Water&Sanitation Jan/Feb 2013

Think water, think WISA! T

Water& Sanitation

The official magazine of the Water Institute of Southern Africa T

Complete water resource and wastewater management

Africa

Is water an untapped commodity?

PANEL DISCUSSION Deliberating on desalination

THE HOT SEAT

REGIONAL FOCUS Increasing Eastern Cape capacity

We have reached the point where GRP composites posites er, cannot be ignored. Jan Krüger, technical manager, Fiberpipe

P22

January/February 2013 • ISSN 1990-8857 • Cover price R40.00 • Vol 8 No. 1

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CONTENTS

Volume 8. No.1

Think water, think WISA! T

Water& Sanitation

The official magazine of the Water Institute of Southern Africa T

Complete water resource and wastewater management

Africa

Is water an untapped commodity?

Volunteers’ efforts ensure a cleaner Mutale River

18

ON THE COVER

Water solutions provider NuWater investigates water as a commodity in the mining water reclamation and reuse context

PANEL DISCUSSION Deliberating on desalination

THE HOT SEAT

REGIONAL FOCUS Increasing Eastern Cape capacity

We have reached the point where GRP composites posites er, cannot be ignored. Jan Krüger, technical manager, Fiberpipe

P22

MEDIA

January/February 2013 • ISSN 1990-8857 • Cover price R40.00 • Vol 8 No. 1

43 Port Alfred WWTW receives an upgrade

COVER STORY Mining water?

4

WISA Presidents message 6 Acting chief executive’s message 8 Patrons honoured 9 WISA: International Conference on Water Reuse for Drinking Purposes 10 Excellence in water research honoured 14 Divisional discourse 15 YWP: Conserving the lower Mutale River 18

HOT SEAT Fiberpipe’s Jan Krüger discusses the organisation’s investment in training and knowledge transfer 22 PANEL DISCUSSION Deliberating on desalination

27

REGIONAL FOCUS: EASTERN CAPE Increasing capacity at the Port Alfred WWTW WTW upgrade on track Quinera WWTW upgrade nearing completion

43 46 49

AFRICAN FOCUS Zambia: Conveying confidence at Chambishi CuSEP Project 51 Angola: HDPE pipes chosen for Angolan Cunene Project 52

Quinera WWTW upgrade near completion

49

TRENCHLESS NEWS

53

FEATURE: LABORATORIES & EQUIPMENT

60

FEATURE: RESERVOIRS

69

REGULARS Editor’s comment Infrastructure news Industry news

3 20 25

60

Is the skills dynamic in South Africa’s laboratories still a challenge?

JANUARY/FEBRUARY 2013

1

Water Purification Plant & Equipment INTRODUCTION SWANSA (PTY) LTD trading as SWAN’S WATER TREATMENT is a privately owned South African company specializing in the design and manufacture of the full spectrum of water puriſcation equipment. Cost effective innovations are incorporated in our process and equipment designs with the plant being customised for each installation. Our extensive in-house expertise, ensures that out advanced technology is applied to the clients best advantage. PRODUCT RANGE • Water ſlters • Moore Airlift Rapid Gravity ſlters • Steel pressure ſlters • Steel rapid gravity ſlters Liquid/Solid Separation • Sludge Blanket Vertical Upƀow Clariſers • Diminishing Intensity Floc Conditioners • Incline Sheet Clariſers • Upgrading of Horizontal Flow Clariſers Chemical Dosing • Helical screw feeders • Rotary disc dry feeders • Water operated dry feeders • Gravity solution feeders • Metering pumps • Gas Chlorinators Efƀuent Treatment • Bioſlter rotary distributors • Aerators • Clariſers Miscellaneous • Package plants • Ammoniators • Sulphonators • Pilot operated diaphragm valves • Laboratory ƀoc testers • Automatic pH control • Comparators • Domestic and industrial cartridge ſlters

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Publisher Elizabeth Shorten Editor Chantelle Mattheus Head of design Frédérick Danton Senior designer Hayley Mendelow Chief sub-editor Claire Nozaic Sub-editor Patience Gumbo Contributors Dawid de Wet Marketing & online manager Martin Hiller Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Financial manager Andrew Lobban Administration Tonya Hebenton Printers United Litho Johannesburg +27 (0)11 402 0571 Advertising sales Avé Delport Tel: +27 (0)11 467 6224 • Cell: +27 (0)83 302 1342 Fax: 086 502 1216 E-mail: avedel@lantic.net

EDITOR’S COMMENT

Welcoming the new year

A

new year always brings with it new opportunities and challenges, as well as a renewed sense of vigour with which to approach these ‒ and the beginning of 2013 is no different.

As we focus on the year ahead, there are a number of

highlights to look forward to, and no doubt a number of new and unique perspectives and solutions on challenges that continue to plague the water sector to be expected as well. One of these opportunities to collaborate and debate on these challenges

Publisher

and opportunities is the Municipal Water Quality Conference, to be held at Sun City from 7 to 11 July 2013. The focus will be on ensuring the financial sustainability of the

Physical address: No 4, 5th Avenue Rivonia 2056 Postal address: PO Box 92026, Norwood 2117, South Africa Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: chantelle@3smedia.co.za MEDIA

ISSN: 1990 - 8857 Annual subscription: R290 (SA rate) E-mail: subs@3smedia.co.za Copyright 2013. All rights reserved. All articles in Water&Sanitation Africa are copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publishers. The views of contributors do not necessarily reflect those of the Water Institute of Southern Africa or the publishers.

water services business within local government, as well as partnership opportunities between the public and private sectors to upscale efforts to improve wastewater services and drinking water management locally. Organised by both the Department of Water Affairs (DWA) and WISA and pertinently themed Together committed to excellent water quality for the future , the conference will focus on

Ensuring the financial sustainability of the water services business within local government

four disciplines, namely wastewater management, drinking

water

quality

management, sustainable economic

municipal

environment and opportunities for partnerships. These themes broadly encompass a number of focal points for submissions and presentations, most of which are also key focus points for Water&Sanitation Africa in the upcoming year. One of these is the importance of credible laboratories, which we have also highlighted in this edition on page 60, along with the achievements of a number of

WISA CONTACTS:

municipalities through the delivery of a number of interesting projects that are cur-

HEAD OFFICE Tel: +27 (0)11 805 3537 Fax: +27 (0)11 315 1258 Physical address: 1st Floor, Building 5, Constantia Park, 546 16th Road, Randjiespark Ext 7, Midrand

rently under construction or have recently been completed in the Eastern Cape. The

BRANCHES

are working towards changing the service delivery dynamic in this region.

Eastern Cape Chairman: Hennie Greeff Tel: +27(0)41 453 3102 Secretary/Treasurer: Chris Dickson Tel: +27(0)41 507 8200

www.ewisa.co.za

upgrade of the Caesars Dam Water Treatment Works in the Addo region is featured on page 46 and the upgrade of the Port Alfred Wastewater Treatment Works to increase the treatment capacity is on page 43. These are two progressive projects that In the previous edition of the magazine, we highlighted SRK Consulting s partner and principal hydrogeologist Peter Rosewarne s 30th anniversary with the organisation. A fuller, more comprehensive version of the article is available on 3S Media s infrastructure website ‒ infrastructurene.ws ‒ as are other interesting articles, events

Free State Chairperson: D.R. Tlhomelang Tel: +27(0)51 403 0800 Secretary/ Treasurer: Riana Wessels Tel: +27(0)56-515-0375

and technologies that are not able to be included in Water&Sanitation Africa due to

KwaZulu-Natal Chairman: Chris Fennemore Tel: +27 (0)31 311 8734 Secretary/ Treasurer: Stephanie Walsh Tel: +27 (0)31 302-4077

for 2012/13 where, as part of the incentive-based regulation approach, exceptional

Western Cape Chairman: Gareth McConkey Tel: +27(0) 21 712 4260 Secretary/ Treasurer: Eleonore Bondesio Tel: +27(0)21 872 0322 WISA mission statement m The Water Institute of Southern Africa provides a forum er for exchange of information and views to improve water resource management in southern Africa.

Endorsed by

the constrained nature of the print medium. Be sure to visit. In closing, the upcoming Municipal Water Quality Conference will also serve as a platform for performance announcements within the wastewater services domain performance will be awarded in terms of the coveted Green Drop Awards ‒ and Water&Sanitation Africa looks forward to sharing these achievements with our readers. Awards such as these are always a positive reinforcement of all the effo ort and dedication that is very much in evidence in the water sector.

Cover opportunity In each issue, Water&Sanitation Africa offers companies the opportunity to get to the front of the line by placing a company, product or service on the front cover of the magazine. Buying this position will afford the advertiser the cover story on pages 4 and 5 and maximum exposure. For more information on cover bookings contact Avé Delport on +27 (0)83 302 1342 or e-mail avedel@lantic.net

JANUARY/FEBRUARY 2013

3

COVER STORY

NUWATER

Mining water? UF Modules at Anglo American Thermal Coal

Water has long been described as a commodity in the same way as coal, metals and oil are. This description becomes more and more relevant as the true value of water starts to be clear, according to water solutions provider NuWater.

A

recent Bank of America Merrill Lynch research report

drainage wastewater reclamation plant at the New Vaal Colliery

describes water as the new oil . Is this just sensation-

near Vereeniging. The New Vaal project involves the treatment

alist? NuWater thinks not and is applying new thinking

and desalination of mine drainage water from a storage dam on

and strategies to water reclamation and reuse that are

the mine and the transmission of the resulting high-quality po-

more common in extractive industries than in water utilities.

table water to Eskom s neighbouring Lethabo power station for reuse as cooling process water. This has environmental sustaina-

Setting sights on sustainability

bility benefits for both Anglo American Thermal Coal and Eskom,

NuWater was established in 2010 following the acquisition of the

as well as economic benefits, says John Holmes, NuWater s CEO,

international GrahamTek 16

describing the project.

reverse osmosis (RO) technology

rights. NuWater quickly consolidated the operations of GrahamTek

Anglo recognised the benefits of our proposal for a completely

Singapore and GrahamTek South Africa, creating an international

modular & mobile (redeployable) wastewater treatment and

technology-led water treatment and desalination solutions and

desalination plant based on our proprietary RO technology. This

services company. It immediately focused its sights on unconven-

allowed us to offer them an economically attractive and flexible

tional desalination applications in the mining, oil and gas, and

solution whereby NuWater charges only for the water treated

power sectors ‒ all large users of water. At the same time, the com-

while retaining ownership and operational responsibility for the

pany has used its credentials in wastewater reclamation for potable

plant. NuWater would simply not have been able to offer this

reuse to drive its business into the more conventional water and

flexible BOO (build, own and operate) model were this a conven-

wastewater sectors. NuWater has developed an impressive portfo-

tional fixed plant rather than our rapidly redeployable design.

lio of reference projects covering multiple industries and geographies from its operations in Cape Town, Singapore and London.

The first high-quality water was produced in December 2010 with production capacity ramping up to its current maximum of 20 000 m3/d. At this current capacity it is believed to be the larg-

4

Modular and mobile

est plant of its type in the world and is confirmation of NuWater s

NuWater started working with Anglo American Thermal Coal

technological and project delivery capability. Johan Fourie,

in late 2010 to deliver a completely modular & mobile mine

technical services manager at the New Vaal Colliery, confirms:

JANUARY/FEBRUARY 2013

COVER STORY NuWater has repaid our confidence in its technology,

in the process of developing some strategic relation-

skills and customer commitment by delivering a world-

ships with providers of distributed power solutions.

class solution.

Active participation Rapid deployment

NuWater is a big believer that the recovery and pota-

NuWater is also currently working with Murray

ble reuse of secondary wastewater from conventional

& Roberts on a project for Gold Fields to deliver two mine wastewater treatment and desalination plants for its mine in Tarkwa, Ghana. Once again, the company was selected for this project based on

wastewater treatment plants presents a major oppor-

Loading Antonov 224 bound for Ghana

tunity to alleviate pressure on water resources. This is, however, a complex topic and goes well beyond technical feasibility. It will require extensive

its proven technology, modular solution and rapid

public consultation to explain the

deployment capabilities.

rationale and discuss concerns about

The project involves two plants, each producing

the suitability of wastewater reclaimed

about 7 500 m3/d of high-quality potable water from

through RO for human consumption.

mine wastewater for reuse or return into the environ-

Holmes

elaborates:

NuWater

in-

ment. The first phase of this project was commissioned

tends to be an active participant in

at the end of 2012, less than four months from the

the

project award, with the balance of the project to be

reclamation and potable reuse both

completed by May 2013. Holmes discusses some of the

in South Africa and in other water-stressed countries

challenges of the project and how NuWater addressed

in sub-Saharan Africa. In Singapore, we have been ac-

them: The Gold Fields Tarkwa project is a logistical

tively involved in the country s secondary wastewater

challenge due to its location and short delivery time

reclamation and reuse strategy and our large-diameter

frames. We have, however, been able to leverage our

(16 ) RO technology is in use at the Singapore Public

operations in Singapore and the

Utilities Board 55 000 m3/d flagship plant at the Bedok

UK to ensure the necessary plant equipment is available on time.

Facing forward NuWater expects to convert more mining-related projects over the next 12 months. In addition, the company is extending its solutions to offer higher recovery to minimise the amount of concen-

NuWater is applying new thinking and strategies to water reclamation and reuse that are more common in extractive industries than in water utilities

trated brine produced from the RO process or to elimi-

discussion

around

wastewater

NEWater Factory, also the site of the national water visitors centre. From a technology point of view, one does not get a much better reference plant than Bedok and this serves NuWater very well when demonstrating the benefits of water reclamation and potable reuse. It has, however, taken a huge investment in public education in Singapore to get people comfortable with the concept of drinking reclaimed sewerage water, even when this is indirectly through recycling of this water back through catchment reservoirs.

nate brine altogether to achieve zero brine, or zero liq-

Whether the value of water ever reaches the lofty

uid discharge (ZLD). According to Jeeten Nathoo, chief

heights of oil remains to be seen. Water is a finite and

technology officer at NuWater: Brine management is a major obstacle to wider and more rapid adoption of RO for large-scale industrial wastewater reclamation projects. Concentrated brine must either be recycled or stored in evaporation ponds, which is costly and,

Anglo New Vaal 15 Mâ„“/d Wastewater Reclamation Plant

increasingly valuable commodity and companies such as NuWater, with the technology and creativity to extract value from wastewater, which would otherwise be considered useless or even harmful, have a valuable role to play in ensuring long-term water security.

in cases of limited space, impractical. Along with both proprietary and externally sourced ZLD technologies, NuWater is developing novel brine concentration processes in order to offer customers brine management solutions as a standard part of its modular and redeployable plant suite. We will be field-testing these on actual brine streams from our existing plants during the course of 2013. Another sector NuWater has targeted for growth is power. Apart from the fact that power and water are considered essential utilities in the modern world, power generally requires significant amounts of water for cooling while water treatment, in particular desalination, requires significant amounts of power. According to Holmes: What is particularly interesting for NuWater is the growth in the market for distributed mid-sized power solutions. Our modular & mobile water treatment and desalination solutions fit very well alongside this growing power market. We are therefore In each issue, Water&Sanitation Africa offers advertisers the opportunity to promote their company s products and services to an appropriate audience by booking the prime position of the front cover, which includes a two-page feature article. The magazine offers advertisers an ideal platform to ensure maximum exposure of their brand. Please call AvĂŠ Delport on +27 (0)11 467 6224/ +27 (0)83 302 1342 to secure your booking.

5

PRESIDENT ’S MESSAGE

We need to position ourselves strategically m sure we can all agree that 2012 passed

developing a database for training

McConkey will drive this process to ensure

like lightning and many of us can count

service providers

that these branches and divisions become

I

successes and positive failures.

• launching our new website.

sustainable and form an integral part of

The end of the year break came as a

It sometimes seems as if WISA is a silent

development in their specific provinces

relief to many, allowing us to have a quiet

partner and does not really take a stand in

and industry.

relaxing moment and to spend time with our

water sector matters, but let me assure you

Anita Pillay and Alvin Lagardien will

loved ones. It also gave us an opportunity to

that this is not the case. We will have our

continue driving the professionalisation

gain some perspective on what we want to

first top-level meeting with the director

of process controllers and there is a huge

achieve in 2013 and how to make it a huge

general of Water Affairs to discuss burning

excitement with regard to the Memorandum

success. In some instances, we know we

issues in the sector and how WISA can

of Understanding already signed between

can achieve more if we do it in a group or

get involved in assisting the department

WISA and the EWSETA.

as a team, so in essence it will be all hands

with

on deck.

and projects.

May I humbly request that as one of your

Melissa Wheal

issues

Similar

discus-

The WISA board recently held a very exciting session to revisit the existing strategy

new year s resolutions, you contribute to

sions will be initi-

one constructive project towards the water

ated with other key

sector, no matter how little? Even if it is just

stakeholders such

to contribute to the upliftment of one indi-

as the CSIR, WRC, tertiary institutions, South

vidual in sector.

African

will ensure the smooth roll-out of the exciting website, which will be the face

of WISA and a website we can identify with.

Association,

I want to congratulate Rand Water on its

WISA will pull out all the stops in 2013,

Energy and Water Sector Education and

Training Academy and have no doubt it will

as the time is right for WISA to endorse

Training Authority, our patron members and

contribute enormously to training in the

its position in the water sector and be the

our international partners.

sector. The City of Cape Town s Bulk Water

Local

Government

voice for constructive consultation and

Now that most of our corporate gov-

Branch achieved the ISO 9001 certification

implementation. During our 2015 to 2019

ernance statutory compliance has been

and it is believed that it is the only munici-

strategic session we were regularly remind-

finalised, WISA has the ideal opportunity

pality in South Africa to acquire such a pres-

ed of the quote by Elon Musk, Imagination

to place itself strategically as a reputable

tigious recognition.

is the limit .

non-profit company.

The key focus in 2013 will be:

Our

• instituting closer relationships with the Department of Water Affairs to local government • expanding into Africa • exhibiting

at

international

and be

• vigorous marketing of WISA, especially

confer-

Well done to the successful Process Controllers open days held in some

branches divisions

reviewed

provinces, giving a clear identity to

will

process controllers.

with their

Let me wish you, on behalf of the

terms of references

board, council and staff of WISA, a

in order to partake

successful and fruitful 2013.

regard

to

in a structured and

ences (SA Water Sector pavilion with

constructive

patron members)

contribution. Valerie

President: Water Institute of

Naidoo and Gareth

Southern Africa

• capacity building and training, and

PATRON MEMBERS • Aecom • Amatola Water • Aveng Water • Baycity Trading 377 cc • BIGEN AFRICA Services • Bloem Water • Botjheng Water • Bushbuckridge Water • City of Cape Town • City of Tshwane • CSIR • Dow Water & Process SA

6

key

• Department of Water Affairs • ERWAT • ESKOM Holdings • eThekwini Municipality • Festo • Golder Associates Africa • Grundfos Alldos • Huber Technology • Johannesburg Water • Magalies Water • Merck • Mhlathuze Water • NCP Chlorchem

Ronald M Brown

sector

• Nelson Mandela Bay Metropolitan Municipality • Overberg Water • PD Naidoo & Associates Consulting Engineers • Prentec • Rand Water • Royal HaskoningDHV • SALGA • SAME Water • Schneider Electric • Sedibeng Water • SembCorp • Siemens

JANUARY/FEBRUARY 2013

• Sobek Engineering • Sulzer Pumps Wastewater SA • TCTA • Tecroveer • Umgeni Water • Veolia Water Solutions & Technologies SA • WAM Technology • Water Research Commission • Water & Sanitation Services SA • WEC Projects • Xylem • Zetachem • ZMG Watech

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Ekurhuleni

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THE HOT SEAT

Dean Mulqueeny, managing director y''s NCP Chlorchem, discusses the company's water treatment solutions P12 P1 12

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WISA From the pen of the acting chief executive:

A warm welcome

W

elcome back! We trust that

will be employing an events coordinator

new database will have many new features

you enjoyed the time spent

to support the events manager. Two of

that will add to the benefits of the mem-

with your families over this

WISA s divisions will be hosting conferenc-

bers, such as allowing members to be able

festive season and that you

es in 2013. The Young Water Professionals

to update their own membership profiles

are well rested and ready to tackle the

will be hosting the 3rd Southern African

and upload their CVs as well as a profile

challenges that may lay ahead in 2013.

Regional Biennial YWP Conference from

picture; the database will be Internet-

WISA has recently established an Events

16 to 18 July 2013 at the University of

based, which will enable WISA and its

Management Unit that will focus on

Stellenbosch. The Membrane Technology

members to access their profile from any-

arranging

workshops,

Division will be holding a conference in

where and enable WISA to provide mem-

conferences and exhibitions. The unit will

2013; the date and venue will be con-

bers with information on the membership

mainly run events being held by the WISA

firmed soon.

status at any time.

events

such

as

Head Office, our branches and/or divisions.

WISA has also established the Process

Patron members will have the added

WISA would also like to partner with and

Controller Division in the past year, with

benefit of being able to host their own

assist our members in hosting events that

branches in Gauteng, the Western Cape,

page on the website where they will be

will provide a platform for knowledge

Mpumalanga, Free State and KwaZulu-

able to upload any information.

dissemination. In order for WISA to make

Natal.

launching

I would like to welcome our new patron

the Events Management Unit a success, it

its Process Controller Division early in 2013.

members to WISA and we look forward to

was found that a dedicated events man-

This

will

having a long and fruitful relation-

ager would be required, as well as events

create a platform for

ship with the following organisa-

coordinators to assist and support the unit.

process

tions: SembCorp, Sobek Engineering

WISA, through due process, appointed

and will assist with

Jaco

the

Seaman

who

commenced

work

Limpopo division

will

controllers profession-

at WISA on 5 November 2012. Seaman

alisation

has already started working hard on the

process controllers.

