Issuu

Promoting professional excellence in the water sector

Water& Sanitation The official magazine of the Water Institute of Southern Africa

Complete water resource and wastewater management

Africa

DOW

Water-perfect

partnerships

Wastewater Energy savings at WWTWs Pipes and pipelines Managing bulk pipelines

in the hot seat

Wastewater and biosolids treatment processes are P16 increasingly being modified for the generation of biogas. Dr André van Niekerk and Theunis Duminy of Golder Associates

media

March/April 2014 • ISSN 1990-8857 • Cover price R50.00 • Vol 9 No. 2

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Contents

Volume 9. No.2

Promoting professional excellence in the water sector

Water& Sanitation The official magazine of the Water Institute of Southern Africa T

Complete water resource and wastewater management

Africa

DOW

Water-perfect

WASTEWATER Energy savings at WWTWs PIPES AND PIPELINES Managing bulk pipelines

ON THE COVER

DOW is creating public-private cooperation p4

YWPs are educating school children on careers in the water industry

Regulars Editor‘s comment Africa round-up Industry news Product news

WISA President’s comment: Engaging 2014 with passion Introducing Lester Goldman: WISA CEO YWP: Reflecting on a year of highlights WRC NEWS Energy efficiency

Wastewater Cost-effective capacity upgrade Wastewater treatment technology of the future Energy savings at WWTWs Pressure filters for wastewater treatment Corrosion resistance ACH flocculants ideal for use in WWTWs Turnkey wastewater solutions at Degrémont Treatment plant races towards completion

MEDIA

March/April 2014 • ISSN 1990-8857 • Cover price R50.00 • Vol 9 No. 2

Regional focus Creative solutions to dam challenges Water loss tackled in eThekwini Western Aqueduct pipeline expanded

78 80 81

water boards Researchers and industry join forces Harvesting electricity Innovative internship programme launched

82 84 86

water Metering Turning revenue collection around Domestic water management in focus

89 90

6 8 13

Pipes and pipelines Managing bulk pipelines Deteriorating infrastructure A three-meter diameter dismantling joint SABS ensures heavy-metal-free pipes SAPPMA and SAICE sign memorandum GRP pipes top choice for Abagold project Completion of R4.3 million pipeline project Ultraflo mPVC pipes Technical paper: Predicting the pressure-leakage relationship

Dr André van Niekerk and Theunis Duminy of Golder Associates

63 65 67 69 70 72 74

HOT SEAT Golder: A positive impact

Wastt Wastewater and biosolids treatment processes are P16 incre e increasingly being modiﬁed for the generation of biogas.

Panel discussion Panel introduction Remy Jaffray, Degrémont Brett Dunbar, Nalco Africa Hennie Roets, Rare Steve Herbst, Prei Instrumentation Rob Holmes, Quality Filtration Systems Adrian Viljoen, Prentec

3 18 22 92

COVER STORY DOW – water-perfect partnerships

IN N THE HE HOT OT SEAT EA AT

24 26 28 31 33 34 37 38 40

44 46 48 50 52 55 57 59

AMD treatment plant nears completion

March/April 2014

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Editor’s comment

Publisher Elizabeth Shorten Editor Maryke Foulds Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc Sub-editor Beatrix Knopjes Contributors Dr Jo Burgess, Kobus Prinsloo, Nicolette Pombo-van Zyl, AM Cassa, JE van Zyl Marketing manager Hestelle Robinson Digital manager Esther Louw Client services & 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 • Email: avedel@lantic.net

South Africa kicks off Water Week 2014 This year marks 20 years of water delivery for social and economic development, says the Department of Water Affairs (DWA).

ater Week, which runs

households and supply

from 17 to 23 March 2014,

2.1 million households

will set the stage for a

with

number of water initia-

The water projects will

tives throughout the country. The key

provide new infrastruc-

message of the DWA is that water is life

ture, rehabilitation and

and needs to be respected, conserved

upgrading

and enjoyed. The provision of water has

ones as well as improv-

been a key priority for government since

ing water management infrastructure. In

the advent of democracy. Since 1994,

expanding the water supply, the following

government has been hard at work en-

projects were recently launched: the Mooi-

suring that all South Africans have access

Mngeni Transfers Scheme 2, including the

to water. Government is committed to

Spring Grove dam in KwaZulu-Natal which

continuing to roll out its interventions to

will boost declining water supply in the area

ensure universal access to water. In 1994,

and benefit approximately 5 million people,

only 59% of the South African population

as well as the newly constructed De Hoop

had access to clean and safe drinking

Dam in Limpopo, which will supply water

water. By 2013 it had progressed to a na-

to towns and poorly serviced communities

WISA contacts:

tional average of 95.2%. This will further

in the Greater Sekhukhune Waterberg and

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

improve through government’s 10-year

Capricorn district municipalities.

Publisher

media 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 Email: maryke@3smedia.co.za

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.

basic

sanitation.

existing

plan to address the water-access backlog.

Other exciting projects for 2014 will in-

Government acknowledges that water

clude the launch of Phase 2 of the Ermelo

challenges still persist in some areas.

Water Scheme, the completion of the

Being a water-scarce country – one with

Ga-Segonyana Community Water Supply

infrastructure and maintenance chal-

Project

lenges – means that the provision of

drinking

water continues to remain a challenge

and Ga-Mopedi), Phase 2 of the Lesotho

in some areas. A lack of engineering skills

Highlands Water Project, the Moqhak Water

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

prevents the proper maintenance of wa-

Project in the Free State and the insertion of

ter infrastructure and water quality is also

acid mine drainage pumps in the Gauteng

negatively affected by pollution.

Central Basin, the handover of the Bulk

Plans for a sustainable water infra-

Water Project Paul Roux, the launch of lower

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

structure is, however, a key focus this

Tugela Bulk Water scheme, borehole rehabil-

year. Through the Strategic Integrated

itation project launch and the launch of the

Projects, South Africa has a 10-year plan

Coffee Bay Bulk water supply project.

BRANCHES 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

Western Cape Chairman: Gareth McConkey Tel: +27(0) 21 712 4260 Secretary/ Treasurer: Eleonore Bondesio Tel: +27(0)21 872 0322

(which water

will

supply

Sedibeng,

sustainable Ncweng

to address the estimated excellence

sector in the water

itation Water& San Africa Promoting

professional

magazine The official T

Com plet e

urce wate r reso

ewa ter and wast

Institute of the Water

man agem

of Southern

Africa

backlog of adequate wa-

Maryke Foulds

ter supply to 1.4 million

Editor

ent

Cover opportunity

DOW

fect Water-per

WISA mission statement The Water Institute of Southern Africa provides a forum for exchange of information and views to improve water resource management in Southern Africa.

WASTEWATER Ws gs at WWT

Energy savin

PIPELINES PIPES AND bulk pipelines Managing

Endorsed by P16

N IN HE THE OT HOT AT EA SEAT

sses are treatment proce of biogas. and biosolids generation Wastt water Waste ﬁed for the Associates being modi y of Golder incree singly increa Theunis Dumin Dr André van

Niekerk and

March/April

1990-885 2014 • ISSN

MEDIA

2 • Vol 9 No. price R50.00 7 • Cover

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 and maximum exposure. For more information on cover bookings contact Avé Delport on +27 (0)83 302 1342 or email avedel@lantic.net

March/April 2014

Cover story

Water-perfect partnerships E

Water from coal may sound impossible but happens every day. By Susan Cole, regional commercial manager sub-Saharan Africa, Dow Water & Process Solutions

ach

day

north-

eastern South Africa, an award-winning water reclamation plant turns con-

ventional wisdom on its head and supplies up to 30 Mℓ day of potable water. Considering a person must consume about two litres of water a day to live healthily, 30 Mℓ is enough daily drinking water for up to 15 million people. Since

2007,

the

eMalahleni

Water Reclamation Plant, situated in the Witbank coal fields of South Africa’s has

Mpumalanga

desalinated

province,

rising

under-

ground water, from four major coal mines (one now defunct) into potable water; benefitting the local environment, alleviating serious operational challenges and meeting up to 20% of the local municipality’s daily requirements. A decade ago, commercial and municipal

water

partnerships

like eMalahleni were rare. Today, many

municipalities

around

the world are partnering with local industries to meet their common water needs. By doing so, municipalities and businesses reduce their capital and treatment costs, improve sustainability

and

meet

ever-growing

local residential and commercial water demands.

Impetus for public-private water cooperation In early 2008, United Nations Secretary-General Ban Ki-moon warned attendees at the World Economic

Forum

Davos,

Switzerland, that a rising global shortage of water resources could mean

increased

conflicts

fewer

economic

opportunities.

and

“Population growth will make the problem worse,” he said, “so will climate change. As the global economy grows, so will its thirst. Many more conflicts lie just over the horizon.”

March/April 2014

Cover story

In response to the SecretaryGeneral’s

speech,

several

water-dependent

large

companies,

Still, the region struggles with its

Highveld’s land and river system,

water supply.

the eMalahleni Water Reclamation Water

Plant treats mine water using a

and

Reclamation Plant was built, the

dual-stage ultrafiltration membrane

SABMiller, joined with international

municipality of eMalahleni was reg-

process. The result, according to

partner organisations such as the

ularly being fined for drawing more

Anglo Coal’s project manager, is

International Finance Corporation

than its permissible quantity of

treated water that’s purer and bet-

to form the Water Resources Group

water from the local dam. “We were

ter than local surface or tap water.

(WRG). The WRG is a unique public/

drawing about 120 Mℓ of water a

On average, the eMalahleni plant

private/civil society partnership that

day, but our license only allowed us

purifies 25 Mℓ of water each day,

“helps government officials and

to draw 70 Mℓ and our people were

of which 16 Mℓ are supplied to

other water sector specialists ac-

drinking water with the animals,”

the fast-growing eMalahleni Local

such

Coca-Cola,

Nestlé

Before

the

eMalahleni

celerate reforms that will

Municipality. The remain-

ensure sustainable water

ing water is sufficient to

resource management for

meet the water supply

long-term

needs of all of the area’s

development

coal plants. Future plans

and economic growth”.

call for expanding the wa-

Key learnings in South Africa

ter plant’s capacity from

That’s why private-public

water daily.

30 Mℓ to 50 Mℓ of potable

water partnerships such able and illustrative of the

A collaborative standard

challenges and opportu-

Technological

nities available to locales

in membrane and water

that follow a similar path

treatment

toward sustainability.

will go a long way toward

as eMalahleni are so valu-

understand

the

benefitting

advances technology

regions

success of the eMalahl-

the world such as South

eni

Africa, which is expected

Water

Plant,

it’s

understand

Reclamation useful where

to have a 17% supply/

and

demand gap by the year

why it was needed in the Witbank

area.

Located

about 90 miles east of South

Africa’s

largest

city, Johannesburg, the

South Africa is expected to have a 17% supply/ demand gap by the year 2013

Witbank coal mines are in

2030, based on current usage levels. That’s why South Africa has created the

Strategic

Water

Partners Network (SWPN), comprised of members

the Highveld plateau, the

such

those

associ-

country’s most vital residential and

said former eMalahleni Mayor Lina

ated with the eMalahleni Water

commercial region.

Malatjie, in a 2010 interview.

Reclamation Plant, to cooperatively

Once filled with teeming grass-

Thus,

the

eMalahleni

Local

find ways between government and

lands over more than 150 000 m2

Municipality

Anglo

private industry to improve water

(an area the size of California), today

Coal South Africa and BHP Billiton

conservation, supply diversification

the Highveld is South Africa’s most

Energy Coal South Africa (BECSA)

and water quality.

vital industrial, mining and farming

to collect and treat rising under-

As evidenced by the initial suc-

region, and is home to the country’s

ground water from Anglo Coal’s

cess of the eMalahleni plant, the

largest concentration of cities. The

Landau, Greenside and Kleinkopje

SWPN and South Africa are well on

Highveld’s meandering rivers sup-

mines, and BECSA’s defunct South

their way toward closing the water

ply much of the region’s fresh water

Witbank mine.

supply/demand gap and creating a

and its peat-rich soil acts as a natural water filter for potable water.

Rather mine

joined

than

water

with

allowing to

leach

polluted into

the

more sustainable water future for all users.

March/April 2014

President ’s comment

Engaging 2014 with passion 2014 will be a busy and important year for WISA. Not only is it hosting the biannual WISA Conference, but it is also focusing on the challenges carried over from 2013. President of WISA Ronald Brown looks at some of the highlights and challenges.

olleagues, I’m sure

throughout the Water Sector in

into the WISA family. He brings

that by now some of the

South Africa.

with him extensive experience as a

objectives that we have

We acknowledge the successes

business executive and we are look-

set for 2014 have started

of 2013 with the highlights being

ing forward to his stewardship to

materialising (at least the ones

WISA’s appointment as the imple-

grow, strengthen the organisation

that we are able to plan for) and

menting agent for the profession-

administratively and operationally

that we have – armed with a great

alisation of the process controllers

with the guidance and support to

sense of positivity, pride and vigour

by the Department of Water Affairs

and from the Board and Council as

– started making great strides to

and WISA’s appointment as the

we together proceed to position

engage the challenges as the year

regulatory institution by the Energy

WISA to the level where it effective-

started off. For some of us the year

and Water Sector Training Authority

ly plays a pivotal role in the water

may have started off with a bang,

for training service providers for

sector. We also extend our sincere

while others are still easing into it.

process controllers and here we

appreciation to Dot Zandberg who

There are also those who’ve kept

acknowledge the ground-breaking

steered the ship during difficult and

the wheels of their organisations

work done by Professor Lagardien

very exciting times.

rolling throughout the change of

and his dedicated team. These are

This is also the year for the WISA

calendar

indeed milestones for WISA and

biennial conference, which will be

have made it to 2014 and we have

prestigious achievements for the

held in Mbombela, Mpumalanga,

to make our plans and strategies

organisation as well.

and I trust you are equally as excited

year.

Nonetheless,

Towards the end of last year,

about the upcoming conference as

the

the WISA Board concluded a very

we are because it will be unique.

progress thereof with due diligence

important process in its administra-

Yes, we have broken the routine

to ensure the desired success and it

tion with the appointment of our

with Mpumalanga by exploring a

is my prayer that we record 2014 as

new CEO, Lester Goldman, and we

new venue in a province other than

a year of immeasurable successes

would like to welcome him warmly

traditional provinces and towns.

for this year a reality by managing, monitoring

and

evaluating

March/April 2014

RR004

President ’s comment

NOW yOu CaN HaVE EyEs iN EVEN THE mOsT DiFFiCulT TO rEaCH PlaCEs!

Let us all strive for at least one major achievement in 2014 that we can use as a benchmark for all our other future projects This we have done in the true South African and WISA spirit to expose the diversity and inclusivity of the landscape wherein we conduct our business – the water sector has no boundaries. We need to support the organising committee and applaud them for the mammoth task they have undertaken with the support of the WISA head office and the respective portfolio chairperson. Collectively we need to move forward, holding hands, methodically assessing and tackling the issues that we are faced with in the sector by assisting where there is a need for it in order to render the water sector a proud sector where vibrant cohesive approaches transforms the perceived insurmountable to definitely achievable and significantly so. WISA needs to be at the forefront of this as it will give effect to our motto “Promoting professional excellence in the water sector” and I call on our members to embrace this motto as we journey through 2014 and beyond. Some of the highlights to look forward to during this year are: • the Blue Drop Certification process • the Green Drop Performance assessment

We operate light and mobile pipeline CCTV inspection systems that can send a camera down a narrow tunnel and video transmit the findings.

• our national elections • finalisation of the Regulation 17. We also acknowledge the opening of the new Colesberg Wastewater Treatment Works by the Honourable Minister of Water and Environmental Affairs, Edna Molewa, and look forward to many such projects which will improve the image of the Water Sector and the lives of our communities

•

Explores pipe diameters ranging from 150mm up to 2 metres

•

Over 350m of transmission cable

•

Pan and tilt camera for enhanced inspections

•

Fully waterproof and explosion proof systems available

•

HD colour footage with precise crack measurements

and their surrounding environment. Let us all strive for at least one major achievement in 2014 that we can use as a benchmark for all our other future projects and let’s get into the habit of sharing our experiences to overcome the slow and disjointed growth in our sector. This one achievement should stand out in such a manner that it will leave a legacy of capacitating and bringing happiness and true character to the lives of all involved and impacted by it. I wish you well and I am also mindful of the fact that there may be some disappointments, but that you will overcome them and more so, I trust that the successes will by far outweigh your disappointments because you would have turned disappointments into opportunities. “Every successful journey starts off with one step and a passion and if guided by a moral compass, the journeying becomes easier, the lessons along the way are well learnt and success becomes the destination.” –Unknown. Ronald M Brown

President: Water Institute of Southern Africa

Tel: 010 040 3219 www.rescuerod.co.za • info@rescuerod.co.za MARCH/April 2014

WISA news

Introducing Lester Goldman: WISA CEO A business manager with particular interest in professional associations, Goldman brings his experience in business and financial management to the organisation. Maryke Foulds speaks to him about his vision for the organisation in 2014.

hat is your background and training? How will it assist in the smooth running of this organisation?

followed by four years as the

Mandela Metropolitan

DBA through NMMU. I hold

COO of another professional

University (NMMU). I further

professional memberships in

association. I have joined

received an MBA from the

the South African Institute of

WISA directly from the

Netherlands Business School in

Professional Accountants as

I have spent 10 years with

South African Institute of

2006 and am currently complet-

well as the Institute of Directors.

leading non-profit organisations

Professional Accountants.

ing my doctoral thesis on the

I feel that many South African

I hold a Bachelor’s of

topic of the professionalisation

professional institutes are

Commerce from Nelson

of associations in pursuit of my

faced with similar challenges

for small business development and youth development,

March/April 2014

Welcome to the future – a future of Mwangaza We are all writing a part of the script which tomorrow’s society will play out. At Royal HaskoningDHV we would like the title to read: ‘Welcome to the future’ - and for our chapter in that script to read ‘Mwangaza’ - a Swahili word which means ‘light’. Together with our partners and clients we consider how we can create a welcoming future - developing efficient and smart living. Whether switching on a light, travelling to work or drinking a clean glass of water - the solutions and work of our engineers surround us, making lives better and brighter. Our work contributes to the sustainable development of communities. Together, we deliver innovative sustainable answers to today’s challenges. Royal HaskoningDHV is an independent, international engineering and project management consultancy.

royalhaskoningdhv.com/za

WISA news

of transforming themselves

accreditation of some of

further such registration

and their industries, dealing

these training programmes

and allied services. All credit

with the brain drain and

are questionable and may

to WISA board and staff in

issues of service delivery and

not hold any credibility.

this regard.

corporate governance. While

WISA has recently become

some have come up with an

recognised as a professional

innovative solution to these

body, and part of its duty

challenges, most haven’t.

as a professional body

Instead of them reinventing

would be to look at the

the wheel every time, I am

accreditation and validation

What are some of the events planned for the year and how will this bring WISA’s message across? The 2014 WISA

trying to develop a strategy

of training organisations,

Conference is the flagship

or a framework to help such

as well as relevant material.

event of the year –

organisations overcome

This would mean that

happening 25 to 29 May in

these common obstacles.

the sector would have

Mbombela, Mpumalanga,

standardised training,

and will provide a platform

which would assist in the

for a sharing of ideas and

development of individuals

information. The various

and the water sector as

process controller divisions

a whole.

will be holding workshops

What are some of the challenges currently facing the water industry in South Africa? How can WISA as an organisation assist the water industry in furthering its aims for an inclusive and representative industry?

and open days throughout the country. The Excellence

assistance on a strategic

What are your thoughts on the current status of technical personnel in South Africa? Can WISA assist with training on a technical front? I do see

level and do see the need

WISA assisting in this regard;

research for the sector.

to strengthen stakeholder

however, this will only be

relationships. Accredited

once relevant resources

training is a major challenge

are available and we are

in the water sector. There

able to deliver. The roll-out

are many organisations

of the new professional

that provide training

designation “Professional

within the water sector,

Process Controller” is

There is a real problem with service delivery in the country. Any thoughts on this that you would like to share with our readers? Service

however the validity and

certainly the catalyst to

delivery, and the resultant

I see WISA providing

WISA news

“Many South African institutes are faced with similar challenges of transforming themselves and their industries.” Lester Goldman, CEO, WISA

in Water Research Awards is due to take place in October 2014, where young researchers will be awarded for their achievements in

symptoms, is something we should address collectively and should include all stakeholders in the resolution process. Solutions and implementation should be well planned. Good governance and transparency is essential to all these processes.

Any other thoughts? I would like to see WISA becoming the pre-eminent global professional body in this sector, and require inputs from all stakeholders, in this regard. I encourage readers to contact me with suggestions, so that we can team up to make a difference in our sector and in our country. MARCH/April 2014

WRC news

Energy efficiency Historically, electricity efficiency measures have not been a priority in the South African water industry due to the relatively low cost of electricity, writes Jo Burgess of the Water Research Commission.

ver the past five to

provide the South African water

in wastewater processes focused

ten years, this situation

and wastewater treatment sectors

on aeration. Simple changes in

has rapidly been chang-

with an objective and logical eval-

control methods and set points have

ing due to the increased

uation of the current and expected

frequently shown substantial quick

demand, lack of electricity generat-

impact and consequences of power

wins and checks on plant, control

ing infrastructure and subsequent

outages on water and wastewater

methods, operational routines and

increase in electricity costs. Energy

treatment services.

will in future remain a high-cost item for municipalities and utilities

Compendiums,

that operate and maintain water and

not been actively pursuing and

wastewater processes.

implementing

South energy

Africa

has

while,” comments project leader Dr Marlene van der Merwe-Botha. One of the WRC-funded studies

savings

investigated and demonstrated the

Energy consumption continues to

projects on a large scale, mainly as

potential hydropower generation in

increase as more people are provid-

result of the abundance of readily

pressurised water supply conduits.

ed with water and sanitation, and

available and cheap electricity in

A pilot installation was erected at

new technologies are implemented

the country. This means that case

the Elardus Park Reservoir (Tshwane

to meet stricter effluent and pota-

studies and operational data are not

Metropolitan

ble water quality requirements. To

readily available. In cases where en-

initial results reflected the benefit

position the water sector globally

ergy savings applications have been

and expected return from such an in-

with regard to energy consumption,

made, the data is poorly recorded

vestment, even if the system is only

the Global Water Research Coalition

and not verified. Hence, the South

operated at a duty of 50%.

(GWRC) has embarked on a project

African Compendium may need to

entitled ’Energy Efficiency in the

be developed to guide towards best

cipality conducted a feasibility study

practice of ‘developmental industry’,

on the Northern Aqueduct in the

as opposed to being a compendium

Durban potable water distribution

of best practice by way of case

system. This project is fairly complex,

study documentation.

consisting of 39 reservoirs, and

Energy consumption continues to increase as more people are provided with water and sanitation

eThekwini

Municipality).

Metropolitan

The

Muni-

Dr Valerie Naidoo, WRC research

water demand is often in danger of

manager, says South Africa has one

exceeding the supply. The feasibility

of the most advanced water and

study was based on the installation

Water Industry: A Compendium of

wastewater sectors on the continent.

of six mini-hydrogenerators, each

Best Practices and Case Studies’,

Understanding the complexity of

capable of providing 150 to 180 kW.

which

best

South Africa’s water supply chain is

Based on this study, invitations for

practices worldwide. The project is

a critical component of analysing

tender were put out by eThekwini

supported by the GWRC partners, as

the impact of power outages on this

Metro for six turbines. However,

represented by the four Continental

sector. Numerous factors influence

these were going to cost in the

Coordinators, in Australasia, Europe,

the amount of energy utilised in

region of R35 million, which was

Southern Africa and North America.

the water supply chain, including

deemed too expensive and as a

Each continental group has pro-

the stage of the water supply chain,

result, the specifications of the

duced a report of best examples

technology utilised, the use of pump

tender were modified in order to

submitted by utilities in their region.

or gravity feeds and the quality of

reduce costs. The modified request

When all four continental reports are

the water being treated.

for tender was for two turbines,

documents

these

available, they will be compiled into

It should be noted that certain

but, to date, the council has reject-

consume

ed this option. The cost of these

The WRC therefore commissioned

more energy than others. For exam-

turbines is expected to be between

a study to help understand the

ple, reverse osmosis membranes use

R6 million and R8 million each. In

potential impact that current energy

significantly more energy than other

the meantime, eThekwini Metro is

supply challenges are having on

filtration techniques.

exploring the option of funding from

the global compendium.

maintenance have proven worth-

Contrary to the UK and US Energy

treatment

technologies

South Africa’s water and waste-

“Up to 50% energy savings have

Eskom, the national electricity sup-

water services. The project was to

been demonstrated by case studies

plier. Eskom has projects in which

March/April 2014

WRC news electricity generation of between

and beverage industries (distillery,

annum

1 000 kW and 1 MW are funded at a

brewery, winery, fruit juicing and

than R300 million

rate of R0.70/kW for a period of three

canning), and domestic backwater

per annum, making

to five years after commissioning.

(sewage). Through this, an estimated

the existing waste-

Should this funding be obtained, the

10 000 MWh can be recovered from

water

project for two mini hydro-genera-

wastewaters in the whole of South

operation possibly

tors in the Northern Aqueduct is ex-

Africa, representing 7% of the Eskom

unaffordable.

pected to go ahead. Rand Water and

electrical power supply.

