SAME Feb2013

S MECHANICAL A ENGINEER FEB 2013

Publication of the Institution of Mechanical Engineering Incorporating News of Associate Organisations

l HAVE ENGINEERS ABDICATED THEIR POSITION OF POWER? l l MANUFACTURING PROGRAMME ANNOUNCED l THE SOUTH AFRICAN MECHANICAL ENGINEER

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AN ENGINEER’S VIEW

For Whom the Bell Tolls…

Chris Reay Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)

You are a Mechanical Engineer. You work in the South African industry. It would be hard to find any activity that in some way does not connect with the South African mining industry. If you are part of a consultancy, a project management group, a construction company, a financial group and countless businesses from large multi-million Rand organisations to SMEs, it is very likely you will have connections with the mining industry. Mining flows in the veins of South Africans and so it should. We have been told that, following a Citibank survey, we literally sit on an un-mined value of some $2.5 trillion in commodities.

The largest in the world.

J

ust what did we do with this asset that has been given to us for free and left to our collective responsibility as a result of our being the residents and citizens of the country?

The early pioneers started out bravely, successfully investing money, technology, hard work and facing unprecedented risk head-on to place South Africa at the top of gold and diamond production world-wide.

We have some 80% of the world’s known platinum ore and a good deal of most of the others.

They are now running the mining industries in Australia, Canada, South America and Central Africa Most admired

We pioneered the mining of high-ash content coal and assisted in the design and development of boilers that can burn it efficiently to evolve some of the best, most admired and low-cost six-pack power stations in the world that supported the mining industry. In the early nineties we had some 800 high tech researchers across the board tackling challenges in the mining industry. We thankfully still have a flourishing mining supply industry that designs and builds bespoke equipment to service the industry here and internationally. We had the best Mining Engineers in the world, lots of them, and the older ones mentored the younger ones as a matter of course. We were King of that shining castle.

many of our talented mining resources?

They are now running the mining industries in Australia, Canada, South America and Central Africa.

Our research group has dropped by a factor of ten.

International investors are openly advising that we do not really feature on their screens at present: the unchecked talk of nationalisation, the regulatory confusion created by the MPRDA and SIMS reports has taken its toll. Perceptions are real, not imaginary as the Department of Mineral Resources (DMR) seems to think.

Call the shots

In my book, if the rule applies that those who set the rules and call the shots must be accountable, then that lies fair and square with the DMR. When the goal is political power at all costs ably assisted by inexperience and an illiterate and innumerate voter support base, then do not be surprised when a competitive nation declines to mediocrity.

If anyone can propose a solution to extricate ourselves from this mess and turn ourselves up again, then we need all the help we can get.

Take a snapshot today. What comes to mind? Marikana, closed platinum shafts, strikes, poor worker living conditions, reducing productivity, rapidly rising input costs, electricity prices rising at a rate to not only render a lot of mining uneconomic, but a lot of industry as well. We have dropped in the league of gold mining countries from first to fifth. Where are THE SOUTH AFRICAN MECHANICAL ENGINEER

PM

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2013

S MECHANICAL A ENGINEER On the Cover

February 2013

Watson Marlow Bredel Tel: (011) 796-2960 www.watson-marlow.co.za

VOLUME 63

Contents Manufacturing

POWER GENERATION TODAY

6

25 Fuel Cells in South Africa 29 Power Generation News

Extending a Lifeline

Cove er Sto ory 8

Covering all Industry Pump Needs

Lettter Le er to th he Ed Edit itor itor 10 Why Have we Abdicted our Position of Power?

Monthly Column 11

Prominent Professionals

All rights reserved. No editorial matter published in “SA Mechanical Engineer” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Steam, Turbines & Boilers 31 New Life for Old Boilers 33 Steam Turbine Contract

Pipes, Pumps & Valves 35 Bigger is Better 38 Vacuum Drying System

A First

Sassda Awards Copyright

NUMBER 2

39 “My mother wanted me to be a Doctor”

13 Top Marks

HVAC

Regulars

16 A Valid Complaint 21 Move Air Legally

3 An Engineer’s View 7 Institution News 40 Market Forum

Opinion 23 Soapbox

The monthly circulation is 4 242

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat / Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R440,00 (excl postage and VAT) per year; R1 100,00 per year for Africa/Overseas.

Disclaimer PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

Printed by: Typo Colour Printing, Tel: (011) 402-3468/9 FSC (Forestry Stewardship Accreditation)

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

February 2013

5

MANUFACTURING

Extending a Lifeline

Industrial Exhibition to cater for worldwide interest in doing business in Africa Johannesburg-based Exhibition Management Services (EMS) has researched and developed an event aimed squarely at African manufacturers and industrialists.

Based on a number of EMS’s exciting and successful exhibitions, The SA Industry and Technology Fair - Indutechas 10 specific focus sectors that have been identified as being of interest to businessmen throughout the continent.

Government has committed funding worth R 5.7 billion to encourage enterprises to upgrade their production facilities, processes, products and up-skill workers. These funds will be distributed through the newly-launched Manufacturing Competitiveness Enhancement Programme (MCEP) under the administration of the Department of Trade and Industry (DTI).

These sectors address the following industries: manufacturing, engineering, petro-chemical, plastics, water, pumps, valves and pipes and energy efficiency.

Tshepiso Makgothi, chief director of the Competitiveness Cluster for the DTI, says the incentive is aimed at promoting enterprise competitiveness and job retention within the manufacturing sector.

Leading business magazine ‘Forbes’ has described economies in Africa as being the most resilient in the world.

At the same time a thriving middle-class community is contributing to a booming manufacturing industry on the continent.

She adds that the programme was established to curb job losses in the manufacturing industry as the economy had lost some 200 000 jobs during the 2008/2009 recession.

Recent South African government legislation to stimulate the country’s manufacturing and engineering sectors has also come at just the right time.

“The National Development Plan, the R5.75 billion Manufacturing Competitive Enhancement Programme and the Preferential Procurement Policy Framework Act are all feeding the demand for new technology,” states John Thomson, Managing Director of EMS. “This has not been lost on international companies struggling with sluggish domestic demand who are keen to supply equipment and services to this rapidly growing market”.

The grant is designed to promote enterprise competitiveness and job retention

Back in South Africa Indutec has been garnering impressive industry support. The Steel and Engineering Industries Federation (SEIFSA), the Engineering Council of South Africa (ECSA) and the Southern African Institute of Welding (SAIW) are just three of the 31 professional industry organisations that have pledged their support to the expo.

SEIFSA, which has over 2 220 member companies, sees Indutec as an ideal conduit to promote their markets and objectives to the metal and engineering industries at large, while Jim Guild Chief Executive Officer of SAIW states: “We take our affiliations with leading industry players very seriously - including our endorsement of Indutec”.

He continues by saying: “These industry ties form part of our strategy to create strong relationships which support our objectives and government’s mandate, to enhance the manufacturing sector in South Africa”.

Indutec takes place at Gallagher Convention Centre, Midrand, Johannesburg from 14-16 May 2013.

The organisers report strong interest from Brazil, India, China, Germany, Austria, Portugal and Turkey.

“We hope that South African companies will wake up to this international marketing opportunity presenting itself right on their doorstep once they are back from their holidays” concludes Thomson.

Exhibitions Management Services, Tel: (011) 783-7250 Email: director@exhibitionsafrica.com

Cash injection

The fund will inject cash into waste management, cleaner production, information technology, logistics, agro-processing and renewable energies, with the exclusion of automotive manufacturers, clothing and textile industries, which currently have a separate incentive specifically aimed for those sectors.

The MCEP will be in the form of a grant that is based on a company’s Manufacturing Value-Added (MVA). “The grant is designed to promote enterprise competitiveness and job retention so going forward, smaller companies will get a bigger share of their MVA while big companies will get a smaller share,” she adds.

Manufacturing

A 100 percent black-owned company with total assets of below R5 million would qualify for a 15 percent MVA, whereas one with total assets with a historic value of R200 million and above would only qualify for a 7 percent MVA. Divided into a production incentive and loan facilities, the incentive is not meant for office equipment, land costs, vehicles or second-hand assets. “We will only reimburse businesses for manufacturing related products and goods utilised in the company, nothing else,” Tshepiso concludes.

The DTI, Rich Hlatshwayo, Tel: 0861 843 384, www.thedti.gov.za

6

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

February 2013

THE SA INSTITUTION OF MECHANICAL ENGINEERING

SAIMechE Training Workshops : 6 March - 30 April 2013

Council 2012 - 2014

Programmes and Registration Form obtainable from Carey Evans, Tel. 031 764 7136 or carey@saimeche.org.za.

Office Bearers

Event Code

Workshop Title

Date

Region

A3213

Duplex Stainless Steels

6 Mar 13

Durban

C6213

Technical Communication & Reporting

6 Mar 13

Cape Town

B5713

Total Productive Maintenance for Engineers

12 Mar 13

Port Elizabeth

B5813

Implementing Continuous Flow Processes â&#x20AC;&#x201C; a 13 Mar 13 Methodology for Engineers in Practice

Port Elizabeth

E5213

Technical Communication 13 Mar 13 & Report

East Rand

C0913

Implementing ISO 900119 Mar 13 2008

Cape Town

C6613

Effective Negotiation Methodologies for Engineers in Practice

20 Mar 13

Cape Town

Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay

F6213

Technical Communication & Reporting

20 Mar 13

Secunda

PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za

F5713

Total Productive Maintenance for Engineers

26 Mar 13

Secunda

C2513

Materials Selection

27 Mar 13

CapeTown

F5813

Implementing Continuous Flow Processes â&#x20AC;&#x201C; a Methodology for Engineers in Practice

27 Mar 13

Secunda

A3613

Project Management - A 3 Apr 13 Review of Essentials

Durban

F2913

Practical Lubrication & Lubricants

3 Apr 13

Secunda

A4713

Capital Budgeting for Projects

4 Apr 13

Durban

F6913

Lubricants & Oil Monitoring

4 Apr 13

Secunda

A6213

Technical Communication & Reporting

10 Apr 13

Durban

C3213

Duplex Stainless Steels

10 Apr 13

Cape Town

D0613

The Engineer as Manager

11-12 Apr 13

Vanderbijlpark

B3213

Duplex Stainless Steels

17 Apr 13

Port Elizabeth

E6013

Finding Inventive Solutions to Engineering 17-18 Apr 13 East Rand and Technical Challenging Problems

A2513

Materials Selection

18 Apr 13

Durban

A6313

The Road to Professional Registration

24 Apr 13

Durban

E3113

Heat Transfer in Practice

24-25 Apr 13 East Rand

President ............................................. KK Nyangoni (Kudzai) Vice President .............................................. D Findeis (Dirk) National Treasurer ........................,................. A Roos (Andre) Immediate Past President............................ G Barbic (George )

Branch Chairpersons

Central ................................................. S Murefu (Stephen) Eastern Cape ................................................ W Rall (William) KwaZulu/Natal ................................................. J Moto (John) Mpumalanga Highveld.............................. L Odendaal (Louis) Western Cape ........................................ Dr D Blaine (Debbie)

Portfolios:

Communications/Strategic Planning/ Specialist Group..........................................CD Reay (Chris) Young Engineers Forum.........Prof B Collier-Reed (Brandon) Education: Universities of Technology....... E Zawilska (Ewa) Membership ........................................... E Zawilska (Ewa) Professional Development Programme...M Black (Malcolm) Technology Programme .......................... SZ Hrabar (Steve) To be confirmed..................................G Bartholomew (Bart)

Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga, Highveld & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Alstom Power Service SA Babcock Africa Limited Bateman Engineered Technologies Bosch Projects DCD Rolling Stock A division of DCD Festo (Pty) Ltd Group (Pty) Ltd Fluor SA (Pty) Ltd GEA Air-cooled Systems Hansen Transmissions SA Hatch Africa Howden Power Howden Projects Industrial Water Cooling

Inenzo Water (Pty) Ltd MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Wedag SA) Megchem Eng & Drafting Services Mod-U-Flow

Osborn Engineered Products SA Rotek Engineering S.A.M.E Water Sasol Technologies SEW Eurodrive Siemens SNC-Lavalin SA Spicer Axle SA Spirax Sarco SA Technical Systems Thyssenkrupp Engineering Transvaal Pressed Nuts & Bolts Ultra-Flow Engineering Services Vital Engineering Weir Minerals Africa Winder Controls

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

February 2013

7

COVER STORY

Covering all Industry Pump Needs Peristaltic pumps come in sizes ranging from small dosing pumps for laboratories, delivering a drop or two at a time, to rugged big pumps moving large volumes of thick slurries in mining applications. So, in essence, the peristaltic is a versatile pump used in all industry sectors, from chemical to food processing, water reticulation and sewerage through to the sugar, mining, and pulp and paper industries.