Municipal

Water

Quality

Conference

be

of

the

The new website

and Baycity Trading 377 CC. We look forward to a successful 2013 in which WISA s main focus will

be

on

implementing

taking place in July 2013 as well as the next

and

WISA Biennial Conference & Exhibition

WISA will go live in

Dot Zandberg

taking place in May 2014. In 2013, WISA

January 2013. The

WISA: acting chief executive

8

database

its

strategic plan.

of

JANUARY/FEBRUARY 2013

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WISA NEWS

Patrons honoured On 14 November 2012, WISA held its Annual Patron Members lunch, hosted by WISA president Ronald Brown and the WISA board. The event serves as a welcome to new Patron Members, as well as recognising the loyal support to WISA by existing patron members.

A

Solution for partially filled pipes

t the event, which was held at the Viva Espãna Restaurant in the Constantia Office Park, WISA highlighted the activities for 2012, and outlined the plans and activities for 2013.

achieve more

Speaking at the event, Brown indicated that WISA is now WISA

NPC, with a newly endorsed vision: the promotion of professional excellence in the water sector through building expertise, sharing knowledge and improving quality of life. In addition, WISA

No need for civil work and flumes anymore!

came up with a new memorandum of incorporation and a new code of conduct, which was to be endorsed at the last board meeting of 2012. According to Brown, the emphasis going forward will be on Africa, with the institute seeking to expand its reach on the African continent. He also indicated that current acting chief executive, Dot Zandberg, would remain as acting chief executive until August 2013 and in future, the Patrons Lunch could possibly be held biennually with the next one scheduled for the WISA 2014 Conference, which is to be held in Nelspruit, Mpumalanga. Mellissa Wheal gave a sneak preview of the new website, which has been completely redesigned to be more interactive, as well as exhibiting updated member profiles online and enabling members to manage their accounts online. Current discussions are under way to integrate the new WISA website with the Department of Water Affairs

controllers

database and an online WISA newsletter has also been proposed, with the content being based on the user/member s indicated interests. Financially, WISA experienced a good year, with income totalling R8.4 million and expenses of just over R3 million. This was, in part, due to subscription payments as well as two very well attended conferences. The reserves are

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currently tallied at R9.6 million, but this remains, as always, an ongoing concern. The budget for 2013, which exhibits a R2 million deficit, was presented to the board for approval on 15 November 2012.

WISA president Ronald M Brown addressing the WISA patrons

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WISA NEWS

WATER RECLAMATION

Timeous water reclamation interventions critical The question is no longer whether reclaimed water should be included in South Africa’s water options, but rather when and how it should be included, finds Chantelle Mattheus at the WISA: International Conference on Water Reuse for Drinking Purposes.

S

outh Africa is at risk if water is not taken seriously

although sufficient alternative water is available, this requires im-

and interventions not applied timeously. This was

proved efficiency and water loss management, reuse, local resource

the primary message from Fred van Zyl, manager:

optimisation through the use of groundwater, desalination and

Planning & Information at the Department of Water

improved control, according to Van Zyl. However, accessibility is

Affairs, when discussing the National Water Resource Strategy 2 as

conditional and comes at a cost, he warned, adding that it requires

the keynote speaker on the first day of the conference, which was

effort and timeous implementation. We need to stretch water as a

held from 9 to 11 October 2012 at the Gateway Hotel in Umhlanga.

resource, water funding and infrastructure.

Currently, the water and regulatory role players in South Africa are proceeding with the revision of the National Water Resource

Correct context

Strategy 2012, led by the Department of Water Affairs. The strategy

Neil van Wyk, chief engineer: National Water Resource Planning

will have a focus on the best use of the limited water resources, in

for the Department of Water Affairs, investigated the idea of reuse

a sustainable manner and to the benefit of society and the environ-

in the context of water supply, covering a number of key water

ment. Water reuse and recycling is one of the key pillars of using

use sectors, as well as highlighting considerations of key strategic

the limited water resources responsibly and efficiently. The confer-

actions that need to be undertaken in the local context before and

ence was aimed at providing a training, education and discussion

while implementing water reuse. According to Van Wyk, reclamation and/ or reuse is a recognised source of water in the water resource planning process, with considerable potential existing for water reuse in irrigation in the agricultural sector, which uses approximately 7.68 billion cubic metres per annum. A very small portion currently uses treated wastewater or effluent. He also highlighted the possible reuse of water for the municipal sector, both in the use of non-potable water and potable water. Direct reuse though is the challenge, said Van Wyk, adding that the main concerns include ‒ but are not limited to ‒ the presence of micro-pollutants, the cost of treatment, the handling of waste or residue streams, the risks associated

opportunity, and delegates included international specialists, local

with operations and management of the reclamation facilities and,

regulators and practitioners in the field of potable reuse of water.

ultimately, public perceptions and acceptance.

According to Van Zyl, there is a perceived sense of water insecu-

Van Wyk said that there were a number of key strategic actions

rity in the local South African context; however, the issue is that up

that needed to be undertaken by the relevant role players in order

until now the main focus has been on infrastructure development

to support a national water reuse strategy, which included pro-

and not on utilising all the water resources available to the water

moting sound decision-making, a clear policy and legislative en-

sector to overcome this shortage. This is despite the fact that the

vironment, clear intentions, information to support reuse and the

country faces a number of challenges in the water sector, the

capacity to implement ‒ not to mention the financing of projects.

most pressing of which is a lack of appreciation for water, its role

He added that there needed to be clear incentives to the up-

and current situation, as well as poor water values and inadequate

take of water reuse technologies, with reuse projects needing

status, and inadequate management and governance.

to be cost effective compared to other water supply alternatives.

Fresh surface water as a resource is at its limit in most areas and

10

The department will take the importance of price signals and

JANUARY/FEBRUARY 2013

WISA NEWS incentives

in

water

reuse

that the solution was no longer

decisions into account when

to build more dams or similar

reviewing the water pricing

infrastructure ‒ direct potable

strategy, said Van Wyk.

use is imminent and will most

Enforcement,

however,

re-

probably be a reality in the next

mained one of the biggest

decade in most catchments

current hurdles, with strict en-

‒ but that it needs to be one

forcement of current discharge

of the multiple solutions sug-

standards

gested and in order to achieve

and

addressing

the management and performance failures of municipal wastewater

treatment

plans

being required and, in fact, critical before due consideration could be given to water reuse. Compliance of existing WWTWs

to

achieve

strict

discharge standards is critical to the future success of water reuse, said Van Wyk.

this political commitment and

“South Africa is at risk if water is not taken seriously.” Fred van Zyl, director, Water Services: Planning & Information, Department of Water and Environmental Affairs

“Reuse of water for potable purposes is an attractive option in all cases.” Johan van

sensitising the public, need to

Rooyen, director: National Water Resource Planning Department of Water Affairs

proceedings seemed to infer that

be encouraged. Speaking on behalf of WISA in the closing, Dr Jo Burgess indicated that the conference the treatment technology was the easy part ,although always having room for improvement. We know what to do, we don t yet know how to do it though,

First forging ahead

said Burgess, adding that the soft issues, relating to community

The Beaufort West Water Reclamation Plant is the first direct (toilet

outreach, acceptance and communication, seemed to be the hard-

to tap) water reclamation plant in South Africa and serves as

er issues in this context, with unity between sectors, regulators and

validation that the idea is more than just a pipe dream .

the public ultimately being possible if this is undertaken correctly.

Beaufort West is well-known for its recurring potable water chal-

We need to focus, going forward, on treatment technologies,

lenges ‒ most notably the continued shortage thereof. In this con-

residue handling and regulator alignment, among others, but most

text, all possible alternatives have been investigated and developed,

importantly on how we communicate, she concluded.

namely managing water losses, installing pre-paid meters and applying local water restrictions ‒ with wastewater reclamation coming up as the only sustainable alternative and the most affordable option, according to Water & Wastewater Engineering s Pierre Marais. The project not only provides a sustainable water supply and sus-

thuthuka group limited

tainable development in the region, but also ensures that the local was achieved through optimising the performance of the existing wastewater treatment works; designing, building and operating a new water reclamation plant under a 20-year public-private partnership concession agreement; and providing a new rising main to the reservoirs. Water & Wastewater Engineering s responsibilities include daily operation, routine maintenance, preventative maintenance and specialised maintenance on membranes, with the company getting paid per kilolitre of reclaimed water. Speaking at the conference, Marais said that key to the process was the communication undertaken with the community by the municipality. The municipality started the process of public awareness regarding reclaimed water with newspaper adverts and through numerous discussions of the matter at community level. In addition, the EIA process was very comprehensive and included the distribution of pamphlets. Not only has the project twice been on the front page of the local newspaper, and school tours through the works are a common occurrence, but the plant also publishes its test results in the local newspaper and hands out water bottles to visitors, as well as insuring transparency with the municipality.

Facing forward The majority of the speakers seemed to fall into two major groupings: the scientific and those dealing with the bigger challenges in public participation. However, the consensus seemed to be

JANUARY/FEBRUARY 2013

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WISA NEWS

WATER RECLAMATION KICKER

Reclamation reality Chantelle Mattheus recently visited the Durban Water Recycling reclamation plant – a local and long-standing example of water reclamation technologies at work. The site visit was part of the WISA: International Conference on Water Reuse for Drinking Purposes.

T

he objective of the Durban Water Recycling reclamation plant is simple: to treat 47.5 Mℓ/d of municipal wastewater to a near potable standard for direct reuse in industrial water

production facilities because Mondi Paper had expressed the desire to increase its off-take of reclaimed water. The treatment philosophy, however, is anything but simple. It involves a novel combination of wastewater and potable water plants to produce this nearpotable-quality water that is supplied to the plant s industrial customers. The treatment process on-site involves, among the other key processes, primary treatment (namely screening, degritting and the utilisation of primary settling tanks through which the settleable solids are removed) as well as the use of activated sludge for the removal of COD and nitrogen pollution. Ozonation is also undertaken on-site through the use of pure oxygen to remove colour and degrade non-biodegradable COD. At the chlorination and storage stage of the process, chlorine is used during the stabilisation of the treated water and the plant has a storage capacity of 21 000 m3.

Construction context Durban Water Recycling is a project consortium made up of Veolia Water, Zetachem, Khulani Holdings, Umgeni Water and Marubeni. It has a 20-year concession agreement with the eThekwini Municipality to supply industrial clients Mondi Paper and Sapref [a joint venture between Shell SA Refining and BP Southern Africa] with water from the plant. Both the operating contract and the construction contract were undertaken by Vivendi Water Systems. The 20-year concession was ‒ and is still ‒ the first public-private partnership (PPP) of its kind in South Africa, with a strong reliance on the relative expertise

of

the

partners.

According

to

Sagren

investment being necessitated for the construction of the recycling plant. This while the project has enabled the creation of a long-term revenue stream for the city from a levy raised on the production of recycled water, as well as resulting

Govender, Veolia Water Solutions & Technologies

in a reduction in the city s operating costs and a conse-

general manager, it serves as a model of success

quent reduced cost of water services

for PPPs in South Africa. This year will be the 12th year of the 20-year contract and, as Govender says, time is a good indication of how successful it has been. Ultimately, the timely construction and completion of the project has resulted in the City of eThekwini being able to delay capital investment for increased marine outfall pipeline capacity, as well as the project delaying capital investment for future bulk potable water supply infrastructure, all with no capital

12

The filtering infrastructure at the Durban Water Recycling reclamation plant

The project has enabled the creation of a long-term revenue stream for the city from a levy raised on the production of recycled water JANUARY/FEBRUARY 2013

to Durban s citizens.

Assessing the impact To date, the project has achieved treatment of wastewater to a very high quality standard, while rolling out a compact design, which was fast tracked along with the construction, and extensively reusing the already existing infrastructure

WISA NEWS on-site. For the industrial customers making use of

according to Govender, and the municipality is actively

the water ‒ Mondi Paper and Sapref ‒ the project has

looking for further industrial users and projects that

enabled a 50% saving in their water tariff, with probable lower escalation of recycled water than potable water and the insurance of significantly enhanced drought supply security. On the environmental side, looking at the plant s im-

Attendees of the conference were also taken on a tour of the facilities

could result. However, these industrial streams bring with them their own sets of challenges, whereas residential and domestic effluent is easier to treat. But the technology is available and the possibilities are there, concludes Govender.

pact on the region s sustainable development of water resources, the plant reduces the city s water consumption by 10% when running at capacity and extends the life of the city s water catchment resources substantially, in that unused water in this context can then be directed to unserviced communities. In addition, waste minimisation and pollution load reduction have also been key focuses. A reduction in the sea outfall pollution load of 24% has been recorded, with the process operating at 97.9% water utilisation efficiency. The plant serves as a model for not only successful PPPs in the local context, according to Govender, but ensures that sewage is viewed as a potential resource, providing a new vision for the future where the production of potable water from sewage could be a reality.

Tale of tomorrow The potential for expansion of the operation exists,

JANUARY/FEBRUARY 2013

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WISA NEWS

AWARDS

Excellence in water research honoured Three South African researchers in the water sector – Dr Inga Jacobs, Craig Sheridan and Dr Heidi Snyman – were recently honoured for their contributions to the sector at the Excellence in Water Research Awards.

H

eld on 18 October 2012 at the CSIR Knowledge

Commons

in

Pretoria,

the

awards were held in honour of Dr Gerrie Stander,

Ronald Brown, as

described

by

WISA

president,

one of the greatest aquarians

born in South Africa . WISA, the WRC and the CSIR hosted the awards evening in acknowledgement of focused, productive, multidisciplinary research dedicated to the growth and intellect of the respective research disciplines.

Young researchers Dr Inga Jacobs of the WRC was honoured as the Female Young Researcher, with a presentation entitled Bringing the United Nations Watercourses Convention (UNWC) home? A multi-level water governance framework in the Orange-Senqu River Basin in South Africa . Apart from her current role as research manager: knowledge management at the WRC, Jacobs is also currently on a number of boards, including that of WISA, and is chairperson of the International Water Association Young Water Professionals. Craig Sheridan, who was honoured as the Male Young Researcher, gave a presentation on Water: The intra/ inter/cross-disciplinary research arena . Currently registered for a PhD, Sheridan is a lecturer at the School of Chemical and Metallurgical Engineering at the University of the Witwatersrand (Wits) in Johannesburg where he is presently supervising 10 water-related undergraduate research projects and co-supervising eight postgraduate students, seven of which are involved in water-related projects.

Memorial Lecture The Memorial Lecture, Water for Individual Growth and Development , was presented by the final honouree for the night, Dr Heidi Snyman, integrated water and waste specialist at Golder Associates and until recently director of water-centred knowledge at the WRC. The standard this year was exceptionally high, according to WISA vice-president Jo Burgess. My personal take-home message is one of enormous optimism. There seems to be a belief that locally we are not up to international standards. The reality is that we compare well and South Africans are leading the world in lots of ways, especially when it comes to water. We are a very passionate sector, said Burgess in closing.

14

Craig Sheriden (top), Dr Inga Jacobs (middle) and Dr Heidi Snyman receive their awards from Dr Mandla Msibi, director: Research and Innovation at Tshwane University of Technology (left) and WISA president, Ronald Brown (right)

JANUARY/FEBRUARY 2013

DIVISIONAL DISCOURSE

WISA NEWS

Focusing on anaerobic and sludge processes Anaerobic and sludge processes are overlapping issues. The WISA Anaerobic and Sludge Processes Division is concerned with the range covered by these, according to Gordon Borain, chairperson of the division. Chantelle Mattheus recently interviewed Borain on the current context and the division’s focus moving forward.

A

naerobic processes are used for high-strength wastes

it was very much area-dependant. We have some disasters and

and may be completely liquid. Sludges have high sol-

we have some very good examples. There are many good people

ids contents and usually have a high organic load.

in the water industry, but they need leadership and budget,

Historically, wastewater works have been designed

he added.

to treat the liquids to discharge standards and insufficient attention was given to the solids treatment and disposal. This has

Benefits realised

resulted in there being a large number of works around the coun-

Borain explained that biosolids have significant benefits due,

try having insufficient capacity to handle the solids produced, as

in part, to their nutrient levels being low relative to artificial

well as skills shortages. Enforcement of the Department of Water

fertilisers, but they have micro nutrients and soil conditioning

Affairs sludge guidelines is exacerbating these problems in the

benefits. Their disadvantages are pathogens and heavy metals.

short term, but is causing the industry to wake up to a worsening

Pathogens are not an insurmountable problem, but heavy metals

situation, said Borain.

need to removed at source.

According to Borain, the resolution of these problems will require

a

change

in

attitudes by authorities and an investment in skills and infrastructure. Education and training are crucial, but the balance between pure theory and applied theory and training needs to be maintained. Pure theory

“Education and training are crucial, but the balance between pure theory and applied theory and training needs to be maintained”

is needed to advance processes, but operation and upgrading of existing infrastructure is a greater short- to medium-term need.

He therefore advocated trade effluent management supporting

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Product quality & energy efficiency Borain believed that the final product quality and energy efficiency are critical areas also needing attention. There are potential budget savings, but the ever-increasing standards that would have to be met are likely to utilise these. When asked which existing plants ‒ or even processes ‒ he considered best practice ideals that the rest of the water community would do well to emulate, Borain responded that that was difficult to answer. There is no best practice. Engineers design to suit the conditions existing at the time and as they see the situation progress-

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ing, he stated. According to Borain, sludge and residuals management has also not been going well, but thanks largely to Green and Blue Drop, there had been a swing in the right direction. When asked what more could be done to remedy the situation, he indicated that

JANUARY/FEBRUARY 2013

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WISA NEWS industry where it can and prosecuting where necessary. Realising the full benefits of anaerobic digestion in the local context is also under question. Anaerobic digestion of municipal wastewater sludge has fallen into disuse over the last 20 to 30 years due to the capital cost of infrastructure. With assistance from Eskom, industry is starting to realise that anaerobic digestion not only has low operating costs, but can produce sufficient methane to provide sufficient power for 40 to 50% of the process needs, said Borain. He added that when a 65 Mℓ/d works has an electricity bill of around R1 million, there

protect the quality of South Africa s water

At the helm

is a lot of potential for savings.

for the use by all its people, particularly in

In May 2012, Borain took over as chairperson

our areas of expertise. Our focus must be

of the division. My strength is in waste-

Processes

on municipal wastewater sludge beneficial

water, so I personally wish to encourage

Division is a part

utilisation and utilising anaerobic processes

anaerobic digestion of municipal wastewa-

of WISA. As such,

in the treatment of municipal sludge and

ter and the use of the methane produced

our purpose is to

high-strength industrial effluents.

to generate power, but I want to support

According to Borain, the Anaerobic and Sludge

the industrial use of anaerobic processes,

“Anaerobic digestion of municipal wastewater sludge has fallen into disuse over the last 20 to 30 years due to the capital cost of infrastructure.” Gordon Borain 16

JANUARY/FEBRUARY 2013

said Borain, adding that the water industry needed all its facets to work as a team. The primary focus in the short term needs to be on training at process controller level, Borain concluded.

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WISA NEWS

WATER CONSERVATION KICKER

Conserving the lower Mutale River Volunteers, including members of the Young Water Professionals, recently cleaned most of the visible waste along the lower reaches of the Mutale River in Limpopo. They also conducted basic water tests with kits sponsored by the IWA. To follow is an account by volunteer Dawid de Wet.

I

t was mid-morning in winter and hot in the

and Ha-Makuya. From here, we followed the river in an

north-eastern corner of the Limpopo province. I

eastward direction past the bridge and down to the

travelled on mountain bike, but often had to push

border of the Makuya Park. We covered 40 km in total

it through the deep sand. The first glimpse of water

and collected 55 bags of rubbish and half a truck tyre.

through the undergrowth was very enticing. There it

Old clothes and nappies formed the bulk of our initial

was, the Mutale River. I squatted to get a better view

cleaning effort. We also found there is much more rub-

and immediately the beauty of the river hit me.

bish in the river than what is visible from the bank. It

Along with Vince Mehers from the Friends of Mutale

is therefore a difficult and slow process. After the first

charity organisation based in Bennde Mutale, we

day, we had collected eight bags of rubbish between

decided to launch a clean-up of the Mutale River. The

the five of us and only covered 8 km. We then made

river emerges from underground below Lake Funduzi

the decision to concentrate our efforts on the following

and flows through some of South Africa s most scenic,

day on certain sections of the river where there is a

undeveloped and isolated countryside areas before

big build-up of rubbish. These rubbish hot-spots are

joining the Levuvhu River in the Kruger National Park.

found at points in the river where people come down

During a reconnaissance walk and visits to different

to wash laundry, vehicles and themselves, and to collect

points on the river, and after consulting stakeholders

water for household purposes. The waste also collects

and experts, we decided to focus our attention on the

on obstructions in the river like rocks or concrete that

lower, more accessible section of the river. Some sec-

forms part of bridges and other constructions. Fishing

tions of the river are totally inaccessible due to reeds

was also a popular activity in the river. This was con-

and other vegetation. One 30 km section flows through

ducted either with rods made from reed or nets.

a canyon just past Tshikundamalema, which we would have had to walk around. Our starting point for the clean-up project was 10 km west of the Sanari Bridge on the road between Masisi

The Mutale River in South Africa’s Limpopo province

We conducted basic water tests at different sites along the river using test kits provided to us for this purpose by the International Water Association (IWA) in conjunction with the Gauteng Young Water Professionals. The results of the tests have been uploaded onto www.worldwatermonitoringday.org. See Table 1 for some of the test results. These tests are great to use as education for kids wanting to know more about the health of their watercourse. The aim of the IWA with these tests is to create as much awareness as possible among young people across the globe. It gives youngsters an idea of the importance of water in their environment. While doing tests and cleaning the area around the Sanari Bridge, we were enthusiastically assisted for two hours by a group of local secondary school boys. This act of responsibility on the school boys part was by far the most rewarding outcome of the whole project.

