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February 2014
MECHANICAL Y
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THIS MONTH:
• SA’s engineered rubber products manufacturer
• Complex design of chute systems at Black Rock Mine
T
• Newtown Junction: from potato shed to green building
• Carbon trading as offsets against the proposed carbon tax www.crown.co.za
⎪ Comment ⎪
Emission reduction: a priority
A
t as recent SANEA lecture at the Sasol Auditorium, Tshilidzi Ramuedzisi,
chief director for energy planning for the Department of Energy, presented
www.crown.co.za
an overview of the Draft 2012 Integrated Energy Planning Report.
Published monthly by While the presentation itself was excellent, I feel relieved that I am not
Crown Publications cc an energy professional.
Crown House For electricity generation, five test cases and a base case were evaluated to meet demand
Cnr Theunis and between now and 2050. The base case simply extends the current trajectory for the purposes of
Sovereign Streets comparison. There are three ‘peak-plateau-decline’ emissions limit test cases, which all assume
Bedford Gardens 2007 we meet currently agreed emissions’ reduction targets of 34% by 2020 and 42% by 2025: “at
PO Box 140 all costs”. These include an all-technologies emissions limiting case; a no nuclear case; and a
Bedfordview 2008 case prioritising natural gas. The fourth test case is the renewable energy target case, which sets
Tel: +27 11 622 4770 out to achieve 10% of generation from renewables by 2030; and number five is the carbon tax
Fax: +27 11 615 6108 case, in which the implementation of a carbon tax on relative technology choices is incorporated
e-mail: mechanical@crown.co.za as the key constraint.
It seems that nuclear generation technology only features in the general emissions limit case.
Publisher: Needless to say, in all of the cases where emissions are the limiting criteria, the coal-fired generation
Jenny Warwick targets will be significantly lower by 2050 – down from 61,2 GW in the base case to 25,4 GW
in all three emissions limiting cases, and to 41,2 GW in the renewable energy target test case.
Editor: The renewable energy test case does not seem to reduce emissions by nearly as much, begging
Peter Middleton the question as to where the 10% renewables target came from. Also, ironically, in the renewable
energy target case, coal is chosen to accompany renewables instead of nuclear, counterintuitive
Editorial assistant: given that the reason for maximising renewables is to reduce emissions?
Erika van Zyl My ‘birds-eye’ view detects a few signals that may be significant going forward. First, the
consequences of a non-nuclear future are being actively pursued, and the emerging results are
Advertising: not that negative. Natural gas, including that ‘from unconventional sources’, ie, Karoo shale gas,
Norman Welthagen is also being considered in the mix and, it seems to me, wind is being overtaken by solar as the
renewable technology of choice.
Design & layout: The Integrated Resource Plan (IRP) 2010-30 has also been updated to reflect “a number of
Darryl James developments in the energy sector”. Most notably, revised electricity sector demand is projected in
the range of 345 - 416 TWh by 2030, down from the 454 TWh expected in the policy-adjusted
Circulation: IRP. “In the shorter term (the next two to three years) there are clear guidelines arising from the
Karen Pearson scenarios”, reads the introduction.
Specifically, “The nuclear decision can possibly be delayed. The revised demand projections
Reader enquiries: suggest that no new nuclear base-load capacity is required until after 2025 – and for lower demand
Radha Naidoo not until at earliest 2035”. Justifications include regional hydro possibilities – such as Igula – as
well as allowing “exploration of the shale gas potential before prematurely committing to a tech-
Subscriptions: nology (nuclear) that may be redundant if the electricity demand expectations do not materialise”.
Wendy Charles On the coal side, renewed optimism for fluidised bed combustion generation is floated as
R410 (incl. VAT) per annum “preferable” to the Coal 3 programme. Also proposed is to “continue with the current renewable
Postage extra outside RSA bid programme, with additional annual rounds of 1 000 MW PV capacity; 1 000 MW wind
capacity and 200 MW CSP capacity – which I think is excellent.
Included in this issue is a summary of a proposal for carbon trading in South Africa by
The views expressed in this
journal are not necessarily
Promethium Carbon. The idea is to allow clean and emissions mitigating projects to register and
those of the publisher or the sell their emissions savings on the JSE as carbon credits. These can then be bought by a carbon
editor. emitter and used to offset the company’s carbon tax liability. This assumes that the proposed
carbon tax legislation will be promulgated in 2015.
Ramuedzisi presented systems’ costs for the different test cases, including those for liquid fuels
for the transport industry, which dominate the total energy costs and would mostly be imported.
Extracting the infrastructure costs for electricity generation, though, the most expensive of the
analyses emerges from the carbon tax test case (R310-billion) and while the base case does result
in the lowest infrastructure cost (R189-billion), the emissions limit and no nuclear emissions limit
cases, at R199- and R203-billion, respectively, are not massively more expensive.
