MechChem Africa November-December 2023

MechChem NOV-DEC 2023 AFRICA

Eco Industrial Parks: towards economic, environmental and social sustainability

This month: SA’s preferred API 610 pump provider

Co-polymer compounds for abrasion and corrosion applications

Mechatronic drive solutions for metalworking machines

Advanced polyurethane products and 3D printing



CONTENTS 30 Water, wastewater and pumping solutions 6 KSB: SA’s preferred API 610 pump provider MechChem Africa talks to Stefano Testi, and Casper Steenkamp of KSB about the company’s preferred provider status in South Africa for API 610 pumps. 9 The role of cutter fans in pump agitation 10 Xylem Africa launches 360 Performance 12 Mill circuit pumps: the key to efficient operations 13 Submersible Pumps Africa’s acid resistant slurry pump Power transmission, bearings, bushes and seals 14 Mechatronic drive solutions for metalworking machines Bonfiglioli is a longstanding leading manufacturer of mechatronic solutions for the metalworking industry, supplying excellence and innovation by staying focused on customers and their manufacturing needs. 17 Polymer fibre composite bearings push applications limits 18 BMG’s smart solutions for farmers 19 Modular design multiplies flexibility for gearbox users Minerals processing and materials handling 20 Advanced co-polymer compounds for heavy impact, abrasion and corrosion applications MechChem Africa meets the directors and management team of Nordbak, South Africa’s leading manufacturer and applicator of synthetic co-polymer and epoxy-based compounds. 23 MultoComposite integrated mill liners to meet miner challenges 24 Mobile high capacity discharger and conveyor 25 A circular approach to ESG in mining Hydraulics, pneumatics and automation systems 26 Process automation and AI Hennie Colyn, direct sales executive for process automation at Schneider Electric, talks about Artificial Intelligence (AI) and the role it can play in process automation. 27 BBE unveils VUMA HUB 28 Innovative bottling and filling solutions 29 Customer service drives growth for rental division PowerGen, PetroChem and sustainable energy management 30 ABB Care for managing power utility assets ABB Southern Africa has introduced ABB Care, a structured approach to asset management for power utilities and plant. 31 Ore beneficiation and optimised steam generation 32 Green Hydrogen: a new frontier for Namibia’s workforce 33 High-performance power products keep wheels turning 34 How kitchen waste is helping to win a war Environmental management and cleaning technologies 36 EnviroServ annual plant shutdowns As the leading waste management company in South Africa, EnviroServ assists many companies in completing their annual maintenance shutdown projects on time and on budget. 37 Waste segregation allows Zutari to buy carbon offsets Special report 38 Bell launches new Bell Heavy Industries division Bell Equipment has opened a new 45 000 m² undercover local manufacturing facility in Richards Bay that complies with the ISO 9001:2015 Quality Management System and welds to the internationally recognised ISO 3834-2 Appendix 10 standards. Innovative engineering 42 Advanced polyurethane products and 3D printing MechChem Africa talks to Saahil Bhartu, product engineer at UMP, about the advantages offered by adopting 3D printing to manufacture complex moulds for the manufacture of polyurethane products. Regulars 2 Peter’s comment: Offshore wind: opportunity and risk 4 On the cover: Eco-Industrial Parks: Initiating sustainable production 40 Products and industry news 44 Back page: CSIR deploys radiometric buoy to collect microalgae 42

Published bimonthly by Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: Editor: Peter Middleton e-mail: Advertising: Elmarie Stonell e-mail: 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 Apr to Jun 2023: 10 391 Printed by: Tandym Print, Cape Town

Front cover: CSIR’s NCPC-SA Contact: Bernd Oellermann

Tel: +27 12 841 3772 Email: Website:

November-December 2023 • MechChem Africa ¦ 1

Offshore wind: opportunity and risk

I received a report from Allianz Commercial insur ance that highlights where we are with offshore wind across the globe. Entitled ‘A turning point for offshore wind: Global opportunities and risk trends’ , the report details the growth opportunities, technology innovations, risk trends and insurance claim patterns for the global offshore wind industry. According to Anthony Vassallo, global head of Natural Resources for Allianz Commercial, “Allianz is supporting some of the most exciting offshore developments, whether as an investor or insurer. In its lately launched Net-Zero Transition Plan, Allianz Commercial committed to revenue growth of 150% for renewable energy and low-carbon technology by 2030. In addition, Allianz has committed a further €20-billion in investments for climate and clean tech solutions. “2023 has been a historic year for the Earth’s climate. July was the hottest recorded month in hu man history and severe events, including wildfires blazing with ferocity and extreme flooding, have increasingly dominated the news as the devastating impacts are seen in Hawaii, Northern India, and São Paulo in Brazil,” writes Vassallo. “It has also been a pivotal moment for energy transition. As the threat of climate change has loomed large, renewable energy usage has ramped up, geopolitical tensions continue, and governments have implemented far reaching policies to reduce carbon emissions and diversify power sources.” He acknowledges that offshore wind farms are highly complex projects and goes on to outline les sons learned from an insurance point of view. In the wind insurance markets of Germany and Central Eastern Europe between 2014 and 2020, Allianz Commercial has seen 53% of offshore wind claims being attributed to cable damage: from loss of entire cables during transport, to bending of cables during installation. On a large offshore wind facility, multi million-dollar losses can quickly accrue because a cable failure can put the whole network of turbines out of commission. Turbine failure is emerging as the second major cause of losses (20%). “Emerging risks need to be explored, too, as developers prepare for widescale deployment of offshore wind around the globe. The size of turbines is ever increasing, wind farms are moving further out into harsher marine environ ments, and technological innovation is constantly progressing. Navigating biodiversity issues in coastal commu nities will also become more important as demand for ocean space is set to increase fivefold by 2050,” Vassallo points out. In terms of growth, the report

