rising social unrest, the increasing risk of violent conflict, and many more. South Africa is not the worst af fected of the world’s nations, though. We have long been aware of the problems raised in the 2025 PwC report, and in an increasing number of industrial sectors, including our energy sector, risk mitigation solutions have emerged. There is no reason for complacency though. Urgent action is needed – especially in the water and wastewater sectors. Effective mitigation, however, will require a col lective effort, with genuine investment and cooperation between business, industry, society, municipalities and all sectors of government.

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2 ¦ MechChem Africa • May-June 2025

Modular industrial drives for mixing and agitating Nord Drive Systems – designed by German precision engineers, Getriebebau Nord and assembled locally by BMG – encompass modular drive configurations that ensure optimum performance of mechanical speed control for specific applications in industry, including mixing and agitation solutions for water, wastewater, processing and raw materials management applications.

“N ord drive solutions, which meet stringent local and international quality stan dards, are known for reli ability, energy-efficiency, low noise levels, extended service life and reduced main tenance,” says Johan (Os) Stoltz, National Product Specialist for Nord Drive Systems in BMG’s Electromechanical Drives division. These modular drive systems incorpo rate advanced drive technology and special design features to meet the precise require ments of every operation. In particular, pumps, mixing and agitating systems are required to meet high demands in environ mental technology, to distribute safe drink ing water, convey wastewater and circulate activated sludge, for example. BMG’s Nord agitator drive systems – which easily move large masses in agitat ing and mixing applications – consist of an electric motor, a frequency inverter, a MAXXDRIVE ® gear unit and accessories. Notably, the Nord MAXXDRIVE ® series is the only complete industrial gear unit system on the market with a one-piece UNICASE lightweight housing for mixing and agitating processes. Johan Stoltz, National Product Specialist for Nord Drive Systems in BMG’s Electromechanical Drives division.

Nord helical and helical bevel gear units – available from BMG in various sizes and speed ratios – offer high operational reliability and protection against leaks through optimum sealing. The robust and rigid design enables the system to cope with excessive loads, while the short total axis spacing results in low bending torques and extended operation times for the entire drive system. BMG also offers a wide range of attach ment options for simple and economic inte gration into mixing and agitation industry applications. “We supply numerous NORD drive components as explosion-protected ATEX versions, for safe operation in hazard ous areas, including Zones 1 and 2 for gas/ vapour/mist and zones 21 and 22 for dust,” Stoltz adds. NORD MAXXDRIVE Industrial Gear Units provide high output torques from 15 to 282 kNm and are perfect for use in heavy duty applications such as agitators, conveyor belt drives, mixers, mills, drums or crushers. They are available as helical gear units or bevel gear units and are constructed with Nord’s UNICASE housing, which was developed to accommodate larger roller

bearings to guarantee longer service life. These compact industrial gear units en sure reliable operation even under extreme conditions and are designed for vertical and horizontal installation to minimise required space. Another important feature of Nord’s MAXXDRIVE-based agitator drive system is the IEC/NEMA approved SAFOMI Seal less adapter for agitators, which prevents vibrations during operation. This adapter includes an oil compensation volume, so additional attachments and wearing parts such as an oil tank and drive shaft sealing rings are not necessary. This results in greater operational reliability and reduced maintenance. “Existing MAXXDRIVE helical gear units with standard IEC/NEMA adapters can also be easily converted for SAFOMI adapters,” notes Stoltz. Nord drive systems for agitators, pumps and mixers used in water, wastewater and process plants are engineered with a VL heavy-duty spread bearing design, which translates to reinforced bearings and in creased bearing spacing. These reinforced and larger output shaft bearings allow the

BMG’s Nord agitator drive systems – which easily move large masses in agitating and mixing applications – consist of an electric motor, frequency inverter, MAXXDRIVE ® gear unit and accessories.