18

JANUARY/FEBRUARY 2013

WISA NEWS At the Sanari Bridge alone we collected 20 bags of rubbish in and directly beside the river.

Table 1: Results from the IWA water monitoring test kits Date and time

Location

Air temp

Water temp

Dissolved oxygen

pH

Turbidity

Use and comments

2.10.2012 16:15

S22.294 E30.502

33°C

28°C

8 ppm

7.5

0.00JTU

Agricultural

3.10.2012 09:00

S22.283 E30.521

27°C

22°C

6 ppm

7.58

0.00JTU

Residential

3.10.2012 12:00

Same (after 32°C groups washed in the river)

28°C

4 ppm

7.5

40.000JTU

Residential

4.10.2012 08:45

S22.375 E30.934

24°C

6 ppm

7.5

0.000JTU

Natural mayflies

This area is particularly popular with people washing and collecting water and while we were there, five sets of boys with

donkey

carts

collected

water, two water trucks and a couple of vehicles were driven down to collect water and to be washed, two groups of women came down to do laundry and boys played in the water. The

28°C

rubbish bags were collected by EnviroServ and taken to the nearby Exxaro Tshikondeni mine. As we continued our hike along the river, we were followed by two young boys who continuously picked up rubbish and ran after us to put it in our bags. It was heart-warming to experience their help. With an awareness campaign in the local villages, much can be achieved with regard to river health and cleaning the river. This has to be backed up with proper services for the people to have the means to get rid of their rubbish. The next day, we continued our walk and were pleased to find that we could remove most, if not all the visible waste along a 15 km stretch to Nkotswi Bridge. When

TOP Volunteers continue to clean the river while local children collect water MIDDLE The last of the rubbish to be collected BOTTOM Dawid de Wet with his assistants at the Sanari Bridge

we arrived at the bridge, we found the area beautifully clean. This is also an area with a high concentration of water use. Volunteers, and 60 local children from the

holiday

programme

had collected 15 bags of rubbish in the morning. For the rest of the way to the fence of Makuya Park,

The interest shown from different role players and interested parties before, during and after the project was very rewarding

we collected rubbish and enjoyed the atmosphere of the river. We counted over 50 species of bird along our walk. The riparian vegetation is beautiful along the river and there is a feeling of wilderness that combines with the rural sounds making this river so special. Nights beside the river brought reflection and a sense of the immense spirit of the place. The utter peace of flowing water is immeasurable, mysterious and difficult to explain. The interest shown from different role players and interested parties before, during and after the project was very rewarding. It shows the need for projects of this nature. Members of the public must take responsibility and should not have to wait for companies or government before initiating projects of this nature. We hope that the project can continue with Vince getting the communities in the area involved on a more regular basis. Education and the provision of adequate services are extremely important for keeping our rural and still relatively untouched rivers clean and safe. Cooperation between all sections of industry is important and in this regard we have to thank our supporters and advisors, especially Coal of Africa, for their generous sponsorship.

JANUARY/FEBRUARY 2013

19

NEWS

THE TOP INFRASTRUCTURE AND SERVICE DELIVERY STORIES MAKING THE NEWS

Increased access to piped water The proportion of

conducted in South Africa

proportion of households

toilets, however, has increased

households with access to

since the 1994 change in

using the pit toilet with venti-

overall, with the number of

piped water has increased

government, Census 2011, was

lation (i.e. VIP) increased from

households having no toilet

since the census conducted in

conducted in October 2011

6.6% to 8.8% in CS 2007.

declining significantly to 5.2%

2001. This is according to the

with a number of population

This could, in part, be

in Census 2011, as opposed to

Census 2011 results released

and household attributes

attributed to the fact that the

on 30 October 2012.

being measured and a number

proportion of households

of indicators generated

living in formal dwellings has

prevalent in the Coloured

from them.

also increased significantly.

grouping with 2.8% of this

However, the census findings

population group using

The findings show that the proportion of households with access to piped water is high

8.3% in CS 2007. Bucket toilets were more

in all provinces, with the high-

Sanitation in the spotlight

notes that the share of black

this as their primary toilet

est proportion of those with

According to the findings, the

African households living

facility; however, at 2.1% total

piped water inside the dwell-

percentage of households

in formal dwellings remains

population usage it was much

ing or yard being in Gauteng

without proper sanitation ‒ i.e.

lower than that of other

less common than in the 2001

(89.4%), followed closely by

households that use the

population groups .

Census (3.9%).

the Free State (89.1%) and the

bucket toilet system or have

Western Cape (88.4%).

no toilet ‒ has also decreased

white population, 98.8% of

serve not only as a benchmark

Whereas 99.4% of the

The Census 2011 results

over the 1996 to 2011 period.

the Indian/Asian population

for continuing research and

holds without access to piped

According to the findings,

and 92.4% of the Coloured

analysis, but also play an

water is highest in the Eastern

households that have flush

population have access to

essential role in informing and

Cape (22.2%), followed by

toilets connected to the sew-

a flush toilet, only 89% of

measuring public policies ‒ in

KwaZulu-Natal (14.1%) and

age system increased to 57%,

the Black African population

this case, relating specifically

Limpopo (14%).

from 55% in the Community

does, with 8.7% of this group

to the provision of water and

Survey of 2007 (CS 2007). The

having no toilet. Access to

sanitation services.

The proportion of house-

The third census to be

Adopt-a-River project gains momentum The deputy minister

of Water and Environmental

Empowerment Group, which has subsequently adopted it. While

Affairs, Rejoice Mabudafhasi has embarked on Sandspruit River

the original team was only 30 women in the Ficksburg area, it has

clean-up in Senekal, Free State.

subsequently grown to 164 people from a number of surround-

One of our biggest challenges in the water sector is high levels of pollution in our rivers nationally, which are the sources of

Marquard. The project is a completely voluntary initiative.

water. If we do not address this challenge we will not achieve our

It is targeting women specifically as we strive for socio-eco-

development goals, said Mabudafhasi when she embarked on

nomic empowerment of women in their communities, explained

the river clean-up as part of the Adopt-a-River project.

Mabudafhasi, adding that empowerment of women is one of the

The department cannot address this challenge alone. We need

smartest investments any country can make towards its develop-

communities to come on board and participate actively in the

ment. We believe that sustainable water resources management

management of water resources and environment. They are the

will be achieved by full participation of women.

ones closer to these rivers and we believe their indigenous knowl-

So far, the women have acquired skills in solid waste manage-

edge can be useful in changing the status quo, said Mabudafhasi.

ment, occupational health and safety, identification of alien

Adopt-a-River was initiated by the Department of Water Affairs

weeds and herbicide application, water safety, snake handling,

in the hopes of encouraging communities and other stakeholders

20

ing communities, including Ficksburg, Senekal, Clocolan and

first aid, environmental education and life skills.

to take charge of the river systems in their area. It forms one of the

The department will engage the private sector and donors in

projects of the River Health Programme, a nationwide monitoring

negotiating funding of this project as we would like to see it grow

system assessing the health of South Africa s rivers.

bigger and we also wish that that these women can become in-

The Sandspruit River is a small tributary of the Sand River that

volved in economic activities. Training will commence early next

runs past the Matwabeng township. The pollution of the river

year, concluded Mabudafhasi. To date, the Adopt-a-River project

by a number of sources was identified by the Setsoto Women

has created 1 000 job opportunities nationally.

JANUARY/FEBRUARY 2013

NEWS

Investment needed in human capital In the protection of

SWAKOPMUND SEWERAGE PLANT

Mechanical works on track

our ecosystems we must invest

Work on the Swakopmund Wastewater Treatment Works

in the most cost-effective

is track and the plant is scheduled to begin treating up to 12 Mℓ/d

ways with regards to human

of sewage by early 2013. The new plant will replace the town s

capital development and

old wastewater works, which are overloaded and no longer

finance. To this end, I would

comply with legislated discharge standards. The Namibian sub-

like to stress that nations that

sidiary of Veolia Water Solutions & Technologies, Aqua Services &

share ecosystems, such as

Engineering (ASE), was successful in obtaining the tender for the

international waters, can most

supply and installation of the mechanical works for the new plant.

effectively plan for their management if they have common

Historical context

regional agendas, said the

Originally built in 1957, the town s wastewater treatment plant

deputy minister of Water and Environmental Affairs, Rejoice Mabudafhasi, at the launch

Deputy minister of Water and Environmental Affairs, Rejoice Mabudafhasi

was situated just outside of predicted boundary limits, but unexpected growth has resulted in residential areas expanding to within intolerable proximities to the plant ‒ where outdoor fly and odour problems pose health risks to residents.

of the Global Environment Facility International Waters

provide knowledge that allows

Science Conference, which

us to make environmental

pump wastewater from various stations into a balancing tank at

was held at the United

interventions at regional,

the existing works in town. But once the new plant is operational,

Nations Conference Centre in

national and community levels.

sewage will be pumped 9.8 km in a pipeline to the new plant,

Bangkok, Thailand.

Importantly, there needs

where it will be treated, says Christian Stöck, MD at ASE.

The conference, which aims to set the International Waters Science Agenda for the next decade , is a science conference for practitioners and academics to provide leadership in finding solutions for the Earth s most pressing transboundary water challenges. It took place from

to be clear linkages that demonstrate the contribution

Nations that share ecosystems can most effectively plan for their management if they have common regional agendas

24 to 26 September 2012. Although gratified to address

Swakopmund s sewage reticulation system will still drain and

High-quality discharge

that local and

The new plant is designed for biological treatment by means of

national inter-

the activated sludge process and includes biological nitrogen

ventions have

and phosphate removal. Final water treatment processes will

towards region-

include gravity sand filtration and disinfection with chlorine. The

al or ecosystem

new plant s discharge water will be of high quality for reuse in

objectives, she

gardening and irrigation throughout the town, states Stöck. ASE

explained.

considered the odour and vector-related problems, especially

According to

in the collection pump station still located in the centre of the

Mabudafhasi,

town, and employed specific technologies to ensure smells

the delibera-

are eliminated.

tions needed to

The plant s mechanical equipment will be installed by ASE,

focus, among

including the inlet works, biological reactors (with mixers and

others, regional

surface aerators), clarifiers, rapid gravity sand filters, chlorination

cooperation and sharing of

and ferric chloride dosing equipment, sludge thickening, and the

information, investment in

anaerobic digester equipment.

the conference, Mabudafhasi

human capital and technology,

ASE started installing the mechanical equipment for the plant s

said that in order to have

and enhanced community par-

activated sludge system in June 2012. The civil works are approx-

effective common regional

ticipation and the utilisation of

imately 80% complete, which means, for us to meet deadlines,

agendas, the agendas needed

indigenous knowledge in the

we needed to begin our installation, despite the civil works not

to be informed by common

management of ecosystems.

yet being complete, concludes Stöck.

databases, management

In closing, she emphasised

plans and common indicators,

that communities could

which could then inform the

not be excluded from the

local plans.

decision-making processes

There should be a clear

The sewage treatment plant in Swakopmund will treat 12 Mℓ/d of sewage by early 2013

involved and that research

definition of how these

and science must not only

indicators and thresholds will

inform, but also support policy

be monitored by individual

implementation. We need

countries beyond the lifespan

to ensure that the research

of any particular research

results are communicated

project. These indicators must

to all stakeholders involved,

be as efficient as possible and

including communities.

JANUARY/FEBRUARY 2013

21

HOT SEAT

FIBERPIPE

Training towards a sustainable tomorrow Ensuring a sustainable tomorrow is all about investing in knowledge transfer and training, while expanding the field services offered on-site, according to Jan Krüger, technical manager at locally based GRP pipes and fittings manufacturer Fiberpipe.

F

iberpipe identified a key focus of its strategy as the need for technical expertise on-site during installation of its products in order to ensure that the pipes are installed to specification and

perform optimally. The current tender climate, with a focus on cutting costs, has resulted in the reduction of supervision on-site, believes Krüger. The field services team is involved in providing technical expertise, as well as monitoring the installation on-site

ABOVE Fiberpipe field services representative, Jannie Liebenberg, giving the contractor training on the installation process

What we have discovered is that we need people onsite full time so that we can visually assess almost every pipe that is installed at any time, ensuring installation is according to the prescribed specifications of both the consulting engineer and us, through our recommendation of the correct type of installation for that specific project and site, says Krüger.

Pipe installation prioritised

to ensure the correct installation techniques are used by

Ensuring the correct installation of the pipe infrastructure

contractors. According to Krüger, it is very simple to install

becomes pivotal when considering that investment in

a pipe. Simply put, it involves ensuring the bedding is straight and level, and compacted to 90%. The key step in the process, however, is that this needs to be tested before the process of backfilling is undertaken around the installed pipe.

22

“Ensuring installation is according to the prescribed specifications of both the consulting engineer and us” JANURAY/FEBRUARY 2013

HOT SEAT the projects is investment in the sustainability of the

Jaco Fourieshowing the contractor of the Kamfers Dam project how to correctly join the pipes with a Reka Coupling

entire water network and could result in huge savings for the state and the water authorities. If you install a pipeline badly its life cycle is no longer 50 years as anticipated. This could possibly be decreased to only 25 years and the replacement costs are huge. Contractors need to be conscientious from the beginning and ensure the pipeline is installed correctly, says Krüger. Fiberpipe s heavy investment in the field services unit through not only training, but also sourcing the correct staff over the course of the last few years, therefore not only ensures the quality of the installation, but is also evidence of the company s undertaking to ensure sustained best performance of its products after installation.

Field services at work

We have spent a lot of time and energy getting the guys equipped and trained, getting them ready, ensuring the

The largest project

gravity line into the Vaal River.

knowledge transfer is taking place and this year we will

undertaken by the field services

This involved the installation of

be focusing on sharing this knowledge and driving their

team to date was at the Kamfers

700 mm diameter rising main,

presence on-site, says Krüger.

Dam, near Kimberley. The dam,

pump station and gravity south

The company has five permanent members of staff

which was initially an ephem-

and north pipelines, which was

in the field services team; however, it has undertaken

eral pan, has increased in size

undertaken through a combined

training of a number of contract field representatives

over the years due to increased

effort by Sol Plaatje Municipality

close to some of its core projects in order to maintain its

discharge from the local waste-

and Transnet.

reach and increase service delivery, ensuring installation

water treatment works as a result

The contractor, Entsha Henra

is done as effectively and efficiently as possible. The

of increased development in

Construction, was commissioned

work is also cyclical, which is partly why we identify

the region.

to carry out the installation and affected

Fiberpipe supplied the physical

and get them to a standard where we feel comfortable,

the stability of an important

pipes and fittings for all the

adds Krüger.

railway

nearby

phases as well as trained the

and threatened the local pink

contractor s staff on the proper

Dedicated to knowledge transfer

flamingos and other species

installation of the GRP pipe.

The biggest focus in 2013 will be increasing the awareness

breeding grounds.

contract field representatives near the site, train them

This

increase line

has

located

In addition, the company s field

and knowledge of composite materials as an alternative.

To stop the continuing expan-

services unit provided a monitor-

Although it isn t a new material ‒ it has been around

sion of the pan, it was decided

ing service to ensure that instal-

since the 1960s ‒ it is still received as a new technology,

to bypass the running effluent

lation procedures were correctly

says Krüger.

currently supplied to the dam

adhered to and provided techni-

into a reservoir and then by a

cal assistance to the contractor.

In addition, it is also a bit more complicated technology than PVC or steel. Where steel is a homogenous material and exhibits strength in all directions, composite pipe involves the inclusion of glass, which can make the pipe stronger in one direction, explains Krüger. According to Krüger, this challenge is further compounded by the lack of training on glass fibre reinforced (GRP) pipe for engineers at the tertiary institution level,

A contractor with his staff who have been trained by Fiberpipe’s field services

who then don t feel comfortable utilising it. If there is a lack of knowledge then people don t trust the product. Engineers are by nature conservative people ‒ they would rather stick to what they know, says Krüger. He adds that the economics of the product also make it a much more viable alternative. Whereas 20 years ago it was more expensive than steel, today it costs less than

GRP pipes, targeted at engineers already in the

steel and is easier to install. We have reached a point

industry; the course will hopefully be CPD accredited.

where GRP composites cannot be ignored.

He adds that teaching engineers of today and tomorrow

Fiberpipe has already made contact with a few univer-

about composites is essential. People don t realise what

sities in South Africa where its campaign will take the

composites are. Composites are used everywhere and

form of two lectures targeted at the engineering students.

if we can facilitate that change in mindset and create an

From there we hope to expand and roll it out at other

understanding of the benefits and advantages of utilising

tertiary institutions, states Krüger. Another knowledge sharing Fiberpipe has initiated is a course on the use and installation of composite

composites in certain applications, then we will have been successful ‒ but until then this will continue to be our focus.

JANURAY/FEBRUARY 2013

23

INDUSTRY NEWS

WILO

Pioneering change International pump manufacturer Wilo has launched a major rebranding campaign as it focuses on a new, more customer-centric value proposition: pioneering for you. Chantelle Mattheus speaks to Wilo South Africa’s MD, Patrick Hulley, on what the rebranding means for local customers and employees alike.

T

his is a really big

Africa to reflect the name of the

decision

parent group in Germany.

for

Wilo.

One of the things that

the

Courage to change

company

has invested a lot of time and effort

Hulley believes that customers look

in is to understand where the Wilo

towards companies that are brave

brand sits on a global scale. It is a

enough to embrace change during

very strong German organisation

these tough economic times and

that had, historically a very strong

the rebranding is just one small

German

expression of this.

and

European

market

This rebranding is really a major

share ‒ and still does today,

step that indicates we are willing

explains Hulley. However,

as

the

brand

to change, we are well in tune with

has

expanded different cultures and

market needs and therefore we need

markets view the branding in differ-

to represent our company as such.

ent ways. From a German cultural

People see so many brands every

perspective the branding is robust.

day. Companies need to ensure ‒ and

In the new markets where Wilo is

Wilo has done this ‒ that when people view these brands they

viewing the new brand. It starts talking towards the

“It starts talking towards the personality of our company. It expresses that Wilo is not only about the product and profitability, but it is also about the people.” Patrick Hulley,

personality of our company. It expresses that Wilo is not

MD, Wilo South Africa

is the Wilo value proposition to

expanding into, according to Hulley, it is not always as well received and so the rebranding focuses on changing this perception to include local contexts, values and perceptions. Products are being promoted around features and benefits. Branding is around the promise to the customer and as Wilo has investigated our brand over a number of years, we have reached the point now where we have got to show the world that we are not only a German-centric or European-centric brand, but we are truly a global brand. Hulley believes the organisation s focus is clear when

are memorable. However, Hulley is quick to clarify that it is not a rebranding of the company s product approach, which will remain one of technology. The branding is merely to support this aim and to allow people to remember what our products stand for.

Different dynamic The change is twofold. With regards to the branding, the obvious change

only about the product and profitability, but it is also

customers, namely pioneering for

about the people internally, about our customers and

you . It is a more emotional approach as opposed to just a

about the end-point users.

product-centric approach, says Hulley.

Setting the scene

Africa evolve into the headquarters of the sub-Saharan re-

Salmson South Africa is a wholly owned subsidiary

gion. Today we are very focused on South Africa and sup-

of the international pump manufacturer Wilo SE,

port our neighbouring countries, but we will now be mak-

headquartered in Dortmund, Germany. An international

ing a conscious effort into the sub-Saharan region. We have

supplier that has continued to maintain equitable and

already hired people in Kenya, Tanzania and Zambia. We

proficient water quality management worldwide, with

already have a strong customer base in Namibia, Angola,

representation in over 70 countries and an annual

Botswana, Mozambique, Mauritius and Madagascar.

Organisationally, the changing focus will see Wilo South

production rate in excess of eight million pumps,

The intention is to continually add people into

Wilo is one of the largest pump manufacturers in the

the sub-Saharan region. The biggest organisational

world today. From 1 January 2011, the locally based

change is therefore really to expand our footprint,

contingent had used the trading name Wilo South

concludes Hulley.

JANUARY/FEBRUARY 2013

25

INDUSTRY NEWS

ANAEROBIC DIGESTION

Increasing biogas generation Tecroveer recently announced the finalisation of its agreement as an official agent for Norway-based Cambi’s range of technologies.

C

ambi

boasts

more

than

25

completed

Some of the advantages of the

projects worldwide over the past 16 years

Cambi THP technology are:

and is a leading global provider of technol-

• generating more energy (higher

ogy that converts biodegradable material to

biogas production)

renewable energy.