points out that, in 2022, 8.8 GW of new offshore wind capacity was added to the grid, with global installed capacity reaching 64.3 GW. Going forward, around 380 GW of offshore capacity is expected to be added across 32 markets over the next 10 years. And while no offshore wind farms exist in Africa and the Middle East at present, several countries including Morocco, Egypt, South Africa, and Kenya are exploring the potential of including offshore wind into their energy mix. At the recent Windaba Conference at the Cape Town International Conference centre, Sean Whittaker, principal renewable energy specialist for the International Finance Corporation (IFC), announced that the IFC was to develop a power road map for South Africa. “Offshore wind has the potential to play a huge role in the energy transition because it is clean, it is huge, and it is power close to where you need it,” he said. The IFC is currently working with 24 countries around the world to see how offshore wind can play a role in their energy mix, with all of them setting ambitious targets. According to the Global Wind Energy Council, South Africa’s high demand for energy, advanced infrastructure and progressive policies have posi tioned the country as a key player in the continent’s renewable energy scene, with huge potential for offshore wind projects along its vast coastline. This potential is highlighted in the World Bank Group’s Offshore Wind Development Programme. Potential capacity for sub-Saharan Africa for fixed foundation offshore wind is estimated to be 372 GW, while for floating wind turbines in and around the Southern Ocean, 2 463 GW could be available. And though floating wind is considered to be more complex and costly in terms of instal lation, the higher speeds and better consistency of prevailing winds raises capacity factors as high as 50%, compared to the 30% typical of onshore installations. And while the investment will also be huge, offshore wind in Europe, as Whitaker points out, is now one of the cheapest forms of new energy. When you consider the fact that South Africa’s failed and very expensive nuclear programme would have delivered 9.6 GW of power in total, offshore wind, be it fixed or floating, is clearly a huge and totally untapped resource. But what of the risks? Insurance companies such as Allianz are willing to invest in and insure offshore wind farms, which must boost confidence in its readiness for local development. And surely the existential risks of unmitigated global warming will be far greater.

Peter Middleton


MechChem Africa is endorsed by:

2 ¦ MechChem Africa • November-December 2023

Eco-Industrial Parks: Initiating sustainable production

Bernd Oellermann, senior project manager of the National Cleaner Production Centre-South Africa (NCPC-SA) talks to MechChem Africa about eco-industrial parks and the symbiotic initiatives being adopted to ensure long-term economic,

environmental and social sustainability. “E co industrial parks are not just environmentally friendly. They involve embracing and balanc ing three key pillars – environ mental, economic, and social sustainability,” begins Bernd Oellermann, senior project manager at the NCPC-SA in South Africa. “There is no point in government and civil society talking about sustainability if we do not take industry along. But to properly introduce and translate sustainability into an industrial space, dealing with all three of these critical aspects is imperative. That is the whole point of the eco-industrial park approach, trying to assist industry to make a balanced sustainability transition that in cludes environmental, economic, and social components,” he explains. He introduces a simple thermodynamic perspective: “In any closed system, resources are limited. In a chemical reaction, for ex ample, the reaction can only continue until one or more of the reactants runs out. Then the reaction stops. “Our planet is facing this issue. It has a limited number of resources we can extract. Based on scientific calculations, we know that we cannot expect to continue using those resources in the same way we have always done. We must become smarter about how industries use the resources they need to manufacture products. But industry needs assistance in making this change,” argues Oellermann. “The amazing ‘side-effect’ of adopting resource efficiency, though, is that it has a direct impact on the competitiveness of in dustry. Even in the shorter term, costs can be reduced, profitability improved, and economic sustainability secured,” he assures. Looking at energy alone, he cites an indus trial symbiosis programme that the NCPC-SA ran with GreenCape a few years ago for a pro ducer of plastic products in the Western Cape. “In just two years, the monthly electricity bill was reduced by 70%. And, if I recall correctly, the bill was not that high to begin with. But this shows just how much cost saving potential there is, even for SMEs,” he says. “And if these kinds of savings could be replicated at significant numbers of industrial