Nico van Schalkwyk, general manager of Watson-Marlow Bredel

P

eristaltic pump specialists, Watson-Marlow Bredel, have traditionally supplied all versions in South Africa for over a decade but have just extended their range to cover most applications in all sectors of industry. "SA Mechanical Engineer" speaks to Nico van Schalkwyk, general manager of Watson-Marlow Bredel in Honeydew near Johannesburg about the features of the new pumps.

An outstanding feature of this pump is that it is three pumps in one – you simply fit any of three types of hoses and you have a different pump altogether Low pressure

“We pride ourselves on covering most applications across all industries, but by listening to what customers want, we realised a while back that there were two areas we did not cover with a dedicated pump,” Nico explains. “Thus development was started about three years ago to manufacture a low pressure, medium size pump for dosing applications.”

After an extensive testing period, the Apex peristaltic pump from Bredel has now been launched on the local market, significantly extending the range of pumps to cover any possible application a peristaltic pump can handle. Nico adds, “An outstanding feature of this pump is that it is three pumps in one – you simply fit any of three types of hoses and you have a different pump altogether.”

Dosing

The other new product on the market is a metering pump developed by Watson-Marlow. “It’s called the M-W Qdos 30,” explains Nico. “This concept is similar to models we’ve had before, but there are new The new Apex pump

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2013

COVER STORY

MasoSine’s sinusoidal pump

W-M Qdos 30 pump

features such as restricted flow of up 500 ml/min.

Revolutionary in the design is the bayonet-type pump head which, when it needs replacement, is discarded completely and replaced with a new one without the need for tools. The advantage is that there is no spillage when replacing the pump head, a disposable self-contained sealed unit. South Africans are reluctant to throw things away, but this head is cheap, equivalent to a disposable element on our bigger pumps.”

Features

The Apex is a general-purpose hose pump optimised for process uptime, higher productivity and lower cost of ownership than most traditional hose pumps.

This is due to improved long-term hose properties, superior heat dissipation for less hose wear and longer maintenance intervals.

It has greater flexibility because the pump can easily be upgraded, making it three pumps in one simply by changing hoses. Although it is a low-pressure pump, a reliable and stable flow up to 1.200 L/h can be reached, yet it handles high speed operation with a direct-coupled drive and is suitable for high product temperatures. Typical applications range from chemical dosing through to slurry transfer.

The W-M Qdos 30 is a no-valve metering pump featuring accurate, linear and repeatable flow under varying process conditions, operating at flow rates from 0.1 to 500 ml/min at 7 bar.

“This design eliminates ancillary equipment such as backpressure valves, pulsation dampeners, degassing and foot valves, strainers and float switches,” Nico elaborates. “In chemical processing the sealed ReNu pump head play has an important benefit in terms of safety during maintenance. Being a sealed unit, it has fluid recovery functionality which adds to operator safety as no chemicals will be spilled on the floor and there are no parts to clean or re-

build as has been the case with this type of pump in the past.”

Gentle handling

The broader range gives the company entry into previously untapped markets. “A good example is the food industry where we have a strong presence in terms of Bredel as well as Watson-Marlow pumps and now also, MasoSine,” Nico explains. “MasoSine’s sinusoidal pump range strengthened our position in the food processing industry which needed a pump that could pump the product without any destruction, such as chicken breasts, for example.

Being a sealed unit, it has fluid recovery functionality which adds to operator safety as no chemicals will be spilled on the floor Adds Nico, “It’s large open cavities, sinusoidal rotor, coupled with a constant displaced volume and gentle transfer of product, from inlet to discharge, ensures that food is not damaged during transfer.

This is a critical aspect of production for any food processor as it reduces waste and the cost associated with the disposal of damaged product.”

Gaining ground

Peristaltic pumps are gaining ground. “In November we recorded an all-time record on order intake to the value of 10 million rand,” Nico says in conclusion. “This is a clear indication of the versatility of our pumps but it also highlights the fact that end-users are recognising the value of investing in premium brand products. Just one order in December consisted of 53 pumps of varying sizes for a mine in Africa.”

Watson Marlow Bredel, Nico van Schalkwyk Tel: (011) 796-2960, Email: nico@wmbpumps.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 63

February 2013

9

LETTER TO THE EDITOR

Why Have we Abdicated our Position of Power?

In the 1960’s the Engineer stood tall in construction. He ran the show with his team, the Artisans, the Supervisors, Quality Controllers, Buyers and the Clerk of Works.

This was a highly successful team and usually did the job to spec, on time and within budget.

T

hen the Financial Director, ever crafty and sly, who watched the whole exercise with interest, spoke to the Clerk of Works. “You are really the one I can trust in this bunch.

I will put you in charge of the next job. You will be called the Project Manager.” And thus began the dilution of the Engineer’s influence.

The Drawing Office, once run by Engineers, became independent when CAD was properly developed.

MAN ITEMS Y BE OFF CAN ER FROM ED STOCK

The Project Manager soon had them “design” for him, using cut-and-paste techniques, from archived plans. The Engineer was not consulted until much later. It was then too late to correct the many technical errors. We, the Engineer, lost more ground!

The Project Manager soon began to formalise the construction philosophy, which the Engineer’s team knew and lived by, but scarcely any of which was written. The PM wanted to extend his influence and to control every conceivable aspect of construction, so he began to demand Reports. With the years his demands became more and more onerous, and drove the costs ever upwards.

Today we have As Built Baseline, Corrective Action Report, Contract Award Baseline, Construction Completion Review, Concept Design Review, Construction Readiness Review, Finalisation Release Approval, Final Specification Baseline, Integrated Design Review, Project Change Request, Project Change Proposal, Ready for Construction, Request for Design, Request for Information, Design Freeze Review, Design Review, Engineering Change Proposal, Engineering Change Notice, Engineer’s Response, Non-Conformance Report, Notice of Defect, etc, etc, etc.

The PM also took the Buyers, Quality people, Supervisors and Planners under his wing and made them independent Departments. This made the vital communication channels more complex and much slower. He introduced Safety, Health and Environmental Departments, Ethics advisers, Psychologists, and other new Cost Centres.

The 1960’s Engineer’s system had all the functions listed above, but was done with hand-written forms, signed off by all the relevant players. Disagreements were ironed out between parties at once and rarely went any further. Play-offs (bargaining points between parties) were used, of course, and kept the job moving. The Engineer, with his knowledge of all the technical aspects of the job (guided by his Clerk for the money aspects), oversaw the safe, timeous, cost-effective construction and also looked after the environment. We, the Engineers, also bore the overall responsibility, as demanded by the Law. Why did we allow this to slip away?

We still bear the overall responsibility, but do not control how the job is done!

Brian Vaughan Kenealy, Pr.Eng, B.Sc, GCC, FSAIMechE

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2013

MONTHLY COLUMN

Prominent Professionals Andrew Rossouw, Technical Leader/ Fellow Engineer for Westinghouse Electric South Africa.

to solve problems in factories and which are still functional today. My association with the IST pilot plant which converted acid mine water into fresh water is close to my heart, because the elegance of using micro-organisms to not simply concentrate the pollutants, but to convert them. The PBMR, had it been developed with a longer term political will on the Korean-model of gradually growing an industry, would have changed the nature of all local manufacturing and engineering industries.

Academic School/ Graduate studies:

High School Montagu/Stellenbosch University, mechanical engineering

Post-graduate

Masters in aeronautical engineering. Several courses through the years at NWU and Westinghouseâ&#x20AC;&#x2122;s in-house university. The company offers formal engineering and skills courses to allow employees to be assessed and accredited for the skills applied, as proof of competence which the nuclear industry requires as part of its culture.

Professional bodies

Registered with ECSA as a professional mechanical engineer.

I participate in the activities of the nuclear industry association and I am a member of the South African Institution of Mechanical Engineering. I hold a GCC (Factories).

Career Path First employer

Started at Kentron as an aeronautical engineer before starting Ingenior, specialising in factory design and automation, machine building and consulting engineering, with partners.

Growth path

Ingenior designed and built machinery for all the major manufacturing industries. I joined IST in 2000, to participate in the PBMR project, because the energy challenge in South Africa had become a special interest. Here I worked as design engineer, a systems engineer and as the engineering manager in nuclear and industrial enginering. In 2007 IST Nuclear was purchased to become Westinghouse Electric South Africa.

At present, I am Technical Leader/Fellow for Westinghouse Electric South Africa. Fellow Engineer is a Westinghouse accreditation, requiring one to be assessed and deemed suitable by an international panel of consulting and chief engineers.

Achievements A design or a project

I am proud of many of the Ingenior machines that we designed

Future â&#x20AC;&#x201C; a concept, a dream or a wish

The IRP has set a plan for a mix of coal, nuclear and renewable energy, and I am looking forward to an energy industry where technologies freely and fairly compete based on proven performance and value, to the benefit of South Africa. I also believe the GenIII+ nuclear plant with modular construction will show its value.

Most Rewarding Project One of the most rewarding projects was a solar pool heating system I built at home, simply because I could play around with it forever and I could enjoy the fruits of my labour directly.

Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?

We need a slower progression of young engineers from engineering into management, in order to transfer practical experience into engineering and project management.

The â&#x20AC;&#x2DC;valueâ&#x20AC;&#x2122; of engineers must be acknowledged to counter the â&#x20AC;&#x2DC;valueâ&#x20AC;&#x2122; they receive as managers. To create this â&#x20AC;&#x2DC;valueâ&#x20AC;&#x2122;, our professionalism must win the respect it deserves through requiring accredited skills and accountability for engineering tasks. The next step would be to counter perceptions of an engineer as a soul-less person doing maths, and communicate the diversity of options the career offers, to attract more participants.

Message to young engineers

Create a broad experience foundation, and guard against early specialisation to the point of neglect of supplementary skills.

Donâ&#x20AC;&#x2122;t be afraid to test opportunities out of your comfort zone.

Learn from â&#x20AC;&#x2DC;failuresâ&#x20AC;&#x2122;.

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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of SAIMechE hosted their annual dinner dance Excellent o

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WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.

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February 2013

For more information contact us on: +27 (0)11 9292600 www.weirminerals.com

SASSDA AWARDS

Top Marks As mentioned in the January issue, the 2012 Sassda (Southern Africa Stainless Steel Development Association) Project Award for Engineering was awarded to Metso ND Engineering, for the successful completion of a mega-project comprising the construction of an ammonium sulphate plant forming part of the Ambatovy Nickel Project.

T

he Ambatovy Nickel Project is located in eastern Madagascar, where ore is mined by open pit; slurried, screened and sent to the metallurgical process plant for further treatment. Nickel and cobalt are then extracted in

Fully fabricated crystallisers in their structure, which was a first for such a large plant

the refinery. The ammonium sulphate plant is fed with stripped solution from the process units within the refinery, producing ammonium sulphate both for sale and reuse. The plant also recovers process water for reuse in the process plant.

Veolia Water approached Metso ND Engineering to build the ammonium sulphate plant on the strength of its modular construction techniques employed on previous projects (such as its digesters for Sappi Saiccor and three massive autoclaves for Uranium One in Klerksdorp).

Largest possible sections

Metso ND developed a project execution plan based on pre-manufacturing the bulk of the equipment (three crystallisers, stripped solution storage, mother liquor feed storage, purging, condensing, centrifuging,

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February 2013

13

SASSDA AWARDS

drying, screening, and nickel and cobalt reduction feed preparation) in modular form at its Bay Head facilities in Durban, for shipment to Madagascar in the largest possible sections for final plant assembly.

The ammonium sulphate plantâ&#x20AC;&#x2122;s proximity to an existing port was an ideal opportunity to employ the modular construction approach. Metso ND offered Veolia fully fabricated crystallisers in their structure, which was a first for such a large plant.

This provided a massive reduction in site costs and construction duration.

Large plate sections, which were 3 000 mm wide, reducing welding substantially

Metso needed to provide full mechanical design and FE analysis for all equipment, as well as information on wind speeds in excess of 280km/h, high rainfall figures and the plantâ&#x20AC;&#x2122;s location in an active seismic zone. All equipment had to be designed for full vacuum and also be able to accommodate a full liquid capacity with an SG of 1.45.

Stagger deliveries

Early in the manufacturing process, it was decided

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Metso was also the runner-up for its Digesters for Sappi Mill

In 2011 Sappi announced that its Ngodwana Mill near Nelspruit would increase chemical cellulose production by 210 000 tons, necessitating six new digesters. Metso ND Engineering tendered for the job in July 2011 and was informed that it was the successful bidder on 24 October 2011.