Failure

treatment

the

Bloem Water are others pursuing this

Energy has also become a key driv-

option, with Bloem Water progress-

er in the wastewater treatment value

ment

ing towards installing a 150 kW unit

chain of Johannesburg and every

would have a dev-

in the next few months, which will

effort is being made to produce

astating effect on

supply electricity to its headquarters.

“green energy” and reduce power

the economy, en-

Another WRC project recognised

consumption. Johannesburg Water

vironment,

opportunities that exist to improve

operates and maintains six waste-

services and social

the current wastewater treatment

water treatment works and treated

activities of the city.

processes by applying new solutions

about 1 million m3 of sewage per day

In line with the Department of

and technologies that can reduce

in 2010. All of the sewage treated

Energy’s Integrated Resource Plan of

energy inputs or generate energy.

wastewater

treat-

operations

health

was by the activated sludge pro-

2010, South Africa needs to increase

A WRC survey conducted in 2009

cess and about 90% of the 260 dry

its capacity by 45 000 MW by 2030.

on the quality and quantity of waste-

tonnes of sludge produced per day

This figure excludes Eskom’s present

waters in South Africa identified the

consisted of waste activated sludge.

capacity expansion projects.

top three sectors with the greatest

It is estimated that by 2020 the cost

potential energy recovery as: the for-

of electricity for the treatment of

mal and informal animal husbandry

wastewater in Johannesburg will

sector (cows, pigs and chickens), fruit

have risen from R97 million per

Dr Jo Burgess

For More questions contact Dr Jo Burgess, research manager, Water Use and Waste Management

March/April 2014

water level measurements â€Ś be inspired â€Ś www.keller-druck.com

Y WP

Reflecting on a year of highlights Not only is South Africa a rather big place, but it also faces a range of regionspecific challenges in the water sector, says Inga Jacobs of the YWP.

his is why the provincial

river clean-up initiatives. Finally,

11 December 2013. The biogas

chapters of YWP are a

development

to energy plant is the first one of

crucial component of WISA

events which focus on nurturing the

its kind installed at a municipal

as they provide ‘closer to

more ‘intangible’ qualities needed

treatment works and was officially

home’ access to provincial events

to succeed in our careers. These

launched last year. The system

and a forum to discuss issues

interventions range from working

involves collection of the biogas

relevant to the water sector in the

on writing and public speaking skills

produced in the anaerobic digest-

province that you live and work.

to improving business development

ers, gas conditioning and scrubbing

knowledge and skills.

and finally the operation of a gas

Provincial YWP chapters aim to

organise

skills

arrange four different kinds of inter-

This article features some of the

to power generator. The electricity

actions. Firstly, we arrange technical

fun initiatives that have been ar-

produced by the generators is fed

events, which usually take the form

ranged by the Gauteng Young Water

back into the wastewater treatment

of site tours and offer a ‘hands on’

Professionals during the past year.

works grid to reduce the reliance on

learning experience to participants. events, which include workshops,

presentation by Shaun Deacon of

lectures, seminars and symposiums.

The

Johannesburg

Thirdly, we arrange outreach events,

organised a tour of the biogas

the process of digestion and the

which can be anything ranging

facility at Johannesburg Northern

challenges and benefits of the pro-

from school education events to

Wastewater Treatment Works on

ject. This was followed up by a walk

arrange

academic

Photo by Jozua Loots

electricity provided by Eskom.

Technical events Biogas tour in Johannesburg

Secondly,

Looking at a career in the water industry

Gauteng

YWP

committee

The attendees were first given a

March/April 2014

Water,

explaining

Y WP

around the facility, guided by Jason Gifford of WEC Projects, where each process in the biogas to power generation facility was described in depth.

Provincial YWP chapters aim to arrange four different kinds of interactions

The

workshop

provided

a platform to expose high school teachers

learners to

and

some

their the

challenges and opportunities

Africa in January and February 2014

facing the water and wastewater

Rand Water Tour

to facilitate the YWP Publications

sector in South Africa. Time was

The Rand Water Technical Tour took

Workshops Series. He kindly made

also spent exploring the diverse and

place on 16 October 2013 at Rand

himself available to do a water-

exciting career and study oppor-

Water Scientific Services and Water

energy nexus lecture during his

tunities that can be pursued in the

Wise. Here, 59 young professionals

YWP Publications Road Show. This

water sector.

participated in the three activities

lecture took place on 24 January

The workshop was marked by the

scheduled for the day. The first ac-

2014 and was funded and chaired

positive participation and enthu-

tivity was a water treatment experi-

by Eskom and the Department of

siasm shown by the learners. The

ment where delegates were divided

Science and Technology.

event was sponsored by Thuthukani

into groups and took part in actual

The aim of the seminar was to cre-

SNF. It was a privilege for Gauteng

water treatment experiments. The

ate an awareness of the important

YWP to engage with such a vibrant

second activity was a train tour of

couplings between water and ener-

group of learners.

the Rand Water treatment plant.

gy. It showed how energy is used in

The third activity was a laboratories

a variety of water cycle operations

tour offering exposure to how water

and demonstrated how water is

is analysed in the Microbiology

used – and misused – in all kinds of

and Chemistry Laboratories. Rand

energy production and generation.

Water

and

the

Vaal

University

of Technology were partners for this event.

Outreach events High School Education Event On 16 August 2013, the Gauteng

Academic Events Water Energy Nexus Lecture, featuring Professor Gustaf Olsson

YWPs

Professor Gustaf Olsson, from Lund

learners and their teachers attended

University in Sweden, visited South

the workshop.

Ponego

spent

the

morning

Secondary

School

with in

Katlehong. About 200 Grade 12

For more details about how to get involved in YWP provincial or national activities, please visit our website: www.sa-ywp.org.za/gauteng-committee.html. Remember, all you need to do is become a member of the Water Institute for Southern Africa (WISA) or the International Water Association (IWA) and register to join YWP. If you’re 35 years old or younger, or are within five years of completing a degree in water, then you are eligible.

March/April 2014

Positive paticipation and enthusiasm marks the work of the YWP Photo by Jozua Loots

Hot seat

A positive impact Wastewater and biosolids treatment processes are increasingly being modified for the generation of biogas, offering a source of energy to generate power and heat. Maryke Foulds speaks to Dr André van Niekerk and Theunis Duminy at Golder Associates.

older is a global con-

reliance on supplied power during

there will be WWTW that will not only

sulting organisation that

power-supply interruptions.

be energy neutral, but will be able to

provides a wide range of

export excess power onto the grid.”

Golder is at the forefront of this

engineering and construction servic-

keep essential treatment equipment

innovative application of technology

es in the specialist areas of earth, wa-

and processes running smoothly.

and expertise. The knowledge of

ter, environment, energy and, more

Implementing

modern-day

generating biogas and converting it

specifically, how to turn a wastewater

technology as part of a more holistic

to heat and electricity is not new, but

plant into a sustainable enterprise

wastewater

strategy,

South Africa is to a large extent only

from an energy perspective.

also enables wastewater treatment

now realising the full potential of the

works (WWTWs) to decrease their

impact thereof on energy and the

carbon footprint.

running costs at WWTWs. While the

independent

consulting,

Following the successful commissioning of a combined heat and

This is an important factor when considering

what

this

needed

treatment

power plant by Johannesburg Water

“WWTWs globally – and increasingly

process itself is essentially straightfor-

recently, Van Niekerk (principal for

in South Africa – have a long-term

ward and technically proven, one of

mine and industrial water treatment)

vision to be energy neutral,” says

the biggest aspects of such a project

and Duminy (who heads up its water

Van Niekerk. “Currently there is no

is retrofitting an existing plant to be

engineering division) are of the view

facility that has yet achieved this on a

able to run efficiently as a biogas to

that this technology will not only

continuous basis, but it is technologi-

power facility.

save on electricity costs, but crucially

cally feasible and definitely financially

“In the past, wastewater as a com-

reduce

viable. It is forecasted that by 2025,

modity was approached purely in

water

service

authorities’

March/April 2014

Hot seat terms of regulatory compliance and was seen as a cost item by water services authorities,” Van Niekerk says. “It is, however, now approached as both a business cost driver and an environmental/social reputational issue. As a global company, Golder can tap into global expertise to assist in the planning phases of such an upgrade or expansion.” Golder’s global operations have been instrumental in assisting with technology transfer. In that sense Golder, in conjunction with South African industry, are on the cutting edge of introducing this type of technology to the South African market. to maximise energy output, a pre-

is performing to a predetermined

Sludge optimisation and the bottom line

cleaned gas supply needs to be

set of criteria reflected in contractual

assured. There are three compounds

penalties and incentives.

Duminy concurs: “Another factor to

of specific concern in biogas that are

consider is how to condition sludge

detrimental to gas engines. Hydrogen

treatment

sulphide in a gas engine can oxidise

approach

capacity. Through processes such as

and form sulphuric acid, which is

although these are limited in

cell lysis, electrical pulse and sonic

detrimental. Any moisture is detri-

the municipal water sector in

technologies, waste sludge can be

mental to equipment – the gas must

South Africa. Due to the spe-

pre-conditioned to enhance biogas

be dry. Another compound or group

cialised equipment, proprietary

production in anaerobic digestion.

of compounds called saloxanes (silica

pre-treatment approaches and

“The use of cell-lysis technology in

derivatives) are contained in the gas.

performance requirements of

the application of biogas-to-energy

If it gets into the gas engine and is

such an installation, this type

for WWTWs is most certainly unique

fired at very high temperatures, it

of facility requires a contractual

in South Africa and Johannesburg

can form hard glassy deposits with

Water is the first water utility to

obvious serious impacts on the life of

make use of such ground-breaking

engines. Effective pre-treatment and

technology in the municipal sector.

the removal of all contaminants from

In essence the business case for

the gas stream is crucial for optimal

biogas stands on two legs: the capital

functioning – impacting directly on

question on what it will cost to retro-

a reasonable pay-back period and

fit an existing wastewater facility and

equipment life.

optimise

available

Given the potential scale of project, public-private is

partnership

also

feasible,

“The funding approach has a significant impact on the best contractual approach.” Theunis Duminy, water engineering manager, Golder Associates approach that optimises the design,

install a biogas-to-energy plant; and

Moving on towards the actual im-

building, operating and maintenance

the life cycle question on what the

plementation and financing of such

thereof within a defined battery limit

payback period would be based on

a project, Duminy says: “The funding

and operating range.

the annual cost saving in electrical

approach has a significant impact

It has been estimated that the

power. To optimise the business case,

on the best contractual approach.

running cost of a WWTW in South

municipalities must carefully look at

There are various funding options

Africa could double in real terms be-

the sources of sludge, how to opti-

that can be considered that ranges

tween now and 2020, a trend driven

mise and pre-condition, as well as the

from the municipality or metro’s

primarily by the increasing cost of

facilities which will be retrofitted to

own revenue funds, grant funding or

energy. Increasing operational costs

maximise biogas-to-energy produc-

co-funding tied to an operations and

provides for a very strong business

maintenance approach.” With the

case to drive these biogas-to-energy

latter, the operator needs to ensure

projects. In the municipal sector,

order

that his equipment and installation

where a focus on capital investment

tion.” I

“WWTWs globally – and increasingly in South Africa – have a longterm vision to be energy neutral.” Dr André van Niekerk,

has dominated in the past, a change towards evaluating projects holistically is gaining ground. Utilities and municipalities are starting to look at the life cycle costing rather than just the initial capital outlay. The fact does remain that a biogas-to-energy plant

principal for mine and industrial water

can pay for itself within five years if

treatment, Golder Associates

all the right criteria are in place. March/April 2014

Africa

Flagship water plant for Zambian mine processes, but will be diverted

A high-end containerised water plant has been earmarked for Kansanshi Copper Mine in Zambia

V BELOW LEFT One of the six 40-foot shipping containers BELOW Fully engineered systems for longterm benefits

for carbon filtration, double-pass reverse osmosis, passed through a polishing filter and continuous electro de-ionisation after passing

eolia Water Solutions

Veolia will completely manufac-

through the initial sand filtration

and Technologies South

ture, test and certify the plants at

skids. The softened water for use

Africa will provide the

its factory in Sebenza, Gauteng,

in the smelter’s processes will be

treatment plant – built

before they are transported to site.

diverted from the demineralisation

into six 40-foot shipping contain-

The 40-foot containerised plants

stream before the second pass re-

ers – to the mine. As part of a new

are designed to be linked up to one

verse osmosis membranes.

copper smelter project, the mine

another on site, and will operate as

Veolia’s position at the upper-end

aims to grow its annual copper out-

a single plant with multiple output

of the containerised plant market

put from 340 000 tonnes in 2013 to

streams to produce a combined

secured

400 000 tonnes by 2015.

42.5 m3 of treated water per hour.

international

contract

against

competitors.

The

“As the world’s eighth largest cop-

“The plant has been designed to

per mine, the new Kansanshi smelt-

ensure maximum viability, so we

and Services Division uses only

er has very specific requirements for

have taken a high-end engineering

best-of-class

boiler feed, process and drinking

approach to match each treatment

is highly specialised within the

water,” says Nigel Bester, project

stage’s

smaller-scale water and wastewater

engineer

requirements.

Veolia’s

Engineered

water

with This

the

mine’s

means

that

company’s

Engineered

Systems

componentry

and

treatment market.

Systems and Services division. “The

boiler feed water, for instance, isn’t

“We have an extensive footprint

result is a flagship water treatment

subjected to all the treatment steps

throughout Southern Africa, which

solution that upgrades river water

necessary for drinking water, which

means we can service our clients

to match each requirement exactly,

is much more viable than treating

comprehensively. As part of the

with guaranteed availability due

all the feed water to high-quality

global

to a duty standby design on all

drinking standards, regardless of its

access to some of the best technol-

process streams.”

application,” says Bester.

ogies, which means that, overall, we

Veolia,

further

have

After clarification, iron removal

provide the entire, fully engineered

and sand filtration, the drinking

package that provides long-term

water train consists of activated

benefits,” says Bester.

carbon

filtration,

ultimately

polishing

and

disinfection.

The

boiler-feed water will be subjected to

the

same

initial

March/April 2014

Africa round-up

Infrastructure news from around the continent in association with

Office of Conflict Management

exploitation of disadvantaged and

and Litigation. In the introduction,

vulnerable populations,” it notes.

Brown says that the report can

availability, quality and access are

of conflict in an area as well as the

traditional practices, water politics,

potential for negotiating peace and

upstream and downstream flows,

building resilience.

pollution, climate change and

The report says that population

natural disasters. Low resilience

growth and movement to urban

to environmental disruptions can

areas pose significant challenges

lower economic productivity, trigger

to governing water infrastructure.

unemployment and damage public

As demand for water grows,

perceptions of the competence of

competition will likely increase if per

government institutions.

capita freshwater availability is not effectively and fairly managed. Effective water management

UGANDA Access to clean water

Other factors that affect water

guide workers in evaluating the risk

“Water is a shared interest even in deeply divided communities and regions,” Chris Kosnik, acting

Uganda to access clean water by

also should take into account

director of USAID’s Office of Water,

constructing two gravity-water

factors like intense agricultural and

said at the Wilson Center. He added:

Water International – Uganda is a

flow systems and seven rainwater

industrial demands, and needs to

“Water can be a powerful connector,

faith-based, non-profit organisation

tanks in Ruhaama county Ntugamo

share water supply fluctuation and

encouraging cooperation and

that helps communities in develop-

district and Nyabushozi, in

water safety data.

negotiation in lieu of competition

ing countries to acquire safe drink-

Kiruhura district.

Living

ing water. It has constructed up to

“Effectively sharing water information during emergencies such

“People in these areas dig water

or violence.” He said that for the first time,

263 boreholes in the north-eastern

dams but when drought comes,

as floods or severe contamination

beginning in 2014, USAID has a

region of Uganda.

the dams dry up, so the water

is crucial for protecting human and

water strategy. The five-year effort

reserved in tanks can be used,”

environmental health and man-

aims to ensure that 10 million

elaborates Muhumuza.

aging perceptions of insecurity in

more people will have improved

tense and tenuous circumstances,”

access to drinking water, 6 million

the report says.

people will gain improved access to

semi-arid Karamoja sub-region

Africa Effective water management prevents conflict

ment is the issue of the lack of

people will get access to improved

where water scarcity has been a

Countries with unreliable supplies

transparency about water rights

agricultural productivity.

big challenge. Most people in this

of water are more vulnerable to con-

and private sector contracts that

region derive their livelihood from

flict, according to a new report from

can mask preferential treatment or

build formal and informal institu-

pastoralism since rainfall is not

the US Agency for International

corrupt governance. “Corruption

tional relationships of collaboration

sufficient to support agriculture.

Development (USAID).

can increase marginalisation and

on water monitoring, management

This move has given thousands of households in the region access to safe water. The north-eastern region of Uganda region includes the

Alex Muhumuza, the programme’s

Also affecting water manage-

Conflict Toolkit, was released 24

office for Living Water International

February at the Woodrow Wilson

– Uganda, says the problem of water

International Center in Washington.

shortage has been a big challenge

It says that conflict is often generat-

to the people of Karamoja and

ed by competition over water and

their livestock.

other natural resources. Effective

“Harvesting rainwater is also a

water management can bring dis-

challenge because people there

puting parties together to prevent

live in grass-thatched houses, but

conflict and foster reconciliation. The Water and Conflict Toolkit is

that can provide clean water,”

meant to be a resource for aid and

notes Muhumuza

development workers in fragile

The agency has also supported communities in south-western

The report urges countries to

The report, called the Water and

manager at the western region

now they have at least boreholes

sanitation and another three million

and conflict-affected areas, says Melissa Brown, director of USAID’s

March/April 2014

feature

Africa round-up and investment. It says that they

is where UNHCR [The UN’s refugee

should make access to clean water

agency] is,” she says. More than

more affordable and equitable,

730 women and children from the

enhance citizen knowledge about

village moved into the settlement’s

water as a resource and water use,

primary school. “When we fled to

improve citizens’ communications

the settlement, the refugees were

with policymakers and take into

generally very supportive and

account the potential for conflict

accommodating because they knew

around access.

what was happening,” says Hawa.

“Fair and effective water resource

Becky Ben Ondoa, UNHCR’s

management is a concern of

community services associate, says:

everyone,” Brown says.

“Even though Amadi village had become a ‘no-go’ area, we knew

South sudan Fresh water brings life back to traumatised South Sudan Village Would you want

that the school would have to be

to live in a village where corpses

were told it was safe for them to

contaminated the only source of

return home.

water? That was the predicament

vacated for the start of the new school year.” Once the fighting ended in Amadi, the villagers

But how could they go back when

Africa High-level energy meeting will benefit African nations The second high-level

Ethiopian Renaissance Dam and the Gibe Three hydropower projects, which will produce almost 9 000 MW of electricity between

that confronted residents of Amadi

there was no clean water in their vil-

meeting of the Africa-EU Energy

them when completed, as well as

village when they tried to return

lage? A UNHCR monitoring mission

Partnership was held recently, with

Ethiopia’s pioneering wind farms

home during a lull in the violence

confirmed what the villagers had

calls from different speakers for

which he said are the largest in

that has wracked South Sudan for

already discovered – decomposing

continued efforts to ensure access

sub-Saharan Africa.

the past three months.

human remains were polluting the

to energy by Africans across the

only source of water.

continent. The energy partnership is

“When our husbands and the village youth went to check the

“It was imperative that we act

one of the eight partnerships of the

Angola Conclusion of energy and water projects on the cards in Angola The National

village sometime after the shooting

quickly,” says Ondoa. “To encourage

EU-Africa Joint Strategy, which was

had stopped, they came across

the Amadi community to return

adopted in 2007.

the bodies of soldiers and civilians

to their village, alternative water

strewn across our cassava fields and

points for the local community had

for Infrastructure and Energy, Dr

government has prioritised out-

in the streams from which we drew

to be found as a matter of priority.”

Elham Ibrahim, focused on the

comes of the main projects in the

progress and importance of the

energy and water sector by 2017.

our water,” recalls Hawa Ladu, a

The African Union Commissioner

A UNHCR partner, ACROSS,

Development Plan of the Angolan

This was announced by the

located a water drilling company

initiatives launched by the African

and in two weeks the village had

Union Commission and its partners,

minister of Former Combatants

the South Sudanese capital, Juba,

two functioning boreholes, ready to

since the inception of the AEEP.

and Motherland Veterans, Kundi

and – luckily for the inhabitants

meet the needs in Amadi. The men

She spoke specifically on the

Paihama, when addressing the main

– only three kilometres from

came first to check on the safety,

Geothermal Risk Mitigation Facility,

act of the celebrations of the 53

Gorom Refugee Settlement, home

their families followed.

which encourages public and

years of the beginning of the armed

private sector geothermal devel-

struggle for the national liberation.

mother of six. The tiny village lies 25 km from

to 2 500 Ethiopian refugees. It

“I cannot tell you how grateful

was to prove a safe haven when

we are for the boreholes UNHCR

opment projects by providing cost

Amadi village got caught up in the

has provided us – and embarrassed

share grants for surface studies and

Development Plan also includes the

violence that erupted in the country

that we continue asking for more

drilling of reservoir confirmation

programme for the rehabilitation of

last December.

assistance,” says Hawa. “However,

wells. “Under the facility, grants

secondary and tertiary roads, as well

under the circumstances, we have

have been awarded to five projects

as the construction of structures of

the villagers tolerated looting of

no choice,” since their farming

in Kenya and Ethiopia, amounting

logistic platform and support for

their food by opposition forces, who

implements had been looted along

to US$22 million (R230 million) and

rural trade.

stole even “the stew in our pots”.

with their food and grain.

other agreements will be signed in

As Hawa recounts it, for a while

Sometimes the soldiers brazenly

March 2014.”

The villagers are busy harvesting

He added that the National

The minister said that greater attention will be focused on the

ordered villagers to carry the looted

the last cassava tubers still in the

The Minister of Water, Irrigation

successful implementation of the

food to their makeshift camps.

ground – a modest provision

and Energy for Ethiopia, Alemayehu

municipal integrated programme

to see them through the long

Tegenu, highlighted the importance

for rural development and fight

seasonal rains.

of appropriate and robust national

against hunger and poverty.

But when warfare engulfed the village in mid-January, it was time

policies and strategies in the suc-

The event was also attended

to run. “Bullets whizzed through the

“Life as we know it has changed

air and some landed in our walls as

for the worse,” says Hawa. “Even our

cess of Africa’s energy ambitions. He

by the provincial governor, Paulo

soldiers advanced on Amadi,” says

husbands have become like women

pointed to several projects which

Pombolo; Media minister, José Luís

Hawa. She, her husband, their chil-

– helpless and fearful – as we all

have been initiated in Ethiopia as

de Matos; Secretaries of State and

dren and their neighbours fled to

wait for the situation in our country

a result of the nation’s focus on

representatives of political parties

nearby Gorom Refugee Settlement.

to resolve itself. As to how long that

integrating energy into the core

with seats at the National Assembly.

They regarded Gorom as the saf-

will be, only God and this country’s

of its national and development

decision-makers know.”

agenda. These include the Grand

est place to seek refuge “because it

March/April 2014

Information supplied by www. allafrica.com

Industry news

Water security project pays off Oudtshoorn, capital of the Klein Karoo, has been linked to good design since the ostrich feather boom of the 1870s, with its flamboyant fashions and opulent palaces.

his year, in a modern

and Turin, with Cape Town taking the

water from groundwater sources to

twist to the story, its munic-

2014 slot. All these cities are dedicat-

a wide area stretching form De Rust

ipal water project has been

ed to using design as a tool for social,

in the east to Calitzdorp in the west,

selected as part of World

cultural and economic development.

including the town of Dysselsdorp.

Design Capital 2014 (WDC2014).

The scheme was transferred to the Oudtshoorn Municipality in 2005.

World Design Capital is a prestig-

submission processes drew 1 253

ious designation bestowed every sec-

entries to be part of the DC2014

The rural component of the scheme

ond year by the International Council

programme. Some 450 projects, in-

accounts for about 50% of the total

of Societies of Industrial Design.

cluding Oudtshoorn’s, were selected.

supply of drinking water. Its main

Previous winners were Helsinki, Seoul

The submission was put forward by

beneficiaries are farm workers and

Societal impact What impact can the project have on people’s lives? The proposed deep groundwater scheme is designed as a secure transition from an increasingly risky reliance on surface water (prone to severe reduction through climate change) to a resource providing a sustainable buffer against water scarcity through drought intervals that may, in future, endure over decades rather than years. Where demand outstrips available freshwater supplies, enhanced community resilience requires that groundwater be managed scientifically in conjunction with surface water and be equally shared among all segments of society. The project will benefit rural and urban communities in the greater Oudtshoorn region. What are the main stages of the project? The main stages of the project have been reconnaissance and research (2003 to 2006); exploration, production drilling, monitoring and aquifer testing (2004 to 2010); and expanded exploration and feasibility studies, alongside final wellfield design (2012 to present). The next stages are wellfield production drilling (2014 to 2017) and supply to Oudtshoorn (2017 to present).