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⎪ Cover story ⎪

gear unit to absorb high radial and axial bearing loads that occur during the agitating process. Advantages of oversized output bearings include quick assembly, large bore capacities, high radial load capacity and longer service life. To enhance efficiency, BMG offers an agitator version VL2 bearing with increased bearing spacing and reinforced bearings, as well was a drywell version, VL4, with an additional oil drip plate with leakage or oil sensors. The bearing spacing of VL2 to VL4 versions are increased with output flange attachments, while the gear unit size remains unchanged. Nord also offers the VL6 design that allows the gear unit to be mounted onto the face of the housing. Coaxial drives are recommended for agitators and mixers that require a double agitator, due to the large size of the tank. Double agitators often consist of agitator blades that rotate in one direction in the middle of the tank, while a scraper blade rotates in the opposite direction. This sys tem is designed to efficiently move mate rial settled around the wall of the tank and return it to the agitation blade. NORD offers the option of operating two shafts inside each other for coaxial agitators. The inner agitator is driven by the upper gear unit and the outer agitator by the lower unit. The direction of rotation and the speeds of the agitator and scraper can be completely independent of each other. NORD IE5+ synchronous motors – with the highest defined efficiency class – enhance the performance of these mixers and agita tors and are also ideal for food processing, pump and conveyor applications. Notable features include a compact and hygienic design, high corrosion resistance and easy cleaning. Because a very high percentage of the total cost of ownership (TCO) of an electric IE5+ synchronous motors and frequency inverters

Left: Nord decentralised frequency inverters are also ideally suited for controlling associated pump applications. Right: NORD IE5+ synchronous motors – with the highest defined efficiency class – enhance the performance of mixers, agitators, pump and conveyor.

increasing the efficiency of entire drive systems. Actuating pump drives via frequency inverters enable different pump charac teristics to be selected, simply by changing the system parameters. Various parameter sets are directly stored in the inverter and pumps can be adapted to different media, flow rates or process requirements. BMG offers fully matched Nord drive systems that are tailored to the exact requirements of every customer’s applica tion. Modular systems are easy to expand or upgrade, using a minimum of different types and sizes of components. Local as sembly by BMG enables prompt delivery of drive systems and the ready availability of spare parts. BMG plays a pivotal role in supporting the productivity and production targets of industrial, manufacturing, mining and agricultural sectors of economies in all the countries it serves. As Africa's larg est distributor, manufacturer and service provider, the company has a reputation for delivering quality engineering consumables and components, including: bearings and seals; power transmission components; drives, motors and controllers; hydraulics, pneumatics and filtration; heavy and light duty materials handling; pumps and valves; lubrication, fasteners and gaskets; and a wide range of specialist maintenance and monitoring tools. www.bmgworld.net

motor is made up of the energy consumed by the motor, these new generation IE5+ motors offer a fast return on investment (ROI). They also offer a constant torque over a much wider speed range, and they are particularly easy to clean, with high corrosion resistance due to their smooth and fan-less motor design. For even greater system efficiency in agitating and mixing processes, BMG spe cialists recommend Nord DuoDrive geared motors, which feature the Nord IE5+ motor integrated into a single-stage helical gear unit. With a system efficiency of up to 92%, this wash-down-capable geared motor has one of the highest efficiencies on the market in this power class. Driven by frequency inverters, these sys tems also achieve high efficiency in partial load operation. Frequency inverters also bring simple plug-and-play commissioning to the drives for systems such as mixers and agitators, all of which, compared to other drive systems, delivers further significant reductions in the operational and total ownership costs for end users. Pumping applications Nord decentralised frequency inverters are also ideally suited for controlling associated pump applications. These units save space in control cabinets, reduce costs for wiring and cables and simplify maintenance, thus

The Nord MAXXDRIVE ® series is the only complete industrial gear unit system with a one-piece UNICASE lightweight housing for mixing and agitating processes.

May-June 2025 • MechChem Africa ¦ 5

The evolving landscape of tailings storage facilities Tailings storage facilities (TSFs) are increasingly being viewed as valuable resources that demand careful stewardship: rather than mere waste repositories. Lili Nupen of NSDV Law talks about the regulatory reforms that reflect this view.

T ailings storage facilities (TSFs) are structures built to store the leftover materials and waste from mining operations, colloquially known as tailings. These facilities are critical components of the mining lifecycle, storing the fine waste particles and water slurry produced during mineral processing. TSFs represent significant environmental, social and safety risks, particularly if not managed effectively. South Africa, with its vast mining industry, is home to an extensive network of TSFs, some of which are among the largest in the world. The value of TSFs is increasingly promi nent in the modern era as technological advances enable the profitable extraction of valuable minerals from historic mine waste. These facilities, once viewed solely as environmental liabilities, are increasingly recognised as valuable ore bodies that can be re-processed using modern extraction methods and technologies to recover pre viously inaccessible minerals. The practice of re-mining or processing tailings not only creates new revenue streams but also offers environmental benefits by removing his toric waste deposits and potentially harmful materials from the landscape. Essentially, it helps to make more money and do more good! The associated risks TSFs pose potentially devastating risks, primarily due to the potential for struc tural failure or mismanagement, leading to pollution of the surrounding areas. The disastrous collapse of the slime dam TSF in Jagersfontein in the Freestate is a recent example of how the mismanagement of TSFs can impact upon the environment and surrounding communities. “The collapse of this slimes dam – a dam designed to store mining by-products – washed away homes and cars, flooding the town with a toxic torrent of mine waste and mud,” says Lili Nupen, co-founder of NSDV Law and head of environmental and mining law. “The risks associated with TSFs, highlighted by the catastrophic col lapse of the Jagersfontein slimes dam, have prompted the proposed amendments to the