sites, imagine the positive impact this would have on our ailing electricity grid?” he asks. Energy and water, he continues, are inter related imperatives for South Africa. They are typically the primary resources of concern for South African industry and a key target for NCPC-SA initiatives. “We first try to improve production efficiency with respect to energy and water before moving on to look at mate rial resource use, because the materials often link back to the design process of a product, so changes require a more intensive engagement with engineering and design,” he explains. “In food production, though, we talk about the food-water-energy nexus. Water consumption is so important in South Africa because our average country wide rainfall is low, in the order of about 400-450 mm per year, on average, which makes South Africa a water scarce country. The Department of Water and Sanitation projects that, by 2030, unless we improve our consumption behav iour, we are going to have a 17% shortfall in fresh water needs across the country – and 2030 is just around the corner,” he points out. But there are a range of initiatives being implemented in this area. “We are losing between 30 and 40% of our potable water through leaks,” he points out. “If we could just reduce that by half, we would be well placed to avoid the 2030 shortfall. We are also work ing with the industries dependant on water, such as the textiles industry, for example, to improve their usage and water recovery rates,

and with agriculture, which uses between 60 and 70% of the available freshwater resources in South Africa. Eco-Industrial Parks (EIPs) The NCPC-SA looks at parks that are zoned for industrial activity. The smallest estates might have 20 companies, while some of the larger ones can cover 1 000 ha and have hundreds of businesses from micro to macro in size. Oellermann cites Wadeville – which includes companies such as MacSteel, Scaw Metals, Protea Chemicals and many more – as a typical example of a large industrial estate. “The Eco-Industrial Park (EIP) framework enables us to assist at the park level, helping industries to collaborate with each other, the local municipality, and the local community and to put in place processes that address environmental, economic and social aspects of sustainability. We strive to unlock these things in a neutral fashion, creating safe spaces where people can engage construc tively for mutual benefit, so they do not get stuck on specific agendas,” he says.

The East London Industrial Development Zone (ELIDZ) is a flagship EIP project and world-class industrial location.

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⎪ Cover story ⎪

Left: South Africa’s largest rolled aluminium producer, Hulamin, believes in regional growth while making a meaningful contribution to sustainable development in South Africa. Right: The Meze Foods plant in the Wadeville EIP.

“Our approach is to ask what companies and people can bring to the table, not so much about what they want to take away. This is a guiding principle of the EIP approach, and it works well in South Africa,” Oellermann believes. When prompted for a flagship example, he cites the East London Industrial Development Zone (ELIDZ). It is a greenfield development transforming over 400 hectares of prime land into a world-class industrial location that at tracts globally competitive manufacturers. “This is one of South Africa’s Special Economic Zones (SEZs) and it falls within the dtic’s SEZ programme. It is also our ‘lighthouse’ eco industrial park in South Africa,” he notes. Developed using support from the dtic, this park currently embraces 51 of the key com ponents included in the global EIP framework for eco-Industrial development. To begin, there exists a well-established governance structure headed by East London Industrial Development Zone SOC Ltd. This operational entity assumes responsibility for the supervision of the industrial park and its associated services. “Carbon emission mitiga tion is a key eco indicator, and this makes the ELIDZ score really high, the total score for the SEZ, according to the EIP indicators, is above 80%,” he says, as measured according to an EIP-monitoring tool developed by UNIDO for evaluating eco-industrial sites. Describing some of the carbon mitiga tion initiatives, he cites the transition to renewable energy as an example. “There are several renewable energy projects currently underway. We at the NCPC-SA are supporting the implementation of rooftop solar PV, and looking at wind energy, which is implemented at park level, because East London is an ideal location for renewable wind power.” In terms of material resources, the ELIDZ

schools, are also being implemented. Many EIP companies have a corporate social respon sibility budget, which they are encouraged to spend on educational and community projects that develop and support the local community in terms of education, training and develop ment, while also targeting future employment needs within the park. “All the work we do at the NCPC-SA helps to transition industry to becoming sustain able. The core programme, which is funded by the Swiss government through UNIDO’s Global Eco Industrial Park programme, is a global initiative that is being trialled in just seven countries in the world, with South Africa being one of them. And at local policy level, the dtic and the National Treasury have adopted the EIP approach as being central to South Africa’s interventions for industrial parks across the country,” notes Oellermann. From an individual company perspec tive, he says that adopting an NCPC-SA programme is commitment-free and need not require expensive investments in green technologies. An initial free assessment sim ply strives to put industrial manufacturers on a long-term sustainable path. “We look at industry’s production process es at factory level, assess their energy, water and resource use, and then seek opportunities for improving that usage. This saves on the real costs of production for each company, while simultaneously guiding us all down the path towards cleaner and more sustainable production processes,” he says. “Ultimately, we exist to help industries to successfully negotiate every aspect of the sus tainability transition and to ensure that they avoid the pitfalls associated with continuing on the increasingly dangerous path we are currently on,” concludes Bernd Oellermann.