Two rigorously adjudicated public

water, energy and earth sciences

previously disadvantaged people liv-

consultancy Umvoto Africa, which

ing in the rural area between De Rust

has worked with the Oudtshoorn

and Calitzdorp.

local municipality for over a decade. Paul

Müller,

acting

The

present

supply

from

the

director:

groundwater source is insufficient to

Technical Services for the municipal-

meet the demand, so augmentation

ity, explained that the current water

of the source is urgent, said Müller.

project goes back to 1999 when

A pipeline from the nearby Blossoms

a visionary councillor, Issy Baron,

groundwater well field would allevi-

dreamed of turning the arid Klein

ate the shortage.

Karoo into an oasis. He wanted to

Groundwater

from

the

deep

ensure water security for all commu-

fractured-rock aquifer in the Table

nities in the region.

Mountain Group (TMG) will augment

The Klein Karoo Rural Water Supply

the existing surface water storage in

Scheme (KKRWSS) was implemented

the Melville and Raubenheimer reser-

by the Department of Water Affairs in

voirs in the foothills of the Swartberg

the early 1990s. It supplies drinking

range, says Dr Chris Hartnady, Umvoto

March/April 2014

Industry news Africa’s technical director. It will also

Africa, local stakeholders, landown-

from

augment TMG and other groundwa-

ers and farming organisations and

is, however, recharged by rainfall.

ter sources from the KKRWSS in the

drilling specialists.

Provided that the abstraction of

the

wellfield.

Groundwater

western part of the Kammanassie

The municipal cost to date has

groundwater by all parties in the

range and thus provide additional

been R24 million and an additional

region is properly monitored and

assurance of supply to communities

R27 million has been allocated by

managed to ensure that in the long

like Dysseldorp and De Rust.

the Department of Water Affairs. The

run less water is withdrawn than the

total cost of the project is estimated

recharge from rain, groundwater is a

at R200 million.

sustainable option.”

The

combined

ground-

and

surface-water sources will be managed conjunctively to ensure that

Rowena

The project area also has potential

yield is optimised and losses are

Hay, says challenges have included

as a geoheritage site – a tourist

minimised in the overall scheme.

siting the deepest, highest-yielding

destination

The Blossoms groundwater will be

production borehole in the hardest,

local and regional economic benefits

piped to a reservoir in Oudtshoorn

most abrasive quartzitic sandstone

throughout the year, she said. This

during the hot summer months, or

formations known. Umvoto also had

would create more income for the

as needed.

to research and manage how water

community and help ensure greater

The proposed bulk water scheme

falling in surrounding mountains

buy-in to the project.

will be designed by WorleyParsons,

reached the wellfield area (where the

which has been involved with the

aquifer is closest to surface, albeit still

feasibility studies to date. Partners

at least 300 m below ground).

have of

included

the

Environmental

Development

Department Affairs

Planning,

Umvoto

Africa’s

MD,

“The main concerns have been

and

proving aquifer yield, evaluating cost

the

benefits and establishing whether

Water Research Commission, the

the farming area in the Outeniqua

Department of Water Affairs, the

region would be negatively impacted

Development

if Oudtshoorn pumped groundwater

Bank

Southern

Groundwater from the deep fracturedrock aquifer in the Table Mountain Group will augment the existing surface water storage

that

would

provide

BELOW Dr Chris Hartnady, technical sirector of Umvoto Africa, discusses the water project with Oudtshoorn Municipality Executive Mayor Alderman Gordon April

Project teams Umvoto Africa specialises in resource development and sustainability. The firm has in-depth knowledge of groundwater modelling, hydro-and-geological, hydrochemical processes and a technical staff complement of 13 with international and national reputations and all postgraduate degrees. Three of Umvoto’s innovative groundwater projects (for the Stanford, Hermanus and Oudtshoorn municipalities) have been selected for WDC2014 to highlight how design can improve the lives of people and communities, and build resilience. See www.umvoto.com. Global company WorleyParsons is a leading provider of project delivery and consulting services to the resources and energy sectors and complex process industries. The Water Solutions consulting practice provides solutions across the entire water spectrum, from resource management and abstraction to treatment and reuse. Consultants with global experience have a particular focus on investigation, troubleshooting, conceptual and functional design, and advisory services.

March/April 2014

Pipes and pipelines

Every year millions of children die from drinking polluted water.

Managing bulk pipelines

Davey have water disinfection covered.

Bloem Water has successfully implemented a bulk pipeline leak detection and assessment project, writes Mokutu Kgwale of Bloem Water and Kobus Prinsloo of SSIS.

Experts in water.

ocating and repairing leaks on large-diameter transmission pipelines is important in maintaining safe and reliable service delivery. These leaks are often more sparse and therefore more difficult to

locate, which can lead to prolonged leakage and extensive waterÂ loss. Utilities that have a leak detection programme in place for their large diameter transmission mains often achieve greater reduction in non-revenue water (NRW), which is the amount of water lost before it reaches the customer.

Experts in water.

Many homes in and around South Africa use water collected from unsecure sources such as rainwater harvesting, rivers and boreholes. All surface water can harbour micro-organisms that are potentially dangerous to your health. Davey Water Products offer a range of products designed to make drinking water safer. From manual dosing with liquid to point of entry filtration, UV, and water softening systems. It is easy to treat all incoming water into the home to ensure water clarity and safety at every tap. Email us on davey@safequip.co.za to find out more about the full Davey range or contact any of the Safequip branches to find your nearest dealer. Gauteng: Western Cape: Kwazulu-Natal: Eastern Cape:

011 021 031 041

397 907 563 451

7723 2500 8807 0026

Davey is exclusively distributed by Safequip.

QUALITY FIRE SOLUTIONS

March/April 2014

Pipes and pipelines Furthermore, a leak detection inspection is a valuable step as part of a condition assessment programme. Utilities can avoid expensive capital replacement programmes by gathering real data on the condition of their pipelines and addressing problems as they arise. Bloem Water, which provides water services to the central region of South Africa, recently implemented an

asset

condition

assessment

project that included a comprehensive leak detection programme using inline methods on a strategic 1 200 mm pre-stressed concrete pipe (PCP) that supplies the City of Bloemfontein with roughly 60% of its drinking water. Inline leak detection is a very accurate method of leak detection because the acoustic sensor used to identify the sound of the leak is brought directly to the source, unlike traditional methods, such as correlators and listening sticks. Such techniques lack the accuracy needed to locate leaks in larger pipes because the sound of a leak dissipates

surveys to provide visual confirma-

indicative

rapidly in large diameter pipes.

tion on the location of the leaks in

accounts to approximately 1 200 kℓ/

leak

sizing

categories

order to aid in the interpretation

day. Interestingly, of all the pipeline

technologies

of findings and plan interventions.

leaks detected, only three leaks

were successfully applied. A total

Sahara is a tethered inline leak

showed any surface signs of leakage.

length of 103 km between De Hoek

location and condition assessment

This reiterates the importance of not

reservoir and Brandkop reservoir

technology that pinpoints the lo-

relying on surface inspections as the

were inspected.

cation of leaks at the same time as

only means of detecting large diam-

the

inspecting the internal condition of

eter pipeline leaks.

Both SmartBall and Sahara Audio Video

inspection

maximise

efficiency,

SmartBall leak detection technol-

the pipeline and verifying the cause

The findings of the latest leak

ogy was used first to cover large

of leakage using a combined acous-

detection surveys were compared

sections of the distance in single

tic

to that of a previous Sahara leak

deployments. The SmartBall tool

CCTV camera.

Engineering evaluation and risk assessment were factored into the development of a pipeline specific management strategy

hydrophone

with

integrated

OPPOSITE Sahara Leak Detection set-up ABOVE SmartBall prior to insertion into the pipeline

detection inspection project perVisual leak verification

formed in 2007/2009 to establish

was also performed at all

trends. This information combined

accessible components

with a first order engineering evalua-

along the pipeline.

tion of available pipeline design and

Leaks were identified

manufacturing data, the failure histo-

and classified as either

ry of the pipeline, operating records

pipeline leaks, i.e. on the

and the hydraulic behaviour of the

pipeline

system were incorporated into a risk

barrel

component

itself ),

leaks

(i.e.

assessment model for the pipeline.

is a free swimming leak detection

valves, air valves, scour valves, etc.)

leak

detection

platform that operates while the

or off-takes. The majority of the

engineering

The

evaluation

pipeline remains in service. It is

leaks were found to be components

assessment were factored into the

equipped with an acoustic sensor

while pipeline leaks were detected

development of a pipeline specific

that identifies acoustic anomalies

mainly on joints (i.e. where the PCP

management strategy. Bloem Water

associated with leaks, the acoustic

was connected with prefabricated

can now implement this strategy as

signature is then analysed to deter-

steel joint pieces). Some of the

a guideline to proactively manage

mine if it is a leak, air pocket or an

leaks on these joints may be attrib-

this valuable asset in order to pro-

external noise.

uted to poor bedding, improper VJ

long its remaining useful life, avoid-

The SmartBall inspections were

(Viking Johnson) connections, etc.

ing expensive capital replacement of

followed by selective Sahara AV

The estimated water loss based on

the asset.

March/April 2014

findings, and

risk

feature

Pipes and pipelines

New for old

Deteriorating infrastructure A statement issued by Edna Molewa ,the Minister of Water and Environmental Affairs, states that non-revenue water losses in South Africa is in the region of 1.58 billion cubic metres. By

KROHNE WATERFLUX meets SANS1529-1:2006 fit for trade metrology – exceeds class D Specifications

Nicolette Pombo-van Zyl, content director for African Utility Week

Replace all mechanical bulk water meters? Now it’s possible with the WATERFLUX from KROHNE.

WATERFLUX – the new electromagnetic water meter – is bringing technological change to the water industry. It measures precisely and maintenance-free very small and large flow rates – from night-time demands up to fire-fighting operations. Throughout its entire service life of 25 years over several custody transfer periods.

his has severe cost implications, not to mention supplied water being wasted each year. Nonrevenue water (NRW) in South Africa is estimated to cost R7.2 billion per year, this calculated at a

nominal production cost of R4.50/m3 in 2013. As South Africa is deemed a water-stressed country it is of vital importance to investigate and implement measures that can be undertaken by municipalities to manage this valuable resource, with one such being the targeted replacement of pipes.

Its unique, RILSAN -lined measuring tube is wear-free and without mobile measuring parts, eliminating the need for maintenance. This reduces follow-up costs for statutory recalibrations – as an overhaul or replacement of the water meter is no longer necessary. ®

It was at the 13th annual African Utility Week conference and exhibition held in Cape Town recently where the question was raised and discussed on whether mains replacement projects results in a reduction in real losses. For this to be realised, water utilities need to recognise that as the water distri-

Both the low initial costs and the significantly reduced operating costs pay off in daily operation. Employ the WATERFLUX instead of mechanical bulk water meters and create financial freedom for new projects – simply exchange new for old.

bution infrastructure is in a continuous state of deterioration;

KROHNE – Water is our world. Please see our website for more information www.krohne.com/waterflux-series KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander j.alexander@krohne.com www.za.krohne.com

March/April 2014

Pipes and pipelines

How to offset infrastructure damage

The question was raised and discussed on whether mains replacement projects results in a reduction in real losses the replacement of mains must be an ongoing, continuous programme. In addition to the above prepara-

of reducing construction times and environmental impacts. • For areas where partial mains

tory considerations, the discussion

replacement occurs, it will be ben-

expanded on the following construc-

eficial over the long term to ensure

tion considerations:

that the pressure across the entire

• Various contractual implementation

supply area is managed in order to

vehicles should be investigated to

ensure that leakage levels are, in

derive the solution that best fits the

fact, reduced

objectives of the water utility. If not

• The mains replacement contractor

conducted in-house, turnkey con-

must be made responsible for the

tracts such as the New Engineering

performance of the new infrastruc-

Contact (NEC) offer a number of ad-

ture and various key performance

vantages to tackling a programme

indicators must be measured as part

of this nature.

of the hand over process. Factors

• provide budget on a permanent basis to cover the cost of annual mains replacement • implement systems to gather and store performance data for analysis in terms of tracking the deterioration rate of water mains in order to predict replacement times • training of employees to recognise the different types of water main faults and sensitise them to the importance of having accurate information in the faults database • analysing the causes of failures must be undertaken and forwarded to the engineers and the procurement department in order to shape future mains replacement material selection and installation methodologies • reducing the pressure in each district metered area must be undertaken as much as possible before mains replacement. There is the added benefit that this reduction may improve the zone performances such that the replacement of the pipes is considerably deferred • have in place consecutive leak detection and repair exercise to minimise losses as much as possible • tracking of the mains failures for at least three years prior to prioritising areas for replacement and determine the Burst Frequency Index (BFI) for both mains and service connections • the prioritised zones must be assessed to prove beyond doubt that the prioritised area will yield significant results when rehabilitated • conducting assessments to determine if it will be beneficial to replace service connections only as this can be done at a fraction of the cost of rehabilitating the reticulation mains.

• Thoughtful consideration should

such as real loss, NRW, MNF, snap-

potential to damage or destabilise

be given to not only the type

shot ILI, fire flow and average pres-

the existing services.

of material used, such as PVC, HDPE, and ductile iron, but also

sure can be used for this purpose • Coordinate

with

other

• Replace

all

service

connections

service

during the replacement of the water mains as these connections

methodol-

providers so as to rehabilitate all

ogy used as each material and

services at the same time where

are often of a similar age to the dis-

methodology

potentially

possible to limit future disturbances

tribution mains and statistically they

offer significant benefits in terms

as these disturbances have the

account for 50% of the leakage.

the

construction can

March/April 2014

ALL IMAGES When pipe infrastructure goes wrong

Pipes and pipelines

A three-metre diameter dismantling joint A significant pipeline located in Southern Africa, which is currently under construction, is expected to accommodate the region’s water demand growth projected to 2030.

s part of the construc-

Africa, which placed the order with

without having to cut into the pipe

tion of this more than 8 km,

South

Klamflex

in which the flow meter is installed.

3.5 m diameter pipeline, a

Pipe Couplings for the dismantling

The purpose of the dismantling joint

number of innovative tech-

joint, explains the background to the

is firstly to ensure an easy installation

nologies were required for what is

project. “The pipeline itself is 3.5 m

and secondly for the dismantling

said to be sub-Saharan Africa’s largest

in diameter, but in the section where

of the flow meter when necessary.

water pipeline. One of these was the

the flow meter has been installed it

Without the dismantling joint, it

design, manufacturing and testing of

is 3 m in diameter and therefore the

would mean that you are left with a

a 3 m dismantling joint.

size of the line at that point has been

very tight tolerance to work within.

reduced” says Rampathi.

This would be very difficult during in-

To account for the water that is

BELOW A section of what will be one of Africa’s longest pipelines

African

company

to be extracted from the Vaal Dam,

The specifications of this flow meter

stallation and also during dismantling,

the electromagnetic flow meter was

are an internal diameter of 3 002 mm,

when inspections are undertaken and

chosen. A tender document was put

with a maximum flow rate of 900 Mℓ/

maintenance is conducted to clean

out to the open market and Krohne

day, thus not only making it the larg-

out the debris that has accumulated

South Africa was selected to supply

est of its kind in the world, but also

inside the flow meter.

the

meter,

a first in Africa. “This is the tenth 3 m

including the dismantling joint and all

flow meter that Krohne has manufac-

Pressure testing

the other accessories required for the

tured,” commented Rampathi.

Andy Lawrence, managing director

electromagnetic

flow

of Klamflex Pipe Couplings explains

flow meter.

What is a dismantling joint?

the manufacturing process of the

The dismantling joint is the piece of

dismantling joint and discusses some

and

equipment that allows for the remov-

of the technicalities encountered.

logistics manager at Krohne South

al of the electromagnetic flow meter

“The dismantling joint had to be

About the flow meter Deon

Rampathi,

projects

March/April 2014

Pipes and pipelines pressure tested to ensure the integrity

to determine what the required thick-

of the welding and the steel structure

ness of the blank flanges should be to

in its entirety. It was specified at the

withstand 15 bar pressure. To be able

outset that the pressure test needed

to withhold such a pressure, reinforc-

to cater for one and a half times the

ing was required and our engineer

design pressure. “Testing at 15 bars

John Somers-Vine, designed eight

for a period of 15 minutes for this

high-tensile tie-rods in the centre,

large diameter is a first for us and

sealed with O-ring seals on the flange

it required changes to our design

that actually held the two flanges

to accommodate for this extreme

together, so that they didn’t bow out

pressure. On a size like this, just one

with the pressure”.

bar makes a huge difference, it goes

The normal operating pressure of

the process was the torque that had

up incrementally and it becomes very

the pipeline where the dismantling

to be applied to the bolts to tighten

difficult,” says Lawrence.

joint will be installed was specified

them. Lawrence explains: “We had

to be 6 bars. Industry standards

to purchase a 90 mm spanner head

dictate that the test pressure must

that you wouldn’t get in your average

Klamflex Pipe Couplings located in

be 1.5 times the working pressure, i.e.

toolbox.

Chamdor, Krugersdorp, to witness the

9 bars. However, for this installation

that we needed close to 3 000 Nm of

pressure testing of the dismantling

the client insisted on a 15 bar test

torque to tighten the bolts on the dis-

joint. “Today, we have proven that

pressure, which is nearly 70% more

mantling joint, which is a lot of force.”

the dismantling joint could take the

than the normal test pressure. The

Having reached a milestone in

15 bar pressure.” Lawrence explains

15 bar test pressure was achieved

design and technological capabilities,

what was required in order to actually

with ease demonstrating the strength

Lawrence adds: “Overall this has

conduct the pressure test. “We had to

and integrity of the Klamflex disman-

proven our design capabilities. We

design and build a test-rig on-site. Our

tling joint.

are now open to many more op-

A team of officials recently visited the

manufacturing

facilities

engineers conducted a finite element

One of the other challenges that

analysis on the actual blank flanges

were encountered by Klamflex during

Sensus iPerl Ad2013(1).pdf

8/18/13

5:20 PM

Our

engineer

ABOVE All dismantling joints have to be pressure tested

calculated

portunities, not only in South Africa, but internationally.”

March/April 2014

feature

Pipes and pipelines

SABS ensures heavymetal-free pipes The South African Plastic Pipe Manufacturers Association (SAPPMA) has welcomed the South African Bureau of Standards’ (SABS) announcement that all PVC pipes manufactured in South Africa have to be free of heavy metals by July 2015.

he General Manager

as sewer, drainage and mine pipes.

membership over the past eight

at the SABS Certification,

“Although lead does not leach from

years and as such has formed part of

Gauteng, Sibongile Dhlamini,

the plastic pipes and does not pose

the regular SAPPMA factory audits,”

confirmed earlier that the

any danger to people once installed,

says Venter.

technical committee of the SABS

we felt compelled to create a safer

Dhlamini concludes: “In the interest

Standards

amended

environment for the manufacturers

of the consumer and good business

series of standards to ensure that all

where lead poisoning does pose a

practice, the SABS strongly promotes

heavy metal stabilisers are removed

risk for their workers. As a result, all

the highest possible product quality

in the manufacturing of PVC Pipes.

PVC pipe manufactured by SAPPMA

standards as well as environmentally

“Local manufacturers of PVC pipes

members

are

friendly manufacturing processes and

who are SABS certified have been

stabilised

environmentally

materials. We therefore urge compa-

granted a window period of 24

friendly materials such as calcium

nies to ensure they comply and begin

months as of 30 October 2013 to get

zinc or organics-based stabilisers

the process of removing heavy met-

their house in order and to comply

instead. Adherence to the policy

als from their manufacturing process,

with the new

has been a requirement for SAPPMA

if they have not yet done so.”

Division

has

relevant standard

are

lead-free

with

and

Standards have been amended to ensure that all heavy metal stabilisers are removed

requirements.” Pipes bearing the SABS mark of quality will have to be resubmitted for testing, after which new permits will be issued. Commenting on this announcement,

SAPPMA

chairman

Jan

Venter says that the association welcomes the decision by the SABS. “Representing a socially responsible industry, SAPPMA already embarked on a voluntary removal of heavy metal stabilisers from PVC pipes back in 2006 because it added value to SAPPMA’s life cycle thinking and took into account end-of-life issues and waste management options. The reason for the initiative was based on health and environmental considerations and was done at considerable cost to our members,” Venter explains. The policy was fully implemented by SAPPMA in July 2009 and applied to drinking water systems as well March/April 2014

Pipes and pipelines

SAPPMA and SAICE sign memorandum The Southern African Plastic Pipe Manufacturers Association’s (SAPPMA) South African plastic pipe industry facilitator has signed a Memorandum of Understanding (MOU) with the South African Institution of Civil Engineering (SAICE).

he MoU encourages the

and on varying media platforms

two parties to cooperate

about each other’s activities. The

to lobby and challenge

parties will have regular consulta-

statutory

and

tion sessions to advise each other

legislation

structures to facilitate the achieve-

on their programmes and activities.

ment of their common objectives.

With SAICE’s backing, SAPPMA will

Some of the areas of cooperation

be able to participate in graduate

agreed upon include the mobili-

engagement

sation of resources, where the two

various universities in the country

parties have agreed to support each

and spread the message about the

other in sourcing funds for the im-

need for engineers who are dedi-

plementation of their activities and

cated to advancing the pipes and

plans that fall within the framework

plastic industry.

of the MOU.

programmes

New plastics programme launched

One of the first tasks of coop-

SAPPMA CEO Jan Venter says:

eration is SAICE’s assistance in

“The cooperation agreement with

distributing

SAICE is aimed at expanding the

published

association’s reach to the new

engineers from their bookshop and

generation of engineers entering

e-sales facility. The 2013/14 manual

the South African market. It is im-

was released in October last year

portant for the local pipe industry to

and provides technical information

ensure an influx of graduates with

on the selection of plastic pipes

qualifications to further develop the

for water supply and wastewater

sector. SAICE is an influential associ-

disposal projects.

ation and, with our target audience being

largely

civil

SAPPMA’s technical

recently

manual

for

“Plastic pipes are one of their

engineering

priority areas of SAICE via its Water

linked, greater access to them is

Division, and we are grateful to

now ensured.”

have a formalised our partnership

The agreement also entails a

with them. As an organisation, they

commitment to enhance and sup-

have the calibre and influence we

port each party in the creation and

need to increase our presence and

maintaining of relations with similar

educate the engineers about the

international institutions, as well as

importance of ensuring high stand-

raising awareness in publications

ards of manufacture and installation

The cooperation agreement with SAICE is aimed at expanding the association’s reach to the new generation of engineers entering the South African market

when

comes

plastic pipes. Similarly, we

believe

partnership

that will

our offer

SAICE value by granting them access to the local plastics relevant

industry

and

information,”

says Venter.

Plastics|SA’s Training Division has launched a brand new learning programme for thermoplastic welding inspectors or future inspectors who need to know more about the criteria for proper inspection of plastics fabrication welded joints. According to Kirtida Bhana, training executive for Plastics|SA, the Thermoplastic Welding Inspection Programme provides an excellent overview for everyone in the thermoplastic fabrication industry. “South Africa has a high demand for plastics welding inspectors, due to the increased use of plastic welding across various industries. Many mining and construction companies are specifying that products traditionally made from steel or metal be manufactured from plastic. Our new course is a non-NQF programme that focuses on plastics as a material of choice and various fabrication methods such as butt welding, socket fusion, electro-fusion, hot air, hot air extrusion and solvent welding, with the main focus being on the inspection of plastics fabrication welded joints,” Bhana explains. Owing to their good properties, plastic pipes are increasingly being used to replace metal and ceramic pipes. However, as with all pipelines and regardless of the materials used, the integrity of plastic pipe joints (welds) is critical to the success of the pipeline. To this end, the Southern African Plastic Pipe Manufacturers Association (SAPPMA), through its Installation and Fabrication Plastics Pipe Association initiative, has welcomed and endorsed the development of the Thermoplastic Welding Inspection Programme. “An entire pipeline depends on the quality of a weld. The repercussions of poor welding could even be life-threatening in mines or at construction sites and our industry therefore needs qualified welding inspectors who would be able to spot poor or inferior quality welding or confirm the quality and safety of the weld,” says Jan Venter, CEO of SAPPMA. The training courses last three days. The pilot programme will be launched at Plastics|SA’s training centre in Johannesburg on 8 to 10 April 2014, after which the course will also be offered at the association’s Cape Town and Durban branches, or presented in-house at a company’s premises. The fee is R4 218.00 plus VAT per learner for non-member companies and R3 796.20 plus VAT per learner for member companies. For more information, contact renee.mclean@plasticssa.co.za Issued on behalf of Plastics|SA.

March/April 2014

Pipes and pipelines

GRP pipes top choice for Abagold project The history of Abagold dates back to 1991 when a pilot abalone hatchery was set up in the Old Harbour in Hermanus.

n 2013, the company reported a record growth of 310 t

and its hatchery produced a record 4.3 million spats. Fiberpipe is proud to have been associated with this leading producer of abalone since 2009.