framework governing TSFs in South Africa,” she adds. In addition, the recent collapse of the Sino Metals tailings dam in Chambishi on 18 February 2025 has undermined global safety efforts while exposing a critical paradox: our growing need for mining despite its dangers. The disaster released 50-million litres of acidic waste into the Mwambashi River, cutting water access for 500 000 Kitwe residents and contaminating farmland already stressed by last summer's severe El Niño drought. The balance between these risks and benefits is shaping the evolving regulatory landscape, with both international stan dards and local laws adapting to ensure that TSFs are managed more safely and sustainably. The EIA amendments The proposed amendments to the Environmental Impact Assessment (EMA) Regulations, 2014, and the associated Listing Notices (Proposed EIA Regulation Amendments) were published for public comment in December 2024. The Proposed EIA Regulations amendments represent a significant shift in South Africa’s approach to TSF management, reclassifying TSFs from waste to resource, reflecting their potential value rather than treating them solely as

disposable waste material. The Proposed EIA Regulation Amendments work in tandem with NEMA (National Environmental Management Act) by virtue of the National Environmental Management Laws Amendment Act, 2022 (NEMLA4), which amended NEMWA to specifically exclude residue stockpiles and residue deposits from the scope of ‘waste’, providing that it will be regulated, instead, under NEMA. The amendments propose to include activities related to the expansion and rec lamation of historical mine dumps, where a ‘historical mine dump’ is defined as any debris, discard, residues, tailings slimes, slurry, waste rock, foundry sand, beneficia tion plant waste, ash or any other product derived from or incidental to a prospecting or mining operation which does not require a right or permit under the Mineral and Petroleum Resources Development Act, 2002 (MPRDA). Proposed MPRDA amendments The regulatory framework governing TSFs is undergoing significant reform. Beyond the Proposed EIA Amendments, proposed amendments to the MPRDA will play a key Lili Nupen, co-founder of NSDV Law and director for Mining and the Environment at the firm.

TSFs represent significant environmental, social and safety risks, particularly if not managed effectively.

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⎪ Minerals processing and materials handling ⎪

role in reshaping how historic mine waste is managed. The MPRDA amendment process has a complex history, beginning with the Mineral and Petroleum Resources Development Bill, 2013 (MPRD Bill 2013). Although the Bill was adopted by Parliament, it was referred back to the National Assembly by the President in 2015 for reconsideration. After years of inactivity, the amendment process regained momentum in August 2024 when the Department of Mineral and Petroleum Resources (DMR) presented its rationale for the proposed changes to the MPRDA. A central feature of these amendments is the introduction of Section 42A, which establishes a regulatory framework for the management of historic residue stockpiles and deposits (i.e. TSFs) that pre-date the MPRDA. The amendments introduce tran sitional provisions that enable owners of these TSFs to either amend their existing mining rights or apply for new ones, formally integrating these sites into the MPRDA’s regulatory regime. Should these amend ments be passed and enacted into law, TSFs which were established prior to the MPRDA will be regulated by the MPRDA and any reclamation activities in respect thereof may require a mining right. This shift, while extremely contentious for a whole host of constitutional reasons, aligns with South Africa’s evolving approach to TSFs, recognising them not as waste stor age facilities but as valuable secondary ore bodies. Kind of like how Crocs became cool after no-one wanted to be seen in them! Global standards Global attention on tailings management has intensified following recent internation al disasters. The Jagersfontein incident, as well as failures at Mount Polley in Canada, and at San Marco and Brumadinho in Brazil, have underscored the critical need for care ful management of TSFs. In 2020, the Global Industry Standard on Tailings Management (GISTM) was launched with the vision of achieving the ultimate goal of zero harm to people and the environment with zero tolerance for human fatality. The GISTM represents the first global standard on TSF management and sets a high bar for the mining industry to attain – integrating social, environmental, local economic and technical considerations for every facility. The GISTM comprises the following six pillars: • Affected communities. • Integrated knowledge base. • Design, construction, operation and monitoring of the tailings facility. • Management and governance. • Emergency response and long-term

South Africa, with its vast mining industry, is home to an extensive network of TSFs, some of which are among the largest in the world.