has Clariter South Africa, one of its investors dedicated to recycling initiatives. Clariter is actively engaged in collecting waste from various companies within the park, evaluating its potential for recycling and repurposing, and advancing the necessary pre-processing procedures to make the endeavour viable. “Notably, it is already processing specific types of waste plastics sourced from park based companies, with the aim of making them available for reuse by other businesses,” he says. From a social aspect, the ELIDZ works with the local Buffalo City Metropolitan Municipality (BCMM), and collaboration is good across East London, contributing towards long-term planning of municipal services and development issues. The ELIDZ, BCMM and local universities also work with the ELIDZ Science and Technology Park (STP), which collaborates on Research & Development (R&D) for the benefit of the park’s sectors and for the city. “The ELIDZ STP is typically looking at inno vative solutions that could eventually assist in resolving local issues, be they service delivery or new innovative products improving the lives of the people. Innovation can be used for resource optimisation for the whole of Buffalo City. It provides a facility for economic devel opment issues to be advanced in collaboration with researchers, academia, and innovators, so new solutions can be developed, piloted and commercialised,” he explains. Many of the social aspects of the EIP are incorporated through South Africa’s relatively strong Basic Conditions of Employment Act 75 of 1997, which specifies the basic condi tions of employment, including the working conditions and amenities for men and women. In addition, though, other community projects such as collectively supporting the community

November-December 2023 • MechChem Africa ¦ 5

KSB: SA’s preferred API 610 pump provider MechChem Africa talks to Stefano Testi, who has a 27-year history with KSB Pumps and Valves in South Africa, and Casper Steenkamp, KSB’s Secunda branch manager, about the company’s preferred provider status in South Africa for API 610 pumps, mainly for the petrochemical market but also for applications in the chemical and energy markets.

“M ost of our new busi ness is currently coming from the petrochemical industry, where Sasol is a key customer for our API 610 pump range,” begins Stefano Testi, project sales for the petrochemical and energy sectors. “As their preferred API 610 pump supplier, at KSB we are very heavily reliant on Sasol, where there has been an increase in the number of new local projects, and which is really good news for us,” he continues. KSB, he says, is in a fortunate position with respect to API 610 pumps, which are typically used for pumping hydrocarbons, often at high temperatures, or dangerous substances such as ammonium nitrate. “There are also applica tions that involve high temperature water or high pressure and temperature requirements, such as at Concentrated Solar Power installa tions. Mostly, though, API 610 pumps are used for hydrocarbon applications at refineries,” he explains. “We are currently supplying our KSB API 610 type OH2 pumps for a number of projects in the Sasol stable, and expect this to continue. There was a time when the Petrochemical Market was booming, so we also have a sub stantial installed base, mostly with Sasol, but also in the remaining refineries.” Describing the API 610 specification for this pump design, Testi says the Type OH2, which makes up some 90% of all API 610

The specification for the Type OH2 pump makes up some 90% of all API 610 business for KSB in South Africa.

KSB Group companies around the world,” he says, adding that the company’s preference is always to manufacture the pumps locally when possible. “We are the only company in South Africa that can locally produce the OH2 design pumps. Competitors can import them and they will perhaps add a motor, coupling and a locally manufactured base plate, but we alone have the ability and capacity to fully manufac

business for KSB in South Africa, is an end suction, vertical discharge, radially split process pump. “We have the option to fully manufacture these pumps locally in South Africa, and have patterns for the majority of the range, which include the casings, covers, impellers and bearing brackets. Where the logistics make sense, however, we can also import components for local assembly, or fully made up pumps from one of a number of

KSB South Africa enjoys preferred provider status for API 610 pumps, mainly for the petrochemical market but also for applications in the chemical and energy markets.

6 ¦ MechChem Africa • November-December 2023

⎪ Water, wastewater and pumping solutions ⎪

KSB has the option to fully manufacture API 610 pumps in South Africa and the company has casting patterns for the majority of the range, which includes the casings, covers, impellers and bearing brackets.

ture these API 610 pumps locally,” he adds. Companies such as Sasol have stringent requirements with respect to procurement and the technical specifications of their products. “KSB meets all these requirements and is, therefore, the preferred supplier to a number of EPC (engineering, procurement and construction) companies in South Africa, including Wood and MegChem. Supply con tracts will generally come via one of these companies. “Local manufacturing also gives us an additional advantage in power generation for high-pressure, high-temperature ap plications. For concentrated solar pow er, for example, we supplied our API 610 pumps for pumping heat transfer oil at the 100 MW Ilanga 1 solar thermal power station near Upington in the Northern Cape, which operates at a very high design temperature. The EPC on this project was from Spain, so our local manufacturing capacity was a key factor in securing the business,” Testi tells MechChem Africa. “Although KSB in Germany has started supplying its own mechanical seals, mostly for water, chemicals and slurry applications, we source the mechanical seals we use for our API 610 pumps from global specialists such as John Crane, AESSEAL and EagleBurgmann, all of whom are suppliers accredited by Sasol and other petrochemical companies,” he says. Also, OH2 pumps are a centreline mounted design, allowing expansion on either side of the casing centre-line to minimise the impact of high temperature – operating temperatures can be up to 450 °C. They are also extremely high-pressure, up to 200 bar. “We supply API 610 pumps to the latest