Transparency You Can See
Average circulation I am convinced that reducing emissions is a priority that outweighs, by far, the cost-based
(July-September 2013) analyses of these different test cases. Surely it is obvious that we need to maximise the use of
3 728
renewables and minimise the use of coal. And surely too, if the base load shortcomings of renew-
ables are an issue, then nuclear is the most obvious coal replacement option.
Isn’t it time to commit to an emissions reduction strategy? Why are we even considering
Printed by:
reneging on agreed targets?
Tandym Print – Cape Town Peter Middleton
Mechanical Technology — February 2014 1
⎪ February 2014 contents ⎪
10 16 24 30
ON THE COVER FEATURES
Proactive maintenance, lubrication and contamination management
10 Fuel overflow protection reduces waste
Procon’s Andy Miller talks about Hydrau-Flo and its proven zero spillage capability
that can result in savings of between R1- and R5-million per year for a single site
mining operation.
13 Local office adds value to service offering
17 A new spin on industrial filtration
Materials handling and logistics
16 Complex design of chute systems at Black Rock Mine
Using its proprietary Weba Chute systems, M&J Engineering has completed the
complex design for ten chute systems comprising two for the tilt conveyors, four
for the silo discharge and four for the crushing circuit at Assmang’s Black Rock
Mine, about 80 kilometres north-west of Kuruman in the Northern Cape.
18 Complex heavy lifts at Port of Ngqura
20 Process equipment must be globally competitive
22 Modular plants, apron feeders and export success
Heating, cooling, ventilation and air conditioning
24 Newtown Junction: from potato shed to green building
The increasing efficiency of sampling Atterbury is currently in the construction phase of its Newton Junction Development
laboratory filtration systems in downtown Johannesburg, which, as well as housing Nedbank’s consolidated
In support of onsite ore sampling at Johannesburg offices, will comprise 36 000 m² of shopping centre, gym and four
well-established local mines and remote levels of basement parking with approximately 2 400 bays. Atterbury Property
operations across Africa, Donaldson Development is also planning to build a hotel on the site in the near future. Mech-
Filtration Systems in South Africa is Tech talks to WSP’s Simon Berry, future cities thought leader for energy and green
developing newer and more efficient buildings; and Lindsay Lund, the company’s technical director, mechanical, about
the HVAC system for Nedbank’s green office space and for the mall below.
filtration solutions for both mobile and
28 Generation 5 positive displacement blowers
super laboratories. MechTech talks to
Hilton Knight, the company’s sales en- Manufacturing technology
gineer responsible for laboratory-based 30 SA’s engineered rubber products manufacturer
systems. Tega Industries South Africa is currently upgrading the manufacturing facilities on
For more information contact: its new 45 000 m2 site in Vulcania, Brakpan. Its Industrial division has already
Hilton Knight moved and the Mining division is set to follow in April. MechTech talks to Kirby
Sales engineer Vermaak, the company’s national sales manager, about engineered aftermarket
+27 11 997 6000 solutions and Tega’s just-in-time manufacturing philosophy.
+27 11 997 6039 Innovative engineering
hilton.knight@donaldson.com 32 Carbon trading as offsets against the proposed carbon tax
www.donaldson.co.za In a report for consultation published recently by Promethium Carbon, a mecha-
nism for carbon trading is proposed that works within the South African carbon tax
legislation scheduled for implementation in 2015. Funded by the Prosperity Fund
of the British High Commission, the report is the culmination of a project started
in August 2013 and completed in January 2014.
REGULARS
1 Comment
4 On the cover: The increasing efficiency of sampling laboratory filtration systems
8 Industry forum
34 Products and services
36 Nota bene
Mechanical Technology — February 2014 3
⎪ On the cover ⎪
The increasing efficiency of sampling
laboratory filtration systems
In support of onsite ore sampling at well-established local mines and remote operations across
Africa, Donaldson Filtration Systems SA is developing newer and more efficient filtration
solutions for both mobile and super laboratories. MechTech talks to Hilton Knight
(right), the company’s sales engineer responsible for laboratory-based systems.
M
ining operations and explo- laden air is extracted from the furnace
ration sites typically have rooms and sample preparation work-
an onsite ore-sampling stations via ducting connected to each
laboratory to enable mine piece of equipment. “All of the dust is
owners and customers to monitor the extracted and passed through a dust
day-to-day yield. Ore samples are collector, such as the Donaldson® Torit®
brought up from the mine and deliv- Downflo® (DFT), a leader in the industry
ered to a laboratory, where it is dried, for over 20 years.
crushed, split and pulverised. Then, DFT dust collectors use Donaldson’s
using ‘fire assay’ processes, samples proprietary Ultra-Web® filter media and
pass through a furnace before being cleaning technology and provide higher through the dust collection system out-
analysed for their metal and other efficiency and smaller footprints than side, therefore reducing the dust loading
mineral content. baghouse dust collectors and most on the filter unit, which in turn allows
“Pulverising, putting samples other cartridge collectors. for a smaller unit to be installed, as well
through a furnace and analysis proce- Knight explains two new and exciting as a smaller fan using less power,” he
dures produce harmful dust and fume, innovations that are again reducing the responds. “This design is fast becom-
so an extraction system is an essential footprint of dust collectors and improv- ing the norm in Canada and the US,
part of any laboratory,” says Knight, ing efficiency: not only of the extraction because it is a more efficient way of
adding that constituents like lead and system itself, but also of the amount of extracting and processing particulate
NiS particles in the exhaust stream dust handling and peripheral equipment from exhaust streams,” he adds.