The evolving landscape of TSF management reflects a fundamental shift in how the mining industry views these facilities – from mere waste repositories to valuable resources that demand careful stewardship.

for public consultation. The initiative aims to simplify mining standards and enhance environmental, social and governance prac tices across the mining value chain. A central focus of the CMSI is the responsible management of tailings, with performance measures highlighting risk-based systems aligned with global standards, including the GISTM and the Mining Association of Canada's Tailings Management Protocol. By promoting trans parency, independent audits and public disclosures, the initiative aims to build trust and drive long-term environmental stewardship and sustainable resource development. The evolving landscape of TSF manage ment reflects a fundamental shift in how the mining industry views these facilities – from mere waste repositories to valuable resources that demand careful stewardship. The convergence of South Africa's regula tory reforms, global standards such as the GISTM, and initiatives such as the GTMI and CMSI marks a pivotal moment in the management and use of TSFs. www.nsdv.co.za

recovery. • Public disclosure and access to information. Within these six pillars, the GISTM incor porates 15 Principles and 77 auditable requirements, covering standards and prac tices over the entire TSF lifecycle. The Global Tailings Management Institute (GTMI) was launched on 21 January 2025, founded by CEO-led leader ship organisation ICMM, the United Nations Environment Programme (UNEP) and the UN-backed Principles for Responsible Investment (PRI) – the same three organisa tions that established the GISTM in 2020. Based in South Africa, the GTMI will oversee independent assessments of TSF compli ance with the GISTM. It provides a platform for sharing best practices and encourages transparency through public disclosure of auditing outcomes. In addition to the GISTM, the Consolidated Mining Standards Initiative (CMSI), supported by partners such as the Copper Mark, ICMM, and the World Gold Council, has released a draft standard, governance model, and assurance process

May-June 2025 • MechChem Africa ¦ 7

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⎪ Minerals processing and materials handling ⎪

ABB to deliver world’s largest mine hoist At 75 metric tons, ABB is set to deliver a friction hoist with the largest production capacity in the world for BHP’s Jansen Potash Project in Canada. Four hoisting systems will be delivered to the project, including three complete friction hoists, all equipped with SIL 3-certified ABB Ability™ Safety Plus systems for hoists. A BB has been selected by global mining company BHP to deliver, install and commission three fric tion hoists and a further electrical

system for a Blair service hoist to its Jansen Potash Project in Canada. Installation of the initial two hoists is currently in progress, while the further two hoisting systems are being prepared for installation and com mission between 2026 and 2027. With land scarcity and soil nutrient depletion, the predicted demand for potash to fulfil global needs is rising. Used in fertilizer, potash will be crucial for both more sustainable farming practices and food security. This is a milestone project for the min ing industry as one of the two production hoists will have the largest production capacity in the world, able to transport payloads of 75 metric tons. Its six ropes will be able to support the heavy loads from 1.0 km underground at a maximum speed of 18.3 m/s, supported by dual 7 700 kW motors. As the mining industry evolves to keep up with increased demand, this project represents a breakthrough in enhanced productivity. The service shaft and production shaft have both been sunk in preparation for the hoisting systems. ABB supplied two hoists to the service shaft, including the cage. At the same time, ABB delivered the hydraulic braking system as well as electrical controls and powertrain for a temporary Blair cage hoist being commissioned in the production shaft, which will be in operation for two years while the higher capacity production hoist is prepared. The latter will then be installed and is expected to be up and run ning for production use by 2027.

ABB is set to deliver a friction hoist with the largest production capacity in the world for BHP’s Jansen Potash Project in Canada. Image BHP Jansen.