• reducing the final amount of

According to Gary Brown, marketing manager of the

sludge ‒ it improves sludge

Tecroveer Group of companies: We are a technolo-

dewatering

gy-driven company that designs processes and equip-

(Dry Solids)

ment, manufactures, installs and commissions world-

up

to

40%

DS

• it ensures sludge pasteurisation,

class turnkey solutions for all wastewater treatment

i.e. a pathogen-free sludge

related industries. The range of Cambi technologies will

• a stabilised and compost-like

further complement our existing technology offering.

product is produced, with 70%

Cambi is a world leader of the thermal hydrolysis process (THP), which involves the pre-treatment of sewage sludge and industrial concentrates before digestion. This presents an entire new offering to the African wastewater sector, thereby meeting today s needs and the environmental requirements of tomorrow. Cambi s technology and product offerings create value from municipal and industrial sludge; bio-waste,

decrease in odour

The Cambi THP Næstved Plant in Norway. The pulper and flash tank are shown in the front with the reactor at the back

• increased speed and capacity of digestion (less digestion volume) • a reduced carbon footprint. THP enables volatile solids reduction with more biogas, faster anaerobic digestion rates, better dewatering and high capacities, in all Cambi models. The B2 models are the latest and smallest models, which are built as single

including food waste and slaughterhouse residues; and

containerised units. These are suitable for small to medi-

by-products and waste from the processing industry and

um sized plants with a capacity of 1 500 t DS (tonnes dry

agriculture activities.

solids) to 6 500 t DS per year. The B6 product is the mid-

Cambi s patented steam explosion THP technology

size model. These are modularised, packaged units, for

makes use of high-pressure disintegration. THP treats

medium to large-sized plants, with a capacity of 6 500 t

municipal and industrial biosolids and biowaste prior to

DS to 19 000 t DS per year. The B12 product is the largest

anaerobic digestion.

and original product. It comprises pre-built components

Biogas production from anaerobic digestion is maximised using existing capacity

that are assembled on-site. This model is suited for large to very large sized plants, with a capacity of 19 000 t DS to 36 000 t DS per year. The use of the THP in sludge treatment at wastewater treatment plants (WWTPs) offers some major advantages in terms of energy, public health and environmental protection. Medium-sized plants can be converted, with

the import of sludge from other nearby plants, into strategic sludge treatment centres. Here biogas production from anaerobic digestion is maximised using existing capacity, generating a pasteurised sludge with high dry solids content. The generation of electricity from renewable sources, produced from biogas, allows the energy costs of the WWTP plant to be reduced and the WWTP may even have surplus energy production. Brown says: Tecroveer is proud to be associated with Cambi, which has been involved in the development of environmental technology since 1989. Cambi is owned by Petrol AS, PEBA AS and Mallin Venture AS, as well as by its employees. The company makes substantial investments in process and product development, and

Cambi 8 reactor THP plant in Dublin, Ireland

26

resources to build, own and operate plants. We have already made some impression in the South African market and hope to install the first full-scale system shortly.

JANUARY/FEBRUARY 2013

PANEL DISCUSSION

INTRODUCTION

Deliberating on desalination Globally there are around 16 000 desalination plants in operation with a total capacity of over 66 000 000 m3/d.

A

ccording

to

the

industry

shortfalls,

in implementation and the constantly

the

although the process is costly and releas-

evolving technologies available, as well

following pages, although the

ing leftover brine back to the ocean has

as the projects being applied, through

desalination market in South

environmental implications.

one-on-one interviews with key industry

experts

interviewed

in

communities

address

local

Africa is still relatively small, it is growing,

So is this the ideal solution to local

and industries, some municipalities and

water scarcity problems in South Africa

water boards are actively studying the

and in the broader African landscape?

use of desalination to meet their current

Ultimately

and future needs.

which some say is a costly solution for the

desalination

role players across the board.

technology,

Given that more than a third of the

world s water scarcity problems, is being

world already suffers from shortages

used more and more frequently in South

of potable water, according to recent

Africa and worldwide to provide water to

reports, and a rise to 50% expected

areas where there are shortages. It is also

by 2025, it is not unexpected that role

an alternative in the industrial arsenal

players in the water industry evaluate

utilised towards sustainable practices

all the tools available to them to ensure

and therefore is definitely worth closer

sustainable supply and management of

investigation. In this panel discussion,

the scarce resource. For example, the

Water&Sanitation Africa seeks to explore

desalination of seawater can help coastal

the advantages thereof, the challenges

27

s Bio-MASS MANAGEMENT AND SLUDGE DEWATERING EQUIPMENT s -INE and industrial water TREATMENT TECHNOLOGIES

So lut ions

s $RINKING WATER PURIl CATION technologies

.

s $OMESTIC WASTEWATER TREATMENT TECHNOLOGIES AND SYSTEMS

e nk ... Tur

Own Equipment Manufacturer (OEM)

and Supply n o sig

f ..

De

JANUARY/FEBRUARY 2013

yW nt ater e m t Trea

Focused Business Areas s "UILD /WN /PERATE 4RAIN

4RANSFER -AINTAIN s %QUIPMENT MANUFACTURE and refurbish s Accredited laboratory services s %VALUATIONS AND !SSESSMENTS s 4RAINING

“Clean water for future generations� by: s Partnering with nature s Creating an awareness s Sustaining a legacy 4EL &AX i n f o @ t e c r o v e e r.c o .z a w w w.t e c r o v e e r.c o . z a

VEOLIA WATER SOLUTIONS

PANEL DISCUSSION

Gunter Rencken, MD, Veolia Water Solutions

Desalination is increasingly gaining prominence. What are the advantages thereof?

This works by separating ionic

nearest competitor. The

components by means of

Southern Africa branch of

cation and anion exchange

Veolia Water Solutions and

Africa has access to an

membranes. Good progress

Technologies has been

extremely large coastline with

is also being made with a

responsible for construction of

an infinite supply of available

mixture of the above main

several plants over the past few

from large membrane

seawater for coastal towns or

technologies such as hybrid

years, including:

treatment processes is being

cities. As more and more plants

systems utilising MED and

• Mossel Bay (2011) ‒ at

treated with the intention

are being commissioned and

RO technology. The other

15 000 m3/d, this is

of reducing these waste

the technology accelerates,

improvements are the use of

the largest operational

streams to near zero liquid

the capital and operating

alternative energy resources

desalination plant in

discharge status. There are

costs of such plants are

such as wind turbines.

South Africa

major challenges with these

• Knysna (2010) ‒ a 2 000 m3/d

constantly reducing.

processes since the nature of

process or discharge standards.

What is the difference between seawater and wastewater treatment technology? As described

Desalination also provides a

above, seawater desalination

was taken to integrate the

solution for industry to move

technologies consists of

aesthetic design of the

towards zero liquid discharge

mainly two types of proven

plant to blend in with the

status facilities.

or conventional technologies

surrounding upmarket

Is desalination the ultimate panacea for our water availability woes? The

tourist area

preferred solution will always

For industrial clients, this is applicable technology to treat high salinity wastewater to

plant, which was completed

the brine to be treated is vastly

within seven months

different to that of seawater

• Plettenberg Bay (2010) ‒ 2 000 m3/d; special care

such as RO membrane or

and the process steps are unique for such applications.

What are the options available? The technologies

thermal processes. If we look at wastewater with high salinity

(2010) ‒ 1 800 m3/d; capacity

treatment where secure

can basically be split between

content, the treatment option

and technology upgrade was

feed sources are available

two main principles: distillation

would be different in terms of

the main focus of this plant.

as it is the most economical

(thermally driven systems)

pretreatment and membrane

All of these plants are based

model in terms of capital and

and membrane-based

configurations. This process

on the conventional RO

operational costs. Municipal

reverse osmosis (RO).

will be totally dependent on

membrane process principle,

wastewater reuse is also a

the composition of the water in

but with many different

viable option for the future.

multiple effect distillation and

terms of suspended solids and

configurations in terms of the

There is currently also pressure

multi stage flash technology.

dissolved ions in the water.

seawater abstraction, pre-

on local authorities to refurbish

treatment and brine disposal.

and expand their existing

Distillation processes include

Historically, these processes

• Bushman s River Mouth

remain conventional water

of energy or heat are

Price is often quoted as a limiting factor. How quickly is ROI recovered? Price

available. This process is very

is relevant if compared to

What are some of the interesting upcoming projects? We have recently

energy intensive.

conventional water treatment

been awarded a seawater

demand for potable water

have been applied where spare or low cost sources

facilities before they consider desalination plants. Once again this is driven by economics. In many large cities, the

RO technology is a newer

plant costs. As a general rule,

desalination plant for Lamberts

has grown to such an extent

technology than the thermal

the cost of water produced by

Bay; the town has grown and

that local municipalities

options, and is growing rapidly.

seawater desalination could

it has to ensure its future

have no other option than

The main advantage is that the

be as much as double that

water security.

moving towards desalination

energy requirement is much

of conventional municipal

lower than that associated

treatment plants.

with thermal plants. The

Veolia Water SA is also working on a project within

to supplement their current resources.

the power industry whereby

The ROI should rather be

concentrated brine generated

only drawback is that the

viewed in the context of

pretreatment requirements

comparisons to building new

for these systems are more

dams and reticulation systems.

Mossel Bay desalination plant

complex and costly.

What could desalination of tomorrow look like?

What are Veolia Water Solutions desalination experiences? Internationally,

Continuous development

Veolia Water has designed and

is being conducted on

constructed approximately

alternative technologies such

15% of the world s installed

as membrane desalination

desalination capacity ‒ about

by means of electrodialysis.

twice as much as the

JANUARY/FEBRUARY 2013

29

www.degremont.com

SEA WATER: SOURCE OF

REUSE

LIFE. © Les Éditions Stratégiques

Degrémont’s membrane filtration technology is suitable for the whole range of treated wastewater uses, from agriculture and landscaping to industry and many others. Already valued by farmers and industries, the clean water produced by this demanding process makes a major contribution to water conservation and environmental protection.

DESALINATION Degremont draws its desalination experience from its portfolio of more than 250 reverse osmosis plants around the world. The process removes mineral salts by forcing water to cross a semipermeable membrane. With the growth in world demand for drinking water - and with 40% of the world’s population living within 100 km of the sea this technology offers a sustainable solution for the supply of potable water.

FOR THIS & OTHER DEGRÉMONT’S WATER TREATMENT PLANT EQUIPMENT, CONTACT : DUMI LUTHULI, Deputy Managing Director dumi.luthuli@degremont.co.za MORNAY DE VOS, Business Develop. Mg mornay.de.vos@degremont.co.za Tel: +27 (0) 11 807 1983 Fax: +27 (0) 10 591 5095 www.degremont.co.za

THE WATER TREATMENT PLANT SPECIALISTS

PANEL DISCUSSION

DEGRÉMONT Miguel Angel Sanz, Director: Development & Innovation, Degrémont

Desalination is increasingly gaining prominence. What are the advantages thereof? Desalination is

micro- or ultrafiltration. Reverse

the largest desalination plant

osmosis or nanofiltration is

in operation in Europe with a

only used when it is necessary

production of 200 000 m3/d,

to remove salts from water

as well as the Middle East,

the solution when there are

or when a double membrane

Western Australia and Bahrain.

no other sources available.

barrier is required.

Seawater desalination uses

This year we are com-

success.

missioning the largest

When RO is employed for

an inexhaustible source, the

reuse of wastewater purposes,

desalination plant in the world

sea, and it can produce water

the membranes are adapted

in Melbourne, Australia, with a

to use in agriculture, industry

for much lower pressure

total capacity of 450 000 m3/d.

Is desalination the ultimate panacea for our water availability woes? Traditional

and also as drinking water.

than seawater desalination

Since 29 September 2012, a

solutions will always be

Desalination could also be

and higher recovery rates of

third of the production from

present and favoured because

applied in wastewater reuse in

the water.

this plant ‒ 150 000 m3/d

of cost considerations, but

of potable water ‒ is

the role and importance of

being injected into the

desalination will increase year

What are the options available? Two main

Price is often quoted as a limiting factor. How quickly is ROI recovered? Price is

potable water network of

by year.

technologies are used: thermal

always a key factor. Minimising

Commercial Acceptance .

energy or membranes. The

the cost of investments is the

some cases.

the city after the Preliminary The first challenge in every

first uses thermal energy to evaporate the water into vapour, which is thereafter condensed back into liquid form. The second uses pressure to filter the water through

There are cases where desalination is the only viable solution to provide potable water or water for industries

The first challenge in every project is adapting the solution to the real needs of our different customers

membranes (reverse osmosis)

from seawater or brackish water. Desalination is getting a bigger slice of budgets every year due to the scarcity of resources. In addition, desalination is the best solution for

to obtain desalinated water.

driver of all decision-makers.

project is adapting the

the treatment of acid mine

In the case of water reuse,

But when you have no other

solution to the real needs of

drainage (AMD) and for many

thermal technologies are

water sources available,

our different customers. The

problems of industrial supply.

not suitable.

seawater desalination is the

second is the selection of all of

solution and then it is not a

our partners to bring the best

matter of recovering ROI, but a

specialities and experiences

When is the application of desalination ideal?

question of necessity.

for these solutions. The third

Desalination is the solution

is to have good engineering,

when no other sources are

construction and commission-

available, like dry areas or

(RO) technology. The trend

What are Dégremont s desalination experiences?

ing teams experienced enough

seasonal scarcities and when

is towards increasing this

Degrémont is one of the

to face all challenges of the

a very good water quality is

percentage in the future,

pioneers of desalination. Our

projects, the known and the

required. It is a solution for

mainly due to the fact that it

first plant was built in the early

new ones.

water shortages and also an

requires less energy and has a

1970s and since then we have

lower carbon footprint.

put in operation desalination

our technologies and know-

a solution to the different

plants with a total capacity of

how, are the levers to our

problems of the world.

What could desalination of tomorrow look like? Today more than 80% of desalination plants use reverse osmosis

What is the difference in seawater treatment versus wastewater? Seawater

technology. Degrémont is one

desalination always employs

market and the only one that

the use of RO membranes

has nine plants with a capacity

to remove salts from the

of over 100 000 m3/d. We also

raw water. For reuse, other

have long-term operation and

technologies can be used to

maintenance contracts for

purify the treated wastewater.

some of these plants.

These technologies are

These three, combined with

arm of the arsenal to provide

over 2 700 000 m3/d, using RO of the top three players in this

Degrémont has been

conventional like coagulation-

involved in the seawater de-

flocculation, oxidation,

salination plant of Barcelona,

clarification, filtration or absorption, or could be membrane technologies like

The Melbourne, Australia desalination plant recently went “live“

JANUARY/FEBRUARY 2013

31

Water comes in. Water gets used. Water goes back out.

We believe customers deserve access to world-class resources, exceptional service, and a commitment to continuous improvement and innovation. Buckman offers an optimal solution for treatment of utility and process water— an extensive portfolio of specialty chemicals, unmatched technical expertise and service, and a network of experienced associates who quickly identify, prevent, and solve problems. Find out how we can help with your water treatment needs. Visit buckman.com or call 800-BUCKMAN (800-282-5626).

In Africa: Hammarsdale – Tel: +27 (0) 31 736 8800 Bedfordview – Tel: +27 (0) 11 997 5100 email: southafrica@buckman.com buckman.com ©2013 Buckman Laboratories International, Inc.

Apply a better biocide. Ensure a better biosphere.

Now you can get a water treatment program that’s tougher on microbiological activity, easier on the environment. The Oxamine system from Buckman is a safer alternative to gaseous chlorine, and it is more effective in an environment where ammonia is present. It provides better performance in high-demand systems, resulting in improved condenser cleanliness. Oxamine is more effective than chlorine on biofilm control while lowering corrosion rates on common system metallurgies. It is 100% mineral and produces no organic toxins, making it the greenest technology on the market. To learn more, contact your local Buckman representative or visit us online at buckman.com.

©2013 Buckman Laboratories International, Inc.

PANEL DISCUSSION

BUCKMAN Dr Andre Maartens, Divisional sales manager: Energy, Buckman Desalination is increasingly gaining prominence. What are the advantages thereof?

important. By combining brine

ROI might be recovered on

pressure harvesting and, for in-

certain areas of the desalination

stance, solar energy harvesting,

process by utilising energy

Desalination has a smaller

a desalination plant could be

recovery systems, effective

footprint, is usually less complex

almost energy self-sufficient ‒

chemical programmes and

and really works. High-quality

but with very high capital outlay

pretreatment steps.

water is produced in one or two

required.

are able to use solar radiation when energy is not available

be combined with various

concentration polarisation,

What are Buckman s desalination experiences?

energy sources, i.e. solar, wind,

membrane distillation and

We have a wealth of experience

er desalination processes when:

nuclear and even play a role

forward osmosis are all going to

throughout the company. We

• forced by legislation

in energy generation (osmotic

gain prominence.

are involved in numerous de-

• there is an inadequate

processes and it can potentially

Graphene sheets, ion

salination applications, ranging

pressure to energy). It can

and small volumes are required. Companies should only consid-

water supply

from potable water production

and can further combine with

What is the difference between seawater and wastewater treatment? Seawater

various technologies to provide

desalination is energy intensive,

Buckman s expertise has always

water of various qualities. High-

but most seawater desalination

been focused on understanding

quality water can be produced

plants use energy-recovery

the water chemistry, membrane

Is desalination the ultimate panacea for our water availability woes? First is Water

from previously unusable water

systems that have resulted in an

autopsies and the correct

Catchment Area management,

sources to supply quality water

80% reduction of energy used

application of our chemistries.

then water saving technology

for industries and for potable

for water production compared

Recent developments have

and low-tech water reuse. When

use. In addition:

to systems 25 years ago. The

opened up a number of new

these things are in place and

• desalination releases the

geological location of the user

opportunitiess for Buckman.

supply is still limited, desalina-

strain on natural water

is another factor. Brine disposal

These developments include:

tion can be investigated. Recent

sources in countries with

is relatively easy ‒ the brine is

• state-of-the-art online moni-

events at the southern coast of

low rainfall

usually returned to the ocean ‒

toring technology, EZeMonitor

but environmental factors may

• specialised Buckman Green

also be designed in modular configuration for easy expansion

• in cases of severe drought, desalination processes can be utilised for the supply of water • process and industrial waste-

to extremely large industrial

• a higher quality of water is required for certain processes.

water reuse applications.

South Africa showed the folly of jumping at technology first.

Toolbox that empowers our

The days of unlimited water use

sales team to do on-site com-

are over, we need to start living

where human activities are

puter modeling and strategic

conservatively with our water.

centred. The treatment

alliance partners on the engi-

influence feasibility. Wastewater is always available

water can now be reused,

technology is more compatible

neering and equipment side.

making/forcing companies to

with alternative energy sources,

All this is putting Buckman in a

take better responsibility for

such as wind or solar. It is

leading position when it comes

Do you see the desalination market growing substantially in the near future?

their waste streams and tak-

also compatible with existing

to providing total solutions to

The increase in desalination

ing care of the environment

pretreatment like biological

our customer

applications should grow faster

and the impact of the waste

sewage or waste treatment. A

streams on the environment

disadvantage of wastewater

as population growth and water availability puts more pressure

is the degree of removal of

When is the ideal application for desalination?

changing in such a manner

human waste products, medical

We recommend RO for salt

growth can be expected, but

that increasing amounts of

by-products hormones, steroids,

water or wastewater when

not a short-term explosion.

energy in the systems are

etc. More pretreatment may be

adequate energy is available.

Growth in South Africa

reused to drive the process.

required and the process may

If energy costs are a factor or

is estimated to be 28% for

be more complex.

when brine disposal is not

the next five years ‒ up to

possible (sensitive environment

530 300 m3/d. By 2030, it is

factors, for example, then evap-

estimated that 10% of the urban

oration is a cheap but effective

water resources would be from

solution. Evaporation systems

desalination plants.

• desalination processes are

What could desalination of tomorrow look like? be thinner, stronger materials

Price is often quoted as a limiting factor. How quickly is ROI recovered? I believe that

for membranes, probably even

costs will become less relevant

nano-based tubes instead of

as the price and availability

current thin film types. There is

of energy escalates. Costs will

much hype about biocidal mate-

probably almost disappear as a

rials and self-cleaning materials,

limiting factor in the near future

but they are not the next big

(3 to 5 years).

Desalination of the future will

thing to change the technology. Various energy sources and brine pressure reuse will be very

on water suppliers ‒ steady

Water reuse will never be cost effective in comparison to the use of natural water sources.

JANUARY/FEBRUARY 2013

33

SUPERIOR TECHNOLOGY. SUPERIOR SOLUTIONS. NUWATER MODULAR TREATMENT PLANT Seawater

Surface Water

Groundwater

NuWater provides a range of products, services and financing solutions to reclaim or treat almost any quantity and quality of water.

Waste Water

Clean Water

Innovative 16" reverse osmosis technology makes NuWater plants more compact and efficient, with lower operating and maintenance costs. Being modular and mobile, our plants are also rapidly deployable and highly scalable, providing ultimate flexibility in a rapidly changing world. People

Mining

Industry

Oil & Gas

Challenge us to clean your water.

Wastewater Reclamation

FROM TOP: Anglo American New Vaal Colliery – Mine waste water reclamation and reuse. Modular and mobile units for clean water where it is needed. Singapore Public Utilities Board – Secondary sewerage water reclamation and reuse.

www.nuwater.co.za

+27 21 531 0641

PANEL DISCUSSION

NUWATER John Holmes, CEO, NuWater

Desalination is increasingly gaining prominence. What are the advantages thereof?

We are, however, a complete

wastewater is generally far less

solutions and services

energy intensive than that of

company, so our competitive

seawater due to the generally

It is important to remember

advantage is also based on the

lower concentrations of salt

that desalination does not just

efficiency and effectiveness

in wastewater. Wastewater

relate to seawater, but to any

of our complete treatment

reclamation therefore presents

the process of delivering two

water with elevated levels of

plants, which incorporate

a major opportunity.

desalination plants for a Gold

salinity that make it unsuitable

multiple technologies.