The digesters needed to be fabricated from SAF 2205 duplex stainless steel. Each would weigh 58 tons and be 20.3m high and 6m in diameter.

Tight delivery dates had to be managed. The first three digesters had to be completed and delivered in 13 weeks; the next three, in 16. Procurement, logistics, manpower allocation and other factors had to be taken into account and planned for.

Technical innovations included the large plate sections, which were 3 000 mm wide, reducing welding substantially. Other innovations were the top crown plate circumference and centre nozzle weld preparation, which were fully machined for improved nozzle location quality and accuracy.

High-definition plasma cutting on internal components and laser cut components were other innovations that reduced component manufacturing duration and improved turnaround and quality.

February 2013

SASSDA AWARDS

to stagger deliveries over three predetermined dates, with a ground-up approach to the structural fabrication erection process. Final shipment had to take place before the heavy lift equipment and SPMTs left site in Madagascar, and deliveries had to be planned around specific site access constraints regarding other major equipment deliveries coming in from other suppliers.

The ground-up approach entailed fabricating and shipping the lower portions of the structures before the upper structures entered fabrication, necessitating additional precautions to ensure perfect matching of all components. Structures bolted together on site had to match perfectly or Metso ND would incur huge penalties.

Three shipping deadlines had to be met: shipment of the lower structures under the crystallisers, access towers and heater and condenser structures; shipment of the three heater and condenser packages; and collection by heavy lift ship of all vessels, ducting, and the three main crystalliser units together with remaining piping and local equipment.

A hand-picked labour force was strictly briefed not to compromise on quality and safety. About 20 000 artisan hours and 25 000 general assistant and grinder operator hours were required to complete the project. Metso ND Engineering’s Bay Head workshop therefore increased capacity from 3 500 to 6 125 hours a month.

Halfway through

The fabricator faced many challenges during the project. The global recession forced the client to secure alternative project funding halfway through the project, resulting in a contract cession that caused Metso ND untold financial difficulties for many months.

Furthermore, the construction of extremely complex and heavily built structural steel components entailed

many technical difficulties: the crystallisers’ high centre of gravity (28m above the structural base, with an individual footprint of only 10m x10m) necessitated a radical approach.

Then, the plant’s location in a seismic zone, directly in cyclone paths demanded full strength connections for all joints: all structures were extremely heavily designed (the main beams were over 1 900mm high, made out of 30mm plate). Metso ND manufactured many of the beams and columns as these sections were unavailable elsewhere.

Up to speed

On resumption, Metso ND came under extreme pressure to bring production back up to speed, compounded by alternative work engaged to maintain the work force. Nevertheless, the first two delivery deadlines were met without much incident.

However, on the final and largest delivery, harbour silting prevented the heavy lift ship from docking directly in front of Metso ND’s wharf. To avoid unplanned multi-million rand dredging costs, the three massive crystalliser structures were moved on SPMTs to the adjacent wharf where the water was deep enough. Metso ND’s innovative modular construction techniques dramatically reduced cost and risk exposure.

With the successful completion of the Ambatovy Nickel Project to a world-class standard and quality using locally produced material, skills and technical know-how – especially at a time when beneficiation of South Africa’s raw materials has become so critically important – Metso ND has proven that it is a formidable force in the manufacturing sector and a worthy recipient of the Best Project Award for Engineering.

Lesley Squires, Tel: (011) 883-0119, Email: Lesley@sassda.co.za, www.sassda.co.za

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HVAC

A Valid Complaint Companies need to strive to find a balance between employee comfort, energy efficient management and the national standards (Figure 1). The key is to find the perfect combination between these three major components.

Employee Comfort

is to ensure that the correct operating times are chosen for your HVAC system. If it is possible to turn the HVAC system off an hour before most of the employees leave for home and the room temperature could stay in range for that last hour, it could amount to a considerable saving at the end of each month.

When temperature measurements are taken in an open plan office space at various random points, the results vary greatly

National Standards

By simply adjusting the HVAC setpoint temperature, users may come close to achieving the perfect indoor temperature theoretically, but that may not be the actual case in the offices – especially open plan offices.

Energy Efficiency

Figure 1: Three components of HVAC management

I

n this article, the factors and barriers will be addressed regarding the balancing of these components to successfully manage a HVAC system.

Factors and barriers

HVAC systems control the ambient environment (temperature, humidity, air flow, and air filtering).

HVAC is an important component, and in most buildings is the only component, controlling the indoor air quality of a building. In general, the HVAC system is the largest energy consumer in an office building and needs to be managed very carefully.

National Standard

SANS 204: Energy Efficiency in Buildings is the South African National Standard which specifies the design requirements for energy efficiency in buildings and the services in buildings with natural environmental control and artificial ventilation or airconditioning systems.

According to the national standard, the temperature in offices should be within the following ranges: 6XPPHU

& WR &

:LQWHU

& WR &

Energy efficiency

One of the biggest and easiest savings to achieve

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When temperature measurements are taken in an open plan office space at various random points, the results vary greatly. In the same open plan office, you will sometimes find data which does not seem remotely related. Although exactly the same HVAC system supplies the entire office space, there are too many variables to assume that the setpoint will be equal to the room temperature. This emphasises the need for monitoring room temperatures.

Variables influencing the indoor temperature Supply vent position

The positions of the vents in an open plan office space play a major role in the distribution of fresh conditioned air into a space and in maintaining it at the correct temperature. There are many cases where air vents do not distribute the air evenly resulting in spot-cooling, where the colder air is localised in one area in an office. Spot-cooling in extreme cases could be so bad, that two desks next to each other could have a temperature difference RI QHDUO\ & RU PRUH $ ORW GHSHQGV RQ KRZ WKH air flows in the room.

Layout and utilisation of office floor area

General office layout is also very important to ensure that there is always a proper natural flow of air in the office space to ensure proper mixing of air and distribution of conditioned air. Often large office furniture prevents proper air flow and distribution which results in uneven air temperatures in office spaces and could create air pockets. Air pockets are the result of poor air flow which leads to stagnant air with poor quality and low concentrations of fresh air as well as temperature pockets.

Uncontrolled air flow also plays a major role in the distribution of conditioned air. Depending on

February 2013

HVAC

Figure 2: Complaints according to gender

Figure 4: Complaints according to culture group of temperatures being too low

and windows to help maintain a constant indoor environment. This makes a significant impact on the operation of the HVAC system.

Employee comfort

Figure 3: Complaints according to culture group of temperatures being too high

the pressure difference in the office and outside, uncontrolled air flow could occur through openings which will have an impact on the HVAC system.

The utilisation of buildings, floors or office spaces is also very important. For instance, let’s consider one HVAC system that supplies two different open plan offices (equal in size and layout) but the density (occupancy and equipment) vary significantly. The two office temperatures will differ from each other although the HVAC system’s setpoint stays the same. The higher the office density, the more heat emitted that influences the HVAC system and air temperature.

Employee behaviour

Behaviour is the obvious first steps towards reducing energy consumption but one of the most difficult to implement and sustain.

Some employees use small heaters beneath their desks in the summer which topples the complete office temperature. Another example is closing doors

Keeping each employee comfortable will always be a challenging task. The American Society of Heating, Refrigeration, and Air-Conditioning Engineers (ASHRAE) defines acceptable indoor air quality as: “Air in which there are no known contaminants at harmful concentrations as determined by authorities and at which a substantial majority (80% or more) of the people exposed do not express dissatisfaction”. Indoor air quality includes indoor air temperature and the above definition would thus be applicable to air temperature.

In the same open plan office, you will sometimes find data which does not seem remotely related It must be kept in mind that there are major differences between the various cultures of employees.

Some cultures prefer a much colder environment, while others would prefer a warmer environment.

The same applies for gender preferences. There are also many smaller factors that could change an employee’s perceived room temperature, such as if the employee has a light fever.

Clothing also plays a role in perceived temperature.

It has been found that in summer some employees are clothed more for a winter’s day. These employees then complain about the high temperatures in the office.

Case study

A study was conducted at a company in 2012 to resolve discrepancies in the workplace as well as to ensure that the company were adhering to SANS 204.

While measurements were taken, employees were

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HVAC

Figure 5: Actual measured temperatures – employee perceived temperature too high

asked to log any complaints about the temperature in the offices. Of all the complaints received, 9% were from male employees and the remainder 91% were from female employees (Figure 2).

From Figure 5 it is clearly seen that only one office was too warm and spiked rather high for the duration of three days during working hours. A maximum of & ZDV UHDFKHG

The complaints received for either too high or too low air temperatures in the office are shown in Figure 3 and Figure 4 respectively, according to three cultural groups.

The complaints were all based on the perceived temperature of the employee. These perceived temperatures are most often far from the actual temperature.

The remainder of the measurements were all on specification or even far below the allowed minimum boundary.

Measuring equipment was placed on the desks of some of the employees who logged complaints. In Figure 5 and Figure 6 the temperatures are shown for a 7 day period.

The green horizontal area on the graph is the WHPSHUDWXUH UDQJH & WR & WKDW VKRXOG EH maintained according to SANS 204 in the summer (when the measurements were done).

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The graph for complaints regarding too low indoor temperatures is shown in Figure 6. While the temperatures are well below the specified range on occasion, they are perfectly in range during working hours (even too high at times).

Recommendations

For this specific case study it is recommended that no change to the HVAC system is necessary except for the very low temperatures recorded in Figure 5.

The occasional spike in temperature could also be investigated. It could be that there is an external heat source located near the meter like a computer

February 2013

HVAC

Figure 6: Actual measured temperatures – Employee perceived temperature too low

fan which would explain the sudden spikes during work hours.

Considering the remaining measuring points in Figure 5 and Figure 6, all adhere to the National Standards when considering weekdays during work hours – thus no adjustment is necessary and most of the complaints deemed invalid.

Conclusion

Measurements were taken on employees’ desks who logged actual complaints. These measurements were taken to determine if the HVAC system should be adjusted and to verify if the HVAC system adheres to the national standard.

The actual measured temperature mostly complied with the specified ranges. In one instance, the complaint was logged for too high temperatures but upon measurement it was found that the actual temperature was too low and far beneath the specification of the national standard.

By taking measurements on a regular basis and

Cobus Aucamp

Prof LJ Grobler

taking the time to analyse the data and investigate the problem areas, a constant and sustainable management process can be established.

Cobus Aucamp, Energy Cybernetics, Prof LJ Grobler, professor at the School for Mechanical and Materials Engineering at the North-West University, Potchefstroom, South Africa.

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Together making the difference

Clean, energy efficient air for every industry - and our planet Atlas Copco is a leading manufacturer of fully comprehensive, technologically advanced compressors; as well as a range of fully compatible filters and dryers. We offer a solution for almost all applications, and are dedicated to excellent customer care and after sales service.

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February 2013

HVAC

Move Air Legally The fan used in a mechanical smoke ventilation system has to be manufactured by a certified manufacturer. In South Africa there are only two companies currently that can manufacture fans to SANS10400T locally. Other companies can import complete units from their mother companies who are certified.

“S

A Mechanical Engineer” speaks to Derick Truscott, managing director of Air Movement Supplies (AMS) in Cape Town to find out more about the new requirements. “The main difference between the old BS (British Standard) certification and what we have now is that each component of the fan has to be certified and the manufacturer may not deviate from the ‘recipe’ for the product,” he says.

“In the old days just the mother company had to be certified and fans could be made by all sister companies around the world as certified fans.

Now each nut and bolt or even the putty used for sealing, has to be certified for each individual sister company which manufactures fans and none of the components may be substituted “Now each nut and bolt or even the putty used for sealing, has to be certified for each individual sister company which manufactures fans and none of the components may be substituted,” Derick explains. “If the

A new fan design

Derick Truscott of AMS

manufacturer changes anything, even just a bolt from another supplier, that bolt has to be tested specifically all over again in order to get the fan certified. The sources for all the components of the fan have to remain the same.”

Certification

The aim is to prevent inferior ventilation products from entering the market. “The EAN and new Sans standards introduced last year will ensure that the products going into a building are safe and can withstand our arduous conditions,” says Derick.

“The reason there are only two companies in South Africa with this certification is probably because your factory has to be audited every year by the body that originally tested your fans for certification in order to maintain your ISO certification. We, for instance are audited by the British Standards Institute for our EAN certification every year.

“It’s a costly exercise, but necessary to prevent life-endangering inferior fans from being installed in buildings,” Derick adds. “It is very likely to soon become a prerequisite for insurance purposes.