Additionally, each mine hoist is being supplied with ABB Ability™ Safey Plus for hoists, the world’s first fully SIL 3 certified safety solution. Safety remains a crucial pri ority across the sector, with 48% of mining companies citing safety as a key motivator for transforming operations in ABB’s recent independently led survey for its ‘Mining’s Moment’ report. ABB’s hoisting systems are leading the way, offering the highest levels of safety in the industry for all mine employees. “The hoists and hoisting systems will play a crucial role in the efficient and safe extraction of potash, giving Jansen its competitive edge,” says Simon Thomas, Vice President for Projects Potash at BHP. “The new contract further strengthens our exist ing strategic partnership with ABB, and we look forward to continuing to work together as we plan to drive productivity, safety, and sustainability.” “Helping customers enhance productiv ity and safety with our solutions is key to

us,” adds Björn Jonsson, Global Business Line Manager for Hoisting at ABB Process Industries. “We are happy to continue our work with BHP on increasing the efficiency and productivity of the Jansen mine while continuously helping to improve the safety of people and operations. ABB’s mine hoists are some of the safest in the world, adher ing to the highest regulations, and we are pleased to combine this with enhanced capacity loading as the industry continues to look for solutions that maximise produc tivity in order to meet demand.” This new contract between ABB and BHP follows a previous collaboration on the inte gration of power management systems for the Jansen Potash Project. The project aims to become the largest potash-producing mine in the world. Initial Stage 1 capacity of the Jansen Potash Project is expected to reach 4.5 million tons per annum (Mtpa), while future development is projected to increase this by a further 16 to 17 Mtpa. www.abb.com

The strategically important BHP Jansen Potash Project site for minerals production. Image BHP Jansen.

May-June 2025 • MechChem Africa ¦ 9

Pioneering Tru-Trac intelligent belt scale

Latest from Tru-Trac Rollers is a groundbreaking intelligent belt scale system that goes beyond simple weighing. Having made its grand debut at bauma 2025, the system also provides insightful long term data that helps with monitoring, decision making and productivity forecasting.

Beyond weighing, the system also moni tors conveyor health, ensuring consistent material flow. Continuous mV readings assess belt alignment, flagging potential misalignment caused by off-centre loading. The belt scale doesn’t just focus on im mediate accuracy – it delivers valuable long term operational insights. By tracking key performance indicators (KPIs) in real time, customers gain a deeper understanding of plant efficiency and productivity trends. “The system’s anomaly detection con

tinuously analyses operational parameters,” adds Ludik. “If any irregularities arise, they are flagged instantly, allowing for correc tive action before small issues escalate. This real-time oversight fosters constant optimisation and operational excellence.” With its groundbreaking combination of AI-driven automation, real-time monitoring and advanced diagnostics, Tru-Trac’s intel ligent belt scale is set to redefine conveyor performance. https://tru-trac.com

I n an era where data-driven decisions are critical, Tru-Trac Rollers unveiled its intelligent belt scale system at bauma 2025. Featuring integrated AI-driven continuous calibration checking and real time load cell monitoring with traditional belt scales, this next-generation solution goes beyond measuring tonnes per hour (tph) to deliver advanced conveyor belt monitoring. Integrating seamlessly with the award winning Rip Prevent+ system, which Tru Trac debuted to its African customers at Electra Mining Africa 2024, this innovation leverages artificial intelligence (AI) to detect anomalies or rip events on all conveyor belt types including steel cord, pipe, and fabric belts. “This intelligent belt scale sets a new standard,” says Tinus Ludik, Sales Manager – Bulk Materials Handling Division at Tru Trac. “It is not just technologically advanced but also user-friendly, providing unprec edented data that conventional belt scales simply don’t offer.” A standout feature is real-time load cell monitoring ensuring millivolt (mV) signals remain within optimal range. Any deviations trigger proactive warnings, allowing for timely intervention and reducing the risk associated with inaccurate or inconsistent readings. By continuously assessing load cell health, the system enhances reliability, repeatability, and accuracy. Unlike traditional systems that require manual recalibration, Tru-Trac’s intelligent belt scale automatically detects and cor rects inaccuracies. Advanced AI algorithms analyse and cross check the belt scale readings against mass flow measurements, identifying deviations and self-adjusting to maintain precise measurements. This elimi nates the need for manual intervention, im proves reliability and reduces maintenance. Tinus Ludik Sales Manager, Bulk Materials Handling Division at Tru-Trac.

More than a belt scale, Tru-Trac’s latest innovation provides complete conveyor health insights and anomaly detection.

The next-generation Tru-Trac belt scale combines cutting-edge AI, diagnostics and automation for industry-leading performance.

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⎪ Minerals processing and materials handling ⎪

Mill liners designed with 3D scanning technology and DEM Multotec has demonstrated the power of 3D scanning technology and Discrete Element Method (DEM) simulation during a mill liner installation at a gold processing facility in Alaska, marking the first time it has used this technology to support an installation remotely.

