MechChemMAR-APR 2021 AFRICA
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MechChem
AFRICA
MAR-APR 2021
Compact radar and universal level switching
This month:
Scalping screen designs for SA’s next-generation valve and Grindex: for long lasting pumping Safer and greener heavy indus-
extended panel life pump specialist solutions trial demolition
CONTENTS
8 14
22 31
Power transmission, bearings, bushes and seals
6 BRAVE: exploring bearing failure, life and artificial intelligence
An experimental verification facility that will provide unprecedented insights into the mechanisms behind bearing failure and
performance prediction is being built by SKF.
8 Robust planetary gearboxes for long service
Published bimonthly by 9 BI consolidates motor brands
Crown Publications (Pty) Ltd 10 New and improved NSK SRBs from BMG
Cnr Theunis and Sovereign Streets 11 Locally assembled drive solutions
Bedford Gardens 2007 Pump systems, pipes, valves and seals
PO Box 140, Bedfordview, 2008 12 Grindex: for long lasting pumping solutions
Tel: +27 11 622 4770 Jordan Marsh of Integrated Pump Technology talks about why Grindex Pumps have become a preferred solution for mining
applications across South and sub-Saharan Africa.
e-mail: mechchemafrica@crown.co.za
14 Sustainability vision for Africa and the Middle East
www.mechchemafricamagazine.co.za
17 Intelligent water treatment solution cuts bacteria growth
Editor: Peter Middleton Hydraulic and pneumatic systems
e-mail: peterm@crown.co.za 18 Pick and place systems with digitised pneumatics
Advertising: Elmarie Stonell This article describes how Festo’s Motion Terminal VTEM system with Motion Apps is revolutionising and simplifying pick and
place positioning applications.
e-mail: elmaries@crown.co.za
19 Nifty nitrogen from Rand-Air generators
Design: Katlego Montsho
Minerals processing and materials handling
Publisher: Karen Grant 20 Scalping screen designs for extended panel life and better material stratification
Deputy publisher: Wilhelm du Plessis MechChem Africa talks to Kenny Mayhew-Ridgers of Kwatani about the company’s design philosophy for large scalping screens.
Circulation: Brenda Grossmann 22 E+H’s IIoT ecosystem for the process industry
24 New DELKOR BQR flotation cell with ‘MAXGen’
The views expressed in this journal are
27 Cyclone evolution improves coal fines recovery
not necessarily those of the publisher or
the editors. PowerGen, PetroChem and sustainable energy management
28 SA’s safer and greener heavy industrial demolition contractor
MechChem Africa talks to Kate Bester of Jet Demolition about new equipment and methodologies being pioneered by the
company for improved safety, reduced environmental impact, maximised material reuse and minimised site contamination.
30 SA Manufacturing base a springboard for Africa growth
Transparency You Can See
31 Integrated solutions address energy security
Average circulation
Q2 2020: 6 305 Automation, process control, instrumentation and CAE
32 OMRON robot streamlines food deliveries
Printed by: Tandym Print, Cape Town In Helsinki in Finland, an autonomous mobile robot operated by OMRON’s solution partner, Dimalog, is taking part in a month-
long trial of a ‘Home-on Demand’ automated courier service.
33 Tectra engineers world-first roof tile solution
Front cover: VEGA Controls SA 34 Optimising DeNOx plants in the cement industry
Contact: Leandi Hendrikse 35 Tenova chooses ABB automation for tinning line
Tel: +27 (0) 11 795 3249 Environmental management, waste and cleaning technologies
leandi.hendrikse@vega.com 36 Software-as-a-Service (SaaS) water quality monitoring
www.vega.com Bosch Capital has been appointed by Carin Bosman Sustainable Solutions (CBSS) to support the commercial development of
the new LEGUAANTM Software-as-a-Service (SaaS) water quality monitoring tool.
Special report
38 NFTN intervention helps lift SA foundry to global standards
MechChem Africa talks to Manini Phokwane Ramagaga of the National Foundry Technology Network (NFTN) about a foundry
intervention that secured the future of 130 jobs.
Innovative engineering
Publisher of the Year 2018 42 SA’s next-generation valve and pump engineering specialist
(Trade Publications) MechChem Africa talks to Moeketsi Mpotu of Brimis Engineering, about next-generation valve and pump services for South
Africa’s power, petrochemical and water sectors.
Regulars
2 Peter’s comment:
4 On the cover: VEGAFLEX and VEGASWING to ensure LNG production accuracy:
Sebastian Harbig of VEGA talks about guided-wave radar level sensors and vibrating level switches for an LNG Project.
39 Products and industry news
44 Back page: Advanced NDT offered by WearCheck AFS
March-April 2021 • MechChem Africa ¦ 1
Climate trends for high-stakes COP26
P
Peter Middleton ostponed in November 2020 due to servation capable of taking up carbon dioxide from
COVID-19, COP26, the United Nations’ the atmosphere several times more quickly than
next ‘annual’ conference, will now take forests on dry land. In 2018, the Seychelles became
Comment place in Glasgow, Scotland, in November the first country in the world to issue a blue bond,
2021. The event is already being described as a and in 2019, HSBC was the lead manager on the
‘watershed moment’ for the recovery of the planet: World Bank’s €200-million blue bond, a financial
to ‘lock in ambitious low-carbon transition policy tool helping to protect Australia’s Great Barrier
goals across the world’. Reef and many other ecosystems around the world.
Global head of sustainable finance for the HSBC With recovery from COVID-19 an ongoing
in the UK, Daniel Klier, writes of five trends that are concern, Kleir’s fifth trend is the potential to use
dominating the run-up to this event. COP26 as a catalyst for tackling climate change
The first is that the US, the European Union and for rebuilding the global economy on a more
and China are now united by a desire to take firm resilient, prosperous footing. “COP26 must be a
action on climate change. Klier suggests that with key moment in securing a just transition, one that
former US Secretary of State John Kerry as special protects jobs, strengthens local communities and
climate envoy, improvements to the 2015 Paris helps out vulnerable economies. It isn’t enough
Agreement; greater international collaboration on merely to lower emissions. Doing so while damag-
technical development and investment; and action ing prosperity across the world would be no kind
on specific economic sectors and industries has of victory,” he says.
become more likely. He warns that the stakes are very high. Despite
He adds that China is now committed to net- the 2015 attempt in Paris to secure an agreement
zero emissions by 2060, the EU by 2050 and the UK to limit the global temperature rise to 1.5 °C, “we
has renewed its Paris Agreement pledges, which are currently on track for a catastrophic 3.0 °C
include a 68% reduction in UK emissions by 2030. increase by 2100”.