Insurance companies will refuse to pay out when a building burns down and they find that the ventilation equipment wasn’t certified.”

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HVAC

Due to the infinite number of permutations, fan selection is clearly not an easy task and to this end AMS has developed a software programme to make life easier

Fan selection

Aside from the regulations and standards governing fans, the right selection of a fan for a specific duty is a crucial factor in terms of operational and energy efficiencies. “Each fan presents huge flexibility in terms of efficiency,” explains Derick. “Fans are much like pumps where you have a performance curve for the pitch of the blade. For example, on each fan you can set the blade pitch at anything from 15 to 35 degrees on each range of fans. But, one range of fans could have 5, 7, 10 or 14 blades, already four permutations. Then, in each of these permutations, you can have 20 different blade pitch settings between 15 to 36 degrees.

Aside from the regulations and standards governing fans, the right selection of a fan for a specific duty is a crucial factor in terms of operational and energy efficiencies “Purely through selection we can therefore not only provide a fan to effectively move the required volume of air for a given requirement, but it would be the most energy efficient fan for that application,” adds Derick. “A noisy fan is an energy inefficient fan. Selecting the right fan thus also means you have less noise unlike just grabbing the cheapest uncertified fan off the shelf which wasn’t made to a regulated standard.

Software tool

“If we provide a fan to certain specifications and it doesn’t deliver to the specification, we as manufacturers are liable,” says Derick. “Yet, so many contractors buy from manufacturers who claim certain performances that have never actually been tested. Some even claim they make fans fitted with 100 percent efficiency blades, but that’s just impossible, no fan blade can be 100% efficient.

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To make sure you don’t fall into this trap, simply ask for proof of the certification tests.”

Due to the infinite number of permutations, fan selection is clearly not an easy task and to this end AMS has developed a software programme to make life easier. “This is our own proprietary software developed locally over the past four years, completely changing the way we do business,” Derick shows us on his desktop PC. “You simply enter the volume and pressure you require and the programme will present all the fans in our range which comply. On selecting one of these fans, the programme presents a full certified report of the fan’s duty and absorption power, including the dimensions of the fan.

Good marriage

“Most consulting engineers already have this programme, but we’ll provide it to anyone who is interested in our product range,” adds Derick. “To my knowledge there is nothing like this available in the world for fan selection. We regularly update the information for the programme on our website and the user simply clicks update in the programme to have the latest information at his fingertips.”

At the end of the day it’s up to consulting engineers and specifiers to help eradicate rogue fan manufacturers who are flooding the market with substandard ventilation products. “Ultimately it is the engineer or specifier’s good name which gets damaged,” Derick says in conclusion. “They should take the responsibility and align themselves with suppliers and manufacturers who are certified, it’s a marriage which will work down the line and uphold their good name for business into the future.”

Derick Truscott, AMS, Tel: (021) 552-1077, Email: dtruscott@airmove.co.za, Website: www.fans.co.za

February 2013

OPINION

Soapbox On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering.

We follow up from last month with two pertinent questions.

A message to young mechanical engineers of the future?

Chris Coetzee of Resonant Solutions

The first thing all young engineers must realise is that when you leave university it’s the time of your life that you know the least. They must cultivate the need to learn something every day and make sure that they’re not in a position where they have to take a job just for the sake of having a job. Get involved in a place where you really want to be otherwise you’ll never develop to your full potential.

Make mistakes and learn from them, otherwise you’ll never be a good engineer.

Willem Sullivan of Hansen

There are few things in life as satisfying as making something out of nothing and we are privileged to do it on a daily basis.

Greg Perry of SEW

The scope in engineering is so massive you will never get to a point where you have nothing to learn or nothing to challenge you.

Brian Volk of PHC Projects

Always try to be the best Engineer possible, do not limit your thinking to your own discipline, learn to think laterally and apply your experiences (mistakes) to problems or situations that are unfamiliar.

Phildy Schlotz of DRA

Byt Vas! – finish what you started and complete your studies. I know it gets real tough at times because it is not the easiest job around, but if you’re positive and forge ahead to finish your studies, it will be well worth your while in the long run.

The scope of mechanical engineering is very wide with an abundance of directions you can follow.

For example, it’s a very good base even to go into business, you’ve just got to be open minded to spot the opportunities.

Thalefang Mtombeni of Schaeffler

It’s plain and simple; be passionate about what you do. You’re going to spend a huge part of your life working, so it might as well be something which you enjoy doing. If it is mechanical engineering you want to do, you’re bound to make a success of it if you’re passionate about it.

Tom Esterhuizen of Tom Esterhuizen & Associates

Any profession where you deal with other people, means you have to learn people skills. Many engineering problems are people driven and therefore you have to acquire the skills to deal with people.

You’ll find that our top engineers are the ones with excellent communication skills. For young engineers; work hard, focus and persevere when the going gets tough.

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Passion Through Our People

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www.zest.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

EML electric motors have established a reputation within the local agricultural and HVAC sectors as quality, affordable motors suitable for driving pumps, fans, conveyors, complete irrigation systems and ancillary equipment. Manufactured to ISO quality standards, these electric motors carry SABS certification and offer reliable performance. An off the shelf stockholding with 24 hour technical support ensure customers have total peace of mind.

VOL 63

February 2013

POWER

POWER GENERATION

GENERATION

T O D A Y

Fuel Cells in South Africa

PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

The price of oil, global warming and a commitment to reducing global emissions is driving the need for cleaner, more fuel-efficient vehicles expanding the likely mix to include batteries, hybrids and fuel cells.

Copyright

TICKER TAPE

All rights reserved. No editorial matter published in “Power Generation Today” may be reproduced in any form or language without written permission of the publishers.

While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Manufacturing of a fuel cell at the Altergy company in the USA

T

he emerging fuel cell industry represents a major opportunity for the global platinum mining industry with significant additional demand widely

South African Trade and Industry Minister Rob Davies has confirmed that government will “most likely” have a “fleet approach” to its planned new nuclear build and localisation programme. South Africa’s Integrated Resource Plan 2010 foresees the construction of a number of nuclear power plants (NPPs) with a total capacity of 9.6 GW by 2030.

East Africa’s second-largest economy said it is banking on international financial institutions fund the 700 MW Mnyera hydropower project, plant will be constructed on the Rufiji river cascade.

predicted by 2020 as most fuel cell systems use platinum group metals as catalysts. In the long term, fuel cell vehicles are likely to be the dominant driver of platinum demand

ABB has won orders worth about $225-million to supply two turnkey photovoltaic (PV) power plants that will be built in Limpopo.

The municipality of Port Louis, the capital of Mauritius, has installed its first 50 kWp photovoltaic (PV) system on the roof of the capital’s city hall.

The installation is expected to generate a minimum of 90 000 kWh a year.

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POWER GENERATION

whatever fuels are available locally.

The numerous and diverse applications for fuel cells include: rural electrification, back-up power for telecommunications, combined heat and power applications for residential, commercial and industrial buildings, portable power and battery charging.

Fuel cells are relatively new in Africa with the complete value chain still under development and presenting significant opportunities for manufacture, assembly, installation, support, maintenance and fuel supply. The development of this new industry will support job creation, knowledge transfer and export opportunities.

What is a fuel cell?

A 5kg 99.99% pure Platinum ingot in the forge area of the Precious Metals Refinery in Rustenburg

while short to medium term demand will result from the introduction of stationary and niche applications. Fuel cells are well suited to the provision of distributed power in Africa. The attractiveness of fuel cells is that their most efficient fuel source, hydrogen, is an energy ‘carrier’ and can be stored.

Fuel cells are relatively new in Africa with the complete value chain still under development and presenting significant opportunities for manufacture, assembly, installation, support, maintenance and fuel supply Hydrogen

TICKER TAPE

Hydrogen is the most abundant element in the universe and any hydrogen-rich liquid or gaseous fuel can be used to provide the hydrogen for a fuel cell. Fossil fuels such as diesel, LPG or bio fuels, for example, can be “reformed” on site into hydrogen for a fuel cell. Even water, via electrolysis, can yield hydrogen for fuel cells and consequently fuel cells can be deployed where they are needed, and use

26

French engineering company Alstom has secured a $325-million contract to supply turbines and generators to the controversial Grand Millenium dam project, in Ethiopia.

The project, which will be the largest hydropower plant in Africa, with capacity to generate 5250 MW, is being constructed by Italian company Salini Construttori and is slated for completion 2015.

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A fuel cell is a device that uses hydrogen (or hydrogen-rich fuel) and oxygen to create electricity.

Fuel cells are more energy-efficient than combustion engines, as they extract more energy from the same amount of fuel. The hydrogen used to power fuel cells can emanate from a variety of sources.

If pure hydrogen is used as a fuel, fuel cells emit only heat and water, eliminating concerns about air pollutants or greenhouse gases. The amount of power produced by a fuel cell depends on several factors, including fuel cell type, cell size, temperature at which it operates and pressure at which the gases are supplied to the cell.

They can be used to provide propulsion or auxiliary power for transportation applications, including cars, trucks, buses, trains, ships, and submarines.

They have been used to provide auxiliary power on spacecraft for decades. Fuel cells are a versatile technology, as each type has its own operational characteristics, which offer advantages to particular applications. As a result, fuel cells have a broader range of application than any other currently available power source. This includes large power plants, vehicles, mobile chargers, toys and household power.

PEM fuel cells

One of the more common types is the Polymer Electrolyte Membrane (PEM) fuel cell. The PEM is a thin, solid, organic compound, which typically

KwaZulu Natal Energy Services (KES), a subsidiary of French power utility EDF, has submitted a proposal to the Department of Energy (DoE) to continue the installation of solar home systems (SHSes) in its rural electrification project in central KwaZulu-Natal(KZN).

Tanzania has unveiled plans to construct a mega hydroelectric plant.

February 2013

POWER GENERATION

has the same consistency as plastic wrap, and is about as thick as two to seven sheets of paper. This membrane functions as an electrolyte, a substance that conducts charged ions (in this case protons), but does not conduct electrons and allows the solution to conduct electricity if kept moist.

Anglo American Platinum’s role

Anglo American Platinum is implementing a fuel cell strategy in order to drive demand for Platinum Group Metals (PGM’s). This is aligned to government’s beneficiation strategy of moving from an extractive economy to adding value where viable, and to potentially creating a new fuel cell industry.

The company is involved in the following initiatives, of which many are in partnership with the South African government.

Equity participation

For many years Johnson Matthey and Anglo American Platinum have collaborated on numerous initiatives through research, as well as the development of fuel cell components and enabling technologies.

As a result of this collaboration, Anglo American Platinum attained an equity stake in the Johnson Matthey subsidiary company, Johnson Matthey Fuel Cell Limited. This company, which was formed as a separate business unit within the Catalysts and Chemicals Division, is dedicated to the development and manufacture of catalysts, membrane electrode assemblies (MEAs), fuel processors, and catalysed components for low temperature fuel cell systems.

Clean Energy Investments, trading as Clean Energy, is a collaboration between the PGM Development Fund, the Technology Innovation Agency, and Altergy Systems, based in the USA. With the support from its founding shareholders, the company continues to roll out fuel cell technology throughout the Sub-Saharan market, focusing on the telecommunications industry.

Demonstration applications

TICKER TAPE

A stationary fuel cell power plant installed near Lephalele in Limpopo on a Coal Bed Methane (CBM) site of Anglo American’s Thermal Coal business continues to provide electricity for the exploration

Platinum’s fuel cell, based in Lephelale, South Africa

operations in the area. The 200kw fuel cell power plant was supplied by UTC Power, a United Technologies Company from the USA. In another application a 150kw platinum-based hydrogen fuel cell was installed as a demonstration during COP17. The zero emission platinum-based fuel cell demonstrated the low-carbon technology to international targeted audiences, as well as the role that it can play in the global climate change debate.

Fuel cells are more energy-efficient than combustion engines, as they extract more energy from the same amount of fuel. The hydrogen used to power fuel cells can emanate from a variety of sources Thirdly a 50kw platinum based fuel cell was used to power Anglo American’s 2012 Mining Indaba gala dinner, held at Vergelegen Wine Estate in Cape Town. The company was able to demonstrate its fuel cell technology to the global mining fraternity and showcase the opportunities that this technology would bring to the mining industry.

Rwanda intends to partner with Burundi, Tanzania and Democratic Republic of Congo (DRC) in the construction of two hydropower plants with a combined generation capacity of 235 MW. A well-designed combination of wind power, solar power and storage in batteries and fuel cells would nearly always exceed electricity demands, while keeping costs compared to today’s electricity expenses, scientists at the University of Dalaware (UD) and Dalaware Technical Community Collage have found.