edition (12 th ) released in January 2021, with our parent company in Germany guiding us with variances that need to be implemented. Mechanical seal companies and pump com panies, including KSB, are represented on the API committee, so they know what the latest revisions are going to be long before they are published. It is all safety driven, though, across the size and capacity range. “The smallest pump we offer has a 25 mm (1-inch) discharge diameter and the biggest we produce in South Africa has a 250 mm (10-inch) discharge.” While KSB pumps are built to the best global standards, what is most significant, according to Stefano Testi, is that KSB Pumps and Valves has support fom the Contracts Division for the execution, delivery and logistics of all project orders. “As soon as we receive an order, it is handed over to our contracts department for processing: submitting all the draw ings and documents required for approval, ensuring that they have the QCPs (quality control plans) approved where applicable, all manufacturing, organising purchases from sub-suppliers, including castings from found ries or possibly imported from KSB Group Companies, etc. “We have 10 additional offices around the country, including one in Secunda and one in Vanderbijlpark to assist Sasol 1, 2 and 3. We also have a very competent SupremeServ Division for services and aftermarket. So, our offering to the petrochemical industry goes well beyond the manufacture and supply of API 610 pumps. We offer project execution Contacts and logistics: the differentiator

and service deployment at a level I do not be lieve other pump companies can,” he suggests. “In addition, our engineering, sales teams and our customers receive support from our service department. We have opened up an accredited service centre at our Secunda of fice, for example, dedicated to the service and repair of the API 610 pump fleet on Sasol’s Secunda site. “We have also established an SES (sys tem efficiency services) team that goes to customer sites to evaluate pump efficiency: for example, to see if the energy efficiency can be improved, and to evaluate the overall performance. When we repair or refurbish a pump, we strive to put it back into service as near to its ‘as-new’ condition as possible. In addition, should the client need it, we can put the refurbished pump through our test ing bay to verify its true efficiency and pump performance,” he informs MechChem Africa . Casper Steenkamp, Secunda branch man ager adds: “Compared to other pump brands, and because of our existing footprint, we have a significant contract with Sasol for the supply of spares for servicing its process pumps.” “With offices close to our key customers, we offer a holistic service for our API 610 Pumps, from cradle to grave: starting with engineering expertise, sales professionalism, contracts and logistics for the delivery of new pump projects and followed by a total pump life service offering to help clients achieve the best possible value from their investments,” he says. “If our aftermarket service were not exceptional, we would never have become a preferred supplier,” Testi concludes.

November-December 2023 • MechChem Africa ¦ 7

Ruaan Venter, Business Development Manager at IPR, the distributor of Toyo heavy duty slurry pumps in southern Africa, sheds light on the functions and applications of cutter fans in pump systems. The role of cutter fans in pump agitation ⎪ Water, wastewater and pumping solutions ⎪

T he integration of innovative features during pump design has enhanced performance and efficiency, with sig nificant benefits for lowering total cost of ownership. One such component, the cutter fan, plays a crucial role in achieving effective agitation and solids handling. “The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps. Toyo Pumps was the pioneer ing manufacturer to incorporate this type of agitation into its designs,” says Venter, adding that its patented curved three-blade stirring attachment, threaded onto the pump shaft just below the suction inlet, became a gamechanger in handling solids-laden slurries. The primary function of the cutter fan is to dislodge and re-suspend solids, creating a slurry. As fluid flows towards the pump suction, the cutter fan redirects a portion of the fluid away from the pump, generating a fanning effect. This redirection and cyclic process results in a concentrated ‘pocket’ of high solid-content slurry directly in front of the pump suction inlet. This maximises the pumping efficiency and ef fectiveness, making it an essential feature for dredge pumps. To protect the cutter fan, a stand is attached to the bottom of the pump. For larger pumps, an additional stub shaft is placed between the pump's main shaft and the cutter fan, providing extra protection and stability during operation. During pump installation, it is crucial to differentiate the cutter fan from other com ponents. Operating the pump with a reversed rotation can lead to unscrewing of components during operation, resulting in potential damages and costly repairs.

To identify a cutter fan correctly, it is advisable to consult the pump's rotational arrow. The cutter fan is easily visible and recognisable as it pushes fluid away from the pump for agitation purposes. Observing the marked arrow during pump wiring ensures the correct rotation and installation of the cutter fan. Cutter fans have contributed significantly to the efficiency and effectiveness of pump systems, particularly in managing solids and enhancing agitation. A deeper understanding of the roles played by the cutter fan’s ability to redirect fluid and maximise solids management exemplifies the advancements in pump technol ogy. By correctly identifying and using cutter fans, pump operators can ensure optimal per formance and avoid unnecessary operational issues,” Venter concludes.

The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps.

Left: Toyo heavy duty slurry pump can be fitted with cutter fans to achieve effective agitation and solids handling in arduous pumping applications. Right: A view of a Toyo pump's cutter fan or agitator with a competitor's agitator (black component) showing the size comparison.

November-December 2023 • MechChem Africa ¦ 9

Xylem Africa launches 360 Performance Partners from across the water sector recently gathered at the Indaba Hotel and Conference Centre in Fourways for the Xylem Africa hosted partner conference to explore ways to solve water problems for customers.