The second trend cited by Klier is the accelerat- “Making progress through 2021 on the five
ing transition to low carbon technologies ‘particu- trends outlined above – more effective climate
larly in industries where emissions are high and diplomacy, faster transition, better climate-finance
hard to abate’. He cites an 81% year-to-date rise in returns, more nature-based solutions, and prioritis-
electric vehicle (EV) sales, and that more than 350 ing a just transition – would help build momentum
different EV models are due for launch across the for a successful summit,” he argues.
world next year. This is, no doubt, an argument from a developed-
In addition, the EU is to renovate 35-million world perspective but Africa and South Africa have
energy-inefficient buildings by 2030. “Buildings much to gain from a successful transition to a less
account for 40% of energy consumed and 36% carbon intensive economy. We already know that
of energy-related greenhouse gas emissions in South Africa’s ailing coal-based grid can’t cope; that
Europe,” says Klier, adding that there is also in- renewable solutions are now cost competitive and
creasing awareness of the need for sustainable that the African continent is primed for industrial
infrastructure in the fast-growing Asian economies. and economic growth should energy constraints
The role of climate finance is Kleir’s third trend. be overcome.
In an extremely bumpy year for equities, he points We have a young population hungry to adopt
out that climate stocks such as renewable energy, new ways of doing things, particularly when it
energy storage, agriculture and transport efficien- comes to new technologies. Most of Africa can
cies made 37% gains, against 11% for the overall leapfrog the developed world with respect to
market. In addition, US$64.9-billion of green bonds carbon-free power infrastructure; and a strong
were issued in the third quarter of 2020 – the high- entrepreneurial spirit has emerged for finding ways
est volume in any third quarter period since the of transforming environmentally friendly product
market’s inception – and total green bond issuance and solution ideas into successful, job creating
is now at almost US$1-trillion. businesses.
Number four is the protection of specific natural Let’s stop looking at the climate crisis as some-
environments and ecosystems such as mangroves, one else’s fault for which we bear no responsibility.
seagrass and tidal marshes through blue bond It is an opportunity. To live in a more sustainable,
investments, which are reserved for marine con- healthier and more equitable world. q
MechChem Africa is endorsed by:
2 ¦ MechChem Africa • March-April 2021
March-April 2021 • MechChem Africa ¦ 3
VEGAFLEX and VEGASWING to ensure LNG
production accuracy
Business development manager Sebastian Harbig, who is responsible for Global Projects at VEGA, talks about the use of
VEGAFLEX 86 guided-wave radar level sensors and VEGASWING 66 vibrating level switches on the Linde-developed Portovaya
LNG Project under construction in Russia’s Portovaya Bay.
C
ompared to pipeline gas, liquefied
gases such as LNG or LPG can be
transported much more flexibly
and they also often have higher
commercial value. A good example of this
can be found in Russia’s Portovaya Bay, the
starting point of the Nord Stream Pipeline,
where natural gas will be processed and
loaded directly onto ships in cryogenic liquid
form. Once the new natural gas liquefaction
plant is completed, guided radar sensors from
VEGA will make a significant contribution to
safe and efficient production there.
LNG processes are among the most chal-
lenging in the process industry. A single plant
can produce anywhere between 40 000 and
8-million tons per year in processing facilities
ranging from small-scale to world-scale.
Two trends are becoming apparent in Having no mechanical moving parts, VEGAFLEX bypass measuring systems operate wear free and
liquefaction plants. First: The future can require almost no servicing. (Photo ©The Linde Group)
swim. LNG plants are increasingly being
designed as ‘floating facilities’ (FLNG). Gigantic ibility and service quality. True to the motto, market demanded in the past. Medium-sized
floating liquefaction plants, sometimes as big ‘We come to you and deliver to your door.’ projects are becoming more and more the
as several football pitches, can produce LNG S e c o n d : L a r g e - s c a l e n a t u ra l g a s thing. These allow project duration and fi-
exactly where natural gas is available, with- liquefaction plants need staying power and nancial investment to be scaled and closely
out first having to transport the gas ashore the willingness to make large investments. matched to demand.
through expensive pipelines. The industry is Current projects are therefore increasingly Production can thus be profitable, even
thus achieving an unprecedented level of flex- moving away from the huge sizes the growth in regions with smaller gas reserves. Also,
such facilities can later be expanded
with comparatively little effort to meet
increased demand because expanding an
existing facility is faster and easier than
starting from scratch somewhere else. An
additional compressor train or turbine or
cold box – the cryogenic chamber where
natural gas is cooled down to minus
162 °C – requires relatively little bureau-
cratic red tape.
The Linde Group delivers compre-
hensive turnkey solutions for the LNG
processes in the plants of its customers.
Just as comprehensive are the level
measurement solutions VEGA creates
for these same processes. A complete
measuring system consisting of a bypass
tube and sensor offers much more than
just the sum of its parts. It includes an
instrumentation concept tailored to the
process and rounded off by comprehen-
sive engineering and support services.
The ready-to-install sensors, which
LNG is the big trend: Linde is building a medium-sized natural gas liquefaction plant with a capacity of 1.5-million come with customised features, documen-
tonnes of LNG near the Russian Baltic Sea town of Portovaya. (Photo ©The Linde Group) tation and the required test certificates –
4 ¦ MechChem Africa • March-April 2021
⎪ Cover story ⎪
all from a single source – are a building block processes, the temperature
Linde can rely on. Using VEGAFLEX 86 guided expansion of the equipment is
radar sensors, most of which come fitted in immense. The components are
bypass tubes, and VEGASWING 66 for point subject to extreme loads and
level detection, delivers considerable savings, even small changes in the compo-
resulting from simplified planning, fast ‘plug & sition of the processed natural gas can
play’ installation and reduced maintenance significantly reduce the overall service
requirements, among other things. life of a machine.