Steam turbines are largest contributor to future power generation as the technology is expected to drive 40% of the global power market’s demand in the medium term, which will average between 230 GW/y and 270 GW/y for the next five years, says French energy equipment vendor Alstom.

New York-listed Flour and Japan-based JGC have announced that their 50:50 joint venture (JV) has been awarded a front-end engineering and design (Feed) contract by oil exploration company Anadarko Mocambique Area 1 for an inshore natural gas liquefaction facility in Mozambique.

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POWER GENERATION

Schematic of PEM Fuel Cell process. (Courtesy of Johnson Matthey)

while providing a lighter more durable product that has an easy refilling mechanism to reduce overall costs. The technical fuel cell company appointed is Horizon Fuel Cells.

Furthermore the company, in conjunction with the SA government’s Hydrogen Economy Strategy (HYSA), supports research in fuel cell related technologies in developing competence and capability locally.

This could unlock and drive the development of a whole new industrial sector in South Africa Fuel cells in mining

Anglo American Platinum initiated a “Fuel Cells in Mining” programme to investigate, develop, and pilot technologies that could improve current mining practices and where viable, adopt the technology. It is an ambitious programme incorporating many aspects of the business in considering the need to adopt new technologies. There are a number of programmes with various fuel cell and fuel companies.

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The fuel cell locomotive project aims to produce a fuel cell/battery hybrid that will operate more effectively and efficiently than current lead acid batteries. In partnership with Air Products (our fuel partner), the participants of this project are leading fuel cell technical partner, Vehicle Project, Trident (locomotive OEM), and Battery Electric (electronics, controllers, etc).

A Dozer is a remote driven machine that performs a variety of functions in the underground environment that enhances the productivity and safety of miners.

It is similar to the locomotive project but with an added feature of producing a fuel cell/battery hybrid power plant which will be more effective than the current powering mechanisms. The participants in this project are Vehicle Projects and Doking (a Croatian based company that produces the Dozer).

The Mining Cap Lamp project aims to produce a lamp that is as efficient in lighting as current products

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The company in conjunction with Dantherm, a Ballard subsidiary, is investigating the opportunity and viability of providing fuel cell technology to power in-house residential housing projects.

The pilot phase will consider the variety of fuel sources as well as the optimal structure to meet the electricity demands required by homeowners.

Unblocking potential

All these activities, programs, and projects highlight Anglo American Platinum’s commitment to drive this technology to commercialisation, to benefit the company, society, and the environment. The main objective is to establish an environment in which fuel cells can be developed, manufactured, and distributed to contribute to the country’s economic growth, the development of rural areas, and the creation of more jobs.

If feasible, this could unlock and drive the development of a whole new industrial sector in South Africa thereby addressing the need for employment, socio- and economic growth, and the opportunity to become a major player in the global green economy. It could also play a part in addressing energy security issues.

Michael Joseph, Tel: 0113736788 Email: michael.joseph@ angloamerican.com

Contact Mark Bennett on Tel: (011) 781-1401 or Email: samecheng@promech.co.za to book your space in this Power Generation section

February 2013

POWER GENERATION NEWS

Blowing Soot “Electrically operated Agram soot blowers efficiently remove soot build-up from boiler tubes typically associated with fossil fuel burning and power generation,” says Arnold Retief, a director of Agram. “This system prevents heat loss in plants, resulting in reduced coal usage for heating requirements. By using a totally automated boiler system in conjunction with electrically operated soot blowers, operating efficiencies improve and running costs are significantly reduced.”

For optimum performance and extended service life of soot blowers, a highly controlled lubrication programme is recommended. This means reduced component replacement costs and clean and corrosion-free blowers that are easy to operate.

Agram manufactures a comprehensive range of boiler energy and combustion management systems, which includes electrically operated soot blowers and automated control panels

Agram, Arnold Retief, Tel: (011) 708 2738, Email: info@agram.co.za, www.agram.co.za

No Grid at All

Significant Breakthrough The Sustainable Energy Society of Southern Africa (SESSA) has applauded Stephen Harrison and Joshua Pearce (mechanical and materials engineering researchers at Queen's University in Canada) who have made a significant breakthrough in solar technology. Their research has led to a new solar photovoltaic thermal (PVT) system that generates both electricity Carel Ballack and heat. Solar PVTs are normally made with crystal silicon cells which generate electricity, but little heat.

They designed and tested amorphous silicon cells in a PVT system. Their research shows increased heat generation because of higher operating temperatures and 10% more solar electric output.

According to the two, amorphous silicon has several advantages over crystal silicon. It requires less material, costs less to manufacture and offers a higher return on investment. The research also shows amorphous silicon solar cells can

be made into thicker cells as long as they are operated at higher temperatures in the PVT system.

For South Africa, where many more people live off-the-grid, such a system could, provided it was built for local conditions and was cost-effective, alleviate the hardships they bear while providing them with the energy they need to study or start a small business. Low-cost low pressure solar water heaters have had major social benefits in many communities, and other sustainable energy solutions, like biogas digesters, are also making inroads in those that are far from the not-so-proverbial 'over-worked grid'. For urban users, many of whom who have yet to make the move to sustainable energy technologies, a two-in-one option may add impetus."

Carel Ballack, SESSA, Tel: (011) 513-4071, www.sessa.org.za

“By distributing smaller generating capacity at multiple locations, the pitfalls of relying on a single remote source of power are greatly reduced,” says Trevor de Vries, MD of 3W Power/AEG Power Solutions, South Africa.

“Distributed generation allows the collection of energy from many sources and provides lower environmental impacts and improved security of supply.

“The right-sized resources, for individual customers, distribution substations, or microgrids, are able to offer important but little-known economic advantages.

Distributed generation reduces the amount of energy lost in transmitting electricity because the electricity is generated right where it is used, and any excess can be fed back into the grid. This provides a financial benefit as well as an environmental benefit,” says Trevor.

The size of most commercial and industrial buildings makes them ideal for the installation of large scale industrial solar power plants, and by making use of the space available to them, these businesses can not only capture huge amounts of energy, but also sell that energy back into the main grid.

AEG Power Solution, Trevor de Vries, www.aegps.com

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Carbon Credit Agreement

Reduce CO2 Emissions

Promethium Carbon, a local carbon advisory firm, has been collaborating with Ingerosec Corporation, a consulting firm based in Japan, through a project by the Ministry of the Environment, Japan (MOEJ), to participate in the development of a new carbon market mechanism as an alternative to the Clean Development Mechanism (CDM).

Robbie Louw, a director of Promethium Carbon, says the mechanism will be known as the Bilateral Offset Credit Mechanism (BOCM). “The Japanese government is one of the first countries to take a proactive approach in developing another carbon trading mechanism. It is aimed at stimulating investment in low carbon technologies, products and services, and to provide a supplementary carbon trading market in line with the UNFCCC’s New Market Mechanisms,” he adds.

“The initial phase of the project will use case studies to establish the principles on which such a market mechanism can be based. The current case study under investigation is an energy-efficiency project at a Gold Fields operation,” Robbie explains. “This phase focuses strongly on Measurement, Reporting and Verification (MRV).”

The project is in progress in six countries in Africa, with Zambia and South Africa the first two SADC countries involved. Over 100 feasibility studies and MRV demonstration studies have been implemented in more than 30 countries globally by MOEJ and the Japanese Ministry of Economic, Trade and Industry. The scheme will initially produce nontradable credits and the plan is to convert into a market for tradable credits over time. The first pilot will be run in Asia from the beginning of 2013.

Promethuim, Robbie Louw, Tel: 011 706 8185, Email: Robbie@promethium.co.za, Web: www.promethuim.co.za

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panels fitted with an SKF Solar Linear Actuator, CASD-60.

SKF announces that the SKF Solar Linear Actuator-CASD-60, a BeyondZero Portfolio product, contributes to the reduction of CO2 emissions by increasing the energy production from one solar panel by 5.8 MWh/year. This equates to a reduction per solution of 4.4 tonnes CO2/year (according to world power grid mix CO2 factor of 0.749 kg CO2/ kWh). On average, a 15% increase in power generation can be anticipated in comparison with rigid PV solar panel systems. Figures are valid for 58 m2

“Harnessing renewable energy is one of the most effective solutions for reducing carbon dioxide,” says Mahdi Sebti, Global Segment Manager, SKF Renewable Energy, Solar. “SKF’s advanced electromechanical technology offers improvements over today’s maintenanceintensive solutions and delivers high performance, accuracy and efficiency by accurately tracking the sun’s position throughout the day and throughout the seasons.”

SKF, Samantha Joubert, Tel: 011 821 3500, Fax: 011 821 3501, Email: samantha.joubert@skf.com, www.skf.co.za

Making a Big Splash Small hydropower (SHP) plants are exhibiting impressive growth thanks to numerous advantages over larger plants. The global installed hydropower capacity increased from 896.9 Gigawatts (GW) in 2006 to 1,072.1 GW in 2011, and is expected to climb to 1,443 GW by 2020. GlobalData’s research suggests that thanks to its reliable and affordable nature, SHP has emerged as one of the most favoured and promising solutions. Small and mini hydro facilities are gaining importance as their effect on the environment, and

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national budgets, is less substantial.

The construction of SHP plants does not disturb the local habitat and the building of large dams and reservoirs is unnecessary, thereby avoiding issues of deforestation and submergence.

SHP plants are consequently much quicker to construct and also offer higher rates of return due to the low capital investment and operational and maintenance costs.

GlobalData, Laura Ward, Email: LWard@globaldata.com, www.globaldata.com

STEAM TURBINES AND BOILERS

New Life for Old Boilers Imported boilers that don’t comply with local regulations cannot be sold in South Africa, even though they often arrive with the latest in emission control technology and other bells and whistles which make them more environmentally friendly than some of the old boilers still going strong locally.

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or those who can’t afford a new boiler, the only option is, therefore, to go for a second-hand refurbished boiler, a market which has become very competitive in South Africa due to the high demand. “SA Mechanical Engineer” visits Christy Boilers in Springs, specialists in boiler refurbishing, to talk to managing director, Gary Schapira.

Gary Schapira

“The company started as a general engineering works over sixty years ago, but later on started specialising in engineering around boilers, repairs to boilers and today refurbishing boilers,” he says. “Essentially we buy in all types and makes of old boilers up to ten tonnes, give them a complete overhaul and then sell them off again.

Refurbishing

“In addition we do the compulsory inspections, services and maintenance on the boilers of a well-established client base across all types of industries nationally and lately also into Africa,” adds Gary. As Christy’s does not manufacture new

boilers, they are dependent on a steady supply of second-hand boilers, a market which has become very competitive locally.

Servicing all brands of boilers has the advantage of broadening the company’s scope, but also necessitates carrying a wide range of spares. “Be it coal, liquid fuel or a gas fired boiler, we have the experience and skills to service, maintain or refurbish any type under the ten tonne size,” Gary says. “Our motto is to provide a complete steam solution, including the installation and servicing of the complete piping system in steam reticulation networks.

Buy in all types and makes of old boilers up to ten tonnes, give them a complete overhaul and then sell them off again The workshop

“We have mobile service teams who do servicing and installation on site, but if it is a major repair or overhaul we bring the boiler to our workshop,” he adds. “This is usually where we have to re-tube the boiler or replace major components like the complete stoker bed, chain grates and the drive or new firewalls for the furnace.”

On our tour through the workshop we find several boilers in various stages of repair. Some are going through checks, looking as good as new with shiny new copper piping leading to safety valves, control valves, gauges and liquid level indicators neatly fitted along the outer boiler shell.

The stainless steel sheet covering the new cladding still has a thin plastic layer to protect the smooth shiny surface from scratches while work is being carried out in the workshop.

It is obvious that everything around the boiler, the pumps, water feed tank, electric motor and gearbox are all

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Boilers are like cars, no matter what you do to the exhaust system of a car built in the fifties, it will always emit excessive carbon compared with a modern car either brand new or have been refurbished to look and function like new.

In the queue

In another area of the workshop, a chain grate is steadily moving forward, almost like a heavy conveyor belt, while a technician makes final adjustments to the gearing to ensure optimum engagement with

the new drive links which have been fitted. Gary points out that the wear and damage on a similar chain grate being dismantled is currently being assessed for damage. Apart from some broken links in the chain bed, the whole drive train has clearly seen many years’ service before seizing up and bending everything around it out of alignment.

Judging by the extent of the damage, this boiler was probably malfunctioning for quite a while before failing completely.

In another corner of the workshop we see some old electrode boilers waiting for repair. There are even two types of vertical, or upright, boilers, one of a welded construction and another which has been riveted, both waiting for the right person to walk in and ask for such a boiler before they join the queue for refurbishment.