Project phases According to Christiaan de Wet, Abagold’s engineering manager, during this initial project for the sea water supply upgrade, Abagold installed two sections of DN700 diameter Vectus GRP lines. The first was a 110 m section to take water from the sea water pumps to the filtration unit and the second was a 500 m pipeline to supply additional water from the filtration unit to one of the grow-out facilities. Both pipelines involved custom-made reducers to connect to the pump discharge outlets and several bends of varying complexity to allow for installation around existing infrastructure. Both pipes are exposed to direct sunlight and were treated for UV protection. “At the time of installation, the aquaculture industry was mainly using HDPE for its large diameter supply pipes and PVC for the smaller diameter. The HDPE was historically more cost effective. However, Fiberpipe’s (formerly Amitech) range of GRP pipes was not only more cost effective in the initial capital investment, but also had reduced friction coefficients

March/April 2014

Pipes and pipelines and lower levels of bio-fouling, both

pipeline set from the primary pumps

contributing to an improved system

to the filtration unit is made up of

efficiency, resulting in a reduced life

GRP Flowtite pipes that were supplied

cycle cost,” says De Wet.

and manufactured by Fiberpipe. This

Installation of the Vectus pipes was

includes the 1 200 mm suction lines

quite a simple process with the basic

with eccentric reducers and the dis-

bell and spigot arrangement and the

charge lines with concentric reducers,

double seal system, which allows for

bends and straight section of DN900

individual seal integrity tests. “This

diameter for each primary pump. The

is a huge advantage when installing

components were all manufactured

long pipelines. Connections are so

off-site and installed with final on-

much faster and cleaner than having

site adjustments and welds. The four

to weld the HDPE sections together,”

primary pumps pump into a collector,

comments De Wet.

from where the water flows under

In 2010, Abagold started with the

gravity through two separate pipes,

Flowtite pipes. De Wet says “the

design and development of a brand

each feeding three of the six swirl

original plan was to go with a pair of

new water reticulation system. This

separators. Pipeline friction, diameter

DN700 GRP pipes, but these proved

was partly to supply additional water

and length were critical in this section

to be too restrictive and the larger

for the new grow-out production

to ensure even distribution to the six

diameter DN1200 pipes were found

facility Abagold was planning to con-

swirlers. Due to the complex nature

to be the optimum size for capital

struct and also to replace the outdat-

and the restrictive environment of

investment versus life cycle cost

ed existing system. “The new system

the swirler connections, these special

for this application. Due to existing

was designed to filter 20 000 m3/h of

fittings were manufactured on-site. As

infrastructure,

sea water to 60 microns (0.06 mm).

a result of the remote location of the

ideas had to be implemented with

A set of four low head, large volume

site, a local installer was trained by

the installation of this line. Complex

primary pumps, each capable of

Fiberpipe’s personnel and the connec-

bends and very difficult on-site

supplying 5 000 m3/h of raw sea

tions were all inspected and approved

connections had to be made and

water, will supply the filtration unit.

by Fiberpipe upon completion.

Fiberpipe’s on-site personnel did a

several

All 15 suction lines for the sec-

tremendous job. Long sections of the

6 swirl separators, 11 fine mesh drum

ondary pumps were manufactured

line were installed into excavations

filters and a large settlement tank and

off-site. These were a combination of

into bedrock.”

treatment area. A secondary pump

DN600 and DN700 pipes. The second-

set distributes water from this filtra-

ary pumps have GRP discharge lines

and commissioned 825 m of the

tion unit to the production facilities,”

to a point where they connect to the

DN1200 line, and a further 220 m

explains De Wet.

original pipelines.

of the remaining 675 m has been

has,

to-date,

installed

Construction started in 2011 and

The main lines supplying the new

installed. The remaining sections will

the system was commissioned in

grow-out production facility are a

be installed and commissioned in the

December of 2012. The complete

paired set of DN1200 underground

near future.

March/April 2014

ABOVE UV protection being applied to the pipe

innovative

The filtration unit consists of a set of

Abagold

OPPOSITE Aerial view of the site of Abagold in Hermanus

feature

South Africa

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Pipes and pipelines

Completion of R4.3 million pipeline project A recent municipal upgrade project in Vosloorus to replace an existing asbestos cement (AC) pipeline installed in the 1980s has been completed.

leading veyance

fluid

con-

pipe difficult to cut and splice to un-

of AVK valves in various sizes, includ-

products

and

dertake repair work,” he explains.

ing; 200 mm, 300 mm and 500 mm.

solutions expert successfully completed its role in

Patji reveals that HDPE is non-toxic

The contract was officially com-

supplying

pleted in mid-2013 without any

supplying the pipes and valves to

drinking water, while the lightness of

major challenges encountered. As

potable water upgrade project.

the material makes it an easier and

municipalities across South Africa

Inceldon was contacted in mid-

quicker type of pipeline to install.

continue to invest more capital into

2012 to supply more than 1.4 km

“The lightweight properties of HDPE

pipeline upgrades, Patji is confident

of 560 mm diameter locally manu-

make it easier for workers to carry

of the future outlook for Incledon in

factured high-density polyethylene

and lay. More pipes can be loaded

the civils market.

(HDPE) pipe.

onto a truck, thereby reducing carbon

HDPE was selected as the material

replace

safe

for

more impact strength than AC pipes, which substantially reduces the risk of

high impact strength, low friction

cracking and subsequent leaks.”

environmentally

friendly characteristics.

BELOW HDPE was selected as the material of choice to replace the existing AC pipeline

emissions too. HDPE pipes also boast

existing AC pipeline due to its and

entirely

the

properties

choice

and

BOTTOM HDPE is non-toxic and entirely safe for supplying drinking water

According to Patji, the SANS 4427 approved pipes, which have a pres-

Robinson Patji, sales representative:

sure rating of 12.5 bar, were delivered

civils, says: “AC pipelines pose some

to the project in 12 m lengths by

potential health concerns for both

Incledon. As part of its comprehensive

workers and end users. These pipes

service offering, Incledon also sourced

are also very brittle and tend to crack

a professional welding contractor on

under stress from trench loads. The

behalf of the municipality, in addition

brittleness also makes this type of

to supplying the project with a range

March/April 2014

Pipes and pipelines

Ultraflo mPVC pipes

966 part 2

DPI Plastics’ proprietary Ultraflo mPVC pressure pipes were supplied in standard 6 m lengths to the Kapinga Irrigation Project in Zambia, which was established in mid-2013.

PVC-M Pressure Pipe SANS 966-2 –PVC-M (modified poly vinyl chloride) pressure pipe systems for potable water conveyance.

he appointed contractor, Inter-Africa Irrigation, selected the Ultraflo range of pressure pipes for the project due to its high-strength characteristics, notes IAIS manager Craig Rawlinson.

“Inter-Africa Irrigation has been making use of Ultraflo

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mPVC piping at its Zambian irrigation projects, due to the fact that the range boasts higher impact resistance and improved ductility. It also features increased hydraulic capacity and a more reliable performance, when compared to standard PVC piping products,” he states. DPI Plastics exports manager Rajesh Naval states that the Ultraflo mPVC pipes were supplied to the Kapinga project in diameters ranging between 11 mm to 450 mm. “The pipes supplied to the project are manufactured in accordance with SABS 966 specifications, which guarantees an operating pressure of up to 18 MPa. What’s more, its lighter mass ensures that the Ultraflo range is easier and more cost-effective to transport, which is a major benefit in a remote area such as Kapinga.” Rawlinson points out that Inter-Africa Irrigation makes use of predominantly locally sourced staff on its Zambia projects. “We have total of about 70

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local

residents

info@dpiplastics.co.za www.dpiplastics.co.za

Member of the Dawn Group

March/April 2014

Pipes and pipelines

ABOVE DPI Plastics export manger Rajesh Naval BELOW LEFT PVC pipe ready for export BELOW DPI Plastics technical & product manager Renier Snyman working on the Kapinga project. Sourcing local staff is important, as it leads to job creation and skills development. This leaves a lasting and meaningful impression on the community, together with the new irrigation system.” According to Rawlinson, the Kapinga project has been running smoothly, with no major challenges encountered to date. “DPI Plastics has proven to be a reliable and trustworthy supplier and that has gone a long way in ensuring that everything remains on schedule. DPI Plastics also boasts a highly competitive cost-to-performance ratio, which is an important aspect in this industry.” Inter-Africa Irrigation specialises in the supply and installation of full scale solutions for drip, micro-jet and centre pivot irrigation projects in Southern Africa. Rawlinson points out that the company has developed a strong market share in Zambia. “Our high-quality workmanship has ensured significant growth in Zambia, an emerging market that holds tremendous promise, due to the high demand for continued infrastructural development.” Looking to the future, Naval is confident that DPI Plastics will continue to gain measurable market share through its Ultraflo range, particularly within the exports market. “There has been a steady increase in demand for mPVC piping, particularly from emerging African economies such as Zambia, the DRC and Mozambique. DPI Plastics has already established a good reputation in these regions and is well positioned to satisfy this rise in demand,” he concludes.

MARCH/April 2014

Technical paper

Predicting the pressureIn this abridged article by AM Cassa

relationship between pressure head

and JE van Zyl, presented at the last

and leak area in pipes with longitudi-

by creating different geometric re-

nal, spiral and circumferential cracks.

gions, establishing separate approxi-

WISA conference, we look at the

It was found that there is a linear

mating functions in each region and

relationship in pressure-leakage by

relationship between the crack area

then joining them together to make

and pressure head for all crack types,

a model containing many small inter-

using head-area slopes and leakage

pipe materials and loading condi-

connected sub-regions of elements.

exponents of cracks in pipes.

tions tested. The impact of loading,

The ABAQUS Finite Element soft-

material, section and crack properties

ware was used in this investigation

problems. Finite Elements are used

on the head area slope were also

as well as the software program

ressure has a major

investigated and an attempt make

SolidWorks, where the pipes are

impact

to find an expression to describe

modelled according to the dimen-

leakage from leak openings

the head area slope as a function

sions required. The study is based

in pipes and studies have

of these properties. Mathematical

on a 110 mm diameter class 6 uPVC

shown that the leakage exponents

relationships were developed that

pipe with a wall thickness of 3 mm

in networks can be sustainably larger

give reasonable descriptions of the

(see Table 1). The pipes that were

than the theoretical orifice exponent

head area slopes of longitudinal,

modelled in this study assumed office

of 0.5. The most important reason for

spiral and circumferential cracks. With

hydraulics and elastic behaviour of

this behaviour is that leak areas are

these relationships, it will be possible

the pipe material. Ten-noded quad-

not fixed, but increase as a function

to predict the behaviour of different

ratic tetrahedron elements were used

of pressure.

types of leak openings in different

throughout the pipes. Sensitivity

pipes and pipe materials.

analyses were done for each config-

the

rate

In this study, Finite Element analysis was used to investigate the

The study focused on three types of

uration to determine the optimal el-

cracks – longitudinal,

ement size. Generally the sizes of the

spiral and circumfer-

elements in the region around the

ential – and their be-

cracks were 1 mm and 2 mm for all

haviour under certain

three types of cracks, while the rest of

pressure

the pipe had element sizes of 5 mm.

conditions.

Three separate equa-

The boundary conditions of the

tions were found that

pipe consisted of clamping the pipe

can be used to predict

along an internal line furthest away

the head area slopes of

from the crack, as well as a point

cracks in pipes. These

on the outside of the pipe adjacent

equations

based

to the internal line. The pipes were

on the crack properties

loaded with an internal pressure from

(orientation, length and

the water in the pipe and an applied

width), the pipe mate-

stress at the ends of the pipe to stim-

rial properties and the

ulate the longitudinal stresses within

pipe section properties.

the pipe material.

Finite element analysis

Leak area as a function of pressure

This study first used

The results of this and a previous

finite

study2 confirmed that the areas of

analyse the behaviour

leaks expand linearly with pressure,

of longitudinal, spiral

irrespective of the pipe material,

and

circumferential

leak type of loading state. However,

cracks in pipes un-

this is only true under linear elastic

der

The

material behaviour and thus doesn’t

Finite Element Method

necessarily represent the behaviour

of all leaks in a distribution system.

elements

pressure. an

numerical

established analysis

The results for 60 mm cracks in lon-

for

gitudinal, circumferential and spiral

obtaining approximate

configuration are shown in Figure 1.

solutions to a wide

This linear relationship has important

variety of engineering

implications for the modelling of

technique

are

used

March/April 2014

Technical paper

leakage relationship Variable

Value

Units

600

kPa

Property or dimension

Varied

Pressure head, h (kPa)

0, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000

GPa

Poisson’s ratio, v

0.4

—

Young’s modulus, E (GPa)

3, 10, 30, 90, 200

Poisson’s ratio, v (-)

Longitudinal stress, σl

5.2

MPa

0.17, 0.21, 0.29, 0.4, 0.45, 0.5

Longitudinal stress, σl (MPa) (excluding longitudinal cracks)

Length of pipe, Lpipe

900

0, 1.3, 2.6, 3.9, 5.2

Wall thickness, t (mm)

2, 2.5, 3, 4, 5

Internal Diameter, ID

104

Internal Diameter, ID (mm)

20, 30, 40, 50, 80, 104, 150, 200, 250, 300, 350

Length of crack, Lcrack

Length of crack, Lcrack (mm)

10, 30, 60, 100, 130, 150

Width of crack, Wcrack

Width of crack, Wcrack (mm)

0.1, 0.5, 1, 2

Pressure head, h Material Properties

Geometry pipe Crack geometry

Young’s modulus, E

Wall thickness, t

change. Note that a logarithmic scale

leakage flows. Using this linear rela-

Keeping all the parameters the

tionship, Equation 2, below, is found

same as the base pipe, except the

for describing leakage behaviour

parameter being investigated, and

As can be seen from Figure 2, the

in any system where leaks increase

varying each parameter in turn ac-

crack length has the dominant effect

linearly with pressure.

cording to Table 2, the relationship

of the pressure-area slope for all three

between the head-area slope and

crack types, followed by the wall

is used on the y-axis.

each parameter was obtained. It was

thickness, Young’s modulus and inter-

This equation is identical to that

also possible to see which parameter

nal diameter. The relationship for the

proposed by May3 and others, but the

affected the head-area slope the

longitudinal stress is also interesting

interpretation given by Casse et al4 is

most. Figure 2 shows a bar graph

to note that, as the crack is orientated

different. Instead of interpreting leaks

with all the parameters against the

away from the longitudinal direction,

as fixed or variable, the results show

range over which the head sloped m

the longitudinal stresses have more of

TABLE 1 (above left) Dimensions and properties of a class 6 uPVC pipe TABLE 2 Variations in dimensions and properties of the pipe

that all cracks have variable areas and it is only the extent of variation that differs. Based on equation, the behaviour of any given leak with pressure can be modelled if the pressure-area slope m of the leak is known. Thus further work was conducted to determine the effects of the different influencing parameters on m.

Effect of parameters on pressureleakage slope m Understanding what role each influencing parameter plays in the behaviours of the crack in relation to pressure, it is important when trying to predict a mathematical relationship describing this behaviour. Initially, a base pipe was studied with only the pressure being varied to study the basic interaction between pressure and leakage, and pressure and the leak area (see Figure 1). Simulations were then run where each parameter was

FIGURE 1 (left top) relationship between area of crack and the pressure head

varied one at a time to study its effect on the pressure-leakage relationship of the pipe. This study looked at the impact of the parameters have on the

FIGURE 2 Graph showing head-area slope range for each parameter

head-area slope only. Table 2 shows the values of the pipe and leak properties that were used for each of the parameters in the analysis. March/April 2014

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Technical paper an effect on the head-area slope m. Once all the relationships for all the parameters were obtained, it was possible to use various data processing techniques to formulate mathematical relationships between the head area slope and the parameters of the pipe and crack. Regression analysis was used on the data to obtain three mathematical models describing the head-area slope m as a function of the parameters of the pipe and crack.

References 1. J M Gere, Mechanics of Materials, 5th ed., pub Brooks/Cole, United States (2001) 2. A M Cassa, J E van Zyl, R F Laubscher, Proc. WISA2006, paper No. 438, (2006) 3. J May, Pressure Dependent Leakage, World Water and Environmental Engineering (October 2004) 4. A M Cassa, J E van Zyl, R F Laubscher, Urban Water Journal, 7(2) p.109 (2010)

The three mathematical models obtained through regression analysis for longitudinal, spiral and circumferential crack respectively are equations 3, 4 and 5 (right), which can be used to predict the head area slope m for any pipe section, material and crack length within the bounds of the regression analysis. The values of m predicted by the equations are compared to the finite element

5. A Chadwick, J Morfett, Hydraulics in Civil and Environmental Engineering, 3rd ed., pub E & FN Spon, London (1999) 6. M Farley, S Trow, Losses in Water Distribution Networks, pub IWA Publishing, London (2003) 7. B Greyvenstein, J E van Zyl, Journal of Water Supply-AQUA, 56(2) p.117, (2007) 8. K H Huebner et al., The Finite Element Method for Engineers, 4th ed., pub. John Wiley & Sons, Inc., New York, (2001)

values in Figure 3 for all three cracks

Conclusion The study showed that regardless of the orientation of the crack, it was possible to express the leak area with a linear equation and then use it to propose a better description for leakage through an orifice. It also investigated the parameters that play a role in the behaviour of cracks in pipes

3 4

under pressure. Longitudinal, spiral and circumferential cracks were analysed. The work shows that the individual properties of the pipe and the geometry of the crack play a more significant role in the area of the crack than previously thought. Regression analysis was used to obtain three mathematical models to predict the head area slope m as a function of the parameters of the pipe and the crack. These equations were only tested for a limited range of parameters used in finite element models and are limited to linear elastic behaviour. These expressions can then be related back to the proposed leakage equation to get three new equations for leakage each for a different crack type.

FIGURE 3 Comparison of Equation 4 prediction of m to the finite element results for all three crack types

March/April 2014

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Wastewater

Cost-effective capacity upgrade Maryke Foulds speaks to Headstream’s commercial director Julian Moore.

eadstream

recently

has

treatment performance to enable it to

In simple terms, the HYBACS process

commissioned

meet nutrient discharge standards,”

is a hybrid BNR activated sludge pro-

explains Moore.

cess where a fixed biomass process

its third plant in South a

“This is very exciting as it demon-

is combined with a conventional

HYBACS retrofit to upgrade the

strates that the HYBACS process is

suspended biomass activated sludge

Hartbeesfontein WWTW.

ideally suited for upgrading con-

process followed by conventional

“While we are extremely proud

ventional activated sludge plants

secondary settlement via a clarifier.

of our first two plants, these were

to increase treatment capacity and

It thus lends itself as an ideal retrofit

greenfield new builds and not an

improve

technology for the widely used con-

upgrade to an existing plant. The

existing treatment infrastructure is

Hartbeesfontein project is the up-

extremely important in South Africa

The fixed biomass reactor, which

grade of an existing plant to double

and it is in this scenario that HYBACS

is called a SMART unit and is unique

treatment capacity from 4 Mℓ/d

is significantly more competitive than

to the HYBACS process, contains a

to 8 Mℓ/d while also improving

alternative technologies.”

very high concentration of attached

Africa,

which

performance.

Upgrading

ventional activated sludge process.

March/April 2014

Cost Effective Upgrade to Increase Treatment Capacity, Improve Performance and Reduce Energy Consumption Hartbeesfontein WWTW - Upgrade from 4Mℓ/d to 8Mℓ/d

2 recent HYBACS upgrades demonstrate its cost effectiveness and ease of implementation: Hartbeesfontein WWTW: HYBACS upgrade to provide BNR and increase in treatment capacity from 4Mℓ/d to 8Mℓ/d: • 100% increase in treatment capacity • 8 SMART units installed • No Civil Works to increase aeration tank volume • 40% saving in kWh per Mℓ/d (installed power)

Tubli WWTW - Upgrade from 40Mℓ/d to 100Mℓ/d

Tubli WWTW (Bahrain): HYBACS upgrade to increase treatment capacity from 40Mℓ/d to 100Mℓ/d: • 150% increase in treatment capacity • 42 SMART units installed • No Civil Works to increase aeration tank volume • 40% saving in kWh per Mℓ/d • R3,6 million cost per Mℓ/d increase • ��cellent �f�luent �uality: • <0,3mg/ℓ Ammonia • <10mg/ℓ TN • <30mg/ℓ COD • <15mg/ℓ TSS HYBACS is supplied in South Africa by Headstream Water Holdings (Pty) Ltd www.headstreamwater.co.za info@headstreamwater.co.za t 011 886 7805

water solutions

Wastewater biomass and also delivers an oxygen

which we estimate to be up to 40%

of the HYBACS upgrade section of

transfer

higher

when compared to a conventional

the plant is 40% lower per megalitre

than that achieved in the suspended

8 Mℓ/d plant, will significantly reduce

treated than the rest of the plant and

biomass

the ongoing electricity costs for the

one can really appreciate the overall

municipality.”

life cycle cost savings delivered,”

rate

significantly

reactors.

Therefore

the

SMART units are able to remove a high portion of the incoming COD

The plant is currently in its initial

in a very efficient manner, which

commissioning phase with the first six

when combined with the existing

SMART units already installed and op-

since

suspended biomass activated sludge

erational. The remaining two SMART

exceptional, despite the plant receiv-

reactors enables the plant to deal with

units will be installed in a second

ing a higher influent loading than

a significantly increased load.

phase in the coming months to take

designed for, with the effluent quality

the treatment capacity to 8 Mℓ/d.

consistently exceeding the effluent

“The HYBACS process was initially

explains Moore. Results at the HYBACS Tubli WWTW commissioning

have

been

completed

standard set: <0.3 mg/ℓ per litre of

to address the key challenges they

upgrade project is the upgrade of

ammonia; <10 mg/ℓ TN; <30 mg/ℓ

faced due to rapid urbanisation

the Tubli WWTW in the Kingdom of

COD; and <15 mg/ℓ TSS. In addition,

and industrial development around

Bahrain completed by Bluewater Bio,

results show a significant improve-

existing plant sites. Thus a significant

the owners of the HYBACS technolo-

ment in sludge settleability with

increase in treatment capacity and

gy. This HYBACS upgrade comprises

sludge from the HYBACS upgraded

an improvement in effluent quality

the conversion of two of the existing

portion of the plant flocculating rap-

developed in South Korea in order

Another

recently

The SMART units at Hartbeesfontein WWTW

were needed, but there was no space in which to expand plants. The key drivers for the development of the HYBACS process was that it needed to retrofit onto existing activated sludge plants and it needed to be able to significantly increase treatment capacity and improve effluent quality within the current plant footprint,” explains Moore. “Additional drivers were cost effectiveness, energy efficiency and the removal of odour, particularly important given that high-density accommodation surrounded many of the plant sites in the cities.” The Hartbeesfontein upgrade was urgently required due to the increased flow into the existing plant combined with the higher loading on the plant from a local abattoir. The upgrade to double treatment capacity to 8 Mℓ/d is

10 aeration lanes and four of the ex-

idly and settling 40 times faster than

being achieved with a HYBACS design

isting 12 clarifiers into a HYBACS plant

the rest of the plant while operating

that involves the installation of eight

by installing 42 SMART units upstream

at a MLSS 3822 mg/ℓ and achieving

SMART units upstream of the existing

of the aeration lanes. The upgraded

a SVI 42.9 mℓ/g. “This is a very signifi-

suspended biomass activated sludge

HYBACS plant treats 100 Mℓ/d mean-

cant development for us as it demon-

reactors. Additional modifications to

ing that the two aeration lanes, origi-

strates the excellent performance

the plant infrastructure include:

nally designed for 40 Mℓ/d, now have

of HYBACS on a large scale as the

• the

a 150% uplift in capacity.

Tubli WWTW is a large plant treating

conversion

the

primary anaerobic

“No additional civil construction was

100 Mℓ/day. The next phase planned

biological

required to increase the volume of the

is to upgrade the next 40 Mℓ/day of

aeration lanes and the entire upgrade

the conventional plant to 100 Mℓ/d so

• increasing oxygenation capacity in

was achieved within the current plant

that the total HYBACS portion of the

the aerobic reactor with an fine bub-

footprint. The cost of the upgrade was

plant is expanded to 200Mℓ/day.

ble diffused air (FBDA) system

US$20 million (R220 million) of in-

“We are confident that when pro-

• the construction of a new clarifier.

vestment for an increase in treatment

fessionals in the industry see these re-

“As no increase in the volume of the

capacity of 60 Mℓ/day. That equates

sults and the cost efficiencies that are

aeration reactor was required, the

to just over R3.6 million per addi-

achievable then they will be willing to

HYBACS process provided a signifi-

tional Mℓ/day of treatment capacity

embrace an innovative solution and

cant saving for the municipality with

which demonstrates the exceptional

recommend the HYBACS process to

respect to reduced civil construction

cost effectiveness of HYBACS in an

their clients, particularly in an upgrade

costs. In addition, the energy savings

upgrade scenario. Add to that the

scenario, so they can save their clients

that the HYBACS process will deliver,

fact that the electricity consumption

both capex and opex costs.”

settling tanks

tanks for

enhanced

phosphate removal

March/April 2014

Wastewater

Wastewater treatment technology of the future ”When chemicals are used to treat water, one is actually adding secondary pollution to the water. In other words by solving one problem, you are creating another one,” says Palmach Zeevy of P2W.

ollution

Water

and how the P2W technology deals

includes the heavy metals, pH and

(P2W) was established in

with such challenges: “What we have

conductivity in the water. Simply

2005 and has a number

found to be constant challenges are

put, P2W makes use of reactors,

sites

that the levels of sulphates often

which remove the sulphates in the

in Europe and Israel. In Africa, the

vary, the pH is not steady and that

water without the need for the use

company currently has four projects

the

of any membranes.

at mines that it operates, at sizes

changes in the contamination of

Zeevy explains that most process-

of 12 to 14 Mℓ/day, treating every

heavy metals. The need for lime

es today used to treat AMD con-

possible contaminate in one system.

in the process also creates large

sume large amounts of lime, which

“All the possible contaminates that

volumes of sludge. All of these as-

results in large amounts of sludge

are found in wastewater are being

pects are eliminated and dealt with

at the end of the process. This

treated in one online process. The

through our technology offering,”

process is known as the high-den-

unique thing about P2W is that our

says Zeevy.

sity

commissioned

cannot

tolerate

sludge

(HDS)

pre-treatment

technology is capable of handling

One of the first challenges is the

phase. It is a two-stage treatment

anything from cyanide to heavy met-

large volumes of contaminated wa-

process, which requires lime and

als and sulphates at the same time.

ter. The system offered by P2W has

makes use of membranes. The P2W

This is all done without membranes

absolutely no limitations in terms of

treatment process doesn’t make

and without chemicals,” says Zeevy,

the size of the system that can be

use of any lime, but rather uses a

who is executive chairman and

used for these volumes.

one-step online process, skipping

founder of P2W.