M ultotec has successfully supplied scientifically engi neered rubber mill and scrub ber liners to mining opera tions across the globe, including the USA, Zambia, Côte d’Ivoire, Botswana, Namibia, and South Africa for various customers in the diamond, PGM, iron ore, zinc, lead, copper, gold, and coal processing industries. These liners are developed using advanced computer simulations to ensure optimal configuration for efficient performance and have been implemented in mills, chutes, and other mining and processing plant equipment. The power of 3D scanning technology was recently demonstrated during a mill liner installation at a gold processing facility in Alaska, marking the first time Multotec used this technology to support an installa tion remotely. This approach enabled pre cise fitting and optimised liner performance. Ralph Hollenstein, Senior Mechanical Engineer at Multotec, notes: “In this case, the client supplied us with 3D scans of the mills, allowing us to design the liners re motely, creating shorter turnaround times and greater accuracy. The liners were then manufactured and sent to site for installa tion, where they fitted perfectly in the mill.” Multotec places a strong emphasis on ensuring that its liner design is optimal for the life of the liners and milling per formance. The company also conducts condition monitoring on installed liners to ensure maximised uptime through proactive maintenance. A scientific approach in its mill liner design is core to this approach, focusing on process flow and charge trajectories to enhance both performance and durabil ity of the liners. By using advanced DEM simulation techniques, Multotec provides mill operators with precise guidelines to keep the mill operating in its optimal regime. As part of the design process, Multotec utilises the Discrete Element Method (DEM) software to predict the behaviour of the mill charge – comprising ore and grinding media – and the performance of the mill throughout the lifespan of the lifter. DEM is also employed to predict liner Ralph Hollenstein, Senior Mechanical Engineer, Multotec.

wear and the evolution of the liner profile over time. “This technology enables us to simulate wear on the liners and track how the mate rial interacts with the changing liner profile as it wears down. From these wear simula tions, we can identify areas of high wear within the mill and use this information to optimise the liner design – adding material in high-wear zones while reducing material in areas that do not require as much rein forcement,” Hollenstein explains. Multotec’s liner optimisation system in tegrates advanced tools, including MillTraj, a first order simulation tool; DEM, for advanced multiparticle simulation; and 3D scanning technology to determine the exact profile of a worn liner and/or the mill shell. These tools enable precise condition monitoring, comprehensive management, and effective liner design for a perfect fit and enhanced performance. MillTraj focuses on the trajectory model ling of grinding mill liners and lifters. Its key applications include: • Simulating lifter designs and configu rations to understand their impact on the motion of the grinding balls and material inside mills. • Optimising mill liner profiles to im prove grinding efficiency and reduce wear. • Providing insights into the trajectory of grinding media to ensure optimal energy transfer and to avoid damaging the mill shell. Furthermore, Rocky DEM offers extensive capabilities for simulating particle dynam ics across various industrial processes. Its functionalities include: • Simulating particle dynamics such as collisions, breakage and flow, for a range of material types. • Modelling and optimising equipment such as mills, crushers, conveyors and screens to improve performance. • Conducting wear analysis to predict and mitigate component degradation and ensure longer equipment life. • Handling complex particle shapes, providing more accurate simulations for irregular materials.

Advanced 3D laser scanning Multotec also employs advanced 3D laser scanning technology to accurately assess mill liner wear. This data-driven approach allows the company to create precise liner replacement schedules and estimate the remaining lifespan of the mill liners, ensur ing efficient relining operations. “The 3D scanning is a service we provide to our customers for condition monitoring in various countries and across multiple commodities. In some cases, customers use similar scanners to perform the scans them selves. They then send us the scan data, and we then interpret the results and generate detailed reports,” says Hollenstein. Additionally, what sets Multotec apart from its competitors is its focus on the en tire comminution circuit as a whole rather than just mill liner design, which ties in with conducting plant audits to assist customers to optimise their efficiency. “When we work with customers, we do not simply sell them mill liners. We take a more holistic approach by helping them to assess and identify any problem areas and work with the entire plant/milling circuit to resolve those issues. Through plant audits, we gain an understanding of the customer's operational constraints and where they want to improve their operations,” says Hollenstein. www.multotec.com Multotec leverages cutting-edge technology to scientifically design mill liners, optimising process flow and charge trajectories for enhanced performance and durability of the liners.