Fields mine in Ghana. These plants will treat wastewater

using technology to purify

What could desalination of tomorrow look like? The

How quickly is ROI recovered? Simple ROI calculations are often not the

quality process or potable

and desalinate water such that

potential for desalination

basis for project evaluation.

water, or to be discharged

it is suitable for human and

applications is limited by two

The fact that access to water

into the environment

agricultural consumption are

major challenges: energy

is considered a basic human

in compliance with

indisputable. The question is

consumption and brine. The

right means that the true

environmental protection laws.

really about economics: what

concentrated waste/ brine

cost of high-quality water has

The extremely tight project

does it cost and what is the

stream must be either stored

historically been masked by

timelines have added to the

economic and social value of

or disposed of. Brine from

government subsidisation.

logistical complexity with

water security?

seawater desalination is

NuWater s focus on providing

equipment being brought

discharged back into the

complete water cleaning

in via our Singapore and UK

What are the options available? Options for the

sea and quickly mixes back

services offers customers a

operations. The first phase is

into seawater, although

simple and transparent basis for

currently being commissioned.

separation of dissolved salts

environmental concerns remain.

evaluating their water treatment

from pure water are limited to

Brine from brackish water is

and desalination projects.

thermal separation through

generally more of an issue as

evaporation or freezing, the

disposal options are limited.

for drinking or agriculture. The benefits ‒ and the necessity ‒ of

What are NuWater s desalination experiences?

to either be reused as high-

Is desalination the ultimate panacea for our water availability woes? Technology risk aversion and

use of synthetic membrane

NuWater is focused on

technology such as reverse

developing and refining its

NuWater is focused on four

limited financing options

(RO) or forward osmosis

technologies to increase pure

industry sectors, namely:

continue to be a problem

(FO), or through electrical

water recovery and therefore

mining, oil and gas, power and

in the industry. NuWater

processes (electrodialysis/

decrease the volume of brine

industrial, and potable reuse.

is tackling risk aversion by

eletrodeionisation). RO is the

produced, while also reducing

In each of these sectors we

demonstrating reliability

default choice for large-scale

energy consumption. This

have exceptionally high-quality

in private sector projects

desalination applications as the

involves in-house R&D, process

reference plants.

and by taking on large

total unit cost of desalination

design improvements as well

(including operational and

as incorporating specialist

had its own challenges, from

owning and operating (BOO)

capital costs) makes it the most

third-party technology to

proving our technology

its own plants. The more

cost-effective technology.

complement NuWater s

performance for one of the

flexible financing options

proprietary technologies.

world s most demanding

presented by our BOO model

water customers in Singapore s

can, however, only have a

PUB, to deploying large-scale

significant impact on the rate

modular plants to leading

of uptake if the physical plant

mining customers within

and related infrastructure

weeks of signing contracts. In

is similarly flexible.

each case, however, success

NuWater s modular and

has been determined by our

redeployable plants provide

technological expertise, the

this flexibility and allow for

quality of our plants and our

distributed infrastructure

unwavering commitment to

rather than traditional

customer service.

centralised infrastructure.

What are some of the interesting upcoming projects? We are currently in

the challenges facing the rapid

NuWater specialises in RO applications where our proprietary large-diameter (16 ) RO provides us with a clear technology advantage.

What is the difference in seawater treatment versus wastewater? Desalination of

Each of our projects has

parts of the risk by building,

NuWater is realistic about and large-scale adoption of desalination, but is playing an important role in changing

NuWater small mobile drinking water plant

JANUARY/FEBRUARY 2013

customer mindsets through demonstrable success.

35

VERDER PUMPS SA

PANEL DISCUSSION

Rob Shaw, Sales engineer, Verder Pumps SA

Desalination is increasingly gaining prominence. What are the implications from the pumps perspective? I

secondary bearing, this pump

and, in contrast to sealed

is suitable for pumping solids

centrifugal pumps, the magnet

in the liquid.

capsule of the Verdermag mag

don t necessarily know about

mag drive pump for all heavy-

how desalination plants work,

duty pump applications for

or the intricacies involved

the best economic prices.

This series is an advanced

or whether or not they are

drive pump ensures a safe and leak-free operation. Even under heavy-duty circumstances, the pumps

balance chamber pressure

remain reliable.

is reduced. This causes the

they would need to pump

What makes these products or proposed solutions different? The Verdermag

seawater (brine) and when it

series consists of mag drive

How do these pumps operate ‒ what is their working principle? The

comes to pumping seawater

centrifugal pumps that are

closed single, enclosed

the balance

the pump seals on normal

sealless and hermetically

magnet impeller/magnet

cha chamber

centrifugal pumps become a

closed. The pumps are also

assembly is

pre pressure

major problem.

available as chemical norm

tate free to rotate

inc increasing.

pumps with ANSI and DIN

and slide on

specifications. Excellent

al the central

corrosion resistance makes

red cantilevered

gaining in popularity. The only thing I do know is that

Why are the pump seals in normal centrifugal pumps a problem in this context? Any seal leaks a little bit of product by the nature of how seals work. When seawater comes into contact with the atmosphere it crystallises due to the sodium chloride present

impeller to react with a net force towards the m motor. t valve is However, the c now closing and

m This moves the to impeller towards suct the suction. ne result The net

This series is an advanced mag drive pump for all heavy-duty pump applications for the best economic prices

sta is a very stable axial position for the impeller. There are no axial bearings and radial bearings always operate in a pressurised fluid environment.

in it, resulting in a build-up of crystals at the mechanical

the Verdermag glandless

shaft. The main flow of liquid

seals and the maintenance

range the most reliable pumps

enters the impeller and is

on mechanical seals therefore

for applications in almost all

pressurised, then expelled

becomes rather costly.

areas of industry. Material

into the volute and out

What or where have these technologies been successfully implemented before? Verdermag pumps

choices such as EPTE, PVDF

the discharge.

are guaranteed to operate

How can this challenge be overcome at desalination plants? Verder can eliminate

(polyvinylidene difluoride),

A small portion of the flow

with zero leakage of product.

PFA and silica carbide provide

passes behind the impeller

To prove this point, Verdermag

great opportunities to use

and through the back wear

pumps were installed more

this problem by installing

the mag drive pumps in the

ring clearance and then into

than four years ago on an ice

our range of magnetic

chemical and process industry.

the balance chamber. This

plant of one of the AngloGold

driven pumps. Verdermag

For the more common

liquid then flows through, past

Ashanti mines pumping brine

non-metallic, magnetically

applications, polypropylene is

the bushings to exit the valve.

water and this project is still

driven pumps have been

a cost-effective alternative.

manufactured since 1998.

The advantages of

forward, the valve is opened

Verdermag drive centrifugal

to a greater degree and the

Our claim to fame is our thrust balanced product

pumps include:

line: the TB ‒mag series. Its

• zero leakage (100%

introduction revolutionised the non-metallic, mag drive pumping industry as the first

packed glands

with the ability to pump solids.

• pump s efficiency ensures a clean and safe operating environment

configurations in total, and

• close coupled design

a tremendous flow range to

• no alignment required

meet with the requirements.

• increased mean time

With SiC as standard material

Brine pumps at Mponeng Mine

leak free)

• no external flushing systems

sizes and 14 suction/discharge

considered successful.

• no mechanical seals or

fully thrust balanced pump Model TB offers three impeller

If the impeller moves

between maintenance.

and patented trust balancing

Verdermag mag drive pumps

and wear rings that work as a

have no glands, seals or valves,

JANUARY/FEBRUARY 2013

37

QUALITY FILTRATION SYSTEMS

PANEL DISCUSSION

Herman Smit, Director, Quality Filtration Systems

Desalination is increasingly gaining prominence. What are the advantages thereof? Desalination results

solutions, particularly in

developments in desalination

industrial desalination.

technologies globally. QFS

rights for a new development

of equipment supplied

in previously inaccessible water

in low-pressure desalination

to various world-leading

sources becoming a valuable

from Memsys. Memsys has

projects to supply desalination

about its first Memsys plant,

resource. Modern technologies

commercialised Multistage

technologies in different

which will pave the way for

provide the added advantage

Vacuum Membrane Distillation.

applications in South Africa

application of desalination

of decentralised water

The first Memsys plant in South

‒ brakish water desalination

where it has previously

treatment allowing for water

Africa was commissioned in

in Gansbaai and munipical

been impossible. The

to be treated and used where

November 2012. The Memsys

wastewater reuse in Beaufort

Memsys technology is based

it is needed. Improvements in

technology allows QFS to

West, for example.

on Vacuum Multi-effect

desalination technologies allow

provide answers to brine

targeting of specific dissolved

management and potential

based technologies and has

is a highly efficient thermal

contaminants and result in a

ZLD by concentrating RO brine

been manufacturing mem-

process in a modular concept.

better and more controllable

up to 300 000 mg/ℓ.

brane plants from 1999.

The Memsys modules consist

QFS has signed the exclusive

taps into the valuable resource

QFS specialises in membrane

Major projects include:

final water quality.

What are the options available? Thermal processes

What is the difference in seawater treatment versus wastewater? The basic

used in the previous century

• Steel mill (2010) ‒ 5 Mℓ/d

Membrane Distillation, which

of flat sheet membranes combined with an innovative

desalination process

plate and frame design made

water filtration plant with

of polypropene. The current

membrane processes are the

a water quality of UF

installation will be able to

have been replaced with

same, but the characteristics of

permeate NTU<1.

produce maximum 500 ℓ/h

membrane-based technologies.

the water is very different. Most

The main treatment tech-

• Municipal wastewater reuse

of distilled water and will

of the differences are in the

(2010) ‒ 2.3 Mℓ/d direct

be completely off-grid. QFS

nology used for the removal

pretreatment and materials for

reclamation plant with a

aims to get a recovery rate of

of dissolved contaminants

the equipment in contact with

water quality of SANS Class I,

more than 80% at pumping

is reverse osmosis (RO). The

the water.

used as potable water.

pressures of around 3 bar.

complete process includes

Wastewater desalination

• Brakish water desalination

supporting technologies as

must aim for water recoveries

(2011) ‒ 1.6 Mℓ/d with a

pre- and post-treatment to RO,

of greater than 90% and

water quality of SANS Class I

the most critical of which is the

approaching ZLD compared

pretreatment.

to a typical 45% recovery on

used as potable water. • Industrial wastewater

Is desalination the ultimate panacea for our water situation? Nothing is the ultimate solution in the water

a seawater desalination plant.

treatment plant (2012) ‒

sector. The combination of

pre-filtration to protect the RO

Municipal wastewaters have

5 Mℓ/d with a water quality

conventional technologies and

membranes and has installed

significantly lower salinity

of conductivity <200 µS/cm,

desalination technologies will

successful dual membrane

compared to seawater and

used as process water.

be important for sustainable

plants. We supply, design,

therefore offer some advantag-

manufacture and install

es in terms of cost.

QFS understands the art of

membrane-related desali-

Technologies across a broad

Price is often quoted as a limiting factor. How quickly is ROI recovered? Price can

range of products and markets,

be a limiting factor when

and has the technical know-

competing with conventional

how and backup to support

water sources that do not

membrane-based technologies.

require desalination. ROI on

nation equipment. QFS has partnered with Siemens Water

• Memsys (2012) ‒ 100ℓ/h low

water supply. The water supply

energy distillation plant for

strategy should make use of

distillate water with conduc-

the most appropriate water

tivity <1 µS/cm.

sources for a region, which is a function of multiple inputs.

What are some of the interesting upcoming projects? QFS is very excited

Desalination plant for industrial wastewater

each project is completely

What could desalination of tomorrow look like? QFS

different and is not often

expects rapid developments

desalination. The main drivers

in the development of low-

are the availability and quality

energy RO membranes that

of the water source.

the driving factor behind

will reduce the operating systems. In addition, there

What are QFS s desalination experiences? QFS s link

is a definite move towards

with Siemens provides it

zero-liquid-discharge (ZLD)

with valuable insight in the

costs of desalination

JANUARY/FEBRUARY 2013

39

PROFILE

ESKOM

Ensuring a sustainable tomorrow

As a strategic water user, South African power utility Eskom has a fundamental responsibility to ensure that it manages water resources in an efficient and effective manner.

policies and practices. Eskom committed itself to the mandate s elements of organising engagement activities and actions that will contribute to the public water policy and management. These actions can be understood in terms of their contribution to the broad policy goals embodied in sustainable water management: direct operations and supply chain management, catchment management and community engagement, public policy advocacy

W

ater plays a significant role in electricity

and transparency.

generation and therefore water is a

The focused objective of the Eskom s water man-

strategic primary energy source. Eskom s

agement policy is for the company to be proactive in

power stations run constantly, supplying

addressing water management issues supporting the

in excess of 95% of South Africa s electrical energy and

national policy and strat-

more than half of the electricity used on the African continent. Without water, this output would not be possible. Eskom is a key stakeholder in the water sector using approximately 320 million cubic metres of water across its power stations per annum for financial year 2012. This accounts for about 2% of the total water

Eskom aims to considerably improve the organisation’s relative and absolute water consumption by 2030

usage nationally.

egies in protecting, using, managing,

controlling,

developing and conserving the nation s water resources in a sustainable manner.

The

utility

is

confident it will be able to

Improvements are happening continuously. This will

achieve this objective by focusing on four primary pillars

lead to decrease in absolute water use by 2030. The

namely: stakeholder management, stewardship, assur-

organisation is therefore committed and determined to

ance and compliance, and training and development.

support the drive to improve the management of South Africa s scarce water resources by putting in place a

Sustained supply

number of both innovative and effective water conserva-

The majority of Eskom s coal-fired power stations are

tion and management strategies, policies and practices.

primarily supplied with water from the integrated Vaal River system, with the bulk water being used primarily

Policy prioritised

for cooling. Eskom has a bulk water use licence for ab-

Eskom endorsed the United Nations (UN) CEO Water

straction of water from the integrated Vaal River system.

Mandate in February 2011. The UN CEO Water Mandate

40

is a model of environmental stewardship, as well as a

Essential element

platform for assisting companies with the development,

Eskom uses most of the water for cooling systems with-

implementation and disclosure of water sustainability

in electricity generation and it has two types of cooling

JANUARY/FEBRUARY 2013

PROFILE systems at its power stations. Wet cooling

as energy and water efficiency measures,

to the use of water, but also the effective

is the most common internationally and

Eskom s

water

and efficient use of water by the power

locally, but the company has been phasing

consumption will improve considerably

generation sector, and good management

in dry cooling systems.

by 2030.

practices between the DWA and Eskom

relative

and

absolute

Wet cooling and indirect dry cooling

Over the past two decades, Eskom has in-

systems both use condensers, cooling

troduced a number of innovative technol-

water and cooling towers. In both these

ogies to save and protect water resources.

in areas of water conservation and water demand management. The DWA and Eskom will share, inform and guide regula-

systems, the cooling water flows through thousands

of

condenser

tubes,

Over the past two decades Eskom has introduced a number of innovative technologies to save and protect water resources

with the steam on the outside. Condensation is achieved as a result of the temperature difference between the cooling water and steam. Warm cooling water flows to a cooling

tory

initiatives

on

water management within

the

power

generation sector. The MOU further undertakes to explore synergistic opportunities between

tower where an upward draft These

of air removes the heat from

include

dry

Eskom s Energy Efficiency and Demand

the water. After cooling, this wa-

cooling,

sea-water

Side Management Programme and the

ter returns to the condenser.

cooling, desalination of

DWA s Water Conservation Water Demand

polluted mine water for

Management Programme (WCWDM).

Unfortunately, during wet cool-

use at power stations and technical

With Eskom supplying 95% of South

that a substantial amount of water is lost

improvements on treatment regimens to

Africa s electricity, new entrants into the

through evaporation because the water

maximise the beneficial use of water and

electricity market will more than likely uti-

that has to be cooled is in direct contact

comply to Eskom s zero liquid effluent

lise their policies and practices as a bench-

with the air. The white plume seen on top

discharge policy.

mark against which to measure the perfor-

ing, the upward movement of air means

of cooling towers at most thermal stations

Most notable, however, is that all new

mance, and would do well to learn from

is pure water vapour. Water is then added

power plants will be equipped with dry

the innovative water usage breakthroughs

to replace evaporation losses.

cooling systems.

introduced by Eskom. While not only setting the stage locally in terms of the

Eskom has therefore started using dry cooling systems in its efforts to conserve

Important impact

South Africa s limited water supplies.

The

in

marking its water usage against that of

Although the expense involved in dry cool-

electricity generation was 1.35 ℓ/kWh in

similar power utilities in the first world and

ing systems is greater than in conventional

the financial year 2011/2012, therefore

continues to aim for peak performance.

wet cooling systems, the limited available

the reduction in electricity demand will

water

relative

benchmark, the company is also bench-

water

consumption

economic

automatically lead to the reduction in the

considerations in determining the choice

demand for electricity generation, thus

between the two technologies.

resulting in water savings.

resources

overrides

Matimba, Kendal and Majuba power

As part of a strategy to secure its water

stations are dry cooling power plants

resources,

currently operating in the world. Majuba

inputs and recommendations into the

operates with half the stations on dry and

Energy Chapter of the National Water

the other half on wet. All new plants will

Resources Strategy (the national blueprint

be equipped with dry cooling systems,

for water resources management) cur-

including Medupi and Kusile which will

rently under review by the Department

then be the largest dry cooling system in

of Water Affairs (DWA) in order to secure

the world.

security of water supply.

Containing consumption

Strategic partnership

Decades ago Eskom recognised that the

Eskom

organisation would need to find ways

Understanding (MOU) with the DWA. The

of decreasing water consumption and

MOU serves to establish a strategic part-

contributing to sustainable water usage,

nership between the parties to encourage

hence it has a well-documented com-

cooperation and participation not only in

mitment to support the drive to improve

the management, operations and main-

water management within operations.

tenance activities within the power gen-

It is expected that Eskom s water usage

Eskom

has

a

drafted

substantial

Memorandum

of

eration sector of South Africa with regard

Look out in the coming issues for highlights of Eskom’s WCWDM programme, including the following initiatives: • Mine Water Recovery: The objective is to identify the treatment and reuse of excess mine water from coal mines as an alternate source of water supply. This will reduce the growing pressure on the freshwater resources. • Sewage Water Recovery: There are few stations that currently treat sewage water and then discharge. These stations have been assessed to determine if the treated sewage effluent can be reused at the power stations. • Water Accounting Framework: The objective of this framework is to prescribe minimum requirements for the monitoring, accounting and reporting of water use at Eskom’s power stations to facilitate sound water and effluent management. • Stakeholder and Awareness: This initiative includes ongoing awareness campaigns to educate employees about water use efficiency. • Facilities and Building Management: Megawatt Park is currently in the process of attaining green star rating.

will increase over the next 10 years, due to the return to service of older wetcooled power stations. However, with the

3RZHULQJ \RXU ZRUOG

introduction of new dry-cooled stations, diversification of the energy mix as well

JANUARY/FEBRUARY 2013

41

±'PIER [EXIV#²

±-RJVEWXVYGXYVI ²

Delivering sustainable infrastructure that improves our world. “DOING GOOD WHILE DOING BUSINESS”

Contact www.bigenafrica.com, or the office most convenient to you: Pretoria (012) 842 8700; Johannesburg (011) 802 0560; Bloemfontein (051) 430 1423; Cape Town (021) 919 6976; Durban (031) 717 2571; East London (043) 748 6230; Gabarone gaborone@bigenafrica.com; Kuruman (053) 712 2882; Mafikeng (018) 386 2111; Mthatha (047) 532 5234; Nelspruit (013) 755 1421; Polokwane (015) 297 4055; Richards Bay (035) 753 1235; Rustenburg (014) 597 3655; Umtata (047) 532 5216; Windhoek +26 461 237 346.

REGIONAL FOCUS

EASTERN CAPE

Increasing capacity at the Port Alfred WWTW Increasing the treatment capacity of the Port Alfred Wastewater Treatment Works is set to dramatically alter the service delivery landscape in the coastal holiday town. Chantelle Mattheus interviews the project role players on the scope and progress on the project, given recent flooding in the region.

T

he Ndlambe Local Municipality, in the Cacadu

London on the R72 on the Kowie River mouth, is home

District of the Eastern Cape, is a predominantly

to approximately 6 500 households, many of which

rural area, with its capital in the coastal holiday town of Port Alfred. Recently, the municipality

has taken a number of steps to address two of the major challenges facing the region and specifically Port Alfred: the significant housing backlog in the area and the provision of waterborne sanitation to most households. The housing backlog has been addressed by initi-

reside in Nemato township

“The project was of such a high priority, the municipality allocated its full MIG allocation for the 2011/12 financial year”

and

numerous

informal

settlements, without any or with limited access to waterborne sanitation.

Planning priority

ating the Thornhill integrated housing development,

Bigen Africa s assignment

which is currently being implemented. However, this

was to provide the planning and detail the designs

development and the sanitation goal have resulted

required to upgrade and extend the treatment facility

in an increased demand on the local bulk water in-

to produce an acceptable quality effluent and to cater

frastructure in the town, which includes the sewage

for treatment demands over the medium term, explains

treatment facility. Towards the end of 2010, the Ndlambe Local Municipality appointed infrastructure development company Bigen Africa Services to upgrade the sewage treatment plant for Port Alfred. The scenic, coastal town, which lies midway between Port Elizabeth and East

Location of the new infrastructure with the existing ponds in the background

Bigen principal and the project manager, Ian Pollard. The project was of such a high priority, the municipality allocated its full MIG allocation for the 2011/12 financial year to the project, says Pollard. At the time, as is still the case, Port Alfred is still being serviced by a series of oxidation ponds with an

JANUARY/FEBRUARY 2013

43

REGIONAL FOCUS

minimise the impact on the natural environment. The

civil

works

contract

was awarded to URSA Civil cc at a cost of approximately R15.6 million (all inclusive). Construction in due

August to

commenced 2011

be

November

and

was

completed 2012.

in

When

Water&Sanitation

Africa

spoke to Pollard at the beginning of November all was on track and well in hand. estimated capacity of 1.8 Mℓ/d. With the plant operating within its design capacity and producing a reasonably good quality effluent, the initial plan was to irrigate the effluent from the ponds on a grass area next to the Kowie River estuary. Unfortunately, due to regular

The upgraded facility will have an initial treatment capacity of 5 Mℓ/d

Mechanical focus In May 2012, the mechanical and electrical works contract was awarded to Lektratek Water Technology in association with Service Electrical, with completion envisaged towards the end of November 2012. Although

vandalism and theft of the irrigation equipment, this

we are the mechanical contractor for the project, i.e.

practice was eventually discontinued, which resulted

we supply the mechanical equipment, we have got a

in effluent discharging directly into the estuary. As the

subcontractor that will do the electrical portion of the

volume of effluent increased, the quality of effluent be-

works, explains Lektratek Water Technology s Johan

ing discharged into the river gradually became worse,

van der Walt.

especially in December when otherwise vacant holiday homes were being occupied, explains Pollard. The upgraded facility will have an initial treatment capacity of 5 Mℓ/d with the option to extend the facility

The value of the mechanical and electrical works is R15 million (all inclusive) and includes a 24-month defects liability period as well as an operation and maintenance contract. According to Van der Walt, the only real challenging

to 10 Mℓ/d if required in the future.

aspect of the project was the flooding experienced in

Sustainable design philosophy

the region in October and November of last year, as this

Pollard adds that the Bigen Africa design philosophy

led to flooding of the access roads to the city as well as

aimed to incorporate the existing ponds as far as

flooding of the access road to the site. We were there-

possible, in order to minimise the cost of the new infra-

fore understandably delayed due to the heavy rains and

structure and to provide an integrated treatment pro-

flooding, he says.

cess that is relatively simple to operate and maintain.