BELOW The site of P2W's plant at Golden Star Resources in Ghana

membranes

In South Africa, the most com-

the HDS stage. Zeevy reiterates

The company has mastered the

monly used systems make use of

that using lime and chemicals is

challenges of acid mine drainage

membranes. Overall, the membranes

not only costly, but adds secondary

(AMD) through its state-of-the-art

are vulnerable and subject to the

pollution to the water. The P2W

technology. Zeevy explains the main

harsh

strong

process eliminates chemicals, which

challenges in the treatment of AMD

pre-treatment

which

is a far more sustainable approach.

conditions

the

process,

Zeevy says: “Our vision and mission is to save lives and the environment each and every day with our treatment technology”. In addition, the P2W process requires very little maintenance and is monitored and controlled online. In terms of challenges such as energy efficiency, P2W requires just 1 kW/h for 1 000 ℓ of polluted water. South Africa has its own unique challenges with AMD. P2W became involved in providing a solution to these challenges when the company was approached at a leading event in Cape Town two years ago. “P2W was approached by government officials at Mining Indaba who asked about our technology being modified specifically for treating AMD in

March/April 2014

Wastewater South Africa. They had heard about

America and Canada that have been

the gold and coal mining sectors

the performance of our technology

specifically set-up to treat cyanide

where it is responsible for several

at several sites in Ghana and were

and sulphates. The biggest break-

state-of-the-art patented solutions

asking whether we could adopt the

through is P2W’s latest development

for the full destruction of cyanide

same technology for AMD.”

in treating slurry directly from the

and sulphates reduction. Based on

In 2012, P2W launched a pilot

mine. The end product results in

its core technology, the company

plant for the treatment of sulphates

decontaminated ore and water of

develops, markets, sells and installs

in mine water in Randfontein. This

such a quality that will allow the

the most efficient, cost-effective and

successfully demonstrated the tech-

mine to discharge it for reuse back

environmentally friendly wastewater

nology’s ability to treat sulphates

into production. Zeevy closes by

treatment systems for heavy metal

in AMD water without the need

stating that the next generation

removal, including arsenic, copper,

for chemicals or for the traditional

of systems and technologies to be

cadmium, lead, nickel, manganese,

reverse osmosis membrane method-

introduced into the market globally

cobalt, etc.

ology. The technology has matured

by P2W are innovative compared to

significantly since then and today

the current treatment methods that

AMD with contaminated levels of

are available worldwide.

BELOW Palmach Zeevy and team on-site at AngloGold Ashanti Obuasi

4 000 to 4 800 ppm can be treated to 250 ppm and below without any

About P2W

lime or other pre-treatment. The

P2W is a privately owned clean-

technology has raised the attention

technology

of both the government and the

research

private sector to provide solutions

engineering

for AMD challenges.

offices located in Ghana and the

company and and

with

its

development, administrative

P2W has invested extensively in

US. P2W also has branches in

research and development. Zeevy

Lima, Peru, and São Paulo, Brazil.

says the company currently has

P2W provides advanced industrial

five pilot plants operating in Latin

wastewater treatment systems to

March/April 2014

METERING

CLEAN POWER

LARGE POWER USERS

WATER

INVESTMENT & FINANCE

TECHNOLOGY | KNOWLEDGE | INTERACTION Find cost-effective solutions to water and wastewater treatment, non-revenue water and metering

13 – 14 May 2014, Cape Town, South Africa Focus days: 12 May 2014 | Site visits: 15 May 2014

14TH ANNUAL

Co-located

Activate your FREE expo pass online and get access to CPD accredited technical workshops. www.african-utility-week.com | www.clean-power-africa.com

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Exclusive for 5 years: 2014 - 2018

T&D / SMART GRIDS

GENERATION

Wastewater

Energy savings at WWTW EFTEC is a supplier and manufacturer of fine bubble aeration systems, diffuser systems, stainless steel air manifolds, air compressors or blowers and complete aeration process control systems. By Maryke Foulds

H BELOW Fine bubble aeration is fast gaining momentum in South Africa

ennie

Basson,

“There are a number of benefits

and the membrane of different mix

of EFTEC, to discuss the

to using the system – the biggest

of EPDM. New developments in

range of products and

of course is an energy saving of

membrane technology have resulted

services on offer, with a

up to 50%, depending on the size

in EPDM membranes coated in a

specific emphasis on its fine bubble

and design of plant. The single

twin layer of PTFE that improves

aeration system which is gaining in

largest user of energy in a WWTW

resistance on diffusor creep (stretch)

popularity throughout South Africa.

is the biological process and this is

as well as the resistance for bio-

It is his view that while this is not a

where the energy saving will occur,”

logical growth on the membrane

new technology, improved materials

says Basson.

itself. PTFE membrane will also keep

have enhanced its efficiency to such

This is in part due to the use of im-

its original form four times longer

a degree that it is now the preferred

proved materials. “Most fine bubble

than normal EPDM. The materials

aeration

aeration systems are manufactured

are also available for tube diffuse

with polypropylene base material

aeration systems.”

system

North America.

Europe

and

March/April 2014

Wastewater In the aeration system, which includes the air manifolds, particular caution must be taken in the design of the air manifold system – airflow velocities in any section of pipework should not exceed a flow velocity of 40 m/second in order to limit the friction and heat generation of the air. Another factor to consider is the removal of condensate from the aer-

Instrumentation is crucial for the control of a WWTW, especially when utilising fine bubble aeration

ation system mounted on the floor. A build-up of condensate can result in tearing of the membrane due to the water being pressed through the membrane. Condensate forms at high humidity together with a high

temperature

generated

compressors. Due to the high pres-

loss of efficiency and capacity of the

is based on the principle of most

sure increase, moisture will condense

plant. Engineers need to clarify in ad-

open valve algorithms. In laymen’s

as soon as the air cools off at basin

vance what the actual requirement

terms that means the more open

water temperature.

is and specify a standard that all

the valve, the lower the friction – the

suppliers can comply with in terms

lower pressure the blower puts out,

Instrumentation

of the performance and output of

the lower the energy cost without

Instrumentation is crucial for the

compressor blowers.

compromising

the

efficiency

ABOVE EFTEC are exclusive distributors of fine bubble aeration technology

control of a WWTW, especially when

Care must also be taken that

utilising fine bubble aeration. You

compressor/blowers must be witness

can only control what you can meas-

tested with an actual job motor. In

that

ure – for each aeration system you

other words, it must be tested with

above, as well as the control system

would need at least one V-Port knife

the motor that will be installed on-

of the blowers, combines all of these

gate valve with a modulating actua-

site. Witness testing must also be

to control the system 24 hours a day,

tor, a mass flow air meter and an LDO

in compliance with ISO 5389. The

seven days a week. It also facilitates

oxygen dissolved oxygen meter.

reason for selecting a specific test

off-site monitoring. Water treatment

the system. The basic control system requires the

instruments

described

These units work in conjunction

norm is that all suppliers for a specific

companies can now monitor the per-

to control the biological air demand

project must comply with the norm

formance of various plants off-site

and will satisfy the demand by sup-

resulting in the client getting the

at the click of a button. It also assists

plying sufficient air volume with the

best value for his money.

the equipment supplier in monitoring the maintenance requirements

correct oxygen mass required. The use of these types of instruments

Equipment

will track the oxygen demand closely

The

24 hours a day. At no point will

includes the small compact units

under-aeration or over-aeration take

from 37 kW to 400 KW and fully

place, resulting in energy saving.

engineered units from 90 kW up

Siemens

and gives preventative maintenance compressor

range

instructions to the end user.

to 3.3 MW and with capacity up

EFTEC products and services As

the

distributor

to 123 000 m3/hour. All Siemens of

machines has got dual point control

International

– the control of the output pressure

(SSI) Aeration Systems from the US,

independently from the output flow

leading diffuser manufacturers in the

rate by means of either inlet guide

world, EFTEC also has agreements

veins or frequency inverters for the

with Siemens Turbo Equipment from

pressure and outlet diffuser veins

Germany for the municipal market

for flow control. This is applicable

for sub-Saharan Africa.

for direct drive units (high-speed

Stamford

exclusive Scientific

When specifying or purchasing

machines with air foil or magnetic

compressors or blowers, specific care

bearings) or constant speed blowers

must be taken in the terminology

without variable speed drives.

used to specify the airflow. The vast specification differences can result

Process control

in electrical motor size differences of

EFTEC utilised the Siemens air bio

up to two frame sizes. It is misleading

control system for biological aer-

and the end user will pay for the

ation process control. The system

t (0)12 803 5486

Main projects • Recent installations include the water recovery growth project for Sasol Secunda where four Siemens KA10 compressors plus two control systems were installed. • The supply of nine 600 kW fully engineered compressors delivering 24 600 normal m3/h each for supply to the city of Tshwane for the Rooiwal WWTW plus three air control systems. The contractor on this project was WEC Projects. • Aeration systems were installed at the following plants. Bushkoppies WWTW for Johannesburg Water and a refurbishment a 4 x 65 Mℓ/per day plant. The main contractor was Eigenbau. • Robertson WWTW – aeration system and compressors, main contractor was Lectratek Water. • Standerton WWTW – 2 aeration systems, main contractor was Eigenbau. • Refurbishment of the Zeekoegat WWTW 40 Mℓ/per day, main contractor Lectratek. • Various projects are also pending finalisation.

March/April 2014

Wastewater

Pressure filters for wastewater treatment Water Purification Chemicals & Plant (WPCP), a multidisciplinary water treatment specialist, manufactures a range of pressure filters designed for the removal of suspended solids and other impurities from water and wastewater.

PCP’s single and

managing director. “These pressure

WPCP DW 6 pressure filters are

dual media pressure

filters efficiently remove materials

available in standard sizes, with

filters are used for the

like iron, manganese, colloids and

diameters between 700 mm and

removal of colour and

other precipitates in ground or sur-

2.7 m. Other configurations and siz-

suspended solids to ensure water is

face water. Even at fairly high filtra-

es can be custom designed to meet

efficiently purified for human con-

tion rates – more than 10 m/h – our

specific

sumption, generally down to a tur-

pressure filters ensure water purifi-

water quality and footprint speci-

bidity level of less than 0.5 NTU, or

cation meets the stringent require-

fications, as well as backwash and

for effluent disposal with suspended

ments of SANS 241 Class 0, or any

flow requirements.

solids removal down to less than

suspended solids specification for

0.1 ppm,” says Martin Overy, WPCP’s

waste and industrial applications.”

March/April 2014

requirements,

including

These pressure filters are available with a manual or automatic

Wastewater

WPCP filter beds are designed for a high solids holding capacity, which results in extended filter service life and reduced backwash requirements

the

polyurethane material of up to

These pressure filters are enhanced

incoming flocculated and settled

1 500 micron. The dirt load capacity

by air blowers, piping and valves, as

raw water is pumped or gravity fed

of these filters ranges from 3 to 6 kg

well as a full set of instrumentation.

over the filtration media, where the

suspended solids per cubic metre of

The latest filtration systems are op-

science of filtration takes place.

filtration media.

erated using a Programmable Logic

operating

principle,

where

The general assumption is that

The backwash system or regime

Controller (PLC) and SCADA system for optimum efficiency.

are

usually consists of air, then air

trapped in the space between the

and water, then water only, with

The appropriate size of filters

media – usually sand. What actually

a final water backwash rate of 25

recommended for each application

happens is the smaller dirt particles

to 30 m/h. The pressure filter se-

depends on the flow rate and

are attracted to the larger sand

lected for each specific application

water/wastewater conditions. WPCP

particles by Van der Wahl’s forces,

determines the underdrain or filter

offers a technical advisory service to

resulting in very clear water, down

nozzles design.

ensure the installation of the appro-

dirt

and

suspended

solids

to less than 0.5 NTU, if operated and

for a high solids holding capac-

backwashed properly. WPCP’s have

pressure maximum

WPCP filter beds are designed

filters,

which

pressure

400 kPa, are manufactured from

ity, filter

which

results

service

life

priate filtration system. The company has made a sig-

extended

nificant investment in the latest

and

reduced

equipment and ongoing research to

backwash requirements.

WPCP manufactures a range of single and dual media pressure filters, designed for industrial and municipal water treatment

ensure optimum efficiency and the

robust materials, including glass

Single media filtration systems

reinforced plastic (GRP) and steel.

generally have a layer of 0.95 mm

total hygiene of every installation.

To ensure resistance to corrosion,

silica sand (800 to 1 000 mm bed

services

the internal lining consists of a

depth) or dual media systems, with

chemical aspects of drinking water

twin pack of solvent-free epoxy

a top layer of Hydroanthrazit (300 to

treatment, the latest filtration tech-

product, of 300 to 400 micron.

400 mm) and a bottom layer of silica

nologies and the design of major

The external coating is a twin pack

sand (600 or 800 mm).

water purification plants.

The company offers a range of

March/April 2014

that

encompasses

the

3847 Wetpaint Advertising

Wastewater

Corrosion resistance When wastewater travels through sewer lines, it can become anaerobic or septic (the dissolved oxygen can become depleted) as a result of the metabolic processes of microbes commonly found in the wastewater.

nder

anaerobic

conditions,

specific

sulphate-reducing bacteria thrive and generate hydrogen sulphide (H2S) as a byproduct of

their respiration.

H2S has a low solubility in wastewater and when it escapes

from the wastewater and moves into the air, it is easily

recognised by its characteristic offensive, rotten egg odour. It can also be responsible for severe corrosion problems and toxic conditions within wastewater conveyance and treatment facilities.

Rainwater Harvesting Systems that last for more than a lifetime

“Andrew Mentis has developed a range of corrosion- resistant floor grating and handrailing in galvanised, 304 stainless steel and 3CR12 options, which are ideally suited to the extreme conditions found in wastewater treatment plants. All products in these ranges are designed and

The world is changing around us everyday. Technological advances demand ongoing upgrades and solutions, but not ROCLA Rainwater Harvesting Systems. Because superb design and leading-edge manufacturing processes ensure that ROCLA provides the truly permanent rainwater harvesting solution. ROCLA’s Rainwater Harvesting Systems offer an unmatched water capture and re-use solution, which greatly reduces dependence on municipal potable water. With the looming water crises, ROCLA’s revolutionary ecoRain™ system offers a sustainable and cost saving water-supply solution to Southern Africa. ROCLA Rainwater Harvesting Systems are ready for the future. ROCLA is ISO 9001:2008 certified and has the SABS mark of approval on all applicable products.

ROCLA

OUR DIFFERENCE IS CONCRETE

Contact ROCLA now on Tel: (011) 670-7600 or Fax: 086 675 8985 Web: www.roclaproducts.co.za

March/April 2014

Wastewater engineered

suit

situations

where the strength to weight ratio is important, such as wastewater treatment plants,” points out Elaine van Rooyen, marketing manager of Andrew Mentis. “The water and wastewater industry encompasses the mechanical and chemical processes used to remove pollutants from wastewater, for reuse in the environment. These processes can create a slippery environment

for

operators

and

technicians, with vapours, water and chemicals creating slick underfoot and handhold conditions near large machinery and tanks,” Van Rooyen explains. An emphasis on safety underpins the development of all Andrew Mentis floor grating and handrailing products. “Weakened handrailings and floor gratings, caused by corrosion and damp, can result in slips, trips or falls. In addition, due to the fact that broken handrailing or floor grating needs to be replaced, downtime is incurred, which negatively impacts on productivity,” Van Rooyen says. Galvanising or using stainless steel in a wastewater treatment plant is not only a safe and cost-effective option, but it does not compromise the aesthetics of the environment. Andrew Mentis’ Rectagrid RS40 floor

grating

manufactured

using a pressure locking system pioneered by the company. The locking

characteristics

guarantee

the structural integrity of the product and further enhance its integrity in a corrosive environment. “The transversals on the floor grating are positively and permanently locked to the bearer bars

corrosion-resistant benefits. These

and the locking method at the

handrails are not only functional,

diameter by 2.5 mm wall thickness

intersections is designed to use the

but also resilient and durable,” says

specifications, and are also available

full depth of the bearer bar when

Van Rooyen.

in 3CR12, 304 and 316 stainless steel

The

stanchions

are

42.9 mm

calculating loads. This attention to

The tubular handrailing system

detail ensures that the load bearing

is complemented by a range of

capacity is top of mind when design

standard angles and matching ac-

handrailing were selected for the

and manufacturing is undertaken,”

cessories, with different bends and

Zeekoegat wastewater treatment

according to Van Rooyen.

end closers adding to the versatility

plant and other treatment plants

steel

of the product. “Enhanced customer

in the industry. We believe that

tubular handrailing is reputed for its

service was a driving factor, with

each application deserves individ-

corrosion and stain resistance qual-

the stanchions and bends forming

ualised attention and as such we

ities. “We have designed the stan-

part of a system of interlinking

customise products to meet specific

chion base plates to allow moisture

components that can be installed

application

to drain from the stanchion itself,

without the need for special tools,”

specified client timeframes,” Van

thus adding further credence to its

Van Rooyen comments.

Rooyen concludes.

Andrew

Mentis’

stainless

polished to a satin finish. “Both

March/April 2014

Rectagrid

and

requirements,

Mentis

OPPOSITE The transversals on the floor are permanently and positively locked to bearer bars ABOVE Tubular handrails are complemented by a range of standard angles and matching accessories

within

bidim

Wastewater

ACH flocculants ideal for use in WWTWs Water Purification Chemical and Plant (WCP) manufactures a range of flocculants at the company’s KwaZulu-Natal facility, which is highly efficient in potable water and wastewater treatment.

he WPCP range of FLOCC

and the use of a streaming current

flocculants is used for the

ion analyser. The dosage rates and

removal of suspended solids

methods

and colour from raw river

applications. These flocculants are

depend

individual

and dam water and also for sludge

available in 30 kg or 240 kg return-

dewatering in waste water treat-

able plastic drums and in 1 t mini

ment,” says Martin Overy, managing

bulk containers.

ACH is used as a primary flocculant in the WPCP FLOCC range and as the key ingredient in flocculant blends

director of WPCP, a multidisciplinary

WPCP also has a full analytical

The company’s range of services

water treatment specialist. “ACH

service from its in-house laboratories.

encompasses the chemical aspects

flocculants, with low iron grade, are

Various forms of disinfection include

of drinking water treatment, the

also suitable for the paper industry

bromine/chlorine

‘Bromochlor’

latest filtration technologies and

and in the pharmaceutical sector for

tablets via a tablet feeder, ozonation

the design of major water purifica-

antiperspirant manufacture.

and hydrogen peroxide.

tion plants.

WPCP manufactures a range of flocculants at the company’s KwaZuluNatal facility

“The advantage of manufacturing at

these the

facility

flocculants company’s

in-house production

Hammarsdale

that

WPCP has complete control over quality stringent al

standards, local

according

and

specifications.

internation-

This

includes

approval from the South African Department of National Health and Population Development.” Aluminium Chlorhydrate (ACH) is used as a primary flocculant in the WPCP FLOCC range and as the key ingredient in flocculant blends. These user-friendly liquids, which are effective over a wide range of turbidities, eliminate the need for alum- or ferric-based coagulants and significantly reduce the consumption of alkali aids. The

company

manufactures

approximately 200 t of ACH per month. The company supports this production with a technical advisory and support service throughout the country. Technical experts advise users on dosing, dosing equipment March/April 2014

24/7

1980

Zest Electric Motors established in Jhb

1961

WEG established in Brazil

Durban branch opens

1991

Cape Town branch opens

1994

Richards Bay branch opens

1997

We push boundaries to deliver n We listen to our customers n We focus on all our customers, big and small

THROUGH OUR PEOPLE

Trichardt branch opens

1998

who care Access to 26 000 people worldwide who care

Angola Botswana DRC Ghana Kenya Mozambique Namibia

Nigeria South Africa Tanzania Uganda Zambia Zimbabwe

www.zest.co.za

Rustenburg branch opens

2002

Middelburg branch opens

Port Elizabeth branch opens

To find out more scan the code or visit: zest.co.za/sustainability

2007

2002

To find out more scan the code 00 ZEST (9378) | www.zest.co.za or0861 visit: zest.co.za/sustainability

Zest acquires IMS Cape

2007

Zest acquires Shaw Controls (est 1986)

2007

BLUE IS THE NEW GREEN

+27 11 723 6000

0861 00 ZEST (9378)

www.zest.co.za

BLUE IS THE NEW GREEN

CUSTOMER FOCUSSED

INTEGRATED SOLUTIONS

AFRICAN MULTI-NATIONAL

Power Generation & Energy Solutions Substations & Electrical Infrastructure n Mobile Power Solutions

Electrical, Instrumentation & Control Engineering n Installation

ENERGY

Zest acquires EnI Electrical (est 1984)

2008

Zest acquires Zest Energy (est 2008)

2009

Zest Electric Ghana opens

2010

2013 WEG acquires Zest WEG Group Zest WEG Group acquires Hawker Siddeley Transformers (est 1956)

2010

Manufacturing facilities on 4 continents n 55 000 motors produced per day n 3rd largest electrical manufacturer worldwide n WEG products distributed in over 185 countries n 2.5% of WEGâ€™s annual net income spent on R&D n

EnI Electrical

Mini Substations Transformers n Switchgear

WEG Transformers Africa

Packaged Switchgear Motor Control Centres n E-Housing n Containerised Substations

Shaw Controls

ZEST Energy

Electric Motors Variable Speed Drives n Soft Starters n Transformers n Switchgear n Diesel Generator Sets

ZEST Electric Motors

2020 And beyond

PRESENCE IN AFRICA BLUE IS THE NEWMARKET GREENOFFERING

WHY TECHNICAL SUPPORT

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PASSION

24/7 technical back-up n Fully qualified technicians n 5 Fully equipped training centres across Africa n 187 site visits into Africa per year

WHERE YOU NEED IT, WHEN YOU NEED IT

SUPPORT

Coralynne & Associates +27 (011) 422 1949

ZEST indentity. Derivative of the proportions of the logo, it is based on a proportion of width and height of 2-to3. The distance between the GRID elements is 1/3 of the height of an element.

Coralynne & Associates +27 (011) 422 1949

Wastewater

Turnkey wastewater solutions at Degrémont The volume of wastewater continues to increase as a result of changing demographics, economic development and urban spread.

rban

wastewater

detergents and so on). Greendaf is a

Sludge treatment

treatment is a techno-

compact package system to remove

To define and select an optimal

logical

economic

phosphorous in case of strict dis-

sludge

challenge; the goal is to

charge regulations. This technology

information is needed: the sludge

preserve biodiversity and protect

is easy to operate, quick to start and

composition in relation to its origin

water resources while ensuring the

functions with little need for reagents.

and the final destination of treated

and

well-being of local populations. To support local authorities with

Combined of

treatment

combining

several

sewage sludge (recycling, recovery, and destruction).

called

The steady growth in the volume of

treatment systems of varying com-

membrane bioreactors. These biore-

sludge generated by water treatment,

plexity based on the quality of the ef-

actors incorporate activated-sludge

linked both to demographic change

fluent to be treated and the sensitivity

biological

and the increasing urban sprawl, leads

of the medium.

ultrafiltration-membrane clarification

to increasingly tighter constraints for

typically

to produce effluent that can be dis-

the municipalities. The treatment of

requires several treatment stages,

charged into sensitive areas or reused.

sludge in order to reduce its volume

including pre-treatment; primary, sec-

Ultrafor Package System is a range of

and transform it into a recoverable

ondary and tertiary treatment; odour

MBR standard solutions for the treat-

product is now a necessity.

removal and sludge treatment.

ment of urban and industrial

treatment

units

following

stages

purification

package

treatment

the

urban growth, Degrémont designs

Wastewater

consists

treatment,

well

wastewater, available in skid

Treatment

form for a smaller footprint

Pre-treatment protects raw water re-

and greater ease of use.

covery, removing anything that could

Depending on the con-

hamper subsequent treatment pro-

centration of the sludge in

cesses. This could include screening,

the tank and the envisaged

straining grit and grit removal treat-

treatment capacity, several

ment. Primary treatment of waste-

solutions may be introduced.

water removes solid contaminants

Odorous

gas

from urban and industrial

(BOD),

demand

wastewater treatment plants

(COD) and suspended solids (SS).

oxygen

must be controlled by cap-

In some cases, this thickens sludge.

turing gases as soon as they

Depending on the quality of the water

are emitted and by covering

to be purified, various primary and

emission areas.