May-June 2025 • MechChem Africa ¦ 11

MEPS regulation and the motor-efficiency revolution The IE3 motor efficiency standard will soon become South Africa's minimum, mandating that all local electric motor suppliers deliver at this minimum efficiency standard or higher. WEG Africa’s Rodrigo Cetenareski outlines the reasons and benefits for this change.

are the new requirements? The new regulations impact low-voltage electric motors in the 0.75 kW to 375 kW range, predominantly two-pole, four-pole, six-pole, and eight-pole motors. Roughly 200 000 electric motor units are sold in SA each year, according to the National Economic Development and Labour Council, with al most 70% of them between the 0.75 kW and 11 kW size range. Yet very few have stated energy rat ings, suggesting that the majority are very inefficient IE1 motors that require frequent maintenance. Under the new regulations, most new motors must adhere to the IE3 stan dard. These regulations do not affect current installations, but it might be more economical to replace broken motors with new models rather than repair or rewire them. “Companies that rely on electric motors will not have to rip and replace what they have. The new regulations focus on new mo tors sold in the country. However, when you look at the advantages of IE3 motors, there is good reason to consider upgrades,” argues Cetenareski. Reduced energy and maintenance demands The costs of owning and running electric motors are incredibly disproportionate. The purchase represents only 2.3% of a motor's

erable impact on both, not least because they consume more than 40% of global electricity supplies. “Most industries are focused on how to reduce their energy bills and increase energy efficiency,” says Rodrigo Cetenareski, sales and marketing director at WEG Africa. “They are also looking to save costs through more equipment efficiency, particularly around maintenance. These factors have made elec tric motors a priority area and put momentum behind MEPS regulations.” A regulated sea change Minimum Energy Performance Standards (MEPS) encourage the use of energy efficient technologies, including electric motors. Managed by the International Electrotechnical Commission (IEC), new MEPS standards were published in 2007. The US updated its MEPS laws in 2011, while European countries followed by 2017, and China deployed similar regulations soon after. Currently, over 57 countries support the new MEPS standard, with more to follow. South Africa gazetted its new MEPS regula tions in late 2023, with enforcement slowly coming online. What are the implications of these new laws? There are numerous benefits that support industries' economic and efficiency priorities. But before exploring those, what

T he world is powered by electric mo tors. First invented in 1835, electric motors are ubiquitous nearly two centuries later, playing roles in running vehicles, elevators, escalators, air conditioners, conveyor belts and pumps, to name but a few. It is a substantial list—even the average modern car can include 40 elec trical motors that handle tasks such as water pumps and automatic door locks. Mechanised motors put momentum behind modernisation. Ancient societies invented water wheels and windmills to turn the elements into torque for production. The invention and commercialisation of steam engines served as one of the early industrial revolution's biggest catalysts. Combustion engines ushered in an era of giant machinery and shortened distances. However, electric motors are at the forefront of powering the modern world, generating over US$150-billion annually in sales, according to Allied Market Research. Yet, industries that rely on these motors are grappling with rising energy costs and con strained networks market spending. Electric motor-driven systems (EMDS) have a consid

South Africa is introducing the IE3 standard, mandating suppliers to sell more energy-efficient electric motors.

12 ¦ MechChem Africa • May-June 2025

⎪ PowerGen,PetroChem and Sustainable energy management ⎪

Left: The new high-efficiency standards make it more economical to replace older low-voltage motors instead of repairing them. Middle: Inefficient motors create financial burdens, with running costs representing more than 96% of the total cost of ownership. Right: IE3 motors produce lower temperatures, reducing maintenance requirements and extending operational lifespans.

lifetime cost, and maintenance only 1%. Almost 97% of the motors total costs go to electricity consumption. IE3-level motors are more efficient than lower-rated models. Even though their margin is only between 4% and 8% to that of an IE1 motor, IE3 motors running for thousands of hours reduce energy losses by as much as 32%. They also produce lower temperatures, radically reducing their maintenance require ments and extending operational lifespans. There are also other peripheral gains, such

as lower carbon emissions. Even though IE3 motors are slightly more expensive than lower-rated motors, they typically recoup the difference in less than five years, and under some conditions even by the second year. The same logic resonates when older motors require repair or rewiring, says Cetenareski: “Rewiring a motor can cost more than half of purchasing an IE3 motor. If you look at the subsequent savings, it makes more economic sense to phase out older motors rather than

repairing them,” he points out. IE3 motors represent a significant ad vancement in electric motor technology. By upgrading, companies reduce energy costs, improve sustainability, enhance performance, and comply with regulations. South Africa's new MEPS regulations and the widening adoption of IE3 motors will un lock considerably more energy at a time when companies and consumers are looking to lower costs, gain value, and boost resilience. www.weg.net/institutional/ZA/en