must be filtered out to comply with necessary for an effective system. Typically, a plenum chamber for a
safety and emissions legislation. sampling laboratory is about 1,5 m
Showing the general layout of a The plenum design deep and sits immediately behind the
‘superlab’ for a platinum mine Knight A plenum is an enclosed chamber that laboratory’s equipment and worksta-
explains that, traditionally, the dust allows substances like dust to collect for tions. A simple vent allows extraction
later safe processing or from the equipment and workstations,
disposal. The plenum while separate ducting is used to con-
dust extraction design nect the plenum to the extraction unit.
involves incorporating A Donaldson Torit DownFlo filter unit
“false walls into the is used to draw off airborne dust from
back of a lab to create the plenum. “The suction created by the
a single chamber. By Downflo fan puts the whole chamber
putting this chamber under negative pressure. This draws
under negative pres- dust and fume from inside the lab into
sure, all of the dust the plenum. The heavier dust particles
from the workstations drop out in the false chamber, which
and equipment gets allows a lower capacity Downflo unit
sucked into the space system to be used,” Knight says.
inside this chamber. Also, by keeping the heavy dust out
The advantage? of the dust extraction system, the air-
“The plenum allows flow speed through the cartridge filters
heavy (high density) can be increased to around 1,0 m/min.
dust to settle out in the “On a traditional system with heavy
plenum chamber. This particulate passing through the extrac-
means that only the tion system, the filter rate has to be kept
Donaldson’s Torit PowerCore technology. Donaldson has already installed lighter airborne dust down to about 0,5 m/min, to prevent
one of these systems for an ore-sampling laboratory in Mauritania. needs to be extracted the dust from blocking and damaging
4 Mechanical Technology — February 2014
⎪ On the cover ⎪
the filter media. By removing the ‘heav-
ies’ before the filter cartridges, this filter
rate can be doubled, ie, increased to
1,0 m/min, which allows the total
filter area when using a plenum-based
designed to be halved,” he points out.
For an air volume of 6,0 m3/s, for
example, or 360 m3/min, using the
maximum industry standard speed
for filtering heavy dust, the air volume
needs to be divided by the filtering area
to give the filtration velocity or air to
media ratio. “For a traditional Downflo
design, therefore, 720 m2 of filter area
will be needed,” Knight calculates, “and
since each cartridge provides 21 m2 of
filter media, the system requires 34
cartridges for effective filtration.”
Comparing traditional and plenum-
based designs, Knight points out
that, because the heavy dust is being
dropped out, the filtering speed can Donaldson’s Downflo DFT dust collectors with proprietary Ultra-Web® filter media in use at a seed
be increased to 1,0 m2/min, hence corn plant.
only 360 m2 of filter area is needed, plenum technologies.
ie, 17 cartridges. “So, by using ple- “Also, on traditional designs, heavier
num technology, instead of needing a dust loading on the media results in
4DF32 – four rows of filters and 32 higher pressure drops (∆P), so you need
Downflo cartridges – one can now use a more powerful fan, making the system
a 4DF16, with only 16 cartridges,” he less energy efficient,” Knight adds.
explains. Working back to calculate the
filter speed for this solution, Knight says Mobile labs
that 16 cartridges of 21 m2 each gives Key historical successes for Donaldson
a total filter area of 336 m2, with an are the Torit filtration systems used for
airflow of 360 m3/min through the filter, mobile sampling laboratories. “We have
divided by 336 m2 of filter area results installed numerous mobile lab systems
in a 1,07 m/min air speed through the over the years through-out Africa. These
media – “perfectly safe for Downflo labs are built into standard 6-ft contain-
Ultraweb filter cartridges extracting ers, which are fitted with all of the test- For most ore sampling laboratories, dust
lighter dusts,” he says pointing towards ing equipment needed by the inspection is extracted and passed through a Donald-
an illustration comparing traditional and specialist, such as SGS. son Torit Downflo (DFT) dust collector.
Left: For an air volume of 6,0 m3/s, for example, or 360 m3/min, a traditional Downflo design limits the air filtration speed to 0,5 m/s and therefore
requires more filter area (720 m2). Because the heavy dust is being dropped out when using the plenum design, the filtering speed can be
increased to 1,0 m/min, hence only 360 m2 of filter area is needed. Right: PowerCore, mostly because of the new cartridge design, has a 50%
smaller footprint than the traditional baghouse and cartridge collectors.
Mechanical Technology — February 2014 5
⎪ On the cover ⎪
The fine fibres of Ultra-Web nanofibre technology enables surface loading, while with traditional media (right) dust is collected
throughout the thickness of the media. Surface loading enables more efficient removal of the dust by a reverse pulse system.