A frica overflows with precious resources, and water is the most precious of them all. The continent is home to some of the globe's most water-stressed countries and feels the pres sure of urbanisation as populations grow. These conditions create many challenges on the ground, which Xylem's vast network of partners tackle and solve every day. Xylem Africa recently hosted its exclu sive partner conference at the Indaba Hotel

and Conference Centre in Fourways, Johannesburg. Under the conference theme Synchronised, attendees embarked on a journey of collabo ration and innovation, shaping the future of water solutions. They attended seminars on the different aspects of water management, preservation, and technology, while experiencing the range of products from Xylem and its global brands. "We themed our partner conference

‘Synchronised’, to amplify connectedness between performance, agility and precision required to deliver lasting water solutions. This conference has been a great opportunity to explore 360 Performance and showcase our solutions. But it was even more enlight ening as a moment where people who solve water problems could gather and connect," said Chetan Mistry, Strategy and Marketing Manager at Xylem Africa. The conference launched 360 Performance, Xylem Africa's approach to comprehensive source-to-tap performance optimisation and delivery across the entire water cycle. From utilities to mining, agricul ture to manufacturing, commercial to residen tial, Xylem has the products and expertise to offer water solutions at every level. Xylem's partners are the experts that deliv er the best options to their customers, deploy ing, enhancing, and managing water systems ing markets for emerging markets. It is portable and configurable and can step up for emergencies or punishing site conditions. Working with customer feedback and usage data from the field, Xylem has re-imagined, re-designed and re-engineered the Godwin 6-inch pump for affordable total life cycle cost as well as improved performance and application flexibility. Features include: a simplified engine control ler; an optimised centrifugal hydraulic design; interchangeable impellers; dual priming system options; and a modular base design. The Flygt Bibo Alpha submersible drainage pump offers true plug-and play performance. Using integrated intelligence, the Bibo Alpha adjusts to a flow and head performance field in stead of a static curve. It reduces wear by up to 70%, adapts speed to prevent snoring and dry running, and always

Left: The Flygt Pareo and Flygt Bibo Alpha dewatering products on display at the Xylem Africa hosted partner conference. Right: The new Godwin BD150 is manufactured in emerging markets for emerging markets. It is portable and configurable and can step up for emergencies or punishing site conditions.

Value-focused dewatering

Mining sites often require elaborate dewa tering solutions, while construction sites frequently have on-demand water removal needs. Flood control, municipal facilities and environmental management also frequently use dewatering systems. Use cases vary between permanent to temporary instal lations, rental and owned equipment, and integrated, remote and ad-hoc operations. Dewatering can require a substantial portion of project budgets. Efficient de watering depends on site conditions and requirements, the water's condition and depth, discharge or recycling options, the presence of solids, dewatering duration— and a suitable equipment deployment plan. The right pumps and system designs substantially shrink dewatering costs and timelines. Xylem supports dewatering operations around the globe: large, small,

permanent and temporary. The company’s products remove water from industrial sites to flood emergencies, creating value with energy-efficient and low-maintenance pump designs, site-specific engineering, and advanced data analytics and performance monitoring software. Xylem continually improves local manu facturing, delivery, and support capacities to help customers gain more dewatering savings, insight and control. These efforts have culminated in the launch of a range of different dewatering systems for the African market: • The Godwin BD family of self-priming stand-alone pumps serves various dewatering applications across con struction, industrial, utility, and more. The new Godwin BD150 is the first of its kind, manufactured in emerg

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⎪ Water, wastewater and pumping solutions ⎪

for optimal efficiency and cost performance. By using market-leading water data and management products, efficient pumps, inspection equipment and more, Xylem and its partners continue to solve water together. During the conference, the partners attended pre sentations on a range

runs in the right direction. Highly portable and not requiring special configuration, Bibo Alpha is ideal for quick deployment, moving between different sites, and works well as rental options. The Bibo Alpha features plug and-play pumping without additional configuration; it adapts pump speed to variable water inflow rates and level sensors avoid snoring and dry running. The compact design outperforms tradi tional drainage pumps, and it replaces existing pumps in the range between 2.0 kW and 10 kW. Flygt Pareo adds intelligence to most Flygt dewatering pumps, enabling them to think for themselves and solve common issues automatically. Operators can check the status of the pump via Pareo's onboard display or remotely through web dashboards. They can also interact with Pareo and its pumps through their smartphone of topics hosted by ex perts, including dewater ing methods, new water treatment options, improv ing water transport, modernising infrastructure, and using digital analytics and transformation in water operations. The conference officially launched the Godwin BD150 dewatering pump system. Designed for and manufactured in emerging markets, this versatile, robust, and mobile dewatering workhorse wowed attendees with its performance and efficiency. Over a dozen pump, metering, and man agement products were on display, including: • The Godwin BD150 Self-Priming Pump: a powerful and versatile dewatering work horse for mobile and permanent uses. The Godwin HL270M High-Pressure Dri Prime ® Pump: a fully automatic priming pump, from dry to 8.5 m. The Flygt BIBO Alpha: a highly mobile submersible dewatering pump with no snoring or dry running. The Flygt Pareo: a reliable smart pump controller that adds intelligence to most Flygt dewatering pumps. The Lowara hydrovar ® X: an intelligent, • • • • •