Although

the

local

branch

of

Lektratek

Water

As such, the first two (anaerobic and primary aerobic)

Technology, based in Port Elizabeth, is responsible for

ponds are retained in the process train for the (a) re-

the installation of the equipment, which has been fabri-

moval of suspended matter to reduce COD loading to

cated at the Potchefstroom head office, no local labour

the subsequent biological treatment process and (b)

will be used in the installation as it calls for specialised

flow attenuation.

skills. This is a specialised installation crew, explains

Effluent from the primary aerobic pond is collected in

Van der Walt, adding that the electrical subcontractor

a small pump sump and transferred to the secondary treatment units comprising an activated sludge reactor and secondary sedimentation tank with sludge recycle facility. It is also possible to recycle a portion of the effluent from the aerobic pond back to the anaerobic pond to minimise the development of nuisance odour conditions, says Pollard. Effluent from the secondary sedimentation tank will be disinfected to inactivate any harmful organisms before being discharged into the Kowie River estuary.

will, however, be using

“It is also possible to recycle a portion of the effluent from the aerobic pond back to the anaerobic pond to minimise the development of nuisance odour conditions.” Ian Pollard

Sludge produced by and wasted from the activated

local

labour

for

the

digging of trenches and so forth. During the peak of civil construction

activities,

between 50 and 60 people were employed onsite as general workers, steel fixers and shutter hands,

many

of

them

sludge process will be routed to one of three existing

from the local community. All building works were sub-

secondary aerobic ponds, which will be transformed

contracted to local emerging contractors and it seems

into sludge lagoons.

highly likely that the contractor will achieve and possi-

The

secondary

treatment

units

and

associated

bly exceed his tendered offer to spend 30% of the value

infrastructure is located adjacent to the existing

of the works on material, services and labour sourced

ponds on the site of a discontinued quarry to

from the local community, concludes Pollard.

JANUARY/FEBRUARY 2013

45

REGIONAL FOCUS

EASTERN CAPE

WTW upgrade on track The upgrade of the Caesars Dam Water Treatment Works in the Addo region of the Eastern Cape will ensure an increased total output of 6 Mℓ/d, GIBB engineer Thulani Gumede tells Chantelle Mattheus. restrictions are implemented and the SRVM restricts water supply during certain periods of the day to allow time for the reservoirs to partially fill up and to ensure limited supply of water to all communities, says Gumede, adding that it was this severe shortage of water in the area that resulted in the immediate investigation of alternative water supply sources to augment the existing water supply quantity.

A bigger picture The original PBWS project started in 2007 with investigations into all possible sources of water to Paterson carried out. Alternative sources were investigated, including sourcing water from New Year s Dam in Alicedale, from Nooitgedacht Dam in Nelson Mandela Bay Municipality, from

T

he upgrading of the Caesars Dam Water Treatment Works (WTW) is part of the Paterson Bulk Water Supply Project (PBWS), which aims to supply water to the small Eastern Cape town

of Paterson and its surrounding area in order to not only meet current water demand in the area, but also plan and deliver for future water demand. The Sundays River Valley Municipality (SRVM) falls

“The original PBWS project started in 2007 with investigations into all possible sources of water to Paterson carried out”

Kommandokraal

Dam

and Slagboom in the town of Colchester, from the Bushmans River and from the Caesars Dam in Addo. The most economical source was found to be Caesars Dam in Addo, says Gumede. The PBWS project consists of a number of different phases, not

under the jurisdiction of the Cacadu District Municipality.

least of which is the upgrade of

Although a large district, the total population of the SRVM

the Caesars Dam WTW in Addo in order to meet the de-

was estimated at only 37 384 in 2007, with a marked

mand of both Paterson and Addo. Other phases include

annual decrease in the population of 1.3% per year since

the construction of water storage reservoirs at the WTW,

1996 ‒ compared with an annual growth rate of 1.1%

the construction of the pipeline from Addo to Paterson,

within the Cacadu District in its entirety.

as well as pump stations and the construction of a water

The need for the upgrading of the WTW is clear when

storage reservoir in Paterson.

taking into account the local water infrastructure landscape and the fact that the increasing demand has out-

Historic context

stripped the ability to maintain a sustainable supply.

Caesars Dam WTW was last upgraded in 2002 to meet the

The water supply situation to the Paterson town is untenable and has resulted in regular water restrictions in the town and surrounding areas. Severe water

Construction commenced 1 August 2012

peak water demand of 2 880 m³/d. The original design was based on the water demand for the Addo area, being Valencia, Nomathamsanqa Township and Addo Elephant Park. The original plant had a steel clarifier with a capacity of approximately 1 200 m³/d, three pressure filters, two pumps with one acting as a standby and one 2 Mℓ fresh water storage reservoir, with the source of raw water for this plant being the Caesars Dam, explains Gumede. The upgrade in 2002 included the addition of a new intake and new intake pumps, the construction of a concrete clarifier and three additional pressure filters. The total output capacity of this water treatment works after the upgrading was 2 880 m³/d. Due to the increased demand in Addo, the two installed pumps are now running in parallel and the output of the plant is currently 3 200 m³/d, hence the plant is operating well beyond its design capacity.

46

JANUARY/FEBRUARY 2013

REGIONAL FOCUS The upgrade is estimated to be completed in June this year

Employment opportunities The dominant employer to date in the region in the formal sector has been agriculture, with SRVM having reported a 48.9% unemployment rate in 2007. The project is still under construction and currently there are a number of local labourers on-site, says Gumede. At peak we expect a total of 25 labourers on-site.

Construction on track Construction on the upgraded portions of

diameter concrete clarifier, a new feeder

Forward planning

the WTW commenced on 1 August 2012

pump and a new set of rapid gravity sand

Gumede adds that additional sludge drying

and is still under way, with completion es-

filters to replace the existing pressure filters.

beds will also be installed to meet future

timated for June 2013. The main contractor

The site upgrade will involve upgrading of

needs and an environmental upgrading of

on-site is Phambili Civils, with the M&E sub-

the ablution facilities, fencing, access road,

the WTW area will also be undertaken.

contractor being Swan s Water Treatment.

pavements and greening of the site.

The WTW is currently only supplying water and

to the Addo area. According to Gumede,

estimated contract value of R13.7 million,

dosing system is to be upgraded, as well as

the upgrade will ensure a total output of

is considered a standard upgrade using

new raw water pumps installed, namely two

6 Mℓ/d. This output will be able to han-

mainly existing tried and tested technologies,

duty pumps with a combined capacity of

dle the water demand of both Addo and

as indicated by Gumede, certain components

266 m³/h and a standby pump. Additionally,

Paterson up until the year 2035.

will still need to be overhauled, upgraded

50 m of rising main will be upgraded from

The quality of water produced by the

or replaced. Among the new components

a 150 mm diameter to a 250 mm diameter

plant will also improve with the upgrade of

of the WTW is the installation of a new 15 m

uPVC Class 9 pipe.

the WTW, concludes Gumede.

Although the project, which has an

Moreover,

the

chemical

storage

47

JANUARY/FEBRUARY 2013

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REGIONAL FOCUS

EASTERN CAPE

Dry curtain grouting contract nearing completion at Cengane Dam Esorfranki Geotechnical is poised to complete a curtain grouting subcontract awarded by Norland Construction at the Cengane Dam in the Eastern Cape, about 80 km from Umtata, where a new dam wall is planned as part of the OR Tambo District Municipality’s Upper Culunca regional water supply scheme.

T

his leading geotechnical services company has provided about 600 m2 of dry curtain grouting under pressure to fill any cavities before Norland Construction begins work on the dam wall.

Grout curtains are used under dams where the foundation would

otherwise pass too much seepage, or create dam instability. A grout curtain usually consists of a row of vertically drilled holes filled with pressurised grout. The holes are drilled at intervals and in such a way that they cross each other, creating a curtain. Grout is injected into these holes with grouting jets, which use a high-

ABOVE Site layout at Cengane Dam showing exposed terrain with large boulders BELOW Typical grouting setup and operation for curtain grouting

pressure fluid stream to erode a cavity. This is the first job of its kind that we ve undertaken for some time and we regard it as a step in the right direction as part of our strategic plan to re-enter the

grouting market, says Anton Naude, director at Esorfranki. Past contracts include curtain grouting of an earth wall at Sun City and at Lydenburg Dam. Before the Esorfranki team could begin work at the Cengane Dam site, it had to blast a number of large boulders using a boulder buster to create a workable surface. The primary holes were introduced at 3 m intervals, with secondary holes at 1.5 m intervals and tertiary holes at 7.5 m intervals. Naude says no major leaks were identified and only minor grouting was required.

48

JANUARY/FEBRUARY 2013

REGIONAL FOCUS

EASTERN CAPE

Quinera WWTW upgrade nearing completion The upgrade of the Quinera Wastewater Treatment Works from 6 Mℓ/d to 18 Mℓ/day is estimated to provide adequate capacity for the region for the next 15 years, finds Chantelle Mattheus.

F

ollowing extensive expansion in recent years,

Upgrade unpacked

the Buffalo City Metropolitan Municipality has

SRK Consulting was subsequently appointed by the

been facing a strong and increasing demand

municipality to investigate and report on the capacity

for residential development in the Quinera

of the works. The findings of the report recommended

area, south of the N2 in East London in the Eastern Cape.

that the works capacity be tripled, through an upgrade

However, this continued expansion will place extensive

from 6 Mℓ/d to a capacity of 18 Mℓ/day and in 2007, SRK

strain on a water treatment system already nearing

Consulting was also appointed to design and implement

capacity and as such has necessitated a major upgrade

the upgrade of the Quinera WWTW, which includes the

of the local Quinera (Gonubie) Wastewater Treatment

design and construction of additional infrastructure to

Works (WWTW).

meet the increased volumetric and organic loading of the works.

According to Buffalo City Metropolitan Municipality spokesperson David Langley, the municipality was

The sludge handling capacity of the works will also be

aware that the works was nearing the limit of its installed

upgraded to accommodate the increase in sludge vol-

capacity, both in terms of effluent treatment and sludge

umes with the construction of additional infrastructure

management. The existing Quinera WWTW has a capaci-

and the implementation of a sludge management plan,

ty of 6 Mℓ/d and concerns about the possible overloading

says SRK senior technologist Marinus Meiring.

of the Quinera WWTW resulted in Buffalo City municipal-

Meiring adds that although the original brief called for

ity placing a moratorium on any new developments in

the whole works to be upgraded under one contract, due

the Quinera and Gonubie areas until the capacity of the Quinera WWTW had been increased. The moratorium has been in place since 8 July 2005, so there has been no overloading of the plant ‒ but there have been no major residential developments.

An upgrade of 6 Mℓ/d to 18 Mℓ/d was recommended by SRK consulting

to budgetary constraints the electrical works could not be carried out concurrently with the civil works and the project was split into two phases. Phase 1 will encompass the civil and mechanical works portion, and Phase 2 encapsulates the electrical and electronic works portion of the project.

Challenging context The project has not been without

its

challenges,

although the majority was faced and overcome timeously and efficiently by the

Project team Client: Buffalo City Metropolitan Municipality Principal agent: SRK Consulting Civil/structural engineers: SRK Consulting Electrical engineers: Taylor and Associates Architect: IDC Architects

Phase 1 Principal contractor: Erbacon Construction Mechanical subcontractors: Huber Technology Sulzer (formerly ABS Wastewater Technology)

Phase 2 Principal contractor: URSA Civils / GIVE Ziyawa Joint Venture Electrical subcontractor: Hlumisa Engineering Services Mechanical subcontractors: Huber Technology Sulzer (formerly ABS Wastewater Technology) JANUARY/FEBRUARY 2013

49

REGIONAL FOCUS clarifier scum disposal system to the waste activated sludge buffer tank were also included in the first phase of the project. Finally, an upgrade of the final effluent chlorination system (including a new chlorine house and extended chlorine contact chamber) was also necessitated.

A final flourish The contract for Phase 2 was awarded to URSA Civils/GIVE Ziyawa Construction Joint Venture in August 2012, with final commissioning of the plant expected in November 2013. This phase includes both the continuation of civil and mechanical works, as well as initiation of the majority of the electrical and electronic works. The civils aspects involves construction of a new substation, a paved access road, design and site staff during the project,

a water reticulation network, and the con-

says Meiring.

crete demolition and repairs necessitated

One of those challenges was undertaking

on the existing aerator basin, as well as

the construction of the new infrastructure

the installation and commissioning of me-

at an operational WWTW without affect-

chanical equipment supplied under Phase

ing the operation or performance of the

1 and the final process commissioning of

existing plant.

the plant.

In addition, the project has also been the

The electronic engineering scope of

first time a number of innovative technolo-

works include an access control system,

gies have been implemented in the Buffalo City municipal region, not least of which has been the dewatering of screenings and

The upgrade, which will be completed this year, is estimated to provide sewer capacity for the next 15 years

grit, as well as the odour control of the inlet

installation,

SCADA

installation,

flow, level and effluent quality monitoring equipment, and PLC controls for the plant and motor control systems.

A detailed

works, which is a fully enclosed building,

aerobic reactor, adjacent to, and matching

specification has been prepared to ensure

and the utilisation of fine bubble aeration

the dimensions of the existing reactor,

that the upgraded Quinera WWTW is inte-

to replace surface aerators.

fed from a modified concrete splitter box,

grated within the Buffalo City Metropolitan

Other firsts on-site include mechanical

as well as the equipping of both aerobic

Municipality wastewater network, operates

sludge dewatering by means of filter

reactors with diffuse bubble aeration, using

in accordance with the licence conditions

presses and a high level of automation with

air supplied by the new blowers housed in

and to provide the municipality s operation

regard to plant operation and monitoring

a new acoustically insulated blower house.

and maintenance staff with the resources

of plant performance in real time.

According to Meiring, a new waste

to manage the new plant, says Meiring.

activated sludge dewatering system also

The total construction cost for both phas-

A phased approach

formed part of the contract and the system

es is estimated to be R95 million including

The contract for Phase 1 was awarded to

comprises of waste activated sludge trans-

VAT, with Phase 1 estimated at about

Erbacon Construction in March 2008 and

fer systems from the two aerobic reactors

R49 million and Phase 2 at R45 million.

was completed in September 2009.

to a waste activated sludge buffer tank, a

The work in this contract included the

mechanical dewatering system comprising

Room for expansion

construction of a new inlet works, which

polyelectrolyte dosing and mixing, two lin-

Langley says that once the upgrade of the

will replace the existing inlet works and

ear dewatering screens and two belt filter

WWTW is complete at the end of 2013,

will consist of a concrete inlet structure

presses, as well as a conveyance system to

up-market, medium income and low-cost

equipped with rotating mechanical screens

lift the dewatered sludge to an overhead

housing in the region will benefit signif-

and a vortex degritter, together with odour

distribution system to facilitate loading of

icantly.

control measures, says Meiring.

skips to take the sludge off site.

works is estimated to provide adequate

Other aspects include a second concrete

A pumping system to transfer the water removed from the sludge

“A detailed specification has been prepared to ensure that the upgraded Quinera WWTW is integrated within the Buffalo City Metropolitan Municipality wastewater network” 50

CCTV

The increase in capacity of the

sewer capacity for future developments in the area for the next 15 years.

to the clarifier splitter box,

The existing works is on a 10.7 ha site,

as well as the installation

but a further 6.7 ha of adjacent land could

of a new secondary clarifier

be expropriated for extensions to the

and the upgrade of the

treatment works. There is a possibility that

system for the return of

the Quinera WWTW could develop into a

activated sludge to the

regional treatment works, with modular ex-

aerobic reactors and a new

tensions as required, concludes Langley.

JANUARY/FEBRUARY 2013

AFRICAN FOCUS

ZAMBIA

Conveying confidence at Chambishi CuSEP Project Pipeline solutions provider RARE recently supplied a complete fluid conveyance solution to the Chambishi Copper Solvent Extraction Plant (CuSEP) Project at Chambishi Metals PLC in Zambia in only 105 days. Chantelle Mattheus speaks to RARE manager: pipeline services, Carl von Graszouw, on the intricacies of supply in the African context.

T

he project has seen the works being constructed at Chambishi Metals PLC, which is situated near Kitwe in the Republic of Zambia. Working in Zambia meant that the planning for equip-

ment, materials and personnel had to be precise. RARE had to ensure that the required materials were checked at source before deliveries could take place and we had to coordinate shipping of materials to ensure optimisation of space, explains Von Graszouw. Another challenging aspect of the project was that South African personnel had to return home every 10 weeks. Planning was put into place to ensure that work on-site carried on during these rest periods, according to Von Graszouw, as RARE allocated eight key personnel from South Africa and used 35 Zambian personnel. Forty people were employed on-site at peak. To ensure that all personnel reported to work on time as well, RARE provided a bus to ferry personnel from the various locations in the vicinity in the morning and drop them off in the afternoons. These setbacks were further exacerbated by the fact that the project had to be completed during the dry season to avoid delays due to heavy rains in the region. Budgets for the day-to-day running expenses also had to be precise and monitored daily, adds Von Graszouw.

Project outlined Chambishi Metals PLC produces cobalt and copper and it operates a mineral processing facility for the production and smelting of cobalt and cathode copper near Kitwe in Zambia. The Chambishi CuSEP Project involves upgrading the plant to produce 50 000 tpa LME Grade-A copper by installing copper solvent-extraction circuits to treat the solution arising from various sources within the complex.

The existing copper electro-winning

circuit will be modified to accommodate the solvent

A portion of the complete fluid conveyance solution at the Chambishi Copper Solvent Extraction Plant at Chambishi Metals PLC in Zambia

its contract, which has an estimated value of R16.5 million, entailed the supply, fabrication and erection of HDPE piping and included steel supports. Although no new technologies were used for the project, fabrication of the HDPE piping was done using heated tool butt fusion and socket fusion. While polyethylene pipe has a firm footing within the world s water, oil and gas industries, its use in the mining industry is fast gaining ground as it is often

extraction strip circuit solution. A solvent-extraction

the best choice when conveying minerals and waste.

step will be installed to remove as much copper as pos-

The abrasion resistant, smooth

sible from the solution that is fed to the cobalt refining plant, says Von Graszouw. The new facilities will be built as a combination of Brownfield s installation integrated in to the existing facilities and Greenfield s installation adjacent to the roast/leach circuit. RARE s scope of works according to

inner surface exhibits a good

Fabrication of the HDPE piping was done using heated tool butt fusion and socket fusion JANUARY/FEBRUARY 2013

resistance to most chemicals and the ever-present threat of corrosion, all while demonstrating a high impact strength, costing less comparatively and

51

AFRICAN FOCUS ANGOLA

HDPE pipes chosen for Angolan Cunene Project As part of the master trans-frontier plan with Namibia to supply safe drinking water in the Cunene province, Marley Infrastructure was awarded a US$15 million contract in Angola. RARE had 105 days from site establishment to complete the project

being more easily installed ‒ as exhibited by RARE in this installation.

its range of HDPE pipes, which

Project consisted of

are endorsed by the Southern

the construction of a

African Plastic Pipe Manufacturers

water treatment facility

Association and manufactured

at Xangongo, so that water can be

according to sound quality

extracted from the Cunene River,

standards, carrying the SABS mark

Systems, Flotek, SPF Trading and Ebenheiser, with no

and treated and then pumped

for SANS ISO 4427.

subcontractors used on the project.

along a 100 km pipeline to

RARE s suppliers in this case included Marley Pipe

From site establishment, RARE had 105 days to com-

Logistically, transporting 16

Xangongo, Mongua and Ondjiva.

trailers carrying 16 x 15 m length

plete and handover works, says Von Graszouw, who fur-

Marley supplied over 98 km of

HDPE pipes each to Angola was

ther reports that the project was successfully completed

630 mm PN6 HDPE pipes as well

no easy feat, and Marley partnered

and commissioned on 30 September 2012 ‒ exactly

as about 2 km of 630 mm PN10

with WP Transport to ensure their

according to schedule.

HDPE pipe ‒ marking one of

safe passage, taking into consider-

Marley s largest contributions to a

ation proper crating and stacking

single project.

methods to ensure minimal roll

Unique competencies Von Graszouw believes that RARE secured and was able

One of the provinces devastated

during transportation. The biggest

to optimally deliver on the contract because of the

by the Angolan conflict, Cunene

challenge, however, occurred once

unique competencies inherent in the company. A com-

has suffered from a lack of proper

the pipes had actually reached

bination of factors made RARE the suitable choice, not

supply and sanitation systems,

the Angolan border. Not only did

least of which are our years of experience in chemical

resulting in low levels of access

Marley and Befesa have to make

plant installations in Africa ‒ specifically plastic.

to clean drinking water. Only 15

sure that all documentation for

to 20% of the rural population

every truck was in order, but WP

the proven ability to mobilise and finish projects on time,

has the advantage of a dedicated

also had to appoint a dedicated

as well as having a locally registered business in Zambia

water source.

person to handle the time-con-

Additionally, Von Graszouw points out that RARE has

and having access to key personnel through RARE

The project, however, was not

Zambia. Key equipment was also located in Zambia,

without its challenges. In addition

process resulting in costly delays

which helped the company to avoid additional charges.

to chief negotiations held by

and standing time.