We install modular ducting systems from each piece of equipment to extract to
the Donaldson filter unit located outside the mobile lab.
“For shipping, we place the Torit DFT and the ducting inside the container. At
the time of installation at the mine, the filter is removed from the container, placed
outside and then coupled to the ducting system. So one can quickly establish a
working sampling laboratory almost anywhere,” says Knight adding that these
mobile labs are used in remote mines all over Africa.
New Torit PowerCore
The second exciting innovation is Donaldson’s PowerCore technology. “We have
already installed one of these at a laboratory in Mauritania, with the PowerCore
system replacing the traditional Downflo system,” Knight reveals, PowerCore,
mostly because of the new cartridge design, has a 50% smaller footprint than the
traditional baghouse and cartridge collectors. PowerCore: every second row of flutes is blocked to
PowerCore has a much larger filter area per cartridge compared to Downflo the outlet, while alternate rows are blocked to the
or any other cartridge- or bag-based filter system – achieved by making use of inlet.
the honeycomb effect to maximise media area. “The dust
laden air comes into the bottom of the collector and enters
rows of triangular flutes in the filter cartridges. Every second
row of flutes is blocked to the outlet, while alternate rows
are blocked to the inlet. The air is therefore forced to pass
though the nanofibre filter media walls that separate inlet
and outlet flutes. This gives a higher filter area and lower
differential pressure.
Along with the fluted design innovation, PowerCore tech-
nology uses Donaldson’s Ultra-Web nanofibre technology,
which maximises surface loading capacities, and a new
proprietary compact pulse cleaning system. The combina-
tion of these technologies offers lower operational pressure
drops and, therefore, more efficient energy use. “One 7-inch
PowerCore filter cartridge pack can be used to replace six
8-ft bag filters,” Knight claims. “PowerCore is ideally suited
to our mobile lab solutions because of its smaller size, and
on the plenum solutions, with their higher filter speed, an
even smaller solution can be used by adopting the new
technology,” he adds.
The smaller size and footprint of Torit PowerCore filter
systems means lower installation costs, while “maintenance
downtime is halved, because you have fewer filters to replace
and these are easily accessible and easily handled from the
clean side of the system”. Currently being widely adopted in
the mature markets of the US and Europe, Donaldson’s Torit
PowerCore solution will be released into the African and South
African markets during 2014.
“Donaldson Filtration Systems has solutions for ore sam-
pling and onsite laboratories for platinum, gold, copper, and
coal mining operations, and with the addition of PowerCore
later this year, we will be in a position to offer the smartest and
most cost-effective solutions available,” Knight suggests. q
Mechanical Technology — February 2014 7
⎪ Industry forum ⎪
Intelligent grinding solution for Kazakhstan copper project
In addition to a grinding mill order Driven by automated control, the solu- process design, engineering, com-
earlier this year, Altay Polimetally has tion is designed to monitor overall plant plete equipment supply, controls and
now chosen Metso as the supplier of a efficiency and to guarantee maximum instrumentation and electrics, trans-
complete grinding system for their new ore recovery,” says Serge de Backer, portation and installation. The project
copper mine in Kazakhstan. The order business manager, Crusher Systems, complements two energy efficient Metso
value is over €30-million. Mining and Construction, Metso. VTM‑4500-C Vertimill® vertical grind-
Altay Polimetally is targeting produc- The order which will be included in ing mill orders under a separate contract
tion of 3,0-million t/year, and including Mining and Construction’s 4th quarter earlier this year.
host rock, 10-million t//year needs to 2013 orders received data, includes www.metso.com/miningandconstruction
be crushed. The plant is scheduled to
begin operation during the last quarter
of 2014. Metso’s solution is designed Multotec sets ups bonded warehouse in Ghana
to ensure that Altay reaches this target. Lead times in the pressurised African need in a matter of weeks. At present
“Metso has designed this grinding mining industry have become a decisive 99% of this type of product is imported
system as a standalone unit, taking differentiator for suppliers. With this from Europe, Australia, South Africa or
full responsibility for plant efficiency. in mind, Multotec has established a other manufacturing hubs, and takes
bonded warehouse at Tema Port on the months to arrive on site from the date
Atlantic coast of Ghana that will drasti- of order.”
cally reduce its equipment supply lead The Multotec bonded warehouse will
times to mining operations in Ghana, concentrate on supplying consumable
Burkina Faso and Mali, all of which are equipment such as mill linings, trom-
within 2 000 km of the new facility. mel panels, vibrating screen panels,
“For many years the West African interstage screens, ceramic tiles and
mining industry has faced lead times adhesives. Vergote says this fulfils the
as long as seven months for imported “speed to market commitment within
items of consumable equipment and the Multotec’s consumables supply model”
move to establish a stockholding at a that seeks to respond as quickly as pos-
more central location is long overdue,” sible to customers’ needs.