Jonathan Holl, product manager for Dewatering at Xylem Africa, presents the key features and advantages of the Godwin BD150 Self-Priming Pump at Xylem’s partner conference.

and SCADA systems. Flygt Parea adds intelligence, autonomy, remote man agement, and savings to dewatering systems. This system has been shown to reduce maintenance costs by half and wear by 70%. It has built-in motor protec tion and remote monitoring and web based dashboards. It can automatically control snoring and rotation and asset management is improved with perfor mance data. The Godwin HL270M Dri-Prime Pump has a higher head and efficient impeller design for handling situations with higher water pressures, such as deep mines or moving water up tall and steep inclines – while requiring less power and maintenance than its peers. Godwin's modular design provides permanent installation and portable options, including skids and wheels. The HL270M's high discharge reliable, and integrated motor and drive pumping solution. Xylem Nexicon: an innovative monitor ing and control platform designed for water use cases. Xylem Avensor: a digital solution provid ing alerts and data-driven insights from water infrastructure assets. Sensus Cordonel: an ultrasonic meter ing solution with flow, temperature and pressure monitoring. YSI 9800 Photometer: a modular and adaptable multi-parameter water qual ity analyser. Xylem SAM PRO: a cloud-based asset management platform for real-time as set condition monitoring. "I want to thank everyone who attended the Xylem Africa partner conference. It was a • • • • • • •

pressure, dry-running, and portability make it the perfect choice for mining, industrial and emergency fire backup applications. A continuously operated priming device requires no periodic adjustment or control, delivers fully automatic priming from dry to 8.5 m of suction lift. Diesel and electric drive options are available, which are compli ant with regional emissions legislation. And a single HL270M pump can replace multi-pump installations. Dewatering solutions are about more than the equipment. Xylem supports its brands with design and engineering teams who develop innovative solutions that align with specific customer and site requirements. Solving water challenges requires col laboration, design, delivery and support— Xylem's growing manufacturing and de velopment investments ensure African solutions for African conditions. q Africa may be facing many challenges with water. But The Xylem Africa Partner Conference 2023 demonstrated that we have the people, skills, and technologies to make a lasting difference. With 2023's successful conference concluded, Xylem's partners are ready and invigorated to continue delivering cost-effective 360 Performance solutions for Africa's most precious resource. fantastic opportunity to connect and explore how we can improve water delivery in differ ent regions and sectors. “These two days have shown that we can, and are, solving water issues, embodied in Xylem's 360 Performance philosophy and delivered to the market through our world class partners," said Vincent Chirouze, Xylem Africa's managing director.

November-December 2023 • MechChem Africa ¦ 11

Mill circuit pumps: the key to efficient operations Marnus Koorts of Weir Minerals Africa emphasises the critical importance of support levels and pump selection for mill circuit operations.

to handle.” Recognising the advantages, Weir Minerals has made substantial investments in rubber production facilities to manufacture these liners for customers. However, when applications demand it, a wide range of metal options is also avail able. Koorts says good examples would be Hyperchrome ® A61 alloy, which is particularly good for fine particle wear that is often seen between the impeller and the throat bush, and Ultrachrome ® A05 alloy which would be used for the shell as it works well with general coarse particle abrasion. “If the wear characteristics are higher than anticipated in an application, this is where the interchangeability of components plays an important role. Most of our designs allow for interchangeability between metal and rubber components based on specific wear characteristics.” Koorts also points out that, over time, changes in the slurry composition or ore grade processed by a plant can affect pump efficiency and increase wear. He says that Warman® mill circuit pumps offer standard and low flow liner capabilities, enabling operators to adjust the flow rate as needed without compromising the original installation. Retrofit optimisations are increasingly com mon as mineral processing plants evolve and seek to reduce their total cost of ownership. Weir Minerals Africa has made substantial investments in an engineering team capable of seamlessly integrating the Warman® mill cir cuit pumps into existing installations, and they work closely with engineering, procurement, construction management (EPCM) contractors, and project houses to ensure all stakeholders can make informed decisions regarding pump selection and configuration. With over 20 branches across Africa and the Middle East, Weir Minerals Africa ensures local technical support is readily available to custom ers. This proximity allows the Weir Minerals Africa teams to gain a deep understanding of each customer's operation and provide com prehensive support to ensure uninterrupted pump operation. To facilitate easy access to parts, the com pany recommends a strategic parts list and en courages customers to keep these components on-site. Critical parts are also stocked at the nearest Weir Minerals Africa branch.