BOTTOM Ultrafor Package System

Polymer injection

Coagulant injection

emissions

such as biochemical oxygen demand chemical

Influent water

BELOW Greendaf TW

GreendafTM TW belongs to the rapid air-flotation systems range and is specially designed for the clarification of cleared water. This process is for facilities with a maximum flow rate of 10 000 m3/h.

secondary settling units may be used, such as the Densadeg primary lamellar settling tank. Secondary treatment is the biological treatment of water using a wide variety of microorganisms, primarily bacteria. These microorganisms convert biodegradable organic matter contained in wastewater into simple substances and additional biomass. The goal of tertiary treatment is to remove unwanted elements such as SS, COD, phosphorus and specific compounds

(pesticides,

metals, March/April 2014

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Wastewater

Treatment plant races towards completion The new acid mine drainage (AMD) treatment plant at the Central Basin’s ERPM South West Vertical Shaft will be ready for operation soon, representing a herculean effort by Group Five and its subcontractors.

enior site agent: civil

being

engineering Wayne Poulsen

necessarily mean the end of Group

reports that the high-den-

five’s involvement, however, as a

TCTA is a special-purpose vehicle

sity sludge treatment plant

12-month defects liability period

established by the Department of

will follow.

Water Affairs to implement emer-

and pump system at the Central Basin’s ERPM South Vertical Shaft,

assessed.

This

does

not

The project is critical to prevent

Holden, a business analyst at TransCaledon Tunnel Authority (TCTA).

gency works water management

near Germiston, is nearly complete.

AMD

River,

on the Witwatersrand Gold Fields,

The

date

which would have the disastrous

with a special focus on AMD. The

had been pencilled in as 29 January

consequence of affecting the water

AMD project comprises construction

2014, while the ready-for-operation

supply to Gauteng. “Without this

of the necessary infrastructure, or

date is 18 April 2014. However,

project, the major impact will be on

upgrading of existing infrastructure,

due to the increase in the scope of

water security for anyone who draws

to extract and treat acid mine water,

certain works, there is a claim for

water, directly or indirectly, from

and then to convey the treated wa-

extension of time that is currently

the Vaal River system,” says Richard

ter to nearby water sources. 

ready-for-trial-operation

entering

the

Vaal

March/April 2014

BELOW The sludge plant is nearing completion

Wastewater Construction of the treatment plant at the South Vertical Shaft began in February 2013, with site hand-over taking place on 8 January 2013. The decision to use an existing defunct shaft was the result of a due diligence study that evaluated the cost of constructing a new shaft. Group Five Civil Engineering was appointed as main contractor, with its full scope of works ranging from civil works to earthworks, building and mechanical and electrical installation. â€œIf you take it that we started on 8 January, are currently installing mechanical equipment and have started with the electrical cabling, plus the bulk of the civil works is nearing completion, our progress has been quite remarkable, despite the difficulties that we have experienced,â€? reports Poulsen. In terms of the basic treatment process, Poulsen explains that an extraction pump station, featuring two

massive

dewatering

pumps,

will pump acid water from the existing ERPM shaft. The water will

March/April 2014

Wastewater

be pumped to the AMD splitter

shaft-structure design for it to be able

213 m at that point, was unavailable

box, where it is channelled into two

to accommodate the pumps.

at that time.

5 m-deep reactors, with a combined concrete footprint of 80 m x 80 m.

“The changes to the shaft pump

“The redesign process was relatively

station were quite significant, due to

quick, but the structure got signifi-

Lime-dosed water is pumped into

the increased quantity of reinforcing.

cantly more complicated as a result

the reactor from the lime-dosing

This was always a bit of a grey area

of the new design. There is a lot more

plant, comprising lime storage silos,

because we had

dosing equipment and eight concrete

tanks (each 16 m in diameter and 4 m

shaft to check for

high). Two thickeners, each 47 m in

any

diameter, will settle out the solids.

and to see what

The treated water will be discharged

condition

via pipelines to the nearby Elsburg

shaft is in. In the

Spruit and the sludge via pipeline to

original

an existing ERPM tailings facility.

there are seven compartments in the

tudinal and horizontal beams, with

shaft and they had planned to use #3

a lot of the design changes being in

and #6.

the reinforcing to be able to accom-

In terms of challenges faced by the project, Poulsen says that the loca-

probe

the

blockages, the

An extraction pump will pump acid water from the existing ERPM shaft

design,

reinforcing. The direction of the beams changed. Whereas before there

were

short horizontal beams,

now

there are longi-

tion of the thickeners, for example,

“However, when we put cameras

modate this. They are now leaving

required more rock-blasting than

down and probed, #6 was blocked,

all seven of the compartments open

had

anticipated.

#3 had a minor obstruction, #2 and

instead of just two, to facilitate mov-

Some of the delay was due to some

#5 were clear to water level, but #2

ing the pumps around and to allow

unforeseen ground conditions, not to

had something else further down.”

access if required at a later stage.”

mention that the programme was al-

Poulsen says this investigation was

Poulsen adds: “Overall, we are

ways tight. However, the main reason

not conducted upfront initially as the

well on track with this project. That

for Group Five’s extension-of-time

equipment to scan below the water

includes mechanical, commissioning,

submission was changes to the

level, which had already reached

the whole complete scope.”

been

originally

ABOVE Treated water will be discharged into the Elsburg River

March/April 2014

Panel Intro

Mine water treatment

Finding sustainable solutions to serious issues Water supplies around the world are increasingly under pressure, writes Maryke Foulds.

his is due to not only the rising

global

water. This is a costly business,

population,

financially impacting on both in-

but the resource demand

dustry and the supply chain. For this

created, resulting directly

reason, the prediction, prevention,

in an increase in industrial pro-

containment and treatment of mine

cesses, pollution and inequitable

water as well as acid mine water

water distribution.

must be considered carefully and

As does

demand the

increases,

abstraction

too

from

our

processes.

with great clarity.

How

the

issues

are

addressed may well affect the sus-

putting

Legacy issues and accountability

tainability of mining in South Africa

more pressure on an already fragile

Because South Africa has such a

for the foreseeable future. In this

water sector.

long history of mining, the country

panel discussion we asked leading

existing

water

systems,

There are two aspects to the mine

has only recently developed and

industry experts their opinion on

water issue. The use of water in the

implemented comprehensive leg-

processes and technologies to deal

mine, the rehabilitation thereof and

islation to regulate environmental

with these challenges as well as the

the creation of acid mine water,

management

way forward for the industry.

and

mine

closure

ABOVE Central Basin’s AMD project is under way BELOW The project at central will prevent mine water entering the Vaal

which is characterised by a low pH and a high salt and heavy metal content. On both scores, it is of vital importance that this water is treated and reintroduced back into the water system or for use into the plant.

What is all the fuss about? According to a recent report by DeLoitte, due to the interconnectivity of ground and surface water systems in South Africa, high volumes of polluted water have the potential to severely impact on the quality of South Africa’s water supply. This impact has the potential to affect all major industries, across the value chain. Preventing the formation or the migration of AMD from its source – i.e. mining pits, waste storage facilities and underground working – is generally considered to be the preferable option, although this is not feasible in many locations and in such cases it is necessary to collect, treat and discharge mine March/April 2014

Degrémont, a subsidiary of SUEZ ENVIRONNEMENT Degrémont Industry, your partner in sustainable, eﬃcient and cost-eﬀective water management

Ensuring water supply, protecting the environment WATER TREATMENT FOR THE POWER INDUSTRY:

To cope with major changes in policy, climate and population, operators of thermal power plants (coal, lignite, fuel oil, gas, biomass, biogas, nuclear and solar) must meet the following objectives: • Maintain or improve their energy plant’s competitive advantage by controlling water quality at the various application points • Comply with increasing environmental and health’constraints within the wider context of sustainable development.

WATER TREATMENT FOR UPSTREAM OIL AND GAS INDUSTRY:

Water is a critical part of the Production process of Upstream Oil & Gas industries which use and produce high quantities of water from Exploration to Production: • External source of water for injection • Produced Water / Waste water • Reuse / Produced Water reinjection

WATER TREATMENT FOR THE DOWNSTREAM OIL AND PETROCHEMICAL INDUSTRY:

• Water is a raw material used and treated in large quantities (injection water, production water, process water, wastewater, rainwater, cooling water, tank cleaning water, domestic wastewater…) by the oil industry, from extraction activities through to the petrochemical and refining process. The Degrémont Industry Oil & Petrochem Centre of Excellence, which specializes in water treatment for this industry, develops cutting-edge technologies for risk control and the ongoing quest for reduced operating costs of the entire water cycle.

WATER TREATMENT FOR THE METAL AND STEEL INDUSTRY:

The steel and metallurgy industries are capital intensive and operate in global markets prone to cyclical variations, meaning that they must be as competitive as possible in terms of both cost and quality. Degrémont Industry operates in all areas of metallurgy and steelmaking: • Tube manufacturing • Pipes • Hollow proﬁles • Steel materials • Steel fabrication products • Production of precious metals and other non-ferrous metals • Founding

WATER TREATMENT FOR THE MINING INDUSTRY Optimum water management and value creation • Understanding of the speciﬁc needs of mining industrialists • In-house expertise in water treatment and project management allowing you to stay focused on your core business challenges • Water quality and quantity guarantee • Acid mine drainage • Worldwide presence, locally-adapted, and custom solutions • Safe and reliable technologies • Expertise in stakeholder management: improving your image and your community relations by enhancing re-use of reclaimed effluents • Ensuring compliance and continuous operations at the mine sites with sufficient servicing capabilities • Optimum OPEX and asset preservation • Continuous improvement in both design and operation

COMMITTED TOGETHER TO WATER, A SOURCE OF LIFE

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Panel discussion

Mine water treatment

DegrÉmont

Remy Jaffray General manager at Degrémont

hy is mine water a key focus for water management?

for each partner, taking into

RJ Mine water is a complex

and opex.

Please list your latest successes and challenges (i.e. projects)

account local legislation, environmental risk, capex

effluent, containing value as well as a high potential environmental risk.

environmental regulation, the water licenses, the price

We are working

What are the reuse possibilities of treated mine water? Technically, we are

of the raw material

on the development of acid

and the implementation of a

mine drainage treatment for a

sustainable economic model

gold mine.

for AMD. is Densadeg, which is a solids

What are your challenges in dealing with this issue?

able to produce drinking water

The main challenge is to

must consider the reuse in the

What is the future of mine water treatment in SA? The

find a sustainable economic

economical context. The reuse

future of mine water treatment

enables the acceleration

model to treat the mine

could be internal use, irrigation,

is linked to the national

of physio-chemical water

water and develop new

drinking water and so on.

cost-saving technologies.

is not unique but multiple,

What is the latest in mine water recovery research and how will this be implemented at Degrémont? The latest in

which means that we must

mine is the valorisation of ore

develop a tailor-made solution

in wastewater.

What makes mine water treatment unique from other processes? Mine water

Another exciting development

from acid mine drainage, but we

contact settling project that

treatment. It is based on a

BOTTOM A copper mine in Chile utilising Degrémont technology BELOW Densadeg process in Louisville, US

dual chemical injection system that ensures its optimum use. Another major advantage is the integration into the same unit of the essential functions.

Optimum water management and value creation Optimum water management and value creation is achieved with the following: • understanding the specific needs of mining industrialists • in-house expertise in water treatment and project management, allowing you to stay focused on your core business challenges • water quality and quantity guarantee • worldwide presence, locally adapted, and custom solutions • safe and reliable technologies • expertise in stakeholder management improving your image and your community relations by enhancing reuse and reclaimed effluents • ensuring compliance and continuous operation at the mine sites with sufficient servicing capabilities • optimum opex and asset preservation • continuous improvement in both design and operation.

March/April 2014

Nalco technologies empower vigorous and effective mine water management.

Nalco can help you use less, save more, and effectively treat water returned to the environment. Look to the highly skilled Nalco sales engineers who are ready to address your mine water challenges, and reduce your operating costs with economically and environmentally sustainable water management solutions. Call Nalco Africa today.

Nalco Africa Operations Building 14, Ground Floor, Greenstone Hill Office Park Emerald Boulevard, Greenstone Hill, South Africa Tel: +27 10 590 9120 Fax: +27 10 590 9130 nalcoafricareception@nalco.com www.nalco.com/sa ÂŠ 2014 Ecolab USA Inc. All rights reserved

Panel discussion

Mine water treatment

Brett Dunbar Marketing communications specialist water and process services Africa

Nalco Africa

hy is mine water a key focus for water management? BD As mining

Nalco has developed a

competing

unique set of innovations and

customers, we

programmes to ensure suitable

hesitate to point to

is one of the driving forces of

water quality management to

individual projects,

the economy in South Africa, it

reduce, recycle and reuse water,

yet with over

has a major role to play in water

at the same time improving

20 000 3D TRASAR technology

industry in South Africa needs

reuse, recycling and recovery

product quality and process

systems implemented across

to continuously improve

due to the water-heavy nature

efficiencies (while reducing the

the world, our customers

its approach and ability to

of the operations, across the

environmental footprint).

globally are saving 808 000 ℓ

streamline processes and

of water every minute. Simply

improve operations. With the

put, daily around the world, 3D

growth of our population,

TRASAR Technology is saving

rapid urbanisation, increased

Africa is one of the most

What makes mine water treatment unique from other processes? The higher

the equivalent of 1.5 days of the

industrialisation and a change

water-scarce countries, it is

levels of metals and solids in

water needs of Johannesburg.

in weather patterns, the entire

imperative for such an industry

the mine water effluent require

to be tackled head-on when

specialised attention and

looking at the challenges of

treatment solutions.

entire sector from underground refrigeration to dust control activities. Knowing that South

What is the future of mine water treatment? The mine water treatment

water treatment industry in

BOTTOM 3D TRASAR Technology for Cooling Water

water management.

BELOW 3D TRASAR Technology for membranes

What are your challenges in dealing with this issue?

What are the reuse possibilities of treated mine water? Depending on

The main concerns are always

the nature of the treatment

around water scarcity and water

programme, treated mine water

quality. Most mining operations

could be used again as process

find themselves in highly water-

water and even potable water.

the region will soon be under pressure to make meaningful contributions to water conservation efforts.

scarce environments where

in order to reduce water use

Where is the latest in mine water recovery research and how will this be implemented at Nalco? With

and ensure treated water can be

over 19 R&D facilities, over 1 600

reused and repurposed. Nalco

scientists and over 6 300 patents

assists mining operations by

around the globe, Ecolab uses

ensuring correct water mapping

the data gathered through the

of the water they use in their

Nalco 360°service to constantly

processes, leading to enhanced

innovate our offerings to

and more efficient operations.

our customers.

their challenges are around ensuring the need to optimise and streamline their operations

The need to ensure that the

always a challenge for a mine

Please list your latest successes and challenges (i.e. projects). Due to the

due to the unique processes

confidential nature of our

involved for mining operations.

operations with our often

quality of the water is suitable for the specific process is also

3D TRASAr technology for cooling 3D TRASAR technology saves our global customers water - so much water that we built a counter to keep track of the savings as part of our eROI approach. Our global society is building road maps to sustainable development that conserve the earth’s non-renewable resources. One of our most precious resources is water. Cooling systems, no matter what their size or design, come with multiple operational challenges. Scale, corrosion, fouling and biological growth... all are threats and all can impact costs. Complicating the situation is the widely varying chemical composition of feedwater. 3D TRASAR technology for Cooling Water utilises unique real-time monitoring, patented actives based control technology, proprietary stress resistant chemistry and 24/7 information management capabilities to detect, determine and deliver improved scale, corrosion and microbiological performance in cooling systems. Therefore, the 3D TRASAR system detects the upsets that precede scaling, corrosion and biofouling and then delivers the appropriate chemical response. The result is a balanced, efficient and safe cooling system. Less maintenance, no over- or under-dosing of chemicals, lower operating costs and maximum asset protection are the key deliverables.

March/April 2014

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plastics A Division of the Rare Group

Panel discussion

Mine water treatment

Rare

Hennie Roets Director: New Business Development at Rare

hy is mine water a key focus for water management? HR Mines

process control is required as

seldom required

mining water pollutants such

•u p to 99% water

use large amounts of water in

to human health. The mining

• f ast into action

hydrometallurgical processes

community is generally slow

– six to eight

and also in pyrometallurgical

to adopt new technology

weeks delivery and one week

1 Mℓ/day demonstration plant

processes to carry slurries

and it take years for novel

operational from arrival on site

was installed at one of the

and concentrates. Mining

breakthrough technologies to

processes normally pollute

penetrate the mining water

large volumes of process and

treatment industry. With global

• s calable and adaptable

electro-coagulation process

cooling water which, if left

commodity prices softening,

• t reats complex polluted water

adjusted the pH, removed

untreated, can result in ground

mines are slow to invest in large

– treats inorganic and organic

metals and reduced sulphates

water pollution.

water treatment plants unless

pollutants simultaneously

without the addition of any

Water is also needed for dust control underground and on

as heavy metals are detrimental

•m odular – very little to no civil work required

operational cost savings can

•v ery low running costs –

be realised.

complex water treated <R2/m3 • low power demand and low

haul roads and waste dumps.

water, provided there are no

What makes Rare’s mine water treatment different from other processes?

contamination risks. In contrast,

Conventional water cleaning

high-quality potable water is

This water can be lower-quality industrial water or mine

recovery

carbon footprint.

Please list your latest successes and challenges A

biggest mining groups in the world. In this application, the

chemicals to result in reuseable water that can be released back into nature. An Advance Oxidation Potential plant of 6 Mℓ/day to reduce cyanide to client specifications will

technologies need significant

What are the reuse possibilities of treated mine water? My view is that reuse

required for domestic purposes

investment in people and

of mine water should be made

with Fraser Alexander Water

in office and administration

infrastructure, and demand

a pre-requisite for mining

Treatment as the design, build,

buildings and in camps at

continuous high levels of

licenses. Most mining processes

operate and maintain partner.

remote mines.

expenditure. Rare Water

do not require water at drinking

be commissioned soon. This project is done in conjunction

Treatment has put together

water standards for certain

policing of water used and

several leading-edge

mining applications. Rare Water

qualities released will force

technologies to deliver a cost-

Treatment has proven at a

What is the future of mine water treatment in South Africa? The question should

mines to become even more

effective system that can treat

coal mining operation that pH

rather be: What is the future of

focused on best practices in

complex contaminated water at

adjustment, metal removal and

mining without water treatment

water management.

at low costs. Features include:

sulphate reduction could be

developments? Arguably one

• simple proven equipment,

achieved in a simple one-step

of the most exciting eras is

electro-coagulation plant.

facing the mine water treatment

Increased legislation and

What are your challenges in dealing with this issue?

with few moving parts that are

Mining waters are complex in

• sludge consists of larger flocs –

nature and seldom require a

less bound water, settles faster

single process to clean, whether it is for reuse or for release. If water is to be used for human or animal consumption, the utmost

industry at the moment.

simple to operate and maintain

• chemical dosing is

Pre-shipment inspection of 40 m3/hour electro coagulation plant

Where is the latest in mine water recovery research and how will this be implemented at Rare? In conjunction with various South African tertiary

Many mining projects are on the drawing board, a large proportion of which became marginal because of lower commodity prices. In a water-scarce country there

institutions, Rare Water

will be pressure to consider

Treatment has adopted

new water treatment strategies

a dual approach

that will give the mining groups

towards research

more options, including:

and development.

• new lower cost technologies

Firstly, the focus is on

• the use of off-balance sheet

pH adjustment, metal

water treatment plants

removal and sulphate

by embarking on design,

reduction in coal mine

build, operate and maintain

water without any

options from reliable water

chemical addition. The second focus is on Advance Oxidation Potential applications:

treatment companies • increased legislation and policing will force existing mines to get their act together.

Cyanide destruction

Time will be of the

and chemical

essence and in future

oxygen demand

implementation time will be an

(COD) treatment.

important consideration.

March/April 2014

Panel discussion

Mine water treatment

Prei Instrumentation

Steve Herbst Managing director at Prei Instrumentation

hy is mine water a key focus for water management? SH South

by the presence of recycled

A number of

sludge. Optionally, air may

variations of this

for sensitive glass

be introduced in this tank to

process exist, as

pH sensors.

Africa is a water-scarce country

oxidise iron and manganese

dictated by the

and every effort must be made

and assist in their precipitation.

chemistry of ARD,

to protect our future supply.

The resulting slurry is directed

its volume, and other factors

to a sludge-settling vessel,

generally; the products of

What are your challenges in dealing with this issue? Prei

gold, platinum, coal, etc., is a

such as a clarifier. In that vessel,

the HDS process also contain

Instrumentation, the

key economic activity in South

clean water will overflow for

gypsum and unreacted lime,

distributor of Hach online

Africa employing many people

release, whereas settled metal

which enhance both its

analysers, has a differential pH

and is the base of the wealth in

precipitates (sludge) will be

settle ability and resistance

sensor that was developed in

South Africa.

recycled to the acid mine

to re-acidification and

1970 to measure pH in harsh

The mining operations on

drainage treatment tank, with

metal mobilisation.

applications, more accurately

most South African operating

a sludge-wasting side stream.

Mining minerals such as

mines is below the water table and requires up to 10 000 m³/ day to be decanted. As soon as the pumping of this water is stopped the mine floods. This water rises until it flows freely from the mine.

BELOW pH sensor with a bit of the lime chipped off to show what colour it should be BOTTOM Hach differential pH sensor totally coated with a lime crust (if left unattended for a few days)

As one can see from the

differential pH has a reference

pH dependant (requires pH

glass electrode in a pocket

control). However with the

of chemically concentrated

quantity of lime that has to be

7 pH solution behind a

added and the precipitated

replaceable salt bridge. This

metals and sulphides, this slurry

chemically concentrated 7 pH

is like cement, not the place

solution will still be poisoned

The biggest problem is where the ground and rock is disturbed and comes into contact with water, this water becomes acidic. Acid rock drainage occurs naturally within some environments as part of the rock weathering process, but is exacerbated by largescale earth disturbances characteristic of mining and other large construction activities, usually within rocks containing an abundance of sulphide minerals. This acidic water is extremely detrimental to the environment and totally unusable for anything until it has been neutralised and purified (filtered). By far, the most commonly used commercial process for treating acid mine drainage is lime precipitation in a highdensity sludge (HDS) process. In this application, slurry of lime is dispersed into a tank containing acid mine drainage and recycled sludge to increase water pH to about 9. At this pH, most toxic metals become insoluble and precipitate, aided

with less maintenance. The

above, this process is very

March/April 2014

Panel discussion

Mining operations on most South African operating mines is below the water table and requires up to 10 000 m³/day to be decanted

environment for equipment

down as better methodologies

and analysers. Wide range of

are developed.

pH, from -3 to +10 pH, heavy

as standard in the municipal

Please list your latest successes and challenges (i.e. projects) All four of the

by the process solution, but

However, in the acid mine

potable or wastewater

acid mine water plants built or

it will take longer for the

water, these differential pH

treatment plants.

being built on the Coalfields

reference solution to drift

sensors still have to be cleaned

from 7 pH, and then it is

and calibrated every shift.

metals, sulphides and so on. None of the above is found

in the Emalathleni area use

will still become “dirty”;

that these sensors have an

Where are the reuse possibilities of treated mine water? The use of treated

however, it is more robust

expected lifespan of one to two

wastewater varies based on

and supporting the staff on

and is therefore easily cleaned

years (in normal applications,

geographic region, treatment

these plants.

and can be replaced. The

life expectancy is five to

method, local discharge

end result is unsurpassed

eight years).

requirements and reuse

replaceable. The Salt bridge

measurement accuracy,

The biggest difference is

Standard combination pH

Hach analysers, supplied and supported by us. We have spent the last few years training

requirements. Acid mine water

What is the future of mine water treatment in SA? Acid

reduced reference junction

sensors have a maximum life

can be successfully treated

mine water treatment will be

potential and elimination of

expectancy of seven days.

and sold as potable water.

extremely important and vital

There are also commercial

for a sustainable environment

uses for the by-products. The

as well as for the water security

costs of the water produced

of our country. This has become

by these plants are coming

an industry in its own right.

sensor ground loops. These sensors provide greater reliability, resulting in less downtime and maintenance.

What makes mine water treatment unique from other processes? Harsh

March/April 2014

Panel discussion

Mine water treatment

Quality Filtration Systems

Rob Holmes technical director at Quality Filtration Systems

hy is mine water a key focus for water management? RH Due to

mining activity takes place in a

is not easy to

region. Unlike other industrial

determine. This

or reused on site.

water treatment, mine

increases the level

New and unique

the nature of the technologies

waters can continue being a

of complexity, both

process designs

available from QFS, through

concern to the environment

from a technical

areÂ required.

our global partnership

for long periods after the

and a commercial perspective.

agreements, we tend to focus

mining activity has ceased.

on difficult applications. Mine

Also, the mine water can

water management is one of

often be a result of multiple

these areas, where the water

entities operating in a region.