says Multotec’s Kris Vergote. “We iden- There is also an intention to identify
tified Tema Port as the ideal site for such opportunities to establish similar ware-
a warehouse, which will be managed by house facilities in other mining centres
our office in Accra, just 25 km away. on the continent during the course of
“We’ve already begun the process 2014.
of negotiating supply contracts with In addition, Multotec has launched
customers in Ghana, Burkina Faso and a dedicated service in Ghana for the
Metso’s vertical grinding technology was chosen for
Mali, who recognise the significant installation of mill liners, screen panels
the grinding system of Altay Polimetally’s new copper value to be gained from being able to and the servicing and calibration of ore
mine in Kazakstan. access the consumable equipment they samplers. www.multotec.com
EU and SA commit to science and technology collaboration
The EU and South Africa will step up support work through respective funding planned association to the EUREKA
collaboration in the fields of global health programmes of the Global Alliance for Network for industrial research. Other
research, earth observation and research Chronic Diseases. possible future areas of cooperation dis-
infrastructures, according to senior of- In the context of the post-2015 strat- cussed were marine research including
ficials following the 12th joint Science egy for the Group on Earth Observations the possible opening of the Atlantic Ocean
and Technology Cooperation Committee (GEO) both parties will explore a possible Research Alliance initiative towards new
meeting that took place Brussels to review joint action to support the AfriGEOSS partners, such as South Africa, minerals
and plan new priorities of collaboration initiative and Africa-EU GEO-related
research and innovation, the bio-economy
under the EU’s Horizon 2020 programme. cooperation. In the domain of research
and water and waste management.
The EU and South Africa pledged to infrastructures, the EU and South Africa
Scientific collaboration between South
mobilise broader African participation. will discuss synergies between the
Africa and the EU was established under
The European Commission welcomed European Strategy Forum for Research
the commitment from South Africa to Infrastructures (ESFRI) and the South the Science and Technology Cooperation
become a full contributing member of African national research infrastructure Agreement concluded in 1996, which
the EU programme’s general assembly. roadmap. Cooperation in the area of radio entered into force in November 1997.
The parties also decided to collaborate astronomy will specifically be encouraged, South Africa is also very committed in
within the framework of the Global including support for the Africa-European playing a role to strengthen EU scientific
Research Collaboration for Infectious Radio-Astronomy Platform (AERAP). cooperation with the rest of Africa.
Disease Preparedness and continue to The meeting took note of South Africa’s www.dst.gov.za
8 Mechanical Technology — February 2014⎪ Industry forum ⎪
ARTsolar and BYD enter production agreement
In brief
ARTsolar, the South African owned PV
manufacturer, has committed a portion Consulting engineering and project imple-
of its KwaZulu-Natal plant’s 75 MW mentation firm Hatch was honoured with the
production capacity to manufacture PV Service Excellence Game Changer Award at
modules for BYD, the world’s largest an awards ceremony on December 9, 2013,
during the Canadian Solar Industries Associa-
producers of rechargeable batteries.
tion’s Solar Canada 2013 conference. A panel
“This agreement is a positive devel-
of judges recognised the firm’s outstanding
opment for ARTsolar, which, apart from services to the Canadian solar industry.
uplifting the profile of PV technology ARTsolar has committed a portion of its
in the sub-Saharan African market, 75 MW production capacity to manufac- South Africa’s Minister of Science and Tech-
has increased local employment and ture PV modules for BYD. nology, Derek Hanekom has visited the UK’s
enhanced skills transfer,” says Ronald technologies, which are designed to STFC’s Rutherford Appleton Laboratory as
part of an ongoing effort to further strengthen
Lange, chief operating officer, ARTsolar. solve global energy and environmental
collaboration between the two countries. “I
“With the production of ARTsolar PV issues.
have been most impressed by what I have
modules, which adhere to stringent BYD’s reputation as a premier global seen and look forward to a strengthening of
quality specifications, BYD is able to partner in the renewable energy field co-operation between South Africa and the
confidently implement its global expan- has been enhanced by participating at facilities located at RAL”.
sion programme.” leading international exhibitions, includ-
CAD House has opened a Personal Manufac-
BYD, the first Chinese enterprise to ing the SPI show in the USA and the
turing laboratory with 3D Design, 3D Scanning
win the “Zayed Future Energy Prize” in Intersolar show in Germany.
and 3D Manufacturing capabilities. The com-
the large enterprise category, has been ARTsolar commenced production plete 3D Development solution is on offer on
acknowledged for its commitment to of PV modules for BYD at the start of a membership plan basis. Training options are
the development of advanced renewable 2014. www.artsolar.net also available and the Lab is open to groups
from schools, universities and businesses who
want to learn or to use 3D Printing processes.