Modifying a boiler

In light of new legislation concerning carbon emissions, we ask Gary whether they can modify the rebuilds, not only to improve efficiency, but also to reduce emission. “To a certain degree we can optimise boiler performance, but there’s not much we can do in terms of carbon emissions on some of the old designs,” he says. “Fitting scrubbers to clean exhaust air is expensive and not the sort of thing the small operators who buy second-hand refurbished boilers can really afford. We can certainly do it, but generally not many clients ask for it yet, in spite of legislation requiring boiler users to clean up their act.

Damaged chain grate for repair

“Boilers are like cars, no matter what you do to the exhaust system of a car built in the fifties, it will always emit excessive carbon compared with a modern car,” Gary says in conclusion. “There are certain things we can add, like fitting a multi-cell grit collector onto the back of the boiler to collect large heavy particles so that they don’t go out the chimney, but we can’t alter the original design of the boiler.”

Gary Schapira, Christy Boilers, Tel: (011) 362-5100, Email: boilers@icon.co.za, www.christyboilers.co.za

Newly casted walls for an old boiler

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Steam Turbine Contract

A TGM condensing extraction steam turbo generator set operating at a paper mill in Brazil. This set is similar to that which will be supplied and installed at Mondi Richard's Bay facility

A new steam turbine is being supplied to Mondi’s Richards Bay mill. This will be the largest turbine, supplied by Zest Energy, and the largest ever manufactured

by Brazilian company TGM Turbinas (model CTE63).

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ot only will the project be the first of its kind to use the combination of a TGM turbine and an alternator manufactured

by Electric Machinery (EM), it will also be a first for both equipment manufacturers to have their equipment installed in South Africa.

Condensing steam turbine to use the additional high pressure steam provided when running the plant boilers at full load Zest WEG Group holding company WEG, a Brazilian electrical equipment manufacturer, and TGM, Brazil’s number one manufacturer of steam turbines, have enjoyed a longstanding and fruitful relationship over the last two decades. And in 2011, WEG acquired EM, a company that custom designs and manufactures motors, generators and brushless exciters that serve thousands of customers worldwide, primarily in the oil and gas and power generation industries.

At full load

The Mondi contract is also the first time since WEG acquired EM, that TGM and EM equipment has been used in combination worldwide.

Mondi has appointed Bosch Projects as the overall EPCM contractor for the project, which began in May 2012 and is expected to take approximately 18 months. The Mondi Richards Bay mill was commissioned in 1984, producing Baycel, a premier grade bleached hardwood pulp made from 100% eucalyptus fibre and Baywhite, a white top kraft linerboard.

“Currently there are two AEG Kanis steam turbo generators installed — one 38 MW extraction back pressure steam turbine and one 34.3 MW extraction condensing steam turbine,” Zest Energy projects manager, Alastair Gerrard, explains. “We are now installing a new 48 MW multi-extraction condensing steam turbine to use the additional high pressure steam provided when running the plant boilers at full load.

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The project scope includes the design, manufacture, delivery as well as complete installation and commissioning of the steam turbine and associated equipment.

Zest Energy will provide OEM supervision services during installation and commissioning and will offer 24/7 oncall support for a period of four weeks after handover.

In addition to the 48 MW TGM multi-extraction condensing steam turbine and the 57 MVA, 11 kV EM alternator, the scope of equipment includes the complete condensing system, lubrication oil system with piping, turbine control panel with HMI, generator protection and control panel and a complete spare parts set to guarantee 98% equipment availability over the next five years.

Long-term service agreement

In addition to the new steam turbine, Zest Energy is poised to enter into a separate long term service agreement with Mondi to cover the maintenance of the equipment for at least the next five to 10 years, applicable to all three units â&#x20AC;&#x201D; the two existing Kanis units and the new TGM turbine.

Zest Weg Group, Jamie Wilson, Tel: (011) 723-6000, Email: jamiew@zest.co.za, Web: www.zest.co.za

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PIPES, PUMPS AND VALVES

Bigger is Better

(Left to right) Deon Venter, Dave Joubert and Jan Venter of Rocktuff Pump & Mining Supplies

To maintain cost-effective margins, mines are constantly increasing processing throughput, calling for bigger equipment to handle the ever-growing volumes of material. Bigger crushers and screens, wider and faster conveyors systems are on the cards.

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nown for the large pumps they’re able to manufacture, Rocktuff Pump & Mining Supplies in Witbank has come up with a 12 inch diameter mobile pump for an open pit mining application. “SA Mechanical Engineer” speaks to Dave Joubert to find out where this is heading. “With the 12 inch pump we’ve now almost reached an optimum ceiling as to how big you can go with a mobile slurry pump design,” he says.

With the 12 inch pump we’ve now almost reached an optimum ceiling as to how big you can go with a mobile slurry pump design “After this, it’s not just the pipe diameters which become cost prohibitive, but the choice of engines is narrowed down to only two manufacturers who can supply an engine powerful enough to drive the pump.

Limits

“Piping this size is generally not available locally in any case and has to be imported, pushing the cost for the pipework to exceed the cost of the pump assembly itself,” adds Dave. In cases where volumes exceed the capacity of such a large pump, Rocktuff recommends that clients rather make use of two medium-sized pumps, providing the operation with more flexibility in terms of pump mobility in any case. “The bigger the pump unit, the more difficult it is to move the unit and the pipe network which goes with it,” Dave explains.

The series of positive, self-priming slurry pumps they manufacture range in size from a 3-inch pump right through to 12 inches. Their range of impellers allow heads of up to 320 metres, making it possible to cope with all mining applications where excavations need to be kept dry. Dave remarks,

THE SOUTH SOUTH AFRICAN AFRICAN MECHANICAL MECHANICAL ENGINEER ENGINEER THE

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PIPES, PUMPS AND VALVES

“Right now our biggest pump, pumping averages of about 700 to 800 cubic metres per hour, can go deeper than most of the other pumps available on the market for this purpose.”

Home grown

Rocktuff was established over 21 years ago by Jan Venter specialising in serving the opencast mining industry with dewatering pumps. “Our pump units are mostly mobile units, electrical or diesel driven,” says Jan. “We own the patterns for all our pump designs. The castings are done locally and after machining in-house, we build the unit onto a custom-designed trailer fitted with any one of the OEM diesel engines available on the market. The choice of engine depends on customer preferences, but in remote areas up in Africa, for instance, we’ll fit the pump unit with an engine which can be serviced by an OEM which has a presence nearby.”

The series of positive, self-priming slurry pumps range in size from a 3-inch pump right through to 12 inches

The company owns the Anvac Positive self-priming range of pumps, the Anwell re-circulating selfpriming range as well as the range of Ansub slurry submersible pumps. Jan adds, “This covers most applications, but, as agents for Sam Engineering, we also have access to larger pumps for those outof-the-ordinary requirements of very high heads that come our way every now and then.”

Service teams

Just as the company has kept abreast of market trends, so it’s kept pace with market demands. Says Dave, “We’ve received lots of orders from most of the countries where mining has increased rapidly over the past two years. In instances, where clients are not familiar with our products, we’ll travel to the relevant country, inspect their requirements and recommend a pump accordingly. We also support these first-time customers by visiting the site, not only to ensure that everything works as intended, but also to train their people to use our equipment correctly.”

The local installed base is well established and sustained by ongoing support in terms of spares and maintenance from Rocktuff. “We have a fleet of service vehicles on the road that periodically visits mines to carry out contract maintenance work on our pumps,” says Dave. “In terms of service, one of our most successful ventures is the large pump rental fleet we’ve established. Currently we have 57 rental units circulating in the opencast mining industry throughout South Africa. Although a large number of these cater for increased demand during the rainy season, many mines prefer to hire rather than buy dewatering pumps.”

Other applications

Specialising in opencast mining, however, does not mean this company shies away from other applications. “We have even sold a couple of flame proof versions of our pump units for underground mining,” says Dave. “Our business philosophy is to never turn a customer away just because we

The range of impellers allows heads of up to 320 metres, making it possible to cope with all mining applications where excavations need to be kept dry

haven’t done something before. We’re always prepared to take a look at a problem and try to find a lasting solution.”

We have a fleet of service vehicles on the road that periodically visits mines to carry out contract maintenance work on our pumps “Service and backup of the products we manufacture to very high quality standards is the key to our success,” Jan says in conclusion. “Above all, such service has to be close to your customers which is why our service teams make contact with our customer base on a regular basis.”

Rocktuff, Jan Venter, Tel: (013) 690-2597, Email: rocktuffpump@lantic.net, www.rocktuff.co.za

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Vacuum Drying System A fleet of six UV16 pumps with booster has been commissioned in Ujjain, India. The vacuum drying method was applied after dewatering with pigs. The considerable volume of 102.000m3 was evacuated down to 0,3 mbar(a) [29, 905 in Hg (V)], which corresponds to a Dew Point of -32o C [-25.6 oF] in 6 days only.

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t the start of 2011, two Pneumofore engineers travelled to India for the commissioning of six vacuum systems model UV16 H B2500B, delivered to Narmada Offshore Construction, specialists in pigging and hydro-testing to serve the oil, gas and petrochemical industry. The pipeline is in Ujjain, near Indore and measures 48 inch [DN 1200] diameter for the length of 90 km [56 miles]. Pneumofore is represented locally by Airt Vacuum Technologies.

Technology has only recently evolved to guarantee good results for water vapour suction Protected

Four double stage vacuum systems with variablespeed-driven roots pumps as second stage (each 3000 m 3/h [1770 cfm] capacity), and two standard double stage systems each 2500 m 3/h [1473 cfm] capacity for the total maximal flow of 17000 m 3/h [10020 cfm] were installed in a 20 feet container, while others simply were placed on the unpaved ground. All vacuum pumps were protected with inlet filters and connected to the central manifold. When the pumps are not operated within a protective container, heavier and special sturdy skid mounted units are usually used.

The special features of the Pneumofore vacuum system are the capacity to evacuate water vapour, to be ready-to-use, completely air cooled with superior efficiency. This solution was chosen due to the large volume in the pipeline, which had to be evacuated down to 0,3 mbar(a) [29,905 in Hg (V)] for the Dew Point of -32oC [-25.6oF]. The drying with this dedicated vacuum was economically far more convenient than the previous drying technique with nitrogen.

Evolved

Vacuum drying has been promoted in theory for decades, but the technology has only recently evolved to guarantee good results for water vapour suction. The total water vapour quantity, that can be evacuated, is 400 kg/h, because one UV16 H can handle more than 66kh/h.

The pipeline drying follows the dewatering process,

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which is executed with â&#x20AC;&#x2DC;pigsâ&#x20AC;&#x2122; pushed by compressed air at the speed of 2 km/h [1.25 mph]. Nowadays the pigs also collect data about the internal geometry of the pipeline, such as constant diameter or oval shape, reduction in thickness and more.

A record

During commissioning, Pneumofore engineers instructed the local team about the vaccum pumps operation and maintenance. The routine operations on the vacuum systems, as well as the periodic checks, are fast availability of cold water for cooling purpose.

With a record of 5000 km [3100 miles] cross country and offshore pipelines, the customer, Narmada Offshore Construction, is a major Indian player, offering a wide range of pipeline services, including cleaning, hydro-testing, dewatering, drying and pre-commissioning.

Pneumofore, Email: info@pneumofore.com, www.pneumofore.com

February 2013

A FIRST

"My mother wanted me to be a doctor....."

Xylem Water Solutions South Africa, part of Xylem Incorporated, recently employed its first ever African, female fitter. Zanele Sithole joined the team this year and she is set to prove that a woman is as capable of handling the challenges of a physically demanding career as any man.

The happily married mother of two completed her N3 at college and proceeded to qualify as a fitter artisan in 2009. From the start of her career, she has been committed to showing that she is capable, strong and intelligent. The combination of these attributes have stood her in good stead in a career that is traditionally viewed as a â&#x20AC;&#x153;manâ&#x20AC;&#x2122;s jobâ&#x20AC;?.

I like the fact that I can show the guys that a woman can pick up a spanner tooâ&#x20AC;Śand that we can all work together towards a common goal Chosen field

Zanele Sithole

Z

anele Sithole (26) hails from Witbank, Mpumalanga originally, where it was evident from childhood that she had an aptitude for all things technological. She recalls how she frequently disassembled broken electronic devices, repaired them and put them back together, before even reaching her teens.