What makes mine water treatment unique from other processes? The

quality is variable and the

Commercially, challenges

challenges are mainly related

mine waters can be readily

treatment challenges can

exist with budgeting for

to sustainability of the

converted into reusable water

be significant. We believe

these projects, as they can be

treatment solution. Often mine

sources. Quality of treated

water treatment requirements

mine water is often not a

become critical for mining

limiting factor in developing

operations to continue and a

a project. In many cases, the

solution is required in a short

quality required for reuse is

time frame. There are several

less stringent that the quality

options available for rapid

required for discharge to the

deployment of treatment

environment, so recovery and

plants. However, the long-term

reuse makes a lot of sense.

The Memsys Vacuum Membrane Distillation process has been readily gaining traction in multiple applications globally our suite of technologies is

capital intensive, and often

sustainability of mine water

uniquely positioned to handle

unplanned, temporary or

treatment must be considered,

theseÂ challenges.

emergency projects. Some

taking into account the energy

What are the reuse possibilities of treated mine water? With the available treatment approaches today,

new business models are being

requirements and final disposal

What exactly are the challenges? Mine water

developed that address these

of waste products. Most mine

Where is the latest in mine water recovery research and how will this be implemented at QFS?

challenges, shifting more

water treatment applications

Much of the research and

treatment is different

responsibility onto service

require a zero liquid discharge

development is now focused

from most industrial water

providers. Additionally, the

approach. The contaminants

on the treatment of the

treatment mainly in the way it

responsibility for treatment

concentrated by the treatment

final fraction of mine water

is created. Mine water can be

of impacted water caused by

process cannot be easily

after traditional desalination

formed before, during or after

historical mining activities

discharged to the environment

treatment. Traditionally, the contaminants are

Steam Raising Cube

removed from mine water by precipitation chemistry, leaving the insoluble salts

Multiple Effect Cubes Condenser Cube

to concentrate in a small volume of effluent (brine). This results in a high strength brine solution of mixed salts. Research is now focused on the most energy efficient way to treat, concentrate and dispose of these salty streams to avoid the construction of additional solar evaporation ponds, which are becoming problematic for mining operations. QFS is bringing international developments in the field of highly concentrated brine treatment to the localÂ market.

LEFT Diagram of membrane vacuum distillation OPPOSITE Photograph of membrane vacuum distillation

March/April 2014

Panel discussion

Please tell us about your latest successes We have been focused on developing new technologies to a point where they can be readily implemented at a practical scale. In particular, our focus has been on building a demonstration plant for a novel new high-salinity treatment process. The Memsys Vacuum Membrane Distillation process has been readily gaining traction in multiple applications globally and has the potential to change the landscape of brine treatment in the mining sector as well. This new technology, developed in Germany, is based on well-known principles of membrane distillation. The breakthrough came a few years ago with the invention of a novel new system to turn the concept into a commercial product that can be implemented economically. Making use of simple materials, low pressures and scalable manufacturing processes, Memsys systems are modular and economical. As the Southern African integrator for Memsys technology, we have successfully commissioned a 12 m3/day demonstration unit at our facility in the Western Cape. The QFS demonstration plant is completely “off the grid” with solar thermal collectors to provide the thermal energy, and photovoltaic cells to provide the electrical energy. We are pursuing further options to pilot and demonstrate the technology in the field. We believe this technology will be a key step on the way to complete zero liquid discharge (ZLD) solutions.

What is the future of mine water treatment in South Africa? We see the technology advancing, with new research and exciting new technologies being developed. The requirement for complete ZLD solutions will drive innovation and implementation of new technologies. By combining proven chemical precipitation, desalination and thermal processes, zero liquid discharge can be economically attractive. MARCH/April 2014

Panel discussion

Mine water treatment

Prentec

Adrian Viljoen Process director at Prentec

hy is mine water a key focus for water management? AV The effect

are exposed to water and air.

water often results

Underground water infiltrates

in a net surplus

brines is an

mining operations and

of water and a

important aspect of

of mining activities impacts

rainwater is collected in voids,

need to discharge

water management

the quality of water through

resulting in the need for mine

water. Most mines

chemical and biological

dewatering to be able to mine.

are situated in areas where

not permitted to infiltrate and

interactions as soils and rocks

Limited surface storage of

they may not discharge water

impact ground water quality.

that exceeds the regulated

Specially lined ponds used as

quality (into the rivers and

evaporation pans are used for

environment). Environmental

brine management; however,

legislation also requires that

there is increasing pressure to

groundwater quality should

eliminate brine management

not be affected through

at mines using lined ponds in

mining activities.

the future.

in that these are

In order to reduce the implement treatment plants

What are your challenges in dealing with this issue? The

to improve the quality of

effective treatment of mine

water before discharge. The

water requires the following:

water treatment may result

• an accurate prediction of the

volumes of water, mines

in a concentration of salts in the form of a brine. The management of concentrated

mine water quality • a process design that can be operated effectively over

March/April 2014

From

concept ...

...to reality

Delivering intelligent turnkey solutions to the water industry since 1974 We have led the way as South Africa’s premier provider of water, sewage and industrial effluent treatment technology. We now expand this know-how into mine water treatment. Prentec’s New Generation Mine Water Treatment incorporates years of experience in process technology, manufacturing and engineering implementation. Our modular LoRO systems use this experience to achieve Low Capital, Low Operating, Low Chemical, Low Energy and Low Waste solutions to mine affected water problems. CNR Proton & Molecule Streets, Chloorkop Ext 1, Kempton Park, Gauteng, RSA PO Box 12181, Kempton Gate, 1617 t +27 11 976 5234 • f +27 11 976 2802 • info@prentec.co.za • www.prentec .co.za

Panel discussion the life of mine (and after

been proposed, the economics

used for mine water treatment

10 Mℓ/d LoRO plant at Exxaro’s

mine closure)

and especially the energy

and is able to complement

Matla Mine.

requirement to produce other

these with new ideas and

chemicals has not as yet been

optimisation to be able to offer

installation of integrated

The chemical quality of the

proven, especially considering

low capital, low operating

wastewater and mine

mine water may be relatively

the low concentration

cost, low chemicals, low power

water solutions at Anglo’s

easy to predict. The prediction

and small quantities likely

and low waste mine water

Twickenham and Xstrata’s

of organic quality and the

to be produced reducing

technology (LoRO). We take

Horizon mines. The

extent of biological activity in

the profitability.

particular pride in the art of

solutions use a combination

uniquely configuring LoRO

of biological processes,

• the ability to achieve zeroliquid discharge.

the feed water has, up to now,

Mine water can be

Prentec has completed the

not always been incorporated

considered a resource. It has

systems to meet the specific

membrane bioreactors and

in the feed water specification.

been proven that treated

needs of each particular case

reverse osmosis to attain our

This poses specific challenges

mine water meets the SANS

for optimal results.

goal of LoRO. In these cases,

to the long-term operation and

potable water standard and

must be considered during the

in some cases exceeds this in

developing new technologies

treatment of shaft water.

plant design.

order to meet the regulated

which will be available for

Glencore has also engaged

discharge standards imposed

the challenges of changing

Prentec to engineer a mine

What makes mine water treatment unique from other processes? Mine

for discharge of water into the

mine water quality.

water reclamation plant at its

environment. The technology

Prentec’s processes offer the

Tweefontein Mine.

for treatment of the mine

opportunity to integrate brine

water is not unique in its

water provides both physical

management with mine water

challenges. When compared

filtration barriers as well as

treatment, thereby providing

to conventional potable water

chemical treatment to be able

flexibility in the operation and

What is the future of mine water treatment in South Africa? Mines will have to

treatment, mine water requires

to ensure the quality of the

ensuring that our processes

continue to treat mine water in

sophisticated treatment

water, with the final treatment

remain low capital and low in

order to ensure environmental

processes and process controls

barrier being reverse osmosis.

operating costs.

compliance. This is therefore

to ensure that it meets the

Stringent process monitoring

required potable or discharge

and effective management

engaged by Coaltech Research

cost of treatment itself and

standards. When compared

of mine water treatment will

Organisation to develop

the water treatment process

to industrial water treatment,

ensure compliance to the SANS

brine treatment technology.

is small in comparison to

the challenges are similar.

standards for potable use.

Coaltech has recognised that

the infrastructure required

South Africa is a water

brine disposal or minimisation

for mine water collection,

Mine water will contain

Prentec is continually

Prentec has further been

zero waste results from the

a necessary investment. The

contaminants dependant on

scarce country and the largest

remains the single biggest

feed dams, environmental

the mining activity (coal/gold/

opportunity is the reuse of

cost driver for mine water

dams, brine dams (if

platinum mining) and may

the water for industry/power

reclamation. On the basis of

necessary) and so on, to

occur as either neutral with

stations and as municipal/

support from Coaltech, Prentec

ensure the management

mineral pollutants or highly

potable water. The treatment

is developing technology that

of mine water on site. The

acidic with significant levels

of mine water will thereby not

will dramatically reduce overall

environmental regulations

of contaminants which need

only reduce the contamination

costs and potentially generate

and demands placed on the

to be removed. The need

of water in the environment,

usable salts from the RO brine.

mining sector – especially

for high recovery processes

but also preserve water in the

thereby reduces the volumes

rivers and impoundments for

of effluents from the mine

other uses.

with regard to “zero liquid

water treatment processes

that makes mine water unique

What is the latest in mine water recovery research and how will this be implemented at the company? Prentec

when compared to other

is able to offer a range of

water treatment.

technologies for the treatment

(mainly as a result of the large volumes of water that need to be treated). This is probably the most significant aspect

Please list your latest successes and challenges (ie projects). Prentec offered

discharge” – and a restriction

a high recovery process for

mine places a challenge on

mine water treatment and

technology to ensure that this

is currently constructing a

can be achieved.

in building brine ponds for residue management at the

of mine water. Prentec has the

What are the reuse possibilities of treated mine water? Currently the only reuse opportunity that has been explored is the separation of sparingly soluble salts during the treatment of mine water using reverse osmosis. Although other processes have

competence and experience in all processes currently being

OPPOSITE A modular mine water treatment plant during assembly at a Prentec workshop RIGHT (From left) Adrian Viljoen, Vivian Moller, Martin Pryor and Kathy Karakatsanis, the Prentec mine water team March/April 2014

Profile

Newcomer in the water supply market Vovani Water Products is a new and exciting company supplying commodity and specialised products for the water industry, especially to original equipment manufacturing (OEM) companies.

BELOW Installation of IMT UF modules in India BOTTOM Fedco pump installation at ArcelorMittal, Vanderbijlpark OPPOSITE ROPV FRP pressure vessels at ArcelorMittal, Vanderbijlpark

ovani was established

vision and business ethics,” says Smit.

Its microfiltration products are most-

in 2004 and has operated

“Vovani Water Products believes

ly used in the food & beverage indus-

in its current form as an

every South African has the right to

try, but its focus has mainly moved

equipment supplier since

potable drinking water, and we want

to its UF products and the treatment

2011. Henk Smit, sales director, is re-

to play a part of making this a reality

of surface water, wastewater and sea

sponsible for the entrance of Vovani

by supplying our products to OEM

water for desalination projects.

Water Products into the market and

companies and getting involved in

manages the sales and marketing

exciting and life-changing projects.”

division of the company.

Vovani offers the Southern African unique

and

unique

SevenBore

fibre, which consists of seven capillary membranes enclosed in an

internationally, which we are intro-

products for the water and food &

asymmetric foam structure, making

ducing into the Southern African

beverage industries, which includes

it 20 times stronger than some of its

market in order to offer these unique

the following:

single membrane fibre competitors.

and price-competitive products to

• FRP pressure vessels for reverse os-

The UF modules are manufactured

all companies in the water industry. I

mosis (RO), nanofiltration (NF) and

in various sizes with various surface

am proud to be affiliated with these

ultrafiltration (UF) applications

areas, to suit your application and

companies, as we share the same

• s tainless steel pressure vessels

configuration. This flexibility allows

•m icrofiltration and UF membrane

Vovani to be able to replace competitor’s membranes in current installa-

modules •h igh-pressure multi-stage and single stage centrifugal pumps •e nergy recovery devices for high pressure RO applications

tions with modules from IMT, with no or little modifications. Vovani can also supply the UF modules in rack systems, with manifolds and inter-

• fl exible couplings and weld stubs

connecting pipework manufactured

• l ow flow ultrafiltration units for

from polypropylene or stainless steel. Fedco specialises in RO feed pumps

various applications • f ogging disinfection units.

for the wastewater, brackish and

ROPV is the biggest FRP pressure

desalination market, especially RO

vessels supplier in the Asia/Pacific

high-pressure feed pumps. These

region and has installed over 300 000

pumps are manufactured in the US

units worldwide. ROPV manufac-

and great care is taken to supply the

tures and supplies high-quality FRP

correct pump and solution for each

pressure vessels for the interna-

application. The pump configura-

tional market for applications from

tions are vast and materials used for

wastewater recovery to desalination.

manufacturing and contact with the

Pressure vessels are manufactured

feed water ranges from 316L SS to

with 8, 16 or 18 inch diameters and

Super Duplex materials.

can house one to eight RO or NF

Fedco also manufactures an energy

elements. Pressure ratings are from

recovery device (ERD) called the

21 bar/300 psi to 83 bar/1 200 psi.

Hydraulic Pressure Booster, which is

Vovani

has

specialised

“We represent well-known brands

market

IMT

polyethersulfone (PES) membrane

represents

Innovative

a one-of-a-kind product in the mar-

Membrane Technologies (IMT) from

ket when considering its engineering

the Netherlands, which manufac-

and operation. The efficiency of the

tures microfiltration and UF modules.

Hydraulic Pressure Booster system

March/April 2014

Profile is rated at 80% and higher, and has a major impact on the operation cost of RO water treatment plants. Vovani also supplies the industry with flexible couplings and weld stubs from PASS. These products are of the highest quality and extremely price competitive. The flexible couplings and weld stubs are especially used with FRP pressure

FRP PRESSURE VESSELS

vessels, but also in the rest of water treatment plants as connection pieces for pipework. Aqua Solutions from Australia has chosen Vovani as its partner in the supply of complete low flow UF units. These UF units can be used for domestic or commercial use, and is an easy system to operate and to maintain. The AquaSentry is a low cost, lightweight (12 kg) and portable water purification unit that requires no energy input. The unit is gravity fed and only requires 1 to 2 bar to operate fully. The AquaSentry can produce 750ℓ/h of potable drinking water from rivers, dams, boreholes or as pretreatment of seawater for desalination. The UF-PRO affords practical, small-scale potable water treatment using proven UF membrane technology. The system controller provides continuous, automatic water production via an Eco-Flush Clean Cycle, with minimal operator input. It is compact, tough, easy to transport and simple to install. The UF barrier filtration process provides primary disinfection by removing pathogens and particulates to supply safe drinking water from the majority of non-saline surface and ground waters. Additional post-filtration treatment includes ultraviolet or chlorine disinfection, or MIOX can be utilised if desired. water

Typical applications: • decentralised

treatment

and

bottled

production

water

• community and rural small-scale • remote mining and resource communities • point-of-entry filtration and RO pretreatment

CMY

• emergency and temporary water supplies.

MARCH/April 2014

Regional focus

Creative solutions to dam challenges About 47% of construction work has been completed on the R212 million Imvutshane Dam, 30 km north west of Stanger in KwaZulu-Natal.

T BELOW Completion of the dam is scheduled for 2015

his dam is a key link in

and supervise the construction of

Municipality, is implementing the

supplying the rural people

the 3.1 million m3 dam, completion

extensive R402 million Maphumulo

in Maphumulo, KwaZulu-

is scheduled for February 2015.

Bulk Water Supply Scheme. This

Natal, with a reliable source

“Excavation on the spillway has

of safe drinking water. Currently

been completed and, to increase

Maphumulo

over 50% of the population are

its depth by an additional 8 m, two

Plant, an extensive network of

without any formal water supply

small explosive blasts have been suc-

pump stations, bulk water-supply

and the remainder depend on an

cessfully carried out. The outlet pipe

pipelines,

unreliable small schemes. During

has been jacked through a rocky hill-

water and the construction of the

winter and droughts, water is scarce

side and has completed two-thirds

Imvutshane Dam.

throughout the region.

of its 106 m journey,” comments

According Engineers

MBB

Consulting

Pietermaritzburg,

ap-

pointed by Umgeni Water to design

Tyler Bain, MBB’s project engineer. Umgeni Water, as bulk water supplier

the

Ilembe

District

includes the construction of the Water

reservoirs

Treatment

for

treated

The design of the dam offered some

interesting

challenges.

Geological studies showed that the rock was badly weathered in the area designated for the spillway. MBB designed a concrete lined spillway that will be anchored into ground; this is a safety measure to ensure the dam can withstand extreme floods. “The 28 m high, 305 m long embankment will be built using different construction methods; a section will be clay core and the remainder will be built of compacted earth with a rock shell. Sufficient clay and rock have been sourced on-site so the amount of materials that has to be transported is minimal.” Another challenge was a pothole where the dam crosses the river,

March/April 2014

Regional focus

ABOVE Outlet pipes will be fitted inside the concrete sleeve BELOW Crew during construction which was unsuitable as a foundation. To mitigate this, jet grouting will be used to create a strong, watertight foundation for the dam’s embankment. This entails drilling into the ground and creating columns of soil and cement by introducing cement grout at high pressure. A series of underground, overlapping columns will be constructed to form an impervious “wall” up to 16 m in height. “The pothole also caused foundation headaches for the outlet pipes. MBB solved the problem, in a fairly cost-effective way, by jacking the pipes through the adjacent hill. A powerful hydraulic jack is being used to push a concrete pipe 106 m through the rocky prominence. While the pipe is being driven through the ground, behind a shield, excavation takes place simultaneously,” he concludes. To ensure the concrete sleeve is watertight, the gap be-

CMY

tween the pipe and the rock is sealed with cement grout and the rock is being grouted at specific places. The outlet pipes will be fitted inside the concrete sleeve and, during construction will divert water away from the site, while continuing to supply water to the treatment plant.

Umgeni Water is implementing the extensive R402 million Maphumulo Bulk Water Supply Scheme

MARCH/April 2014

Regional focus

Water loss tackled in eThekwini All available resources will be deployed to reduce the escalating rate of water loss in Durban.

Fixing water leaks is critical to offset water losses

oncern

has

been

water leakages because water will

2% year-on-year. Despite this chal-

expressed that water loss

soon become an expensive commod-

lenge, the Water and Sanitation Unit

continues to rise, with the

ity if nothing is done to conserve it.”

has made some positive progress in

indicating

Sithole said the administration is

this regard, with interventions like the

non-revenue water having risen from

exploring all possible remedies and 55

installation of new pressure reducing

34% to 37%.

people have already been employed

valves (PRV), removing illegal con-

The City Manager, Sibusiso Sithole,

to detect water leakages. “We have

nections, metering unmetered prop-

will take all possible measures to

to try and use every available mecha-

erties, maintaining existing PRVs and

deal with this challenge, including

nism to save water and that is why we

conducting active leak detections.

the use of technology and local

now have hired people to detect wa-

Meanwhile, a stern warning has

communities to detect and fix water

ter leakages where they use a GPS to

been issues to land invaders who

leaks. The chairperson of the Human

map the exact location of the leak and

continue to occupy pieces of land

Settlements

Infrastructure

this enables our maintenance teams

illegally in different areas in the city.

Committee, Cllr Nigel Gumede, said

to immediately attend to where a

Sithole warned that the municipality

the problem was further complicated

leakage has been identified.”

would continue its effort to demolish

latest

figures

and

by illegal connections and the mushrooming of informal settlements. He said there was a need to educate the people on water saving and to

He said the municipality was also

illegal structures and was looking

looking at models from other cities

at strengthening the Land Invasion

as to how they were dealing with the

Unit. “People who continue to invade

issue of non-revenue water.

land must not have hope that we

put a stop to illegal connections.

The municipality is currently paying

will provide them with services. We

“People need to learn to use water

an excess of R163.6 million towards

need to send a strong message that

sparingly, and they need to be

non-revenue water annually and the

we cannot allow people to do as

properly trained about how to detect

trend is growing by approximately

they please.”

March/April 2014

Regional focus

Western Aqueduct pipeline expanded eThekwini municipality is taking extra measures to bring shortterm relief to communities in the northern areas of the city affected by water shortages.

municipality

will

invest

additional

R116 million to expand the diameter of the existing pipeline in order to increase the flow of water to the affected areas. This is in addition to a new fleet of

water tankers that have been bought to ferry water to com-

munities as well as 100 extra JoJo tanks. The executive committee conducted an inspection on the progress of the Western Aqueduct water pipeline project in

CMY

Hillcrest, which is expected to provide a long-term solution to water supply challenges in the Inanda, Ntuzuma, KwaMashu (INK) areas and new developments like Cornubia. The R3.3 billion Western and Northern Aqueduct projects involve the laying of an almost 100 km of pipeline. The first phase of the Western Aqueduct, which included a 19 km pipeline, is completed and three other phases are being rolled out simultaneously after the council provided an additional R580 million last year to bring forward the completion date by two years to 2017. The contract was also unbundled and awarded to different contractors after legal challenges delayed the project. City manager Sibusiso Sithole says the municipality will be identifying extra resources to fund the short term interventions for the INK areas. “Our infrastructure is presently running at full capacity and the short-term solution is to increase the diameter of existing piping. We are looking at an investment of about R116 million to supply water to these areas, translating to 116 km of piping.” Mayor James Nxumalo says they are pleased with the progress of the Western Aqueduct Project. “The visit gave us an understanding of how far the project has gone. We are happy that it is proceeding according to plan and once it’s completed it will relieve the pressures of water supply in the affected areas. We urge people to continue using water sparingly and to report illegal connections which often cause damage to our infrastructure.” MARCH/April 2014

Water boards

Researchers and industry join forces A new research chair, sponsored by the East Rand Water Care Company (ERWAT), will focus on innovations in water research, as well as upping water treatment and water management skills in the water sector. About ERWAT The East Rand Water Care Company (ERWAT) was established in 1992 as a Section 21 company. Its shareholders are the Ekurhuleni Metropolitan Municipality (majority shareholder), Johannesburg Metropolitan Municipality and Lesedi Local Municipality. ERWAT provides bulk wastewater conveyance and a highly technical and proficient wastewater treatment service to some 2 000 industries and more than 3.5 million people who have access to sanitation services. It is currently custodian of 19 wastewater care works, treating a combined capacity of some 696 Mℓ of wastewater per day. The majority of the operations are in the Ekurhuleni Metropolitan Council (Eastern Gauteng).

and management skills of scientists,

history of working and cooperating

engineers and technical personnel.

with, as well as supporting different

Wolfaardt recently returned from

universities and research institutions

Canada, where he has held a Canada

over a number of years. The compa-

Research Chair in Environmental

ny looks forward to build on these

Interfaces and Biofilms since 2004.

accomplishments, now in this formal

Prof Eugene Cloete, Vice-Rector: Research

and

Innovation

Stellenbosch University and chair-

and

structured

association

with

Stellenbosch University. “In

water-scarce

country,

man of the SUWI Advisory Board,

we are continuously faced with

says ensuring a safe water supply

ever-changing

for South Africa and Africa is pos-

and constitutional challenges in the

Wastewater

Management

sible, but will require innovation

water industry. We need to find sus-

will

hosted

and action.

tainable solutions to these challeng-

ERWAT be

Chair

technical,

financial

University’s

“We are very excited about the

es to ensure the protection of our

Water Institute (SUWI). Prof Gideon

establishment of the ERWAT Chair

environment and water resources,”

Wolfaardt, a recognised expert and

and the opportunities it provides for

maintains Twala.

leading researcher in the biological

world-class research and innovation

and engineering aspects of water

in South Africa’s water sector. The in-

research, will be the first research

stitute is also the ideal home for this

professor to hold the chair.

chair, as we pride ourselves on con-

Stellenbosch

The focus of the new ERWAT chair

tinually exploring new approaches

will be on scientific and technical

to water treatment that are durable,

advances in wastewater manage-

cost-effective and more efficient,”

ment, water quality, water use and

he says.

demand, as well as fostering partner-

ERWAT’s managing director, Mr

ships to improve the water research

Pat Twala, says ERWAT has a proud

March/April 2014

About the Stellenbosch University Water Institute (SUWI) Established in 2010 in response to the formidable and unprecedented challenges that face South Africa and the African continent at large, SUWI is a multidisciplinary research enterprise that coordinates research from a multitude of academic disciplines such as natural science, social science, agricultural science, engineering and law. Research is done in collaboration with government and industry to solve water-related challenges, to provide technology transfer and to develop human resources.

Water boards

Partnering with industry Maryke Foulds asks Prof Gideon Wolfaardt, the new ERWAT chair at the University of Stellenbosch, about some of the issues in the water industry today.

hat is the biggest challenge facing SAâ€™s water industry? The increasing

demand for good-quality water for industry, to service the needs associated with rapid urbanisation, and food production in the context of finite resources. This is compounded by pollution of both surface and subsurface water reserves. As a result, and similar to many other countries, South Africa is faced with the challenge to make difficult choices in terms of water allocation with potentially serious economic, social and environmentalÂ consequences.