Set Point Laboratories expands into Gabon
According to the Institution of Chemical Engi-
Set Point Laboratories (SPL), A Division credited sample preparation procedure.
neers (IChemE), fears that the world is about
of the Set Point Group has announced “Our client base in Gabon are as- to run out of helium are subsiding, but major
the complete set-up of a mineral sample sured of quality analytical results in technological advances are needed to ensure
preparation facility in Libreville, Gabon, quick time, with the added benefit the long-term supply of this valuable, but
West Africa. of reduced courier costs,” says Gerrit elusive element. The latest assessment of the
Aligned to its vision of being the Fouche, regional manager of Set Point future supply of helium was recently published
preferred supplier of analytical services Laboratories. “Savings are also passed by co-authors William Nuttall, professor of en-
to exploration and mining industries on to our clients thanks to our com- ergy at the Open University; Bartek Glowacki,
throughout Africa, the new facility, petitive pricing. These savings, coupled professor of energy and materials science at the
located next to the railway station in with our attentive, personalised service University of Cambridge; and Richard Clarke,
a Fellow of IChemE.
Libreville, is the latest in a host of is what distinguishes us,” continues
mobile facilities intended to serve the Fouche. ECSA’s acting CEO, Edgar Sabela, has
African Mining industry. Set Point Laboratories Gabon will congratulated the class of 2013 on passing
The samples are prepared at this also serve as a sample drop-off point their matric examinations. “The 2013 matric
facility (dried, weighed, crushed and for clients requiring water analysis. The results are gratifying,” he said, but “we are
split, repacked), and couriered to Set samples can be dropped off at the prep concerned about the overall quality of the
facility, and Set Point will coordinate results coupled with inadequate performances
Point Laboratories in Johannesburg,
in the mathematics and science fields, both
South Africa for analysis. The sample the transport of the samples to their
critical markers for acceptance into studying
preparation is conducted according to accredited laboratories in South Africa.
engineering at a tertiary level.
Set Point Laboratories ISO 17025 ac- www.setpoint.co.za
Xylem Water Solutions South Africa, has
promoted Heinrich Louw to regional market-
Lincoln Lubrication SA moves to new premises ing and communications manager (Middle-
Lincoln Lubrication SA (LSA), renowned for lubrication and fast fill systems, has East and Africa). “The appointment was an
moved from Fifth Avenue, Alberton North to Indianapolis Boulevard, Raceway obvious choice due to Louw’s strong strategic
Industrial Park, Gosforth Park, Germiston. marketing background and potential to lever-
The move has been eagerly anticipated, stemming from the group’s growth age marketing synergies between the African
over the past few years. The new 800 m2 and middle-eastern regions,” says Said Zelna
Mare, HR manager, Xylem Water Solutions SA.
of office space and 2 000 m2 workshop
will enable LSA to streamline service Earthmoving equipment manufacturer Shantui
requirements and turnaround time. has displayed its commitment to expansion
Founded in 1992, LSA provides a in the African mining and quarrying sectors,
range of asset protection management following the official local launch of its new
products and services. www.lincolnsa.com 48-ton SE480 excavator.
Mechanical Technology — February 2014 9⎪ Proactive maintenance, lubrication and contamination management ⎪
Fuel overflow protection reduces waste
Today more than ever before, it is the responsibility of companies and their employees
to be aware of pollution and its environmental consequences. While the first principle of
environmental management is that prevention is better than cure, accidents and spills do
happen. It is for this reason that Procon Environmental
Technologies was established in 1993.
T
he company of- authorised distributor
fer a full scope of the range in August
Procon Environmental of environmen- last year.
Technologies chair- tal products and According to
man, Andy Miller.
technologies, specialising Procon’s, Andy Miller,
in systems that minimise the impact the Hydrau-Flo
of contamination on the environment range’s proven
and surrounding areas, as well as zero spillage
remediation services if contamination capability
does occur. means that a
Overfilling, spillage and tank rup- single mining op-
tures are persistent challenges in the eration could save anywhere between
international mining sector where large R1-m and R5-m per year by changing to
fast-fill fuelling systems pump diesel the Hydrau-Flo range. “Hydrau-Flo fea-
at up to 1 000 ℓ/min. An ineffective tures advanced zero-spillage technology
overflow protection solution could, that substantially minimises safety and A cutaway of
therefore, equate to more than 16 ℓ of environmental hazards associated with the leak-free
Hydrau-Flo fast fuel filling
diesel being spilled per second – result- fuel transfer,” says Miller.
valve system.
ing in considerable environmental dam- Although new to the South African
age and higher costs related to wastage market, Miller adds that Hydrau-Flo has is now fitted with Hydrau-Flo.”