Having no mechanical moving parts, The mid-scale plant now being built
VEGAFLEX bypass measuring systems oper- in Russia’s Baltic Bay liquefies gas from
ate wear-free and require almost no servic- a compressor station that has been in
ing. Besides pre-assembly and adaptation to operation since 2010. The process
existing plant conditions, the scope of delivery for converting natural gas into LNG is
even includes detailed parameterisation, such based on three steps: pre-treatment;
as false signal suppression. Only SIL safety compression; and cooling/liquefaction.
functionalities, as required by law, have to Because natural gas contains im-
be calibrated live on site with the original purities such as water, mercury or cor-
medium that will later be measured. rosive components that can freeze
When designing LNG facilities, the top during the compression phase,
priority is to make sure all system components it has to be pre-treated. The
have sufficient robustness and performance methane is only allowed to en-
reserves. Only in this way are the sensors able ter the liquefaction trains of the
to reliably monitor the complex processes the LNG plant in a highly concentrated form. In Left: VEGAFLEX 86 guided
media are put through. This core task hasn’t the various storage and process vessels, only radar level sensors are robust
changed much in spite of all the technical two sensor types monitor the widely different and measure independently
advances over the past few decades. Yet, media during the entire production process. of the medium. This makes
in terms of efficiency and process reliabil- These range from dry natural gas, condensed them suitable for almost
all substances and level
ity, today’s measuring systems are almost hydrocarbons and cold flare gas to ethane,
measuring tasks in the
unrecognisable. LNG, hydrocarbons, fuel gas and wastewater. LNG process. Right: The
On their journey to the LNG construction Consistently high quality is essential VEGASWING 66 universal
site, the ordered level sensors are accompa- for LNG processes. In today’s competitive vibrating level switch reliably
nied by a thick bundle of papers. The aim is environment, industry must strike a balance detects limit levels with
to comply with the strict legal regulations between cost pressure and environmental millimetre accuracy.
and the often even stricter country-specific awareness. But when it comes to quality, no
requirements of the end customers. Besides compromises can be tolerated.
production acceptance tests, the focus is on Efficiency and plant availability, which Portovaya LNG project
numerous certificates and licenses. are significantly improved through stan- The engineering division of Linde AG in
The Portovaya project is a so-called ‘short- dardisation in all areas of the plant, including Munich is currently licensing a medium-sized
track’ project. “The entire plant is being built instrumentation, guarantee high quality and a plant complex in Russia’s Portovaya Bay for
in an unusually short time,” explains Business real cost advantage. Guided radar sensors are the production, storage and transport of
Development Manager Sebastian Harbig, who especially suitable here, as they can reliably liquefied natural gas (mid-scale LNG) with
is responsible for Global Projects at VEGA. withstand extreme pressure and temperature an annual LNG production capacity of
“Delivery time was therefore a major criterion conditions. And vibrating level switches, with 1.5-million tonnes.
in awarding the contract,” he adds. their compact design and millimetre accuracy, The Portovaya project is an ideal oppor-
This is not the first time VEGA has sup- are also just the thing for many applications tunity to further standardise proprietary
ported the EPC (Engineering, Procurement in the LNG plant. liquefaction technologies. Linde will again
& Construction) specialist in medium-sized VEGA’s Global Projects Team, to which use its patented, multi-stage natural gas
or large projects. VEGA is responsible for the Sebastian Harbig also belongs, has developed liquefaction process to help medium-sized
complete, ready-to-install measuring point, into an experienced partner for worldwide plants achieve world-class performance,
the customer-specific documentation, as well plant projects with extensive knowledge especially in terms of energy efficiency,
as all necessary certificates. of the critically important interfaces. To be This plants key features include:
Especially for international projects, deliv- able to supply customers in the best pos- • LNG production capacity of
ery from a single source is an advantage that sible way, it is always important to provide 1.5-million t/year; approximately 0.5%
has multiplication potential, because a project detailed solutions that are far removed from of annual global needs.
like the one in Portovaya involves Linde teams, day-to-day business. Optimal technology, as • Medium-sized floating facility the size
locations and suppliers all over the world. the project in Portovaya shows, can only be of several football pitches.
The work across borders has to function like the basis on which to build. The actual task • Patented, energy-efficient technology
a well-oiled machine, with every gear wheel includes much, much more: working out the from Linde
syncing perfectly with all the others. Any technical details, making quotations as well as • Complete solutions for level measure-
delay can cause multiple delays downstream. communicating regularly with the client. And ment with VEGAFLEX 86 guided-wave
Machines in an LNG plant, especially those it does not end with setup and commissioning, radar level sensors, mostly in bypass
used in the liquefaction process, are exposed but continues throughout the entire life cycle tubes, along with VEGASWING 66
to extreme operating conditions. Between of the instruments, ensuring their availability vibrating level switches.
start-up and full operation of the cryogenic and efficiency. q
March-April 2021 • MechChem Africa ¦ 5
BRAVE: exploring bearing failure,
life and artificial intelligence
An experimental verification facility that will provide unprecedented insights into
the mechanisms behind bearing failure and performance prediction is being built
by SKF at its Research and Technology Development (RTD) centre in Houten, The
Netherlands.