Her family quickly realised that Zanele was suited for something a little different than what they might have envisioned for her. â&#x20AC;&#x153;My mother wanted me to be a doctor,â&#x20AC;? Zanele says, jokingly. â&#x20AC;&#x153;But grease is so much better than blood!â&#x20AC;? Her family proudly supports her to this day.

â&#x20AC;&#x153;I look at a problem with a great deal of forethought,â&#x20AC;? Zanele explains. â&#x20AC;&#x153;Solving a problem in your mind beforehand allows you to employ economy of strength to achieve the same result as brute strength.â&#x20AC;? Initially, Zaneleâ&#x20AC;&#x2122;s male colleagues were surprised to see a woman in the workshop, but it didnâ&#x20AC;&#x2122;t take long before their surprise turned into respect. â&#x20AC;&#x153;I like the fact that I can show the guys that a woman can pick up a spanner tooâ&#x20AC;Śand that we can all work together towards a common goal. On top of that â&#x20AC;&#x201C; I have been told that I make the workshop smell nice,â&#x20AC;? Zanele says.

With her appointment at Xylem South Africa, Zanele is eager to maximise the opportunity to hone her skills in her chosen field. She also looks forward to growing and to perhaps mentoring other young women who would like to enter the workforce in a similar fashion. â&#x20AC;&#x153;There is no limit to what you can achieve if you have a dream and you set your mind to achieving it,â&#x20AC;? Zanele concludes.

Xylem, Zanele Sithole, Tel: (011) 966-9300 Web: www.xylemwatersolutions.com

WEâ&#x20AC;&#x2122;RE ENGINEERED TO SHARE Over R7.3 billion LQ SURĂ&#x20AC;WV VKDUHG EHWZHHQ RXU PHPEHUV* LQ WKH ODVW \HDUV NRZ WKDWâ&#x20AC;&#x2122;V D XQLTXH EHQHĂ&#x20AC;W RI PXWXDOLW\ )RU PRUH EHQHĂ&#x20AC;WV DQG LQIR S0S Âś0E&Hâ&#x20AC;&#x2122; DQG \RXU NA0E WR YLVLW ZZZ SSV FR ]D RU FRQVXOW D 33S SURGXFW DFFUHGLWHG Ă&#x20AC;QDQFLDO DGYLVHU 33S LV DQ DXWKRULVHG )LQDQFLDO SHUYLFHV 3URYLGHU *0HPEHUV ZLWK 33S 3URYLGHUâ&#x201E;˘ 3ROLFLHV THUPV FRQGLWLRQV DQG VWDQGDUG S0S UDWHV DSSO\

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MARKET FORUM

High Performance Levels

Saving Billions

A leading colliery in Mpumalanga called upon Hansen Transmissions South Africa (Pty) Ltd (HTSA) to supply 24 off 200kW complete power packs for underground drive applications.

Jenny Heyes, HTSA Sales & Marketing Manager, believes that this order was mainly due to twelve years of reliable performance of the large installed base of Hansen industrial units at the coal mine.

Eskom’s Contractor of The Year award

A new type of gland packing that eliminates high pressure valve leakage is set to save the petrochemical industry billions in high-value product lost to atmosphere.

Hansen I4 Invertible Industrial Gearbox

“The 33 Hansen industrial gearboxes that have been driving underground conveyors, surface conveyors and ventilation fans at the mine since 2000, have delivered high levels of performance and reliability with minimum maintenance and subsequent reduced downtime, cost savings and increased productivity”, explains Jenny.

Recognising the significant cost and space saving benefits offered by the locally designed Hansen industrial I4, the local coal mining industry has largely standardised on the unit.

“The invertible left- and right handorientated Hansen I4 industrial gearbox for multiple underground drive conveyor systems can be turned 180 degrees for either handing, eliminating the need for separate drives” Jenny concludes.

Hansen Transmissions, Jennifer Heyes, Tel: (011) 397-2495 jheyes@HansenIndustrialGearboxes.com, www.hansenindustrialgearboxes.co.za

40

The packing, scheduled for launch later this year, will replace a highly successful product already in use and developed specifically to minimise high pressure valve leakage at power stations. This existing product, an installation- and maintenance-friendly live loading stack, was formally adopted as Eskom’s preferred packing for high-pressure applications early in 2012.

Eskom’s adoption of the stack is significant for petrochemicals production, where valve leakages of chemicals and petrochemical end-products are many times more costly than leakages of steam, and where refineries also face increasingly strict emissions legislation

regarding the potential threat to health posed by products and processes.

Aesseal approached Eskom almost three years ago to discuss the leaks, and flew in specialists from Europe to examine the problem. Exhaustive and successful trials followed, culminating in Eskom’s specifying the Aesseal solution as a stock item at Tutuka, and introducing it to other power stations as well. Aesseal is now working closely on a collaborative venture to develop a further type of packing that will completely seal any type of high pressure valve. This advanced product, which reduces emissions to atmosphere to zero, is currently on trial in underwater valves on oil rigs, and is expected to become available in South Africa towards the end of 2013.

Aesseal, Rob Waites, Tel: (011) 466-6500, E-mail: rwaites@aesseal.co.za

A Milestone As the supplier of the world's largest vertical roller grinding mills, in November 2011 Loesche obtained a contract for the first ever 4-roller coal mill for the injection of pulverised coal into a blast furnace (PCI technology).

The Loesche Mill Type LM 43.4 D has a capacity of 120 t/h and will be installed in the iron and steel plant of SSI Redcar in Great Britain. This will be, together with the Loesche Hot Gas Generator Type LOMA LF 28 with a maximum heat capacity of 17 MW, the world's largest

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single coal grinding plant for PCI. A step forward in the development of the multiple lance burner (MLB) allows for operation of the hot gas generator with blast furnace gas as well as with coke oven gas also at maximum throughput of the mill.

The complete injection system will be implemented by Siemens VAI and is planned to start operation at the beginning of this year.

Loesche SA, Tel: (011) 482-2933, umeyer@loeschesa.co.za, www.loesche.com

MARKET FORUM

Exciting New Range

Winning Recipe “Many operators in the Southern African mining industry are currently focusing their efforts internally to stabilise the business, with Johan Theron, a Director at a very strong Deloitte Consulting emphasis on cost. Effective cost management can however create opportunities for growth when armed with tried and tested business processes and a business software solution such as Sage ERP X3,” says Johan Theron, a director at Deloitte Consulting.

Goscor Power Products, MD, Mark Bester

Goscor Power Products (GPP), part of Imperial’s Goscor group, has been appointed the sole distributor in southern Africa for China Lutian Machinery Company Ltd (Lutian), one of China’s leading industrial corporations.

Lutian manufactures electric, diesel and petrol engines, water pumps, generators and a range of welding machines. They also specialise in high-pressure washers, which can be powered by any of their engines.

GPP MD Mark Bester says that the synergies between his company and Lutian are very strong. “They make excellent quality products at very competitive prices, which will enable us to trade more competitively in the price-sensitive segments of the market,” says Mark.

The Lutian products will, of course, be backed and supported by Goscor’s nationwide dealer network. “Having been in the business for more than 25 years, the Goscor Group has built an enviable reputation for supplying reliable and dependable world-class products with service and parts back-up to match across the southern African region,” concludes Mark.

Goscor Power Products, Mark Bester, Tel: 0861 467 267, Email: powerproducts@goscor.co.za www.goscor-power-products.co.za

Deloitte’s mining industry expertise coupled with Sage ERP X3’s sector specific software capabilities are the two core ingredients to a winning recipe.

Organisations within the mining sector utilise ERP solutions for a diverse number of reasons. “Smaller companies may only utilise an ERP solution to manage their finance and purchasing, whereas bigger operators need to structure their business solutions around a more complex collection of needs. A scalable ERP solution is therefore essential to adapt to the business’ needs however they may expand or change,” explains Johan.

“Sage ERP X3 was designed with the mid-to-upper end business in mind, which makes it a great match for the mining industry, among others,” he adds.

The ERP solution excels at streamlining all operating and processing aspects of single or multiple business operations.

During 2011 Deloitte embarked on a partnership with Sage ERP X3 that was aimed at the delivery of a cost-efficient Enterprise Resource Planning (ERP) solution to its Mining Shared Services Division.

Sage ERP X3 effectively forms part of a Deloitte service delivery model that allows mining companies to co-source and/or outsource transactional and knowledge processes and take advantage of the cost benefits offered by consolidating and streamlining back office processes.

“The product is essentially a complete web-based integrated management suite, covering all operational needs in terms of production management, distribution, logistics, asset maintenance, finance and human resources,” says Johan. “It is a multi-legislative, multi-lingual and multi-currency solution that can be seamlessly integrated on both a national and international level.”

South

First

Deloitte, Johan Theron, Tel: (011) 806-5000, www.deloitte.com

Afrox has introduced a new radiationfree TIG tungsten electrode imported from Wolfram Industries in Germany that offers safer, more economical and more efficient welding than any other TIG tungsten electrode currently on the market.

“These world class electrodes will set a new benchmark for this type of product in South African industry,” says Afrox’s Ferdie Pretorius. “They offer absolutely reliable arc-striking on any weld metal, a low burn-off rate and the highest quality of arc,” he adds. “The arc remains stable at all times, without any flickering or movement. Significant power consumption reductions are already being achieved by customers, along with prolonged service life, reduced set-up costs and gas consumption reductions of up to 50%, when used in combination with the correct accessories. Results are 100% reproducible.”

The burn-off rate is very low compared with other electrodes and the electrode tip doesn’t change during welding. Importantly, TIG tungsten electrodes don’t contain thorium and are therefore free of radioactivity. The tungsten electrodes are environmentally friendly, owing to significantly lower material consumption.

Afrox, Ferdie Pretorius, Email: Ferdie.Pretorius@afrox.linde.com

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MARKET FORUM

Beyond-Expectation Success

Minerals Africa’s Phalaborwa branch, says the Warman 200RC DWU pump was installed on site at Foskor’s current flotation plant to handle dirty plant water from thickener overflow. The DWU pump was set up for the complex system curve in this particular application and it performed beyond expectation. Warren comments the pump proved itself in the application which is one that can be challenging especially when not all the thickeners are in operation.

The 200RC DWU pump provides reliable return process water to the entire plant and jointly serves as the high pressure water motor system to drive the plant’s many venturi thickener tunnel spillage pumps. The 200RC DWU produces at the same flow rate as the previously installed clear water pump.

Warren adds, “It has been in operation for several months and is outperforming the predecessor pump that had struggled to maintain 10.5 bar pressure.

Based on the unprecedented success of Weir Minerals Africa’s new Warman DWU dewatering pump at the existing Foskor flotation and filtration plant in Phalaborwa, Foskor has ordered a number of new DWU pumps for its new flotation plant which is currently under construction at the same site. The total order includes three 125 DWU pumps and one 150 DWU pump for the upgrade and three 200 DWUs which will be supplied in 2013 for the new plant.

The first prototype DWU model pump was introduced at Foskor in early 2012 and following its successful performance, this new generation dewatering pump is gaining popularity within the mining sector. Weir Minerals Africa in South Africa designed and developed this model and has now become the global hub for the manufacture and supply of the DWU pump as well as owning the intellectual property rights.

Warren Taylor, product specialist at Weir

“The new DWU pump is a dewatering pump that is capable of handling slurrylike dirty water, but it has the energy efficiency similar to that of a clear water pump. It’s also well suited to high pressure applications. We’re thrilled to be able to offer the global market a dewatering pump that can handle dirty process water without the compromise on energy efficiency experienced with a normal slurry pump,” Warren emphasises.

Weir Minerals, Rene Calitz, Tel : (011) 9292622, Email: r.calitz@weirminerals.com www.weirminerals.com

15km of Pipes Fluid conveyance and pumping solutions expert Incledon has supplied more than 15 km of ductile iron and PVC piping products to the R41-million Mbuzini bulk water augmentation scheme in Mpumalanga. The project, which began in January 2012 and is due for completion in February 2013, entails the construction of bulk water infrastructure to increase the capacity of the bulk lines from Khombaso, to Tsambokhulu and Mbuzini. The project infrastructure involves the construction of two pump stations, two 3-Ml concrete reservoirs, a 1-Ml concrete reservoir and 15,4 km of water pipelines.

Incledon national product manager for civils Kelly Wilson points out that the company supplied the appointed civil contractors, Gabby Construction and Thakitsi Construction, with a total of

42

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9,5 km of 300mm and 4,5 km of 250 mm Hydroclass ductile iron pipe, in addition to 1,4 km of 110mm uPVC pipe, waterworks valves, water meters steel specials in order to complete the contracts.

"The Hydroclass ductile iron pipes and fitting systems are produced by internationally-recognised French manufacturer St Gobain PAM, which is one of the first companies worldwide to comply with international EN 545:2010 and ISO 2531:2009 quality standards.