and downtime. been tried-and-tested in Australia since Miller says Hydrau-Flo is “a consid-
The Hydrau-Flo fuel filling valve its introduction in 1997. “The product erably safer and more effective alterna-
system is manufactured by Australian- has gained unprecedented popularity tive” to industry standard pressurised
based mineral process equipment man- during this time as a result of its zero- overflow systems. “In these types of
ufacturer, Weir, and environmental man- spillage capabilities. This is clearly systems, the pressure does not entirely
agement expert, Procon Environmental evident in the fact that about 80% of prevent spillage, but rather slows it
Technologies, was appointed as an all heavy mining equipment in Australia down. And a large build-up of pressure
Procon’s new MD reveals the company’s 2014 objectives
P
rocon Environmental Technologies, to this portfolio,” he reveals. gies market. He
has officially appointed a new Kerlen believes his knowledge of the believes that the
managing director, Kuno Kerlen, African mining and petrochemical market, outlook is posi-
who boasts a wealth of experience and ex- together with his engineering skills and tive for the long
pertise in the international petrochemical strategic management expertise, will as- term, as South
and mining engineering industries. Kerlen, sist him in achieving his objectives. African industries
who took up the reins at Procon Environ- “I gained experience as a petrochemi- are becoming more aware of their broader
mental Technologies in November 2013, cal project manager in the Netherlands social role in the communities in which
plans to increase Procon’s “geographical and South Africa before moving into an they operate.
footprint through expansion into strategi- executive position in the petrochemical “These companies understand that
cally selected African markets”. and mining engineering sector. I also polluting their local operating environ-
“A number of African countries offer a have experience in the local automotive ment does not endear them to the local
great opportunity to expand our market, supplier industry, dealing with OEMs as communities and, by extension, the local
especially since we offer such a unique a key account manager. I will be leverag- government. Procon is uniquely positioned
product range and service offering. Also, ing all of this experience to achieve key to benefit from this, as its products offer
we have plans to enhance our current objectives,” he says. superior performance compared to tradi-
product offering through technical innova- Kerlen is optimistic about the future of tional systems, which often do not meet
tion and add some exciting new products Procon and the environmental technolo- environmental discharge standards.” q
10 Mechanical Technology — February 2014⎪ Proactive maintenance, lubrication and contamination management ⎪
could result in rupture, which is associ- on investment
ated with significantly higher fuel wast- (ROI). Miller
age and the risk of injury to personnel.” is confident of
Although similar products are cur- the outcome.
rently available in the local market, “The results are
Miller says Hydrau-Flo is the only expected early in 2014 and,
system that boasts zero-spillage and a judging by the overwhelm-
three year warranty. “Hydrau-Flo is a ingly positive response re-
better quality product than any similar ceived by the onsite engineers
offerings, and the unrivalled warranty to date, I believe that the ROI
is clear proof of this. It is also the only will be highly competitive.” Hydrau-Flo’s proven zero spillage
capability can result in savings of
system of its kind that cannot be over- Despite the proven advan-
between R1-m and R5-m per year
ridden by the operator, which ensures tages of Hydrau-Flo, Miller for a single site mining operation.
no human error.” admits that it will be “chal-
Miller reveals that the first installed lenging” to promote a new product in expenditure. The long-term cost savings of Hydrau-
Hydrau-Flo system in South Africa is a “volatile” mining market. “Commodity Flo have been proven in international markets and
currently being used on a trial basis at prices are not faring particularly well, we will use this as our main focal point moving
a coal mine in Mpumalanga. “Procon and this is prompting mines to reduce forward.” q
was able to install the systems on all
the relevant mining equipment within
an hour and, since officially adopting
Procon Environmental Technologies
Hydrau-Flo, the client has reported that Procon Environmental Technologies’ core focus is the prevention and treatment of oil
spillage has been entirely eliminated.” pollution in soil and water. The company has installed over 300 oily water treatment
As part of the trial project, university solutions across Africa varying in value from R150 000 to R65-million. Its experienced
students who have obtained bursaries teams handle bioremediation projects varying from 200 ℓ to 400 000 ℓ spills for major
clients throughout southern Africa.
through the mine are currently calculat-
The project management team is able to offer standardised or custom-built solutions as
ing the amount of spillage that occurred
per client requirements and the company has secured exclusive partnerships with several
before the implementation of Hydrau-
international companies that are world leaders in their field of expertise.
Flo, in order to quantify an exact return
Mechanical Technology — February 2014 11⎪ Proactive maintenance, lubrication and contamination management ⎪
Local office adds value to service offering
Professional consulting services provider, GMC Global, which was acquired in
2012 by engineering consulting firm, SMEC, has established a local office in
Johannesburg South Africa, to expand its geographical footprint.
increasing market activities to promote He discloses that GMC Global
the company’s services. recently assisted an internationally
“GMC Global assists clients in estab- recognised mining client in “increasing
lishing and executing their vision and its revenue by more than US$17‑million
strategies, by supporting leadership through the implementation of a
capabilities and enhancing technical custom-designed maintenance improve-
skills to deliver optimal and sustain- ment programme”.
able results. One of its key roles is in Prinsloo says that, in addition to
the evaluation and implementation of providing “a measurable increase in
SMEC South Africa’s CEO, Dr Thomas
Marshall.