There are numerous reasons why bear- its Research and Technology Development
ings can damage or fail. Generally speaking, (RTD) centre in Houten, The Netherlands,
around one third fail as a result of fatigue, which has started work on the construction
while another third fail because of lubrication of an experimental verification facility that
issues. Contamination causes a sixth of bear- it will use to increase its knowledge of the
ing failures, while the balance is accounted mechanisms that cause bearings to fail. It
Team Leader for Bearing Steels, Urszula Sachadel. for by factors such as improper handling and will also use the facility, which will be called
mounting, heavier or different loading than Bearing Rigs for Accelerated Verification
S
ome ten billion bearings are manu- was anticipated, and poor fitting. Experiments (BRAVE), to develop ways to
factured each year and, given the When attempting to predict how, and predict the remaining useful life of these
harsh conditions to which they are perhaps more importantly when, a bearing critical components rapidly, accurately and
often subjected, they are incredibly will fail, a huge number of variables must be repeatably.
reliable. Indeed, approximately 90% of these taken into account, including the application Team Leader for Bearing Steels, Urszula
bearings outlive the equipment to which they for which it will be used, the environment in Sachadel; and Edwin Tummers, Team Leader
are fitted. Only 0.5% of bearings fail in service, which it will operate, the lubricants used and for Experimental Verification at SKF have
but this still means that some 50-million are the loads to which it will be subjected, to name been running this project. “We needed a flex-
replaced due to damage or failure every year, a few. As such, when developing new bearings, ible testing facility where we could simulate
and each of these failures will likely have verifying their performance and for how long different application conditions and see how
financial implications for their operators in they will last can be a slow, expensive and a bearing system, including the materials
terms of lost production, damage to adjacent complex process. from which it is made, and the lubrication
parts and the cost of repairs. SKF is looking to solve this problem at employed, performs when operating under
SKF BRAVE experimental verification facility will provide unprecedented insights into mechanisms behind bearing failure and performance prediction.
6 ¦ MechChem Africa • March-April 2021
⎪ Power transmission, bearings, bushes and seals ⎪
different loads and at different speeds. We abling a wide range of tests to be performed.
also needed to be able to do that in a way In this way, Sachadel says, SKF researchers
that allows us to perform investigations on can screen many different variants of bearings
that system, so we can determine how defects very quickly to determine the best solution for
are generated, how they progress and how a given application.
long the bearing will last until maintenance Test procedures will be developed, con-
is required,” says Tummers. trolled and monitored closely, and all of the
When completed, BRAVE will feature data, regarding things such as vibration, tem-
a number of rigs specifically designed and perature and load history will be recorded.
tailored to meet SKF specifications, which This data can then be analysed in detail during
will be used by researchers to develop and or after the experiments.
experimentally verify bearing failure models. Sachadel continues: “Using BRAVE, we will
The functions of these rigs will be categorised be able to quickly evaluate potential bearing
as ‘contaminate’, ‘initiate’ and ‘propagate’, and solutions, screen them, and understand the
they will often be used in sequence. impact of different manufacturing processes
Sachadel explains: “With the contaminate on their performance. Further, in the future,
set-up, for example, we can generate defects, we can use the data we gather to support
such as dents, abrasion, electrical damage our development of artificial intelligence (AI)
and corrosive damage in the bearings in and machine learning techniques to predict
different ways. We can also apply different or improve the performance of our bearings.”
lubricants. In the initiate set-up, we can then BRAVE will be of particular benefit to
Edwin Tummers, Team Leader for Experimental
run the bearings under certain conditions to SKF’s Rotating Equipment Performance (REP)
Verification at SKF.
create some initial damage to them. Finally, in business and its remanufacturing operations.
propagate, we can determine how different Sachadel explains: “We plan to look at the for completion in early 2021. “We’re going
load and speed conditions influence the rate bearings after different stages of remanufac- to learn a lot of new things through BRAVE,
at which this damage spreads.” turing, to determine how the process affects which we look forward to sharing with our
Each set-up type can also be used in isola- their performance and how to boost it.” customers,” Sachadel concludes.
tion, or in a ‘mix-and-match’ approach, en- Work on the facility is currently scheduled www.skf.com/africa
Redesigned coupling give new life to old generator
SKF has come up with a practical design and potential production losses, the customer from SKF produced the final CAD drawings
manufacturing solution that now enables immediately contacted SKF Authorised of the new connection, which is a flanged
customers to purchase standard off-the- Distributor, Bearing Services (BSA), for as- shaft manufactured as one solid piece.
shelf replacement parts for their dated die- sistance. BSA consulted SKF who was able to “Also known as a stub shaft adaptor, the
sel generators, ensuring that the machine come up with a practical solution that added new connection suits a standard SKF tyre
is ready for operation for sustainable plant great long-term value. coupling,” explains Odendaal. “In addition
uptime in the event of power outages. SKF designed and manufactured a new to easy replacement of the tyre element,
As downtime is simply not an option for connection for the fly-wheel that is compat- the new maintenance free connection of-
the leading glass manufacturing company ible with a standard off-the-shelf coupling. fers additional advantages including the
based in Johannesburg’s East Rand, the cus- Using a sample of the old coupling to ensure ability to absorb vibration as well as some
tomer relies heavily on the 130 kW diesel alignment of mounting bolts, misalignment.”
generator to ensure uninterrupted produc- etc, a draughtsman Now armed with short lead times on
tion during power failures. “Considered standard items, facilitated replacement
as critical equipment, the generator procedures and maintenance planning going
has been serving the company for many forward, the customer has minimised the
years and, due to old designs and generator’s downtime in the event of a
dated technology, some of the breakdown. Furthermore, the risk of the
machine’s replacement parts are machine being inoperable during a power
now becoming increasingly diffi- failure with consequent loss of produc-
cult to source or are simply no tion, is also reduced.
longer available,” explains SKF According to Odendaal, the cus-
product manager for Power tomer has since contacted BSA
Transmission, Frans Odendaal. regarding a chain solution on a dif-
When the coupling be- ferent section of the plant which
tween the generator’s fly- SKF is currently investigating. q
wheel and motor failed, the
customer was unable to find a SKF offers a wide range of standard
suitable off-the-shelf replace- couplings to meet diverse application. For
older machines, however, shaft, coupling and
ment. Facing an urgent lead
other adaptors can be engineered to ensure
time to prevent plant downtime and compatibility with SKF’s standard range.
March-April 2021 • MechChem Africa ¦ 7
Robust planetary gearboxes for long service
The G3 full line of planetary gearboxes from Zest WEG is among the most robust in the world and capable of running
for 10 years before major servicing is required. Manufactured in Brazil by WEG company TGM WEG, these units are now
successfully operating in sugar mills in Zimbabwe and Angola.