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May-June 2025 • MechChem Africa ¦ 13

Boiler selection for optimal thermal energy performance

The changing world of boilers means companies wishing to improve their thermal energy efficiencies, while containing costs and environmental impacts, must make careful and informed decisions, advises Dennis Williams of steam and boiler operations and maintenance service provider, Associated Energy Services (AES).

pressure. “Improvements should rather come from the application of the latest control systems and combustion technologies, as well as waste heat recovery on the back-end,” he advises. A fire tube, coal-fired boiler with a large chain grate stoker feeding fuel to the boiler can be retrofitted by removing the stoker and replacing it with a burner that uses liq uid fuel or gas on the front end. To convert a liquid or gas-fired boiler to biomass, a Dutch oven – essentially a refractory-lined furnace that combusts wood biomass on the outside and then takes heat through the flue into the boiler – can be placed on the front-end. However, William warns that changing the flue gas characteristics may change the output capacity. When converting to biomass with high moisture content of up to 40%, a boiler designed to produce 20 t of steam per hour may only achieve a maximum output of 12 or 14 t. Certain fuel types also allow the use of additional equipment to optimise the perfor mance of existing and new boilers, according to Williams. An economiser, for instance, uses a heat exchanger to recover some of the lower grade heat from the flue gas exiting the stack to preheat the boiler feed water. This reduces fuel usage. Recovered heat can also be used to raise the temperature of combustion air entering the boiler. Fitting an economiser is possible with biomass but not advisable with coal, because the flue gas will contain sulphur dioxide that will cause acid-dewpoint corrosion. Williams says AES’ rich pool of experi ence, ability to keep pace with new steam trends and technologies and understanding of their clients’ production processes can all assist clients to weigh up different options in a careful and informed manner. “This is where thermodynamic modelling and project design comes in, as well as understanding what dif ferent boiler manufacturers can offer. “The last thing clients want is a cutting-edge plant that becomes problematic to operate or maintain three or four years down the line. We can provide a viable and optimal boiler solution, not just based on capital cost, but also from an operational perspective,” Williams concludes. www.aes-africa.com

Fire-tube boilers are typically used to handle steam pressures of 20 bar or less.

S outh African industry relies mainly on two types of boilers: fire tube boilers, handling lower steam pressures of 20 bar or less; and water tube designs, catering for greater steam tonnages, higher operating pressures or unusual fuel sources and novel combustion mechanisms. Water tube boilers are used by large utilities, as well as the sugar and paper industries. Key considerations for making a choice are the amount of steam required per hour and the steam pressure, followed by specific on-site requirements. Challenges could include everything from configuration and space to environmental is sues: “For example, companies in the Durban South Basin would not get permission for a 50 t per hour coal-fired boiler installation, due to stringent cutbacks on sulphur dioxide. Sulphur content needs to be less than 1%, even in coal. Here, a gas-fired unit would be prefer able,” says AES’ Dennis Williams. “Boilers can be catalogue or quite special ised,” he continues. In the industrial steam space, there is a wide selection. Large util ity boilers facilitate more specialised design, while, for those processing unique fuels or waste streams, there are craft boilers to pro vide bespoke solutions, which reduce waste while saving costs and boosting efficiencies. A food manufacturer in KwaZulu-Natal,

for example, added a boiler to process chicory grounds from coffee-making, avoiding the cost of treating and dumping this wet slurry. Up until now, most boilers have been coal fired, as this fuel was abundant and affordable. Now, there are also boilers fired by gas- and liquid-fuels, which are perfect for companies operating them intermittently or for short periods. “These allow the fire tube design to operate at a slightly higher steam pressure because the combustion flue is smaller,” Williams explains. In the past, electrical steam generation was popular with breweries, textile and tyre manufacturers, which used electrode boilers. Due to loadshedding, electricity was no longer a reliable power source, so companies began operating with costly heavy furnace oil. “They had to decide what they were go ing to do long-term. Many of our clients are former electrode boiler users who converted to coal or biomass, moving away from heavy furnace oil as a backup,” Williams says. Replace or retrofit A choice between a complete upgrade or a retrofit depends on a client’s individual steam requirements. Williams notes that an original 20 bar boiler cannot be transformed into a 45 bar boiler, as the metallurgy and steel thicknesses are unsuitable for this level of

14 ¦ MechChem Africa • May-June 2025