RARE s vision is to become the leading supplier of

Marley MD, Louis Albertyn, and his

suming and rigorous customs

Against all the odds, Marley took

innovative fluid conveyance solutions, with specific

team to assess the critical factors

on the project at hand with the

emphasis on the African continent and the ease at

and risks that the project would

same determination that it puts

which this project was completed seems to indicate

present, Marley s pipes were also

into every venture. For Marley, this

they certainly have the potential to do so.

There

stringently tested for quality con-

project was about more than just

are definitely opportunities for RARE to continue to

trol to evaluate the most suitable

business; it was an opportunity to

be involved in the maintenance of this new/updat-

pipe supplier according to the

uplift communities by giving them

ed infrastructure in Chambishi Metals,

exacting requirements of the cli-

access to the most fundamental

ent. Marley came out on top with

resource of life ‒ water.

Von Graszouw.

52

T

he Cunene River Water

concludes

JANUARY/FEBRUARY 2013

TRENCHLESS

TECHNOLOGY SASTT contact details: Web: www.sastt.org.za President: Michael King Tel: (021) 417 2900 • Fax: (021) 417 2999 E-mail: mike.king@smec.com Honorary director: Joop van Wamelen Tel: (012) 567 4026 • Fax: 086 668 4026 E-mail: director@sastt.org.za

Downhole drilling success A recent drilling project crossing under the N1 in Centurion, near the active Gautrain high speed rail, proved tricky until the right contractor for the job, armed with the right equipment, managed a breakthrough. he project involved the installation

T

Craig Burnie, MD at Vermeer Equipment

takes a lot of specialised skill, warns Garcia,

of four ducks of 110 mm in diameter

Suppliers, says was sourced from Vermeer s

adding that the hammer and rig that Vermeer

over a distance of 130 m through

Beijing Factory. The rig itself was designed for

supplied was supported by training from a

solid rock, crossing under N1 in

large-diameter HDD projects and, according

Pioneer specialist from the US, with Vermeer s

Centurion and under the very active Gautrain

to Burnie, has the features and power need-

assistance, who showed Garcia and his team

rail lines. Several companies had failed and

ed for demanding job site conditions .

exactly what the hammer and rig were capa-

the project had been waiting for a year or

In addition, the open-top vice increases

ble of. This allowed the already highly skilled

two for the right contractor, says Robert

visibility for the operator and offers the ability

team to push the equipment to the limits of

Chico Garcia, JCS Pipeline s operations and

to set large tooling in the vice with ease.

its capabilities on-site in order to deliver on time and according to exacting specifications.

horizontal directional drilling (HDD) manager,

The hammer in this case was used to trav-

adding that the evidence of previous contrac-

erse the approximately 130 m of solid sub-

I was very impressed with the team from

tors attempts to get all the way across were

surface rock, after the initial hole was opened

Vermeer. They always give us outstanding

cleary visible.

to a diameter as prescribed by the consulting

service and their aftersales service is also

engineers. Using the hammer was Step 1 ‒

excellent, concludes Garcia.

Challenging conditions

the hammer is only 160 mm in diameter ‒ but

The biggest challenge on-site was the hard

it allowed us to get all the way across, which

rock. South Africa has some of the hardest

then allowed us to proceed with the rest of

rock in the world, says Garcia. The majority

the project, explains Garcia.

of the bore was solid rock, tested at over

The entire drilling process took only 15 days

300 MPa. The continuous traffic on the N1

for Garcia and his team from JCS Pipelines,

was also challenging, according to Garcia,

with the pilot bore itself done in only a cou-

as well as the fact that the drilling had to

ple of days. Several days were required for a

cross under the tracks of the Gautrain line.

sizeable single jump to the final 355 mm hole

All of these are very different obstacles that

opener (rock reamer). The hammer and rig

not everybody can overcome, but we did,

worked very well in the South African condi-

states Garcia.

tions, adds Garcia.

The entire drilling process on-site pictured below took only 15 days

The equipment of choice in this challenging context was a downhole hammer supplied

Training essential

Pioneer,

Not many people have the experience to use

on a Vermeer D130x150 drill rig, which

the hammer and the related equipment. This

by

Vermeer s

alliance

partner

JANUARY/FEBRUARY 2013

53

TRENCHLESS NEWS

TRENCHLESS TECHNOLOGY

A challenging context The use of trenchless technologies is increasingly gaining momentum in the local infrastructure arena, given the advantages in both efficiency and cost they offer. Chantelle Mattheus speaks to TT Innovations’ director, Neil van Rooyen, about the challenges faced in rolling out these technologies.

A

s with most infrastructure related projects, best practice on-site is always key, but this is under-

A compact pipe

taken in a challenging environment with many factors contributing to an increasingly complex

context under which these projects are rolled out. Infrastructure already in place on-site also provides its own challenges at times. For pipeline rehabilitation projects, this does not pose too much of an issue as the existing plans and records are fairly accurate and are easily verifiable, either by conducting a camera survey of the existing pipeline (gaining access via the manholes) or for pressure networks by locating pipeline markers on the surface such as valves, hydrants or tees, says Van Rooyen. However, the latter is not an option for new trenchless installations by means of horizontal directional drilling or pipe ramming as-built records are crucial. Any discrepancy could lead to the existing services being damaged during the installation process. As a best practice for new installations, all existing services are required to be positively identified (by verifying the depth and location)

favourable for both contractors and clients as projects can

and superimposed onto a long section drawing where the

be rolled out on a more consistent basis ‒ making it easier

proposed installation alignment has also been plotted.

to allocate funding and resources ‒ as opposed to reactive

The local authorities that issue wayleave documents

planning, which only allows for crisis management.

therefore play a critical role in this phase of the project by providing accurate wayleave documents. Any delays

Residual resistance

from these departments usually result in the entire project

Despite the numerous advantages of the trenchless

being delayed.

technologies available, there is still some resistance in

Comprehensive planning process When addressing the challenges relating to planning and the roll-out of these projects, Van Rooyen stresses that clients need to be able to make informed decisions regarding the assets under their control. This can only be done once comprehensive asset condition assessments are undertaken. Proper asset management and resource allocation should therefore be the

Innovations director

the

infrastructure

environment.

Resistance

to change is a common human

tendency,

which is also common to ‒

implementing often

new

misunderstood

‒ technology,

says Van

Rooyen. He states that

main priority of decision-makers. Utilising the appropriate

most clients have various misconceptions regarding

trenchless technology results in reduced overall costs

trenchless technology; these are based predominantly on

and increased asset performance. Unfortunately, most of

hearsay and perception.

the asset management work is undertaken on an urgent basis due to failing infrastructure, he says.

These misconceptions include a belief that the technology is too expensive to implement in smaller rural munic-

He adds that by failing to forecast scheduled mainte-

ipalities and that the process is too mechanised, which re-

nance, project specifications are often hastily prepared.

sults in no local labour participation. However, by using

This allows for a wide range of bid submissions to be

actual data collected from completed projects, both these

accepted, which conforms in principle but not necessarily

misconceptions have been refuted, Van Rooyen explains.

in performance ‒ a further consequence of which is a dis-

A further hindrance is the lack of trenchless construction

proportion between the contractors prices. This dispro-

specifications, which limits the client and engineers

portion is generally indicative of varying product quality.

ability to administrate and evaluate trenchless projects.

He advocates pre-emptive planning strategies as being

54

“Proper asset management and resource allocation should therefore be the main priority of decision makers. ” Neil van Rooyen, TT

Conventional construction is then chosen in favour of

JANUARY/FEBRUARY 2013

TRENCHLESS NEWS trenchless technology, compounding the

is essential to ensure project success and

resistance to change, he says.

also largely reduces the risk both parties are exposed to, he says.

Construction circumstance These misconceptions aside, the practical

Best practice by far

challenges on-site are what ultimately

According to Van Rooyen, simply the use of

impact delivering the project on time.

trenchless technologies can be considered

With proper project planning, mitigating

best practice in itself. Trenchless technology

measures and allowances can be made to

offers

deal with unforeseen site circumstances.

to install, upgrade and replace ageing

An

underground infrastructure. With limited

inherent

challenge

with

trenchless

efficient

construction

means

is

trenching required and a small site footprint,

undertaken underground and out of sight.

this form of no-dig construction is hard

Underground obstructions and difficulties

to refute.

technology

is

the

fact

that

work

This is reinforced by the fact that, for the

therefore do arise ‒ which are largely beyond the contractors control. Unfortunately, many clients pass this risk onto the contractor,

Compact pipe: a renovation procedure for trenchless rehabilitation

same project outcome, trenchless construction requires far less resources than a comparative conventional open-cut operation.

which inherently increases project s cost (as contractors then make allowances for these

effective, and second, clients have unrealistic

This leads to significant reductions in public

risks in their pricing).

expectations regarding the capability of

inconvenience usually caused by construc-

According to Van Rooyen, a far more

the applied trenchless methodology. Both

tion activities, lower health and safety risks

effective mechanism would be for clients to

viewpoints might lead to the entire process

as long open trenches are avoided, and a

allocate contingency amounts to deal with

being viewed negatively.

lower carbon footprint as less construction

Van Rooyen notes that only in recent

plant and natural resources (filling sand and

Safety, on the other hand, is often a

years has the technology been rolled out to

aggregate for reinstatement and road layer

highlight on-site, with safety statistics often

tertiary and training institutions. The pro-

works) are utilised.

improved on a trenchless site versus a

motion of trenchless technology is therefore

conventional open cut operation, predomi-

intrinsic to educating clients and engineers

and

nantly due to the limited trenches. The fact

‒ an ongoing process.

sympathetic to construction inconveniences,

these unforeseen occurrences.

56

an

With increased environmental awareness the

general

public

being

less

that work is undertaken underground and

The technical nature of most trenchless

trenchless construction should therefore,

therefore out of sight can result in unallo-

operations necessitates the use of dedicat-

according to Van Rooyen, be the first

cated services being damaged, which might

ed staff for specific equipment operation,

consideration when undertaking work in

prove hazardous to work crews though,

which also requires the appropriate train-

urban environments. Unfortunately for the

warns Van Rooyen.

ing. Incorrect operation of equipment, in

majority of project awards, clients (largely

particular for new installations (horizontal

mandated by procurement policies) award

Education essential

directional drilling, pipe ramming, etc.) could

contracts based on price only.

Unfortunately, a lack of understanding

lead to damage of equipment, surrounding

consideration needs to be given to the

regarding

the

infrastructure and underground services.

contractor s performance record and the

processes

and

trenchless its

technology

implementation

More

has

A project milestone approach that high-

another consequence, according to Van

lights certain project risks at different stages

in

Rooyen.

He says the reason for this is

and allows for the necessary contingencies

outcome. Stringent contractor evaluation,

twofold: First, role players utilise trenchless

to be in place should be presented to the

performance and accountability are crucial

construction as a

for all

client. This co-accountability and open com-

to ensure the sustainability of this fledgling

pipeline work, which is not always cost

munication between client and contractor

sector, he concludes.

miracle cure

JANUARY/FEBRUARY 2013

selected methodology s achieving

the

appropriateness required

project

DURBAN’S WESTERN AQUEDUCT

TRENCHLESS NEWS

Pipeline begins again The urgently needed second phase of the Western aqueduct pipeline is under way once again. eil Macleod, head of eThekwini

N

fraternity and has selected 16 contractors

Water and Sanitation (EWS), says

to form two panels: one made up of com-

that bids have been received for

panies qualified to deal with large diameter

the first sector of the pipeline

pipes and one comprising companies that

project. These will be adjudicated and the

are able to work with pipes with smaller

tender awarded early this year. The second

diameters. This process was concluded in

sector will also be released for tendering at

September 2012. The 16 contractors includ-

the beginning of 2013.

ed on the panels will be invited to tender

He says EWS has unbundled the 55 km pipeline project into six individual projects,

An aerial image showing the progress of construction in the vicinity of Inchanga Station – part of Phase One of the Western Aqueduct Project, which is almost 80% complete

for the different contracts that make up the overall project.

Macleod states that further delays to this

which will be rolled out over a seven-year

The entire 55 km second phase begins

project will have detrimental consequenc-

period. The 7 km long first sector, valued

at Inchanga Station and ends at Ntuzuma,

es for Durban as current water supply

at approximately R125 million, will stretch

and includes two branch pipelines to

infrastructure is unable to cope with the

from Inchanga Station to Alverstone Neck.

Tshelimnyama and Mount Moriah. It is

forecasted future water demand. In addition

The second, which begins at Alverstone

expected to significantly strengthen the

to large commercial and industrial projects

Neck and has a similar value, will end at

capacity of bulk water supply to the west-

that are on the drawing board, the city s

Ashley Drive in Kloof.

ern regions of eThekwini, injecting up to

population is expected to increase by at

Construction is expected to begin during

400 Mℓ/d. At the same time, it will ultimately

least 20% by 2030. Only the current heavy

the first quarter of 2013. EWS has called for

boost much needed water supplies to the

rains are saving the city from major water

expressions of interest from the contracting

north of Durban.

restrictions, he warns.

JANUARY/FEBRUARY 2013

57

TRENCHLESS NEWS

SLIPLINING

Sliplining Parktown’s ageing water pipeline infrastructure Subsurface pipeline construction and rehabilitation company Trenchless Technologies recently completed a 12-week contract for specialist contractor ConSolve Civils and MPA Consulting Engineers, which saw the company slipline more than 270 m of steel piping at the Parktown reservoir for Johannesburg Water.

T

renchless Technologies

general

manager, Marco Camarda, says that

the

Parktown

relining of Reservoir No 2 and pipework of

says that Trenchless Technologies portion

Reservoir No 1 and No 2.

of the contract involved the sliplining

Reservoir,

Johannesburg

Water

awarded

the

of 275 m of high-density polyethylene

which was built in the 1950s, has

R19 million contract to MPA Consulting

(HDPE) pipe measuring 560 mm in diam-

been in need of a refurbishment for many

Engineers and Con-Solve Civils, which

eter into an existing 600 mm steel pipe,

years. As a result, Johannesburg Water put

then subcontracted a portion of the con-

which serves as the main water feed from

out a tender in September 2011 for the

tract to Trenchless Technologies. Camarda

Rand Water to the Parktown Reservoirs No 1 and No 2. The

Southern

African

Society

for

Trenchless Technology technical standard for sliplining was used by Johannesburg Water on this contract to ensure the quality of the sliplining works. Upon commencement of the project, we conducted closed-circuit television (CCTV) investigations on the pipeline in order to determine its condition and to look for obstructions. The investigations determined

that

the

pipelines

were

badly corroded and pitted, and were in dire need of refurbishment. It was also

Butt-welding of 560 HDPE PE 100 PN 10 in progress

58

JANUARY/FEBRUARY 2013

Trenchless Technology Specialist

Our range of services include: • Pipe Bursting • Horizontal Directional Drilling • Pipe Rehabilitation

• Pipe Ramming • CCTV Inspection • Dewatering

• HDPE Welding • Deep Excavation and Shoring • Underground Service Detection

• Slip Lining

• Industrial Pipe Cleaning

• Close-fit lining: COMPACT PIPE

For more information you can contact us: +27 (0)21 761 3474 F +27 (0)21 797 1151 E info@tt-innovations.co.za www.tt-innovations.co.za

TRENCHLESS NEWS discovered that the pipeline lay at a

through the entirety of the pipeline. The

steep gradient and that there was a tight

only obstacle that we faced was a severe

bend at one section of the pipe. These

bend in the pipeline, at which point we

conditions

had to excavate a pit and remove this

necessitated

a

significant

amount of preparatory work, all of which

bend, describes Camarda.

had to be carried out within very short

Once Trenchless Technologies deter-

shutdown periods to avoid interrupting

mined that the pipeline was clean and

the supply of water to the residents of

free of any obstructions, it commenced

the neighbouring areas, including the

the sliplining works. Four sliplining sec-

Johannesburg General Hospital, which

tions were undertaken in total. Additional

is positioned next door to the reservoir,

works

explains Camarda.

600 mm diameter fabricated tees, bends,

included

installation

of

new

All of the preparatory work, which in-

spool pieces and valves. The contract was

cluded the CCTV investigations, cleaning

completed by the company in less than

of the pipeline and sliplining test work,

12 weeks.

as well as the actual sliplining work, was

The only interruption experienced by

carried out through a small work footprint

Trenchless

consisting of a launch pit at the southern

having to lay a steel pipeline underneath

end of the pipeline and a retrieval pit at

the access road to Reservoir No 1, just

the northern end of the pipeline.

below Reservoir No 2. Here Trenchless

After having cleaned the pipeline, we had to remove any protruding objects by running a spring-loaded steel fingered cleaner through the pipeline. We then carried out sliplining test work using a 2.5 m test piece of HDPE pipe that we ran

Technologies

was

that

of

Technologies excavated across the road,

TOP Delamination and corrosion of the existing steel pipe ABOVE Sample of a removed corroded section of a 600 mm diameter steel pipe

JANUARY/FEBRUARY 2013

laid the steel piping and connected it to a new steel tee piece at one end and onto an existing 600 mm diameter flanged gate valve at the other end. The road was reinstated in just 24 hours.

59

LABORATORIES & EQUIPMENT

COMPETENCE AND CREDIBILITY

Laboratory lessons As far back as 2011, the Water Research Council, along with the National Laboratory Association and Umgeni Water, highlighted gaps in water testing laboratories in South Africa. Itâ&#x20AC;&#x2122;s been almost two years after the revealing study undertaken by Jeffares and Green; Chantelle Mattheus investigates the current state of the dynamic and changing laboratory environment.

S

outh Africa has a limited number of laboratories undertaking water quality testing and the initial research highlighted that staff shortages in these laboratories remained the biggest

problem, with the main concern lying with the laboratories with little or no training at all. There are various challenges within this arena but perhaps the most challenging is staff competence and retaining staff in this era of young working adults, says

Venetia Mitchel, customer liaison manager at independent environmental testing facility Talbot & Talbot. Competent staff is the basis on which we build a quality management system. Without competent staff, the quality system would not function. It is these staff

effluent to sewer, or is suitable for livestock watering

members that drive the crucial requirements of the

or irrigation purposes. A water source sampling service

quality system, says Mitchel, adding that on inter-

by field samplers is also available to assist in the correct

viewing staff we find that our expectations are not

collection of samples for further testing at the labo-

always met in terms of qualification and experience.

ratory. The organisation receives an average of 2 000

In-house training and investment provides us with the

samples per month.

further competence requirements we need.

in one key respect, according to Mitchel: Accreditation

tent and established competitors in the market, but

to the ISO 17025 standard is what sets the competence

we are seeing small emerging start-ups in this field .

base for a laboratory. It provides international recogni-

And while the accreditation of laboratories is what sets

tion of the work undertaken and implies competence of

the quality standard in the industry, Mitchel thinks the

staff and confidence in the results of analyses.

prevalence of established water authorities exploring

She adds that in terms of water testing, the confi-

commercial work also limits the small established

dence of the results of anal-

independent laboratories in terms of competing in a tight market.

Dynamic differences For drinking water testing, Talbot & Talbot provides a suite of analyses that encompasses testing to establish if a specific water source is suitable for human consumption, whether it meets appropriate standards for discharge to a natural water resources or as trade

60

Water testing laboratories are different from other labs

According to Mitchel, there are currently few compe-

â&#x20AC;&#x153;Competent staff is the basis on which we build a quality management system. Without competent staff, the quality system would not functionâ&#x20AC;? JANUARY/FEBRUARY 2013

yses is crucial for example in a prosecution case. Quality in any laboratory provides the user with the confidence in the results and speaks to the validation and quality control established in the lab procedures. The quality control provides a point of

LABORATORIES & EQUIPMENT reference for the measurement where

doing analyses at competent laborato-

information from its laboratories for any

standards also provide a reference point

ries, says Swart.

test to confirm the credibility of results

for the measurements.

for which the laboratory is not SANAS

Accreditation key

accredited to perform the specific test on

or competent laboratories speaks to the

The role of SANAS accreditation in the

a water sample. Every year since inception

changes in the market expectations and

process cannot also not be underestimated.

of the Blue and Green Drop certification

the understanding of the importance of

However, this also needs to be viewed in

programmes, the quality of information

standardising measurements, according

the larger context of the current laboratory

submitted by laboratories on behalf of

to Mitchel.

environment,

The growing needs for accredited and/

gaps,

the

municipalities

laboratories

has

credibility and traceability of results has in-

Affairs (DWA) reporting requirements, the

also been identified as being skewed. It

creased. DWA believes this is a positive sign

need for confidence and standardisation

should remain the aim for laboratories

that should be further encouraged as a first

of the measurements provided is para-

doing municipal water quality analyses to

step for some laboratories to comply with

mount to the validity of the database of

be SANAS accredited. We have to, however,

the requirements of SANS 17025, she says.

information being built on the catchment

acknowledge that this is not going to happen

Swart believes that until such time that

and potable water samples taken at dif-

sometime soon without considerable effort.

the country has a surplus of appropri-

ferent points nationally. This provides a

But not having accredited laboratories all

ately

comparison point where known standards

over the country does not mean all results

distributed around the country to ensure

and methods are being applied, which

are not to be trusted.

accessibility in each of the provinces,

If we look at the Department of Water

geographic

where spread

besides of

countrywide

to

confirm

accredited laboratories relatively

It is my opinion that laboratories per-

it remains true that South Africa has

forming municipal water sample analyses

a shortage of SANAS-accredited labs.

have really increased their efforts to im-

However, she adds that as the sector that

prove quality assurance systems within

understands that SANAS accreditation, for

and

their laboratories. Various systems have

instance, applies to the methods of analy-

accredited laboratory staff, as well as

been put in place, varying from ensuring

ses as used within a specific laboratory, I

being a properly accredited laboratory in

continuous calibration of equipment (and

encourage that the industry find ways to

itself, is therefore critical in ensuring safe

keeping records thereof ) and training of

better phrase the shortages of accredited

drinking water for consumers ‒ especially

staff to participation in proficiency testing

labs around the country so that the public

in light of initiatives like the Blue Drop

schemes (the recognised NLA micro and/or

‒ and this can also now include the mu-

Report. While the Blue Drop certification

SABS chemical programmes), says Swart.

nicipal sector that has to make use of the

implies comparison of the same aspects when reporting results.