The TGM WEG G3 boasts a bearing designed for over 100 000 hours of operation and a pioneering electronic monitoring system that checks oil temperature,
pressure and vibration variables to ensure the gearbox is not subject to over-torque.
T
he G3 full line of planetary gearboxes not subject to over-torque. This guarantees
from Zest WEG is among the world’s smooth and reliable operation within the
most robust and capable of running established limits, allowing optimum equip-
for 10 years before major servicing ment usage and reduced maintenance costs.
is required. Manufactured in Brazil by WEG company
With an output torque range from TGM WEG, the leading gearboxes include
400 kNm to 8 750 kNm, the range boasts components that are heat treated in world-
bearings designed for over 100 000 hours class facilities in accordance with API-6
of operation. These gearboxes are popular standards. Committed to quality and environ-
in central drive applications in diffusers mental responsibility, TGM WEG is certified in
and sugar mills, where they are also used as terms of ISO 9001 and ISO 14001. The com-
pinion-less and assist drives. pany’s modern industrial complex features
In addition to their high mechanical ef- gear machining centres, milling machines,
ficiency and robust gear and bearing sets, grinding machines, a bearing manufacturing
the gearboxes are flexible in their installation. department, a lubricating oil analysis labo-
The high performance hydraulic system has ratory and an assembly and testing unit for
quality lubricant oil filtration, with 10 μm gearboxes and multipliers.
absolute filtration elements and an air-oil heat With an extensive footprint in the South
exchanger for optimal cooling. American market, these units are now
The pioneering electronic monitoring successfully operating in sugars mills in
system checks oil temperature, pressure and Zimbabwe and Angola. Manufactured in Brazil, the TGM WEG planetary
vibration variables to ensure the gearbox is www.zestweg.com gearbox is ideal for mill dewatering applications.
8 ¦ MechChem Africa • March-April 2021⎪ Power transmission, bearings, bushes and seals ⎪
BI consolidates motor brands
Following the successful introduction of ABB’s high-efficiency IE3 electric motors and the launch of the ALPHA Drive Micro
and the ALPHA Drive Plus range of Variable Speed Drives, Bearings International (BI) is excited to announce the rebranding
of its BAUER range of Tier 2 motors to ALPHA.
T
he growth of BI’s market share in ingly difficult trading environment. The MA range of BAUER motors performs
electric motors is one of the major “With our premium Tier 1 brand now extremely well, even in the toughest envi-
strategic initiatives it undertook being ABB, we have decided to consolidate ronments. This range has been designed to
in 2019, culminating in the recent our Tier 2 electrical products into one brand give reliable performance, and is also easy to
announcement of its partnership with ABB name, namely ALPHA. Therefore the BAUER maintain. With a 0.18 kW to 7.5 kW output,
to include high-efficiency IE3 electric motors. electric motors will be changing to ALPHA the motors are lightweight and have low noise
The advantages of the partnership with from January,” reports BI product manager emission.
ABB include dealing with a local supplier Andries Barnard. www.bearings.co.za
versus direct imports and the availability The part numbers, colour, quality and pric-
of quick technical back-up and support. BI ing will all remain the same. The only change
has extended its motor range in size, with a will be on the nameplate of the motor itself,
400 V and 525 V offering, allowing it to be from BAUER to ALPHA. “Our ambition is to
able to supply projects in the mining industry. align the brands of our electrical products,
ABB, in turn, will be able to leverage from compared to our power and transmission
BI’s extensive 42-branch network across products, with these two clear brands,” notes
South Africa, covering all the major mining and Barnard.
industrial areas where BI has a key footprint. BI has a wide range of aluminium frame
The availability of IE3 high-efficiency motors electric motors and aluminium housing three-
from ABB will be especially welcomed by phase asynchronous motors, all with the latest BAUER electric motors from BI are now part of the
these sectors, where cost-effectiveness and design and selected quality materials that ALPHA range of products, which also includes ALPHA
total cost of ownership are key in an increas- conform to the IEC standard. Drive Micro and ALPHA Drive Plus variable speed drives.New and improved NSK SRBs from BMG
BMG’s range of high-performance NSK spherical roller bearings (SRBs) is perfectly suited to operate in demanding
environments, including foundries, forges and die-casting applications.
T
he NSK HPS range, which has a ing. To counter this, NSK has developed a uniform surface is formed compared to con-
running life nearly double that of special treatment on the surface of the outer ventional bearings. Maximum limiting speed
conventional bearings of the same ring that improves the traction of rollers and is significantly increased and cage wear in
size, also ensures reduced mainte- better controls their rotational speed,” says harsh operational applications is reduced.
nance costs, substantial energy savings and Wayne Holton, business unit manager for Robust HPS spherical roller bearings,
downsizing in product design. The maximum Bearings, Seals and Gaskets at BMG. “This which are available nationally from BMG,
limiting running speed of these spherical advanced technology, which has extended come in bore sizes from 40 mm to 130 mm.
roller bearings has also improved by 20%. the service life of these bearings by up to These bearings offer extended service life,
“During rotation of conventional twice that of conventional spherical reduced maintenance and enhanced perfor-
spherical roller bearings, slip roller bearings, also increases mance in heavy-duty applications.
between the raceway and the bearings’ dynamic load BMG’s specialist divisions have advanced
the rollers causes fa- rating,” he adds. technical skills to support the company’s
tigue, which eventu- NSK applies a spe- commitment to applying technical knowl-
ally leads to flak- cial nitriding treat- edge and depth of experience to maximise
ment to the sur- efficiency and profitability for every cus-
face of the cage tomer. The company has secured distribu-
so that a finer, tion and service agreements with some of
harder and more the world’s most respected manufacturers
of bearings, including NSK, NTN, Timken,
IKO and Rollix.
BMG’s extensive bearings portfolio is
carefully selected in terms of consistent
quality controls, compatibility, standardisa-
tion, reliability and extended service life.