These quality standards were set as a benchmark to ensure that all ductile iron products comply with preferred pressure classes, in addition to reducing their environmental footprint during the manufacturing process," Kelly concludes.

Incledon, Kelly Wilson, Tel: (011) 323 0800, Email:kellyw@incledon.co.za

MARKET FORUM

Underpinning their Sucess

Baseplate-mounted Soméflu chemical transfer pumps

Ecochem Pumps’ projects division has shipped fourteen baseplate-mounted Soméflu chemical transfer pumps, fitted with mechanical seals and automated seal support reservoirs, to a platinum concentrator plant in Northwest Province.

The seals are themselves kept continuously below gas-combustible temperature by re-circulated water from the seal support reservoir.

The Ecochem Projects system provides for detection of primary seal failure, which is indicated physically by a flow indicaThe pumps will transfer tor connected to the seal and dilute bulk deliveries of xanthate, a volatile Michael Muller, director of Eco- support vessel, and which mining reagent essential chem Pumps’ projects division automatically trips the pump and transmits an to the platinum recovery process. Although not flammable itself, alarm signal to the central control room. uncontained xanthate releases a poten- All system components are ATEX aptially explosive carbon disulphide gas. proved. The pumps themselves feature To eliminate any possibility of fire or stainless steel liquid-end housings and explosion, Ecochem Projects designed impellers, and are driven by S9 duty rated a system in which double mechanical motors fitted with variable speed drives. seals provide fail-safe containment of the reagent with redundancy in case of Ecochem Pumps, Richard Rudling, Tel: (011) 455-5710, primary seal failure.

N o Lo n g e r “ Wa s t i n g Awa y ” The Hakhano Colliery, which forms part of Umthombo Resources, operates a coal processing plant and produces in excess of 1.5 million tons of domestic as well as export coal per annum. Enprotec was contracted to design, supply, construct and commission a filtration plant at Hakhano. The purpose of the filtration plant is to eliminate the use of slimes ponds by dewatering the arising thickener underflow as arising ultra fine coal from the main plant. It is imperative that the moisture of the filter cakes is as low as possible in order for the water recovery to be as high as possible, thus the Enprotec plate and frame filter with full filter functionality was the ideal solution.

Not only was Enprotec able to reduce water consumption at the mine from 0.298m3 per ton to 0.051m3 per ton, but the amount of slurry generated was also reduced and a by-product of filter cake will now be produced which can be sold off to certain markets, which in turn means little to nothing goes to waste.

“Hakhano also required an immediate re-use of process water, to prevent this precious resource from simply going to waste and costing millions of rands,” comments Jayson Jacobs, Enprotec’s Operational Director. “Enprotec’s solutions ultimately alleviated Hakhano’s environmental problems associated with slime ponds, as well as reduce the mines’ raw water consumption by at least 60%.

Enprotec, Tel: (013) 246-1399 Email: info@enprotec.co.za

Email: richard@ecochempumps.co.za

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MARKET FORUM

DNA Processing

Non-Traditional Market

A HC cyclone cluster

barcode at the bottom. The barcoding prevents fiddling and exchange of samples. After reading the barcodes, the system collects a pre-packed rack of 48 sample tubes from a magazine.

It reads the 2D barcodes and matches them with the barcodes on the empty tubes. The sample rack is then fitted upside down on the rack containing the filtered tubes. Using a very specific motion profile, the system is then inverted to prevent spilling and capillary leaking.

The electrical drive system from Festo complies with sanitisation standards necessary for accurate results, and is controlled by CanBus protocol connections in Labview.

Especially useful for solving crimes, modern-day DNA profiling, called STR analysis, is a very sensitive technique, needing only a few skin cells, a hair root or a tiny amount of blood or saliva.

Festo South Africa has recently assisted Vertex Automation in offering its client a highly accurate electrical solution for the positioning aspects of reliable DNA processing.

A HC cyclone

Multotec has expanded its cyclone technology base to include potassium and other salts.

“Beneficiation of salts and potassium is performed under extreme conditions, including high temperatures, viscous liquids and mechanically and chemically corrosive environments,” Ryan Magner, project engineer at Multotec, says. “As a result, there are few equipment suppliers able to support this industry. Multotec’s move into the non-traditional minerals market has been a natural progression and we pride ourselves on the quality and depth of our process ability, which

44

For the processing, the inverter receives a rack filled with 48 tubes. Each tube in the rack contains a solid sample, such as a cloth or other material containing DNA. A liquid is added to the tubes before they are fitted with a special filter cap. Each tube also receives a 2D

In the next stage of the process, the liquid is transferred to the tubes without filters, leaving the solids behind.

The assembled set is then returned to the handling system, which transfers the assembly to a centrifuge that spins out all liquids from the solids.

The assembly is then returned to the inverter, which strips away the rack with solid material and discards. The rack filled with liquid is returned to the handling system and transferred to other laboratory equipment for further processing.

“In satisfying the client’s requirements for its forensic DNA sample inverter, which required a minimum use of compressed air, conducive to the highly clinical and sterile laboratory environment, and high position accuracy in addition to aesthetics, Festo supplied an electrical drive solution that is clean, powerful, economical and versatile, in addition to offering the high level of accuracy that is so important in this particular application,” explains Gerhardt Strydom, systems sales engineer, Festo.

Festo, Tracey Swart, Tel: 08600 FESTO (33786), Web: www.festo.co.za

allow us to comprehensively identify the application requirements.”

ing equipment into the salt and potash industries worldwide.

The company has invested extensively in ongoing research and development as well as new tooling to be able to support this growing sector of the market which demands specialised and complex application of cyclone technology as well as detailed process knowledge. The demand for potash mining is on the increase, primarily owing to population growth and the decreasing availability of arable land, and the Group is ideally positioned to support this demand, with a robust history of supplying process-

Ryan adds that in some instances, cyclones have been manufactured using surgical grade stainless steel, harnessing complex manufacturing procedures to ensure that quality and reliability are not compromised. In less harsh operating environments, polyurethane and rubber have been used successfully both as materials of construction and as linings.

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Multotec Group, Bernadette Wilson, Tel: (011) 923-6193, Email: bernadettew@multotec.co.za, www.multotec.com

MARKET FORUM

Louis Visser

Structural steel specialist Portal Frame Structures has supplied steel beams to the R90-million Euro Steel production and storage facility construction project in Vereeniging.

The new plant comprises a production facility, administration block, ablution facilities and storage, in order to facilitate a hot-rolling steel mill that is expected to produce up to 5 000 tons per month of long product such as angles, channels and window sections. Euro Steel expects to increase production by 30 percent and reduce manual labour by 38 percent with the new plant, as the entire mill has been automated to ensure accuracy and efficiency.

Portal Frame Structures general manager, Louis Visser, points out that the company has successfully manufactured approximately R5,2-million worth of steel beams for the Euro Steel mill project to date, by making use of the specialised

Metso ND Engineering, through

its affiliation with the Global Metso Group of companies, is in a position to offer the latest technological solutions, supported through a combined worldwide network.

Our South African offices and manufacturing facilities are based in Queensburgh, Durban within easy access to major roads and harbour facilitating the transport of equipment.

The acquisition of up-to-date technology has given Metso ND Engineering (Pty) Ltd the enviable reputation as a market leading fabricator of Stainless, Alloy and Carbon Steel products of varying codes of design and manufacture.

We specialise in the Manufacturing

R5,2m worth of beams

prefabricating beamline machine, which it acquired from Proroof in June 2012.

"The beamline machine is capable of manufacturing steel beams and columns to exact engineered specifications, by applying a total of three strips of bulk steel in coil form – two for the flanges and one for the web," he explains.

According to Louis, the beamline machine continuously supplies the material through accumulators to a high frequency electric welding process, and can be adapted to

manufacture beams with varying flanges as well as ‘T’ sections. "The beamline machine’s welding system enables high power density to be concentrated at the welding surfaces, and enables continuous welding at high speeds with low heat input. This machine welds three strips together, as opposed to the ‘universal beams’ available in South Africa that are hot rolled."

Portal Frame Structures, Louis Visser, Tel: (016) 450-5800, louis@portalframes.co.za

of Pressure Vessels, Storage

Tanks, Heat Exchangers, Filter Drums, Distillation Columns, Mechanical Equipment, Conveyors and Turnkey Projects.

Our workshop versatility enables us to satisfy a broad client base each with their specialised process requirements; necessitating the use of exotic materials and innovative welding technology for the paper and pulp, petrochemical, mining, chemical and sugar industries.

www.metsond.co.za Tel: (031) 464 0510 Fax: (031) 464 0625 Cell: 083 449 5540 Contact: Nolan Green

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MARKET FORUM

New Bearing Slide Range

Index to Advertisers Aesseal Atlas Copco

4 20

Engen

14

Engineer Placements 6 Eskom Inside Back Cover Genrec

Outside Back Cover

Horne KSB Pumps

18 36

Loesche

23

Multi Alloys PPS Robor

10 11, 39 Inside Front Cover

Yellotec

32, 34

Verder Watson Marlow

19 Outside Front Cover

Weir Minerals Zest

12 24

Tectra Automation has become the first official distributor of Accuride International’s complete range of industrial telescopic and linear ball bearing slides in South Africa. With load handling capacities of up to 600 kg, the range has improved Tectra’s leading service and engineering capabilities in the industrial and factory automation sectors.

In addition to linear motion track systems which include light-, medium-, heavy-duty and vertical slides, Accuride’s locking handle kits are also available locally. Accuride’s slider products are corrosion resistant and comply with the environmental RoHS standards.

Tectra represents a number of premium brands locally, including Bosch Rexroth, Schmalz, Datasensor and Easy Conveyor – among others – and considers Accuride a valuable addition to the company’s ability to provide turnkey designs and engineered solutions.

Tectra Automation, Greg Calder, Tel: (011) 971-9400, greg.calder@tectra.co.za www.tectra.co.za

Ideas and Solutions says Carl Martin Welcker, general commissioner of the EMO Hannover 2013.

At the beginning of the year, more than 1 600 companies from 34 different countries had already signed up. The current registration status is significantly higher than the comparable figure for the preceding event.

“Meet the world at EMO” is one of the most important arguments for participating. It’s not only German manufacturers who have registered for large-size stands. Asian companies are particularly prominent in showing the flag, firms from Japan, China, Taiwan and Korea who are keen to play a bigger role on the global market.

Carlos Poñe

ABB has announced the appointment of Carlos Poñe as Chief Executive Officer for ABB in the United Arab Emirates (UAE) and manager of Southern Gulf (UAE, Qatar, Oman) and Pakistan, with effect from 1 February 2013.

Rolf Steinhaus

Multotec has appointed sampling specialist, Rolf Steinhaus.

46

In 2013, Hanover will once again be hosting the EMO. From 16 to 21 September, all the metalworking sector’s important international players will be meeting up at the world’s premier trade fair for the metalworking sector. Under the motto “Intelligence in Production”, the EMO will be showing what modern-day production technology looks like and who is offering it.

“Everyone wants to be there. That’s why once again the EMO Hannover is well set to continue its success story”,

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Customers are seeking ideas and solutions for efficient production operations at widely dispersed locations with highly disparate prerequisites. What counts is innovation not only on the machine, but also for the components, in the production process and for the services involved.

And Martin concludes, “We can already guarantee our international trade visitors a top-class, comprehensive exhibition programme.”

EMO Hannover, Carl Martin Welcker, www.emo-hannover.de

MOHLALENG_ESKD_562 / E25 / Demand Response

Yes,

our company wants

to be part of Demand Response Rewards Programme because…

We don’t use all our electricity all the time We want to increase our bottom line We want to help conserve the environment

If you’ve ticked most of the boxes then join the Demand Response Rewards Programme today.

The programme offers a financial incentive to businesses that minimise their electricity consumption at critical times or generate their own power. This will help relieve the pressure on the national grid.

To join the programme simply cut out this page, scan and e-mail to drrewards@eskom.co.za or contact your nearest Eskom Energy Advisor by calling 08600 37566. You can also scan the QR code below or visit ww.eskom.co.za/idm for more information.

Company name: Contact name: Tel:

e-mail:

4S[IVMRK ]SYV [SVPH Eskom Holdings SOC Limited Reg No 2002/015527/06

THE SOUTH AFRICAN MECHANICAL ENGINEER

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THE SOUTH AFRICAN MECHANICAL ENGINEER & NBJM TBMFT!HFOSFDFOH DP [B t 8FC XXX HFOSFDFOH DP [B VOL 63 February 2013