How will you foster the partnerships in the industry? For

CMY

me it has never been a question whether I should collaborate with industry and government partners. These collaborations often lead to interesting new questions and are often the base of subsequent fundamental research. Successful collaborations are founded on a good match between academic and industry partners; important criteria for this to develop are honesty about expertise and capacity (academics) and realistic expectations (non-academic partner). These worked well for me in the past and I hope to continue along theseÂ lines.

What is the role of research institutions? There is an increased awareness of the fact that our health, food supply, economic stability, etc., are all dependent on a healthy ecosystem and related ecosystem services. The numerous pressures on the ecosystem are well described in both scientific and popular literature; however, a defining challenge of our time is that we do not have decades to solve serious problems and challenges related to natural resources. These problems are complex and we need to transcend disciplinary boundaries. Research institutions are best positioned to provide the platforms for forming teams with experts from disciplines ranging from economics, humanities, science/ engineering to law, and with sufficient agility so that the problem can dictate the relative involvement of the different disciplines versus putting teams together looking for a problem to solve. MARCH/April 2014

Water boards

Harvesting electricity Recently installed hydroelectric technology has proven to be a huge success for Bloem Water’s head office in Pellisier, producing 96 kW/h of energy from a pressurised conduit.

mines, all owning and operating gravity water supply distribution systems that could be considered for small-, mini-, micro- and pico-scale hydropower installations. Most of these water distribution systems may be equipped with turbines or

ABOVE Large amounts of raw and potable water are conveyed daily under pressurised and gravity conditions OPPOSITE Bloemfontein has suffered crippling power outages in the past

pumps as turbines, supplementing

outh Africa is acknowl-

edged to not be particularly

been

endowed with the best hy-

where

power energy may be used on-site,

dropower conditions, as may

around 30 kW/h of power is being

supplied to the national electricity

occur elsewhere in Africa and the rest

generated in the pipeline at the exit

grid, or fed an isolated electricity

of the world. However, large quanti-

to the Elardus Park reservoir. This was

demand cluster.

ties of raw and potable water are con-

followed by the Bloem Water instal-

Africa is the most underdeveloped

veyed daily under either pressurised

lation, converting to a sustainable

continent with regard to hydropower

or gravity conditions over large dis-

energy source as the main supply of

generation, with only 6% of the esti-

tances and elevations. The University

energy for operating its head office

mated potential exploited, explains

of Pretoria, supported by the Water

in Pellisier. The Bloem Water facility

Marco van Dijk, project leader from

Research

will be the largest unit to date in the

the University of Pretoria.

engaged in a study investigating

country, producing 96 kW/h of ener-

and demonstrating the potential of

gy from a pressurised conduit.

Commission

the

technology

successfully

Tshwane

has

and reducing the requirements for

demonstrated

pressure control valves. The hydro-

Municipality,

Municipalities

consume

around

60% of their energy requirements

exploiting the excess pressure or hy-

The Caledon-Bloemfontein potable

in the distribution of water services

dropower energy available from pres-

water supply system supplies the

cost. For example, energy accounts

surised water distribution systems.

majority of the water demand in

for around 40% of Rand Water’s cost

This type of energy generation,

Bloemfontein. The water is supplied

in the production of water. With in-

referred to as conduit hydropower,

to the Brandkop Reservoir, which is

creases in electricity costs, this could

where Bloem Water’s head office is

possibly reach 55% and more.

different

hydropower

(WRC),

date,

the

conventional

generation

usually

located. Excess energy is dissipated

associated with large dams. The

through

excess energy available in pressur-

before

ised conduits (pumping or gravity),

the reservoir.

pressure being

control

discharged

For the Bloem Water project, a

valves

96 kW crossflow turbine and syn-

into

chronous generator will be installed. This is about 10% of the full potential

which is normally dissipated through

According to the WRC’s executive

of the pipeline. The turbine will be

a pressure-reducing valve, is trans-

manager, Jay Bhagwan, pumping

housed in a turbine room, currently

formed into clean, renewable hydro-

systems account for nearly 20% of

under construction, located next to

electric energy by means of a turbine.

the world’s electrical energy demand.

the Brandkop Reservoir. The Bloem

In other words, it is simply harnessing

In South Africa, for example, there

Water head office will be directly

what is already available in the exist-

are 284 municipalities and several

connected to this hydropower plant,

ing water infrastructure.

water supply utilities, as well as

says Mokutu Kgwale, director for

March/April 2014

Water boards Infrastructure Development, Operations & Maintenance at Bloem Water. Approximately 30% of the water supplied via the CaledonBloemfontein pipeline will be diverted through the turbine. The turbine’s runner will be turned due to the water passing through it, which will excite the generator allowing hydroelectric energy to be generated. After passing through the turbine, the water will be discharged through a constructed opening in the roof of the south-west corner of the reservoir. Control equipment will regulate the flow and pressure through the turbine, resulting in the generation of clean, stable electricity at the correct voltage and frequency of 50 Hz. The generated electricity will be connected via the control equipment to the main supply of the head office. Sufficient renewable energy will be generated to supply the peak demand of Bloem Water’s head office as well as meeting the electricity requirements of the reservoir terrain. About 800 MWh could be generated annually with this micro-hydropower installation. Bhagwan further comments: “This demonstration project will provide huge savings for Bloem Water, as well as a quick return on investment. Bloem Water, if able to exploit all the opportunities in its networks, can become a serious player in energy as well. A good international example of such could be drawn from the German company Zweckverband Landeswasserversorgung, which delivers water to three million customers in Baden-Württemberg and Bavaria. Since the early 1970s, it has been using power generated continuously from energy recovery”. Hydropower schemes have very long lifetimes and high efficiency levels with low operating and maintenance costs. Hydroelectric energy technology is a proven technology that offers high efficiencies as well as reliable and flexible operation, confirms Van Dijk. Conduit hydropower requires a small capital investment and has a short return on investment

CMY

period. As long as people use water, renewable electricity can be generated.

MARCH/April 2014

Water boards

Innovative internship programme launched Magalies Water has launched the pilot of the innovative Magalies Water Capacity Building Programme. The programme is designed to address the need for skilled and employable students. Magalies water in a nutshell The water board Magalies Water was established in 1969, mainly to supply the needs of the platinum mines in the Rustenburg and Thabazimbi areas. For this purpose, the Vaalkop Water Treatment Works was constructed next to the Vaalkop Dam with an initial capacity of 18 Mℓ/d. Currently, the entity’s infrastructure traverses three provinces: the North West (Bojanala), Limpopo (Waterberg) and Gauteng (part of Tshwane). The Magalies Water area of supply spans 42 000 km2. Growth in water demand in the area of supply has resulted in the extension of the organisation’s infrastructure and footprint in order to deliver water in bulk to these areas. Magalies Water currently owns and operates the Vaalkop, Wallmansthal, Klipdrift and Cullinan Water Purification plants. In addition, Magalies Water also operates the Temba Water Purification Plants on behalf of the City of Tshwane.

agalies provides

Water water

as a strategic intervention for job creation, skills development and community development. To this end, Magalies Water has partnered with its professional service providers involved in the implementation of its capex programme and selected tertiary institutions to

ser-

provide practical on-the-job train-

vices in the following

ing to the selected students. The

provinces: North West,

following three tertiary institutions

Limpopo and Gauteng. New op-

were selected by Magalies Water to

portunities for accelerated capacity

build strategic partnerships with to

building for students were identified

commence with the programme:

in the organisation’s extensive pro-

Orbit Further Education and Training

gramme to upgrade existing and

develop new water infrastructure

University of Technology (technician,

technologist level) and the University

meet

growing

demand

for

potable water. Infrastructure

Brits

(artisan

level),

Tshwane

of Pretoria (engineer level). The studevelopment

has

been identified by the government March/April 2014

dents were selected after a rigorous selection process.

Water boards In addition to technical in-service

expenditure is in the order of R2 bil-

development. Magalies Water plans

training that the interns/students will

lion. Some of the projects are part

to leverage its capex programme to

receive, the programme draws on

of the Strategic Integrated Projects

accelerate skills development in the

international mentoring best prac-

coordinated by the Presidency.

water sector. The general skills that Magalies Water and the broader water

tices to allow for open channels of their educational institutions, the

Infrastructure development and skills development

contractors and professional service

Infrastructure

providers overseeing the interns and

catalyst to job creation and skills

communication between the interns,

development

sector have identified as a need are engineers, technicians, technologists, a

artisans, scientists, process controllers, and plant operators, among others.

Magalies Water’s operations. Magalies Water is supported by ONYXX Human Capital and Royal HaskoningDHV in the development and implementation of this unique capacity-building programme. The

programme

launched

January 2014 at Vaalkop Plant with seven

students

who

have

been

offered internships for the 2014 calendar year – four TUT students/

OPPOSITE Practical on-thejob training

graduates and three FET students. Magalies Water has an extensive infrastructure programme for the

LEFT The programme was launched at Vaalkop plant

upgrading of existing water infrastructure and for the development of new infrastructure. The total capital

March/April 2014

Water me tering

Turning revenue collection around A local municipality situated in the West Rand of Johannesburg was losing a significant amount of revenue from faulty and non-operational water meters at an upmarket housing estate located in its area of jurisdiction.

n analysis conducted

Kent prepaid water meters in this

installed on the consumer’s own

at the time showed that as

particular estate,” says Basson.

property shows how much credit is

many as 37% of the water meters in the residential

on the meter and how much water

About prepaid metering

has been used.

estate were not operating at all. As a

With prepaid metering, the consum-

The prepaid metering system has

result, the local municipality appoint-

er is in control of their own water

numerous benefits, including the fact

ed Utility Management Solutions

usage, as they decide how much

that any water leaks on the premises

(UMS) to undertake the installation of

water to purchase according to their

can be detected immediately as

Elster Kent prepaid water meters to all

requirements at any one time. This

they will be shown on the meter.

the homes in the residential estate.

system ensures that the consumer

From a water services authority’s

Leon Basson, sales and marketing

can now budget for their water bill

(WSA) perspective, the Elster Kent

director at Elster Kent Metering,

and that they will not receive any

prepaid metering system is a reliable

explains that the project included

surprise bills from the water utility. At

system that is an effective income-

the replacement of 1 022 existing

any time, the system that has been

generating system for water sales.

water meters with Elster Kent prepaid meters. The payback time including installation was 7.6 months. This has since resulted in the local municipality now being able to collect revenue

GRAPH 1 (left) The average water consumption, per consumer meter per month, since the project was initiated

that was previously lost due to inoperable prepaid metering systems. Although the local municipality has been involved in prepaid metering for over 10 years now, it had identified that as a result of some of the residents in the estate being undercharged for their water consump-

BELOW Elster Kent prepaid water meters

tion and in certain cases not being charged at all, urgent interventions were required due to a significant loss of revenue. Basson says that the increase in water sales in the estate from the start of the project was a massive 197%. In the first four-month period, water sales amounted to an average of R138 070 per month. This obviously takes into consideration that the months from January to April are in the summer season of Gauteng

where

residents

would

water their gardens. During the next four months, water sales increased to an average of R300 949 per month. “This shows the turnaround in water billing as a result of the new Elster March/April 2014

Water me tering

Domestic water management inÂ focus Utility Systems, a Durban-based company, is an industry leader in the field of domestic water management, including the fields of electronic flow limitation and prepaymentÂ metering.

March/April 2014

We do not inherit the earth from our ancestors, we borrow it from our children Tel: +27 (0) 31 700 4143 Fax: +27 (0) 31 700 4147 enquiries@utility-systems.co.za www.utility-systems.co.za

Water me feature tering

he Utility Systems prepaid

installation. It goes without saying

metering system is, in fact,

that this greatly increases consumer

the only prepayment sys-

acceptance of the metering system.

tem that is approved by the

STS Association for water metering.

The WMD has a built-in radio that communicates by radio frequency

Utility Systems is a supplier to all

over the ISM band to mobile or

major metros in South Africa, and

fixed data collectors, which in turn

also supplies over 50 municipalities

uploads data into a database for use

and water service providers coun-

by water service providers.

trywide. Internationally, there are

The WMD also uploads reports on

projects in Africa, the Middle East

leaks and tampering, enabling the

and South America.

Utility Systems data bridge software Utility Systems’ Data Bridge software converts technical data mined from the water meter through the built-in data log in the WMD, into usable and easy to read information enabling utilities to: • accurately and electronically read meters and collate data • seamlessly integrate it into an existing municipal billing and/or management system without the need to run a proprietary system in parallel • detect leaks • discourage endemic corruption or tamper by dishonest meter readers and/or consumers • engage in water demand management • carry out accurate synchronised water balancing.

consumer to be notified and, in turn,

Easy

Product quality and after-sales

address leaks on their premises, and

payment networks

Pay

and

other

similar

support offered by Utility Systems is

for the water service provider to take

• cell phone-based vending

of the highest standard, and it is this

corrective and punitive measures

• Internet-based vending.

excellent product and professional

should the consumer tamper with a

service that results in repeat sales to

meter installation.

is based on the STS standard, it

many satisfied customers.

The Utility Systems User Interface

the

utility

systems

vending

means that, unlike the more dated

At the core of Utility Systems’

Unit (UIU) is a customer interface

prepayment

product offering is the electron-

that is linked to the meter installa-

service provider does not have to

ic control valve and the Water

tion by means of a radio link. It has

purchase and maintain a proprietary

Management Device (WMD). When

an LCD display that displays the

vending system. Customers are free

fitted to a pulse output water meter,

meter reading as reflected by the

to use any of a number of vending

WMD, the remaining credit

When fitted to a pulse output water meter, the WMD allows for a wide range of metering applications

systems,

the

water

service providers.

allocation, leak and tamper

The bulk meter is a large bore

alarms, and is the portal

version of the WMD and not only

through which the tokens

controls the flow of water to places

are entered in a prepay-

like schools and factories if required,

ment metering application.

but also enables water service pro-

As the Utility Systems

viders to undertake real-time zonal

prepaid metering system

water balancing with an installed

of metering applications. Well over

transfer specification (STS) associ-

Utility Systems also offers the

600 000 of these devices have been

ation, it allows for a wide variety

Aquadata device for purely AMR

sold both locally and internationally.

of prepayment vending options,

installations and is ideally suited for

which include:

gated communities that have a bulk

with a pulse output meter in one

•p oint of sale vending terminals

water supply but want to recover

of the meter box housing systems,

• i ndependent vendors such as the

The WMD is generally housed

and can be electronically modified in the field to implement any one

accredited

major

grocery

the

standard

base of WMDs.

the WMD allows for a wide range

chains

through

the volume of water for each household as it actually consumes. The

Utility

Systems’

advanced

of a number of different metering

metering system offers cutting-edge

system options, all at full pressure.

smart metering and demand man-

These include:

agement to water service providers,

• the

allocation

finite

and, in doing so, drastically reduces

pre-negotiated daily or month-

non-revenue

ly allowance – ideal for those

water – the scourge of most water

who only receive the free basic

service providers. Utility Systems is

water allowance

part of the JSE-listed MICROmega

• prepayment metering

and

group of companies.

unaccounted

OPPOSITE USC prepaid water metering system BELOW USC User Interface Unit (UIU) and Water Management Device (WMD)

• automated meter reading (AMR) • advanced metering infrastructure (AMI) – the ability to read meters and to control the flow of water to a household remotely. The advantage of this is that every meter installation looks identical but the water service provider is able to tailor the appropriate solution for each individual customer without any physical change to the March/April 2014

Produc t news

New service offerings Consulting engineering firm GIBB has expanded its environmental offerings with the introduction of two new service lines: waste engineering and geographic information systems (GIS).

his

follows

research

into

environmental

extensive

expertise in waste landfill design and

in the rest of Africa where there is a

emerging

contaminated land management.

lack of data); slope analysis and visual

services

trends in international and

African markets.

“Importantly, being part of an integrated

engineering

impact assessments.”

company

He said GIS is not just about

means waste engineering can utilise

mapping and data capturing. “An

General manager for the envi-

the services of power and energy and

important aspect of what we offer is

ronmental services sector at GIBB,

GIBB Capital to deliver a complete

spatial analysis, for example: least-

Dr Urishanie Govender, says GIBB

solution,” said Govender.

cost-route analysis allows us to take

identified waste engineering as an

Deon de Witt, who heads up the

all factors into account and come up

important growth area for the firm

GIS service line, says his unit provides

with least-cost models. Often projects

following a market gap analysis. “We

spatial data on projects, ranging from

commence without proper GIS anal-

responded to the market through

base maps to spatial analysis. “Some

ysis being conducted. This can mean

organic growth and forming strate-

of our major offerings include least-

going back to the drawing board to

gic partnerships with key players in

cost-route analysis, catchment delin-

find solutions to challenges that could

waste engineering, who have specific

eation, remote sensing (particularly

have been dealt with upfront.”

March/April 2014

The Intelligent Choice With a solid track record spanning over half a century, GIBB has established itself as a partner of choice. Backed by a Level 2 BBBEE rating, GIBB provides engineering solutions to a diverse range of markets across the African continent.

People • Expertise • Excellence marketing@gibb.co.za | www.gibb.co.za | +27 11 519 4600

Produc t news

30 years in the industry Maryke Foulds asks Mannie Ramos of Abeco about some of the company’s highs and lows, and whether have things changed during that time.

hat are the highs and lows you have experienced since 1984?

urban poor, often lacking

groundwork for our long-term

Abeco offers a unique

access to safe drinking

growth. Africa is the future and

perspective on potable water,

water. In order to address

to date we have supplied over

wastewater, fire protection and

We started out with the aim of

this issue of water scarcity,

30 countries in Africa with our

industrial liquid applications.

satisfying the ever-increasing

investment is required to

tanks. We have modernised

We know the merits of each

need for hygienic storage

improve wells and rainwater

our factory and invested in

type of construction, allowing

of water. Thirty years on, we

catchment systems.

modern equipment allowing us

us to objectively propose

to adapt to the changes in the

the right type of storage for

industry and meet future growth

each application. The biggest

anyone else. The way business

What are the latest products or trends? We have enhanced

projections. We are actively

challenge is to maintain both

was done has changed over

our product range and

looking at potential acquisitions

quality products and top-notch

the years as technology has

introduced a powder-coated

that fit in with our company

support to continue driving

progressed and profit potentials

tank to our range which can hold

objectives and strategy.

customer loyalty and in so doing

have been eroded. Today you

up to 30 284 m3, which is very

can lose a deal for 5% but

competitive against concrete

then be called to fix someone

tanks. We have also introduced

else problem because inferior

wastewater treatment, digesters

products have used and no after

and industrial liquid tanks to our

service is available on a lot of

liquid containment solutions.

foreign products.

We have also entered the dry

have erected more water tanks in Southern Africa than

maintain our dominance as the

How can you assist in the challenging water industry?

bulk storage with tanks, which

What is the most pressing issue facing the water industry today? Africa is

can hold anything from bottom ash to dewatered sludge.

after Australia and those

What is planned for Abeco in the future? Through hard work

who suffer the most are the

we have been able to lay the

the second driest continent

biggest supplied of water tanks in Southern Africa.

Abeco highlights •R eaching over 25 000 installations • T he installation of the first 5 Mℓ rectangular tank back in 2008, which is still the biggest bolted steel tank in Southern Africa to date • T he installation of the first 3 Mℓ circular bolted tank in 2009 • T he installation of 5 x 500 m3 tanks on 25 m stands on the north-eastern coast of Central America – the structure had to be designed to withstand hurricanes, which had historically played devastating roles in the area •W e have supplied tanks to 30 countries •B eing the first steel tank manufacturer to get ISO 9001 accreditation in 2010 •C elebrating 30 years of manufacturing tanks •G etting the right to apply the SABS certification mark – we are the only sectional tank manufacturer with this certification.

March/April 2014

Th e N a me t h a t Re a lly H o ld s Wa ter Est. 1983 Manufactured in South Africa Specialists In: Pressed Sectional Steel Tanks • Structural Steel • Supporting Towers • Water Storage

Abeco House, 6A Bradford Rd Bedfordview, South Africa

Tel: +27 11 616 7999 | Fax: +27 11 616 8355 E-mail: Abeco@icon.co.za

www.abecotanks.co.za

All water is rainwater Harvest yours today… it’s free! With the cost of water likely to increase and the escalation in water outages in many urban areas, smart homeowners are supplementing their municipal water supply by installing rainwaterharvesting tanks. Harvesting free rainwater to water the garden, clean the house, wash the car and flushing the loo, significantly reduces your dependence on municipal water supply. The good news for styleconscious homeowners is that JoJo tanks not only come in a wide range of sizes (from 750Lt to 20 000Lt), they’re also available in fashionable colours that suit most home colour schemes. JoJo tanks are made from the best quality virgin food grade materials and is the first tank with an 8-year warranty. Tough and good-looking… that’s why we proudly write our name on the outside of our tanks.

013 262 3021

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JoJo-Tanks-South-Africa

@JoJo_Tanks

Produc t news

Rain harvesting systems In an age where water resources are tightly controlled and regulated, it is incumbent on greenhouse growers to make the most efficient use of water they have and to look around for additional water sources that are freely available.

ainwater can be one

A pressure booster pump then dis-

of these additional free

tributes the water for irrigation use.

Rainwater can easily be blended to other municipal or borehole

water sources. For small,

JoJo water tanks are an ideal

water sources and can be used to

medium or large commer-

method of storing this relatively

irrigate the crop. Rainwater is a soft

cial growers, with large greenhouse

clean water source, as the darkened

water and may prove beneficial if

roof areas, the potential to capture

tanks prevent algae growth, and

your borehole water is hard. This

large volumes cannot be underesti-

splitting of your water storage

may help reduce chemical costs

mated. A 6 000 m2 greenhouse roof

means that maintenance can be

as softener use may decrease. It is

with an annual rainfall of 700 mm

done on tanks without having to

easy to blend these water sources

can harvest around 3 302 Kℓ of wa-

empty your entire water storage.

in a buffer water tank that is fed

ter in a year. To capture rainwater

Split water storage also can spread

separately from the rainwater stor-

from a 20 mm rainfall event would

risk, as if one tank is damaged, your

age system and borehole storage

require storage space of around

entire water storage system is not

system. Small holding or buffer

100 Kℓ, which would require either

lost. Sealed water tanks also prevent

ten 10 000 ℓ tank or five 20 000 ℓ

biological, chemical and physical

tanks. The systems are relatively

contamination from easily entering

simple to set up and consist of

the tanks. A modular format also al-

gutters, downpipes, pipework and

lows you to expand storage require-

adequate pre-filtration of rainwater.

ments as needs and budget allows.

Rainwater can easily be blended to other municipal or borehole water sources and can be used to irrigate the crop

Drip irrigation has been shown to increase crop yields, compared to traditional large droplet spray irrigation

March/April 2014

Produc t news

It makes sense to use the captured rainwater with waterwise efficient drip irrigation systems

tanks with this mixed water supply

water resources. As drip irrigation

allow the grower to test the water

systems irrigate more slowly, in

and treat it if pH levels etc. require

litres per hour, it may be possible

adjustment. It is also easy to mix liq-

to use the smaller kilowatt pressure

uid fertilisers into these small tanks

pump, saving in pump costs as well

for fertigation requirements.

as electricity costs. These pumps can

Capturing rainwater from green-

easily be used in conjunction with

houses, tunnels, etc., is also useful

photovoltaic systems with battery

as you are capturing water from

back up.

the immediate area for use on site. It also can help tremendously

Water facts

with stormwater mitigation and

• Some 1.1 billion people, or 18 % of the word’s population, lack access to safe drinking water, and over 2.4 billion people lack access to adequate sanitation. • More than 2.2 million people in developing countries, most of them children, die each year from diseases associated with lack of access to safe drinking water, inadequate sanitation. • A report released in early October 2009 by the Water Research Commission of South Africa found that South Africa has 4% less water than 20 years ago. • Rand Water is predicting that demand for water in South Africa will outstrip supply by 2025. • In Cape Town, the scenario is not much better with a water shortage prediction by 2016. • If South Africans continue with their wasteful water practices, there simply will not be enough water to meet the country's future needs and we may have to start paying even more for water! • South Africans can change the scenario by changing their behaviour towards water usage and becoming water wise and savvy about rainwater harvesting.

can help prevent flooding and water damage. It makes sense to use the captured rainwater with waterwise efficient drip irrigation systems. Correct filtration of the rainwater, both before it enters the water storage tanks as well as after the pressure booster system, prevent clogging of drip emitters and is part of good drip irrigation design. Drip irrigation allows the grower to use less water to achieve the same or better results. Drip irrigation allows the grower to place the correct amount of water, mixed with the right ingredients, at the right place at the right time. This allows uniform distribution of water and nutrients. Drip irrigation systems can also reduce labour costs. Drip irrigation has been shown to increase crop yields, compared to traditional large droplet spray irrigation systems, while utilising less

Index to Advertisers 14th Annual African Utility Week 47 Abeco Tanks 93 Aquadam 6 Atlas Copco 11 Degrémont 64 DFC 30 DOW OFC DPI Plastics 38 Eftec 48 Elster Kent 88 Endress + Hauser 20 ERWAT IBC Fiberpipe 34 Gast International 62 GIBB South Africa 92 Golder Associates 16 Hansen Industrial Gearboxes 87 Headstream Water Holdings 44

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March/April 2014

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