The BMG team is committed to working
closely with customers in all industries to
investigate the source of bearing problems
and to provide cost-efficient solutions
for optimum productivity of machinery,
extended service life of the system, and
BMG’s NSK HPS range of spherical roller bearings has a running life nearly double that of conventional minimal maintenance requirements.
bearings of the same size, with maximum limiting running speeds improved by 20%. www.bmgworld.net
Durable scraper chains for boilers and burners
BMG’s Power Transmission division supplies “Ash removal systems play a key role productivity and minimises abrasion.”
a wide range of conveyor chain that ensures in the boiler and burner industry by safely BMG’s range of robust chain conveyors
efficient and trouble-free transport of slag removing the waste. BMG specialists work is optimally tailored to suit the material that
granulates, ash or smelting residues from closely with each customer to install the needs to be conveyed. Optimum chain qual-
beneath boilers, burners and furnaces. most suitable conveying method, in terms ity and reliability of every system are vital to
According to BMG specialists, conveying of reliability, simplicity and efficiency. ensuring profitability, high productivity and
dry or wet ash is one the most challenging Regardless of whether dry or wet ash re- extended serviced life.
applications a chain can be subjected to. moval is used, BMG’s focus is primarily on BMG’s robust ash removal chain is
“Conventional chains installed in these harsh harmonising the processes, from collecting, enhanced by a wide range of sprockets,
facilities normally only function effectively extinguishing and cooling down ash, to safe available in varying grades of steel and
for about a year, due to abrasion and the storage in the ash bunker. other metals. The company also offers
varying temperatures of ash,” explains “Customisation of ash removal chain split sprockets for ease of disassembly and
Gavin Kirstein, BMG’s Tsubaki product is paramount to achieving optimum ef- optional lightening holes to reduce weight,
manager “However, BMG’s range of high- ficiency of the conveyor chain for every and additional surface hardening is available
performance ash conveyor chain, which application. The flexibility of BMG’s ser- for rollers and bushes.
undergoes a high-tech manufacturing pro- vice includes the manufacture of chain BMG’s technical support service includes
cess, ensures extended service life, even in to suit exact requirements – with various analysis of chains when replacement is
harsh conditions. Special attention is given options, including materials, custom coat- required, which involves metrics on chain
to dimensional accuracy, constant geometry, ings, lubrication and accessories – to cre- wear life that further optimises the convey-
high surface quality and lubrication. ate an ideal scraping solution that boosts ing process. q
10 ¦ MechChem Africa • January-February 2021⎪ Power transmission, bearings, bushes and seals ⎪
Locally assembled drive solutions
Henco du Plooy, Managing Director of Bonfiglioli in South Africa, talks about
his company’s heavy duty bevel helical and parallel shaft gear units.
technical design department was quick to Since 2008, we have been building our
meet the challenge to implement the neces- project capability. This includes access to
sary upgrades required to overcome these a global technical platform. Through this
B
ased on our products’ proven track conditions. Standard oil seals were replaced communication portal, our local engineer-
record and performance on previ- with silicon based versions that could handle ing department has access to a worldwide
ous installations, we were invited the extremes in temperature, while oil heat- database of applications, which enables us to
by our clients to tender for the ers were installed on all units to pre-heat offer technically proven solutions with very
supply of multiple large conveyor and feeder the gear reducer prior to start-up in the cold quick turnaround times. Our local capability
drives for an Eastern European Gold mine ex- conditions. can tailor our product offering to suit most
pansion project. The delivery timeframe was As a result of this success, we were environmental conditions.
critical. Each conveyor drive train assembly awarded eight projects for six different mines Bonfiglioli has organised its market sup-
(power-pack) needed to include a motor, high in the area. port and customer assistance functions along
speed fluid coupling, gearbox, low speed side Due to our extensive local stock holding clear ‘customer- first’ guidelines. Aware that
flange coupling and safety guards, all assem- of components, all fifteen conveyor power our direct presence in local markets is the
bled on a customised fabricated baseplate. packs and five feeder drive units could be built key to long-lasting success, we guarantee
For the high torque, low speed feeder from stock, which enabled our local assembly the same high standards of Bonfiglioli quality
drives, we provided a compact drive solution centre to meet the necessary deadline as re- anywhere in the world at any given time. q
which consisted of a primary helical-bevel quired by the client. We are accredited by our
gearbox coupled to a final stage planetary parent company to assemble up to the HDP/
reducer. Site conditions posed some techni- HDO 140 size in South Africa. The same strict
cal challenges that needed to be overcome. build and quality standards applied at the fac-
The installation site would encounter tem- tory have to be adhered to. This means that all
perature swings from -35 °C in the winter branches accredited to assemble gearboxes
months, to +35 °C in summer. Our local do so to European factory standard.
March-April 2021 • MechChem Africa ¦ 11Grindex: for long lasting pumping
solutions
Jordan Marsh, the recently appointed national sales manager for Integrated Pump Technology, talks about the company’s
geographic footprint, the operating philosophy of its distributor base and some of the reasons why Grindex Pumps have
become a preferred solution for mining applications across South and sub-Saharan Africa.
O
riginally established as the official company’s distribution philosophy, which “From our premises in Jet Park, near the OR
distributor for Grindex Pumps strives to maximise the local support available Tambo Airport in South Africa, we then offer
in sub-Saharan Africa in 2014, to operators of its pumps: “Since 2014, we higher-level support to ensure that each lo-
Integrated Pump Technology have been developing a skills-based distribu- cal distributor is able to deliver local backup,
now has a large installed base across all of the tor network. This involves putting pumping maintenance and technical service support
mining regions of sub-Saharan Africa. “On the specialists into all major mining areas, people at the levels needed by mine operators. We
Grindex range, our focus is on mine drainage who are able to support our mining customers strive to empower each distributor to pro-
and slurry applications, in South Africa as well via a local and accessible hub,” Marsh explains. vide a rapid after sales service response so
as north of our borders,” begins the company’s “Technically trained sales representatives as to keep our Grindex pumps delivering as
new national sales manager, Jordan Marsh, with knowledge of the local people, problems required and preferred by everyone who uses
who was appointed to the role on January and needs are chosen to deliver our offering them,” he adds.