Impact on water quality Having

the

programme

correctly

has

trained

been

designed

to

However, she goes on to clarify that the

services of the laboratories ‒ understands

evaluate and award excellence in the

DWA requires a municipality to obtain

what they should look for when sourcing

entire business of drinking water quality management at municipalities, and the Green

Drop

evaluates

certification

and

awards

programme

excellence

in

wastewater management practices, actual compliance of drinking water quality to SANS 241 (the South African standard for drinking water) and compliance of wastewater

discharges

to

legislative

requirements forms a large components of the assessments. Not only is it therefore important that the Blue and Green Drop assessments be done against credible information, but

municipalities

must

continuously

furnish the department with data that is representative of the water at the time of sampling to prove that they provide water that is, without a doubt, safe for human consumption, but also return effluent to the environment without add polluting the environment,

says DWA scientist

Mariette Swart, for the Directorate: Water Services Regulation. It thus speaks for itself, most municipalities that have obtained Blue or Green Drop status would not have been able to do so without the support of competent laboratory staff managing and

JANUARY/FEBRUARY 2013

61

LABORATORIES & EQUIPMENT

a laboratory that will be able to do analyses on water for them .

Challenging context When asked what Swart considers to be the biggest challenge facing the laboratories sector, she says that it is difficult for her ascertain as she doesn t work within

“The DWA-LIMS has been designed to expedite the transfer of water quality data into the regulatory systems”

able analytical methods will be used and that results are being interpreted against the latest relevant legislation.

DWA-LIMS unpacked The DWA-LIMS is a Laboratory

the lab sector, but as the regulator for water services and someone that has been actively involved in the

Information Management System, similar to other

revision of the new standard for drinking water (SANS

LIMS systems available on the market, which was

241), a challenge that we hope the lab sector will address

developed by the DWA and is available on request ‒ in

is the additional determinants that municipalities now

particular by municipal owned laboratories. The

has to monitor as part of the SANS 241 .

system is being developed as part of the larger project

An example of this is the risk assessment requirement

of the DWA to ensure receipt of credible municipal

that Cryptosporidium and Giardia spp have to be

water quality data, with specific reference to drinking

monitored (this is only one example, other determi-

water and wastewater quality data in this case.

nants have also been added to SANS 241). While it is

According to Swart, the department is also making

acknowledged that not all laboratories will be able to

the system available to private laboratories primarily

do these analyses, a challenge is posed to the sector to

provide services to municipalities, specifically Blue and

ensure that centres be established to ensure that in the

Green Drop data. The DWA-LIMS has been designed

near future these analyses could be done in at least one

to expedite the transfer of water quality data into the

establishment in each of the provinces, says Swart.

regulatory systems.

She adds that laboratories are also encouraged to

The department commenced rollout of the LIMS

become actively involved in water services delivery in

earlier in 2012 as part of the final development of

their areas. Do not limit your involvement to sample

the system. The DWA was grateful for the comments

analyses only, ensure that you interpret the results for

received by the users, but also the few external sector

municipalities, maybe even going the extra mile to en-

partners who were invited to view the system; overall

sure that municipalities acknowledge receipt of results

responses were positive. The department will now

(especially non-compliant results).

categorise previously received requests, and imple-

She is, however, firm in stating that if a laboratory

62

results, confirming that accept-

mentation of the system is to follow on a more coun-

accepts this responsibility, the laboratory should then

trywide basis as per availability of the DWA IT team,

accept the responsibility to confirm the credibility of

concludes Swart.

JANUARY/FEBRUARY 2013

Omnia Group’s new chlorine plant on track Protea Chemicals, a member of the Omnia Group, recently confirmed that the Environmental Impact Assessment for its new chlorine packing facility has been approved and that the project is targeted to be commissioned in mid-2013.

T

PROVIDING WATERCARE SOLUTIONS FOR MORE THAN 30 YEARS

he new chlorine packing and

our customers this significant extension

distribution

facility

to our product range.

constructed

on

will

the

be

existing

The product range that Protea Chemicals

Omnia site in Sasolburg. Protea

offers the municipal water treatment

Chemicals has a long-term agreement

market extends from basic commodity

with Sasol for the supply of the required

acids and alkalis to performance products

bulk chlorine. Protea Chemicals will build

such as organic and inorganic coagulants

and operate the new packing facility and

and flocculants, and will soon offer

distribute the packed chlorine nationally

chlorine as a sanitising agent.

through its existing and well-established distribution network. This significant new chlorine investment by Protea Chemicals is its third in recent

We have worked hard to position ourselves

as

to

water

the

a

full

service

supplier

treatment

industry,

says Brimacombe.

years and is targeted at increasing the

Protea Chemicals has a wide and well-

company s capacity to supply products to

established network of sales offices and

the water treatment industry.

distribution centres throughout Southern

The

first

was

the

acquisition

of

Zetachem, a manufacturer of organic coagulants and sodium hypochlorite, with both products being widely used in

the

water.

treatment The

of

was

the

with Nalco Company, called Nalco operating

Southern Nalco

is

and a

throughout East

highly

coast of Africa. With

its

expertise

and

intimate

understanding of the water treatment

potable

second

establishment of a joint venture Africa,

and East Africa, and recently the west

Africa. respected

global leader in improving water, air and energy efficiencies in industrial applications.

The new chlorine packing facility will further develop our offering to the water treatment market and enhance our capacity to provide customers with a full range of products and services

Gavin Brimacombe, the MD of Protea Chemicals, says: Protea Chemicals

markets in regional Africa, close on

has long been a supplier of commodity

50 years of experience in storing and

and

performance

into

the

chemical

products

distributing

treatment

industry.

throughout the region, the full support

The new chlorine packing facility will

of its parent company, Omnia Group,

further develop our offering to the

and

water treatment market and enhance

meeting

our capacity to provide customers with

Chemicals is particularly well placed to

a full range of products and services.

successfully deliver on this project and is

We

this

tremendously excited at the prospect of

new facility into production on budget

being able to do so in partnership with its

and on time, and being able to offer

customers, concludes Brimacombe.

look

water

forward

to

bringing

its

hazardous

absolute customers

JANUARY/FEBRUARY 2013

chemicals

commitment needs,

to

Protea

63

We understand that running a business is about ensuring continuous supply, delivery on time, accuracy and providing good old fashioned service. Protea Chemicals is a longstanding and well respected distributor of speciality, functional and effect chemicals in sub-Saharan Africa. The company operates from 21 sites located in all the major centres throughout the region. The provision of safe drinking water remains one of the country’s top priorities. Protea’s entry into the packing and distribution of chlorine will make it easier for you to achieve your objectives by combining the bene¿ts of a new effective supplier with the history and experience of a long term industry leader. For more company information and contacts for nationwide branches please visit www.proteachemicals.co.za

LABORATORIES & EQUIPMENT

SAMPLE KICKER ANALYSIS

Its only as good as the sample The sample is usually the greatest limiting factor in obtaining a true result, therefore sampling is one of the most likely potential sources of error in chemical analysis. Without exception, when collecting a sample, the analyst needs to be sure that the sample is truly representative. y doing analysis in

B

sampling. Adlem chose Sigma

sets up easily and quickly in the

the field, the analyst

SD900 Samplers.

field, and it is simple to operate.

has the advantage of

There

are

many

features

Reduced

maintenance

and

being able to even

that allow the Sigma SD900

reliable results are assured. The

further minimise errors. Callie

Sampler to be ideally suitable

user-friendly keypad for easy

Adlem from CSIR Consulting

for the purpose of field anal-

set-up makes it even easier.

and

ysis. Its durable, heavy-duty

Analytical

Services

The double-walled insulated

changed over to using various

construction

Hach meters for measurement

harsh environments, requires

cool means the sampler can

of pH, EC/TDS, ORP, dissolved

minimum

also

oxygen and turbidity in the

is known for its reliability. The

tive collection of toxic and

field. After making this change

Sigma SD900 Portable Sampler

conventional pollutants.

can

withstand

maintenance

and

base

that

keeps

perform

samples

representa-

he decided that the only way he could do justice to his instruments was to find samplers that are guaranteed to lessen problems

associated

with

Callie Adlem (CSIR) and Christian Loots (Aqualytic cc) inspecting the HACH Portable Colorimeter II for Chlorine and 2100Q Portable Turbidimeter. The Sigma SD900 Auto Sampler will be left on-site to do discreet sampling

64

JANUARY/FEBRUARY 2013

Your Total Water Solution

measuring instrumentation. Laboratory and process solutions for p your drinking water and waste water requirements.

Contact us for your local distributor

Unit 16A, APD Industrial Park, Elsecar Street 2163 Kya Sand, Johannesburg, South Africa Tel: +27 (0)11 708 3705/6 | Fax: +27 (0)11 708 2619 www.hach.com | www.ott.com

LABORATORIES & EQUIPMENT SAMPLE ANALYSIS

DR 6000 lab spectrophotometer newly released Following the success of the widely popular DR 3900 spectrophotometer, launched last year, Hach has launched the new DR 6000 UV VIS spectrophotometer.

Wireless communication Distributed level measurements via the GSM network allow for convenient observation and monitoring from the office. eller AG für

K

measurement per minute. Two volt-

Druckmesstechnik has

age inputs (0 to 2.5 V), two digital

developed a universal,

inputs, a BUS interface (RS 485) for

energy-optimised

operating up to five level sensors

radio module with integrated data

or optionally the SDI12 interface

logger. The GSM-2 remote data

for water analysis units, make the

transmission unit and the free PC

GSM-2 data logger a universal data

software allow you to conveniently

acquisition module for wide area

he new spectrophotometer combines the new

observe levels, measurements and

measuring networks.

features introduced with the DR 3900 with

trends, and monitor limits from the

An air pressure sensor and a

the application of an ultraviolet measuring

comfort of your office. This applies

temperature sensor are already

range <320 nm.

to groundwater levels, wastewater

integrated in the GSM-2, in order

levels and the filling levels of mobile

to take level measurements using

ern UV VIS (ultraviolet visible) spectrophotometer with

tanks on vehicles. However, it also

pressure sensors with long-term

the efficiency of over 250 preprogrammed methods,

applies to completely

stability such

including the most common testing methods, guided

different measure-

as the Keller

procedures and integrated quality assurance software.

ments from appropriate

30 series. The

sensors with suitable

actual sensor no

output signals.

longer has to

T

The DR 6000 combines the quality standards of a mod-

The DR 6000 meets all technical requirements of a modern UV VIS lab photometer. In combination with the preprogrammed procedures, the DR 6000 delivers the high-

be connected

est flexibility in performing specific methods, routine anal-

Design dynamics

to the ambient

yses or convenient, ready-to-use Hach tests. Using TNTplus

The cylindrical design

air via a capillary

chemistry provides the highest quality analysis, traceability

of the GSM-2 with

tube in the

of lot numbers, expiration date check and call-up of the

a diameter of just

Certificate of Analysis provided by the 2D barcode.

48 mm has been chosen so that

The measuring accuracies that can

supply cable.

Where required, the DR 6000 supports regular quality

the data logger, which self-dials in

be achieved from the difference

measures using advanced AQA program features. The ad-

accordance with user requirements,

between the probe signal and the

vanced data management, via Ethernet and LIMS compat-

can simply be placed in the top of

air pressure signal are within the

ibility, rounds out the efficiency of the system. The method

a normal 2-inch diameter sounding

range of a few millimetres.

data set can be extended for drinking water, brewery and

pipe that is used in groundwater

enzymatic food analysis for convenient evaluation of the

measuring equipment. Installation

Flexible functionality

branch-specific parameters.

takes a matter of seconds. The

The GSM-2 DataManager, which

housing is designed to withstand

is flexible and convenient, takes

Basic features include:

condensation and being underwater

over the key functions of a

• proven reference beam technology

for short periods. The GSM antenna

monitoring, acquisition, control and

• 10-fold measurement for fingerprint and scratch

is covered with a lockable covering

organisation unit. The DataManager

cap made from solid plastic.

acquires the measurements,

elimination • wavelength range 190 to 1 100 nm

allocates them, displays them in

Energy efficient electronics

graphical format, provides a signal

Equipped with energy-efficient

when limits are exceeded and then

electronics and a robust lithium

stores them in a mySQL database

battery (3.9 V/32 Ah), the logger

for which no licence fee is required.

• wavelength scan with 0.1 nm resolution

can send the results of 24 meas-

Third parties can access the meas-

• single- and multi-wavelength, time, course, scan,

urements to a PC at headquarters

urements using various export

by e-mail or transfer them to

and Internet functions, and

a mobile phone via SMS. The

integrate them in their data

maximum measuring speed is one

acquisition systems

• multi-adapter for rectangular (10, 20, 20, 50, 1 ) and round (1 ) vials • carousel

adapter

for

mini-series

and

accumulating measurements

user programme • USB interface for storage devices, keyboard, printer and barcode scanner.

JANUARY/FEBRUARY 2013

.

65

Pumps, Mixers, Compressors and Controls that Keep Going – and Keep Saving ABS Submersible Sewage Pump XFP Pumps and Impellers for World-Class Savings The ABS submersible sewage pump XFP was the first pump with a submersible motor meeting the premium-efficiency IE3 standard. Today it still leads the field for reliability and energy performance, thanks especially to new advances in the Contrablock Plus impeller technology, specifically engineered to handle today’s tough wastewater.

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Two factors decide the configuration of the ABS submersible mixer XRW. The first is the required intensity of the mixing and flow. The second is how premium efficiency can be achieved most economically. Three motor configurations provide the best possible balance.

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05:56:19

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troller is mainly designed for use in municipal wastewater pumping stations. Its many advanced features minimize operational costs and increase the availability of pumping stations and networks throughout their entire life cycles.

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Bringing water to Africa and now to the rest of the world

Ground Level Tanks Elevated Tanks: ABECO offers full-service design, manufacture and installation of support tower steelwork. Basic towers consisting of support steelwork with a caged access ladder to the roof of the tank are offered in the absence of further specification. Walkways around the base of the tank or rest platforms on access ladders are available on request. Access is required all around the pressed steel tanks to tighten bolts. The recommended minimum space around the four sides and above the roof is 600 mm and 450 mm beneath the tank Circular Sectional Steel Tanks: In developing sectional steel tanks, ABECO recognised a need for tanks that have the following features: ¾ Low-cost hygienic water storage ¾ Rugged and easily transportable ¾ Minimal site preparation and foundations required ¾ Quick and easy to install ¾ Can be installed using basic equipment ¾ Durable and long lasting ¾ Can be dismantled and re-erected at new sites.

Elevated Tanks

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Ground-Level Tanks: Ground-level tanks are commonly supported on reinforced concrete dwarf walls fitted with steel capping strips. The purpose of the capping strip is to spread the weight over the full load of the support wall and to provide a level platform on which to erect the tank. For practical reasons, concrete cannot be cast with sufficient accuracy of level. The capping strips should be positioned in place before the installation of the tank starts. Recommended tolerance is ±2 mm. Care should be taken to ensure that foundation walls are parallel and square to each other. Foundation walls must protrude beyond the edge of the tank by a recommended distance of 150 mm. The tapered top section of the wall assists in providing access.

FEATURE

RESERVOIRS

Large-scale Letsemeng tank installation successful SBS Water systems has installed a 3.3 Mℓ tank in Letsemeng in the south-western Free State. Chantelle Mattheus interviews SBS Water Systems MD, Delayne Gray, on the challenges involved in the manufacture, supply and installation of the large-scale tank.

Although Gray admits it was speculated that transportation of the large size tank would be problematic, this proved unfounded during delivery. All parts were transported to the site with our vehicles and no challenge arose, he states.

Tight delivery Complete supply and installation was undertaken by SBS, which resulted in a number of advantages for the company, including having fewer role players involved. The team still adhered to a tight delivery schedule, however, and manufacturing time was kept to the bare minimum of one week. Construction commenced on-site on 2 August 2012, and the construction of the tank was completed less than three weeks later on 21 August 2012. According to Gray, this could only be achieved through teamwork. We

W

hat makes the endeavour even more interesting ‒ apart from the remote nature of the site ‒ is that a number of firsts were achieved while undertaking the

project. Gray tells Water&Sanitation Africa that this is

Construction commenced on 2 August 2012 on-site

had the most enthusiastic, supportive and dedicated team that made this project a success. Our workshop and installation teams certainly put in their best efforts, often working late hours to get the project completed in a timely manner.

SBS Water System s first 3.3 Mℓ tank to be manufactured,

This is in part due to the fact that all installers have the

supplied and installed to date. It is the biggest capacity

necessary in-house training, says Gray, adding that all

tank we offer, says Gray.

team leaders are also qualified in HIRI, legal liability and

In addition, the accompanying infrastructure had to be

have first aid training. The installations team consisted

on a larger scale than ever before. This project required

of a project manager, team leader and four assistants.

the manufacturing of the biggest set of roof trusses ever

However, the whole company is involved in each pro-

done by SBS, he explains, adding that this was achieved

ject from start to finish. We have our own finance, HR,

using one jig only and welding multiple material pro-

technical, drawing and marketing departments that all

files, which ensured the production of lighter and more

contribute towards making a project a success.

cost-effective trusses for the project.

Established in 1998 and based in South Africa, SBS

Water stored in the reservoir will be used for drinking

Water Systems is a Proudly South African, Level 2 BBBEE

and not irrigation. The estimated cost of the entire

business specialising in bulk water storage. SBS is led by

project depends on fittings, as indicated by Gray, but is

the three original shareholders operating from its head

speculated at just under R2.5 million.

office in Pinetown, KwaZulu-Natal, and has a regional office in Gauteng and distributors throughout South

Cold fronts and snow

Africa and internationally.

The conditions on-site also proved challenging in their

With dedicated and efficient

unpredictability, with heavy snow fall blanketing a large

staff and over 14 years experi-

portion of the country during the time of installation.

ence in the prefabricated water

Due to the cold weather during the time of installation,

storage industry, we have the

the installation team set up camp on-site and worked

power to add value to the South

from sunrise to sunset, often in very wet and cold condi-

African market as well as com-

tions, explains Gray, adding that camp took the form of

plete any project presented to

a number of tents erected on-site and in the near vicinity.

us, concludes Gray.

JANUARY/FEBRUARY 2013

69

FEATURE

RESERVOIRS

Reservoirs further social upliftment The Western Cape Department of Agriculture, assisting the Genadendal Farmers’ Union under the 2008 Flood Relief Scheme, has installed two permanent water reservoirs near Voorstekraal, an Overberg village on the outskirts of Genadendal, to enable market gardening as a means of job creation.

D

uring the last week of September 2012, villagers helped install the two panel-type Rainbow reservoirs at a prepared site on a mountain slope overlooking the village.

The reservoirs will supply water to community vegeta-

ble gardens, where crops will be commercially cultivated for sale at the fresh produce market held weekly in nearby Greyton.

The reservoirs will supply water to community vegetable gardens, where crops will be commercially cultivated

It is hoped that this project will encourage related village microenterprise through plans for a monthly market encompassing a broader range of local, organic products, including environmentally friendly cleaning products and cosmetics. In Voorstekraal, water has previously not been available in sufficient quantities for bulk irrigation of semicommercial agricultural ventures.

The

department

selected

Rainbow Reservoirs as the supplier for these reservoirs for reasons of product design. Besides

robust

construction

and long life, the Rainbow reservoir requires no concrete base for capacities up to 400 000 ℓ, a sand

foundation is used instead.

Rainbow reservoir installed on Overberg mountain slope overlooking the village of Voorstekraal

This was an important consideration in the ecologically sensitive Overberg, where the municipality wanted to avoid heavy vehicles ploughing up muddy local tracks to deliver foundational concrete. It also meant that local labour could be used to help with reservoir construction. At the time that the Rainbow irrigation reservoirs were

Reliant on a mountain stream some distance away for

installed

in

late

all water supplies, reticulated water for domestic con-

September

sumption became available only in January 2011 when

trench

the Theewaterskloof Municipality built a weir to enable

ration

water to be tapped in sufficient volumes for purification

laying was at an

and properly reticulated delivery to the village.

advanced stage.

2012, prepa-

for

pipe

For this potable water project, Rainbow Reservoirs in-

At the time of

stalled an initial reservoir of 153 000 ℓ, fed by gravity from

writing, the project

the weir.

was expected to

For the vegetable gardens, two reservoirs of 240 000 ℓ

be

complete

by

each ‒ also gravity fed ‒ have been installed. Although

November

a single tank of larger capacity was considered, strict

preparatory garden

Overberg conservation laws dictated the installation of

cultivation was al-

twin reservoirs with capacities below the legal limit.

ready under way.

and

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Buckman

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34 TT Innovations

58

Echochem Pumps

56 Protea Chemicals

63 Utility Systems

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9 Tecroveer 44 RARE OFC Thuthuka

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Fiberpipe

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47 SEW-EURODRIVE

Hach South Africa

64 SMEC

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36 55 72 OBC 24

71

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