arduous operating conditions on individual customer sites and need to be configured to achieve the requisite hours between scheduled maintenance shutdowns,” he says. “Close collaboration with customers and a comprehensive understanding of the plant's operating parameters are crucial to ensure the solution provided will meet the operational requirements,” he adds. One of the primary considerations when it comes to mill circuit pumps is the ability to handle large particles and high flow rates. Wear and tear in these pumps is directly proportional to the size of particles passing through, neces sitating specific construction materials and design features. Koorts says a major differentiator is that Warman ® mill circuit pumps are physically larger for the same flow rate, reducing wear by operating at lower speeds. This strategy has paid major dividends for customers and is one of the reasons for the popularity of the brand in Africa. “Another crucial aspect is the engineering of the hydraulic chamber, which enhances wear resistance and increases efficiency. This is achieved through the unique design of the vanelet, which significantly minimises unwanted turbulence and reduces both wear and energy consumption,” he explains. The reduced energy consumption not only contributes to the bottom line but also ensures a relatively short payback period on the capital investment. “Material selection for mill pumps often sparks debate, but experience in the field has shown the undeniable benefits of rubber lin ers,” Koorts says. “Rubber liners extend wear life, handle impact associated with large par ticles, and are more cost effective and easier

T he requisite levels of support are criti cal to ensure optimal performance of a mill circuit, as is the correct selection of the mill circuit pump. Attention to both these aspects will facilitate cost efficient and optimum operation of the circuit; how ever, cautions Marnus Koorts, General Manager Pump Products at Weir Minerals Africa, each is as important as the other. Weir Minerals Africa has a focus on deliver ing reliable solutions to customers that will pro vide the required performance while facilitating the lowest total cost of ownership. This, Koorts says, has seen the Warman ® mill circuit pump become the preferred choice across numerous plants in Africa. Commenting further, Koorts says that the requisite support level often requires significant investment by the pump equipment manufac turer and means having the correct parts readily available on, or close to, a customer site. This should be backed by the technical competency required to keep the pump running, he says. “A mill circuit pump is not an off-the-shelf solution. Mill circuit pumps are engineered to provide optimum performance under the The Warman mill circuit pumps reduce wear by operating at lower speed-to-flow ratios.

Weir Minerals Africa’s large branch network enables the company to deliver local services and technical support for customers.

12 ¦ MechChem Africa • November-December 2023


⎪ Water, wastewater and pumping solutions ⎪

Submersible Pumps Africa’s acid resistant slurry pump Rui Gomes, sales and marketing director for the local pump manufacturer, Goodwin Submersible Pumps Africa, introduces the company’s new 100 SDSS ANZE acid resistant submersible slurry pump, which is ideal for acidic mineral processing, chemical ponds, acid tank cleaning and seawater applications. “W e have made significant advances in the mining and dewatering industries since our inaugural opening in South Africa in 2016, with growth spearheaded by our flagship 100 ANZE® submersible slurry pump,” says Rui Gomez of Goodwin Submersible Pumps Africa. commissioned in September and is operat ing extremely well. “So much so that we are in negotiations for additional pumps for their various plants,” he adds.

The SDSS has also been successfully used at a Uranium producer in Namibia for sump clearing, pond cleaning and various acidic applications through the plant. Goodwin Submersible Pumps Africa is strategically positioned to service Goodwin pump users across South Africa. “Our com pany head office is in Edenvale, Gauteng, but we have regionally located sales engineers to service the whole of South Africa. We have also recently expanded our footprint into Zambia and Ghana to of fer in-country support, stock and improved turnaround times for supply.

Ideal for tank cleaning, sump pumping, emergency clean-up or replacing unreliable vertical spindle pumps, the Goodwin 100 ANZE submersible slurry pump is an extremely portable and versatile pump and the most popular one in the Goodwin range. Available in three wet-end configurations to suit any pumping problem, it uses a 3-phase, 30 kW motor, and can be supplied for voltages ranging from 380 V to 1 000 V. “A recent new introduction to our range is the 100 SDSS ANZE acid resistant submersible slurry pump, which has been designed spe cifically for pumping corrosive slurry and is constructed of the highest quality alloys to extend the pump’s lifetime,” Gomez continues. The SDSS pump is available in one size, 30 kW with a 100 mm outlet, and offers the same pumping performance and reliability as the standard 100 ANZE slurry pump. “All parts of the pump that are in contact with slurry are made from super duplex stainless steel alloys to give exceptional corrosion resistance. This enables the pumps to be operated in slurry densities of up to 2.8 kg/l – 65% by weight – at pH levels of 0-14 and at temperatures of up to 90°C. “Normal stainless-steel pumps regularly fail in chemically aggres sive applications where there is a solid handling element of pumping. The Goodwin SDSS is more corrosion resistant than normal stain less steel and has the abrasion resistance to pump slurry – there is no comparison,” Gomez asserts. This makes the SDSS ANZE pump ideally suited to acidic mineral processing, chemical ponds, acid tank cleaning and seawater applications. Goodwin Submersible Pumps Africa recently supplied a major gold producer in Saudi Arabia with an SDSS pump. The pump was

The new Goodwin 100 SDSS ANZE pump has all its wet-end components made from super duplex stainless steel alloys to give exceptional corrosion resistance.

Goodwin Submersible Pumps Africa recently supplied a major gold producer in Saudi Arabia with an SDSS pump.

November-December 2023 • MechChem Africa ¦ 13

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