1, 2021. A key aspect to this growth is the on a best fit for purpose basis,” he continues. Members of the distributor network
sign agreements with Integrated Pump
Technology year on year which specify the
services that will be offered locally and the
support each distributor can expect from the
Jet Park facility. “We prefer our pumps to be
serviced and repaired locally, so we strive
to find distributors with repair workshops
and a test bay, so the pumps can be looked
after properly, repaired and refurbished
to the original specifications and tested to
maintain the high standards expected of the
Grindex brand.
“We also keep exceptionally high stocking
levels of all wear parts and spares for every
pump in our range, which usually enables us to
deliver to our distributors on a next day basis,”
Marsh tells MechChem Africa.
“There are always some repairs that are
too large or complex to be handled in smaller
workshops, though, so we make our large
workshop here in Jet Park available for any re-
pair that cannot be completed locally. As well
as being able to repair the full Grindex range,
we can service almost any other pump brands,
including all other high-end Swedish pumps.
Marsh assures that Integrated Pump
Technology’s Grindex distributors are compli-
ant with B-BBEE initiatives and committed
to conforming with the current localisation
requirements of the Mining Charter. “We have
also initiated onsite pump and technical train-
ing for our distributors and for end users. This
includes routine operation and maintenance
requirements as well as the local refurbish-
ment of worn pumps.
“We see this as part of our responsibility to
transfer skills to local people and to raise their
employment prospects. Many of the pumps
in mines are not being used very effectively,
A Grindex Bravo being installed on a mine. and by pointing out how this can be improved
12 ¦ MechChem Africa • March-April 2021⎪ Pump systems, pipes, valves and seals ⎪
and upskilling local pump operators to realise better energy efficiency and, because en- has a dedicated engineering team that pro-
how a pump’s performance can be optimised, ergy costs of pumps outweigh initial purchase vides custom-designed solutions for the chal-
mines can become a little more sustainable, costs, this rapidly reduces the total cost lenges facing customers. “We pride ourselves
which enables them to support more jobs,” he of ownership. “For a recent application in on being able to fix problems where others
says, adding that basic pump knowledge can Polokwane, for example, we looked at our have failed. We are so much more than a pump
go a long way in this regard. Grindex Bravo 600 22 kW pump as a replace- in a box reseller.
Best fit for purpose solutions ment for a currently installed 30 kW submers- “Going forward, our strategically placed
“Grindex pumps are the Rolls Royce of the ible. Our 22 kW pump performs at the same account managers are seeing a lot of potential.
industry,” Marsh believes, as is evident from duty as the current pump, but it draws over Mines still have to operate and many are now
the 30-month warranty offered with every 25% less power, so it is much more energy effi- looking at performance efficiency opportuni-
new Grindex purchase. “This, we find, gives a cient. Adding to this, as with all Grindex Bravo ties as well as expansion projects and new
high level of confidence to mining engineers pumps from 400 up, this pump has a built-in developments. Our distribution network is
with respect to quality and value for money,” cooling jacket, which means that the Bravo ready and waiting to support them in all of
he notes. 600 does not need to be fully submerged for these areas,” Marsh concludes. q
He says that Integrated Pump Technology the pump to be effectively cooled.
is able to identify a pump solution for almost “In this operation, the operator cannot
every mining application it encounters. “For keep an eye on it 24/7, so the water level
dewatering, we can offer pumps with twin often drops below the safe level for keeping
impellers that offer very high heads – up the pump cool. We think our pump, being
to 200 m – for pumping water from deep more rugged and better cooled, can solve a
underground. Our biggest is a 90 kW and whole lot of the problems they are experienc-
we go down to 0.75 kW units. For below ing. Most importantly, though, the improved
ground use from multiple mine stopes, 5.5 to energy efficiency will reduce electricity con-
37 kW pumps with high head H-impellers are sumption, which will result in a TCO saving
preferred, while closer to the surface, we can of 51% over a five year operational period
use the 90 kW Grindex high flow pump units of the pump
with N-impellers to transport the water out “Two of our Bravo 600 units are currently
of the mine and into surface storage facilities,” on trial and performing as expected, so we
he explains. expect this to lead to the steady replacement
Adding to the suitability of the submers- of the existing fleet with Grindex Bravos over
ible pump range for the harsh conditions of the next few years,” Marsh predicts. “Through
African mines, he says Grindex pumps in the our sister company Integrated Pump Rental,
power range of up to 18 kW have their own we also have a substantial rental fleet, which
built-in smart device for self-monitoring, we can use for demonstrations in situations
which protects against phase rotation, dry such as those on a trial basis. This helps to
running and overheating. “This is a huge allay purchasing risk concerns and to assure
advantage in remote underground situations operators that our solutions will deliver as The Grindex Bravo pump has its own built-in
where access is difficult,” notes Marsh. promised,” he adds. smart device for self-monitoring offering optimum
Every mine, however, requires a different In addition, Integrated Pump Technology protection.
solution with respect to dewatering, water
transfer or slurry. “We see our role as devel-
oping pumping solutions that are perfectly
tailored to a mine’s needs,” he assures. “We
then present mine managers with the cost ef-
fectiveness of the solution we have identified,
typically breaking down the total lifecycle or
ownership costs based on efficiency, perfor-
mance, life and reliability gains. This enables
users to do a like-for-like comparison of our
Grindex solutions compared to an existing
installation or to a less well engineered, and
therefore cheaper, alternative.
“We recently compared one of our Grindex
submersible pumps to a vertical spindle solu-
tion for a dewatering application, for example.
Mostly due to the significantly longer life
and a much lower installation cost of using
a Grindex submersible pump, the total cost
of ownership of the Grindex solution was
51% lower than the vertical spindle option,
making it easy for us to present a convincing
argument,” Marsh relates.
A good fit Grindex solution in many mining
applications will usually deliver significantly Every new Grindex Bravo submersible pump carries a 30-month warranty.
March-April 2021 • MechChem Africa ¦ 13Sustainability vision for
Africa and the Middle East
Grant Ramsden, regional managing director of Weir Minerals Africa and Middle
East, talks about how the company’s successful 150-year evolution is continuing,
with a strong forward looking sustainability vision.
A
ccording to Grant Ramsden, Weir for us remains our high-pressure GEHO sibly even procuring the necessary spares,”
Minerals Africa is focused on positive displacement pump range, where we he says. “Synertrex has already proved itself
partnering with customers to continue to see substantial interest,” he says. in South Africa’s minerals sands segment,
drive efficiencies using its proven “These pumps represent the latest advances and similar interest has been expressed
technology-driven solutions, with a strong in hydro-transport, and will also add to the from other commodity miners in our region.
sustainability vision for the modern mining, efficiencies we can bring to mining across This system can also streamline procurement
minerals processing and cement industries. Africa.” GEHO pumps can handle slurry con- by alerting customers when new spares may
“As our mining sector customers look to centrations of up to 85% and temperatures be needed.”
reduce their carbon footprint, we are engi- exceeding 200 °C, making them ideal for Ramsden emphasises the value in Weir
neering solutions for a future that prioritises transporting thick, hot and very abrasive Minerals’ wear resistant technology (WRT),
energy efficiency and raises productivity,” slurries. which has demonstrated increases in the life
says Ramsden, who stepped into his new role In the context of the COVID-19 pan- of impellers and throat bushes of Warman®
during the economic lockdown in 2020. “With demic, Ramsden says that Weir’s Synertrex® slurry pumps by up to 30%. These improve-
leading brands all the way from ground- condition monitoring and smart analytics ments significantly extend pump life and
engaging tools to processing equipment platform will attract more attention in 2021. reduce total cost of ownership for the com-
across the mill circuit, we have an exciting Developed by Weir Minerals to complement pany’s customers.
year ahead with our continuously expanding its portfolio of mining equipment, Synertrex® As an established original equipment
equipment range. monitors product operation and feeds data manufacturer (OEM) in South Africa, Weir
Among the solutions that will raise most automatically to the cloud and control sys- Minerals Africa is planning further invest-
interest, he says, are the company’s high pres- tems. This also allows for remote monitoring ment in upgrades and process improvements
sure grinding rolls (HPGRs), which are more where employees or management may not at its Isando foundry. It will also be directing
energy efficient than traditional ball mills and have regular physical access to plant opera- resources for a technology upgrade at its
utilise dry processing. With most of the global tions. “With our service-focused approach, Isando rubber plant, one of two local facili-
mining sector having readily embraced this we are able to become directly integrated ties contributing to the company’s range of
technology, there is still plenty of scope for into the customer’s operation, through having IP-protected rubber products.
its adoption in Africa. one of our own experts in the mine’s control “After a difficult 2020 for everyone, it
“Another exciting area of opportunity room helping to monitor equipment and pos- will be exciting to be investing and expand-
The foundry at Weir Minerals Africa’s Isando facility where further upgrades and process improvements are planned.
14 ¦ MechChem Africa • March-April 2021⎪ Pump systems, pipes, valves and seals ⎪
ing to assist our customers meet their
production targets,” he says. “We also look
forward to continuing our investment
in local skills, which includes supporting
22 graduates – 90% of whom are drawn
into our business after qualifying from their
university studies.”
Ramsden highlights the importance of
the Weir Minerals’ Mill Circuit University in
providing essential training to staff – help-
ing to keep the company and the broader
mining industry operating at the highest
levels of performance. “The technical ex-
perts in our business constantly leverage
new technology, applying it to our products
to the benefit of our customers,” he says. An Enduron high-pressure grinding roll (HPGR) installed at a sand and aggregate plant. HPGRs are more
energy efficient than traditional ball mills and dry processing reduces plant water requirements.
“The use of 3D scanners, for instance,
enhances the capability of our process
engineers when they visit customer sites.
This enables them to quickly generate the
measurements they need to develop quality
proposals for productivity solutions.”
He is also confident about the prospects
for the Middle East, where comminution
is the main focus of the company’s offer-
ings – serving the considerable demand
for infrastructure works in that region. Its
local capacity has been further enhanced
by the recent unveiling of a new world class
service centre in Dubai in the United Arab
Emirates.
“This aligns with our mission to be avail-
able wherever and whenever our custom-
ers need us,” Ramsden concludes. A GEHO positive displacement pump operating at a platinum mine. GEHO pumps can handle slurry
www.minerals.weir concentrations of up to 85% and temperatures exceeding 200 °C.
Contactless and precise volumetric flow measurement
GEMÜ, a manufacturer of valves, measurement and control systems, is introducing its new GEMÜ 3040 ultrasonic flowmeter,
which can be used to determine conductive and non-conductive volumetric flows of liquids in a contactless process.
T
he GEMÜ 3040 ultrasonic flowme- the important operating parameters can be
ter is distinguished by its suitability read directly on the flowmeter and it comes
for a wide range of nominal sizes with integrated empty pipe monitoring and a
(DN 10 to 50), its lack of moving quantity measuring device as standard. In or-
parts in the media-wetted area and its in- der to optimise integration into different ap-
creased accuracy and reproducibility of mea- plications, all of the standard electrical and
surement results. The device can be used to mechanical connections are also provided.
measure both conductive and non-conductive As sensor systems are also often used
media within a pressure range of 0 to 16 bar in control circuits as part of process auto-
with an accuracy of 2% of the value measured. mation and monitoring, the GEMÜ 3040
The flowmeter can be used in a temperature measurement device can be combined with
range of between -10 °C and 80 °C. a GEMÜ valve and GEMÜ positioner or pro-
Its high-quality plastic body means that cess controller to form a complete pressure
the GEMÜ 3040 can be used for corrosive control system.
media, such as acids and alkalis. Its use in cool- With the launch of this ultrasonic flow-
ing circuits, chemical processes and water meter, GEMÜ is further expanding its prod-
supply projects makes up just a small part of uct range of measurement systems. In ad-
the flowmeter’s diverse areas of application. dition, the GEMÜ C38 SonicLine ultrasonic GEMÜ 3040 ultrasonic flowmeters can be used
The illuminated display, which is installed flowmeter remains available for ultra-pure to measure both conductive and non-conductive
as standard, means that programming can applications. media within a pressure range of 0 to 16 bar
be carried out directly on site. In addition, all www.gemu-group.com within an accuracy of 2% of the value measured.
March-April 2021 • MechChem Africa ¦ 15You can also read