enterprise asset management systems revenue”, the implementation of the
for mining companies,” he says. maintenance programme also provides
G
MC Global regional manager Marshall adds that SMEC tailors the client with a 600% return-on-
for Africa, Schalk Prinsloo, its mining sector engineering services investment while increasing plant
says, “GMC Global will focus to meet local conditions, particularly availability by 16%, obtaining a 5%
on strategic asset manage- for mines located in remote regions. improvement in plant throughput, and
ment work pertaining to mining and oil “SMEC recognises the importance of achieving 66% completion of planned
and gas projects, by drawing skills and sustainable infrastructure services such maintenance strategies.
knowledge from existing departments as energy generation and telecommuni- He concludes: “The maintenance
in the GMC Group as well as local cations for the development of mines. improvement programme was designed
resources.” The company is at the forefront of to improve plant performance and parts
SMEC SA CEO, Thomas Marshall, developing sustainable energy solutions availability, while increasing enterprise
adds that combining the expertise and and utilises this knowledge to imple- resource planning to drive value. Through
experience of both companies will prove ment sustainable project outcomes for disciplined work management practices,
“highly beneficial to all clients in Africa, clients. With the combined strengths such as a coaching programme for all
as there are few local companies that of the two companies, I am optimistic maintenance staff and the introduction
will be able to provide similar high-level of the future role that we will be play- of the practical and technical aspects of
consultancy services”. ing in the development of the African global mining best practices, we assisted
“GMC Global provides professional marketplace,” he says. the client in adopting a more proactive
consulting services to the global mining, approach, which has proved to be highly
oil and gas industries and has significant successful.” q
practical maintenance, supply chain, re-
liability, professional consulting, change
management and systems experience.
I believe that the combination of GMC
Global’s asset management services
and SMEC’s mining consultancy and
management capabilities will provide
existing and new clients in Africa with
a more comprehensive and value-added
service offering,” he predicts.
Marshall adds that the acquisition
will also enable SMEC to diversify into
the resources industry and enter new
geographic markets in North America
and South America, where GMC Global
has a strong presence. “This forms
part of SMEC’s growth and diversifi-
cation strategy, which the company
is successfully implementing through
a combination of organic growth and
strategic acquisitions.”
Prinsloo discloses that, over the next SMEC tailors its mining sector engineering services to meet local conditions, particularly for mines
two years, GMC Global will focus on located in remote regions.
Mechanical Technology — February 2014 13⎪ Proactive maintenance, lubrication and contamination management ⎪
A new spin on industrial filtration
High-efficiency, maintenance-free cyclone technology is replacing conventional dust and
exhaust filters because of the rapid ROI due to a smaller spend on filtration maintenance
and replacement.
C
Ian Fraser, chairman
urrent industrial filtration into the atmosphere,” Fraser explains. vide sufficient
of RTS.
methods often require costly filtration for
maintenance and filter mem- Constant resistance, most environmental applications,
brane replacement on an on- consistent performance such as transformer rooms and control
going basis. However, Tshwane-based “Unlike conventional filter membranes, rooms, without the addition of second-
Rand Technical Services (RTS) offer which clog due to pressure build-up ary filters.
robust, highly-effective inertial spin over time, the pressure drop across “In applications requiring secondary
filter technology for industrial dust and the spin filter module never increases. filters to remove finer particles, such
exhaust separation, which is virtually The units are self-cleaning and do not as in air compressor intakes, the spin
“maintenance-free”, says Ian Fraser, block when correctly installed, thereby filters substantially extend the life of
chairman of RTS. offering consistent performance with the secondary filters. Conventional filter
“Spin filter units are a high-efficiency constant resistance. They are highly membranes are left with very low dust
application of cyclone technology. Air to energy-efficient too, as the pressure loadings and last far longer. There is
be separated is blown through a module drop though the spin filter is constant also a beneficial ripple effect on cost-
that consists of a series of small vor- and does not increase as dust is re- saving throughout the plant.
texes. The air flow is induced to spin by moved,” he says. “Downtime from planned and un-
fixed vanes at the entry to the vortexes, “Not only is pressure constant for the planned shutdowns is greatly reduced
and centrifugal force then drives the dirt life of the unit, but the unit itself has – and with less damaging friction from
particles to the outside of the vortex,” an exceptionally long working life. We dust particles, this means less equip-
explains Fraser. have installations still going strong after ment wear and tear, or failure.”
“The dirt-laden air is purged through 23 years. The sturdy, high density poly-
an annular port at the end of the vortex propylene construction of the blocks is Protects switchgear and
tube. A purge fan is used to keep the highly resistant to erosion. Spin filters electrical systems
dirt-laden waste air in flight, from where are proving to be very effective in mining Fraser says that a “substantial reduc-
it is either dispersed or collected as applications with heavy dust loads. This tion in switchgear and other electrical
required. Clean air then exits to pro- technology is finding wide application system breakdown is achieved once
cess,” he explains, adding that 98% in coal, gold, diamond and other min- spin filters are installed. Even when
of particles of 15 µm and larger are ing environments and is also meeting planned maintenance for other equip-
removed by this simple process. arduous dust removal challenges in ment is delayed or overlooked, the units
“In some industries this is particu- underground applications. deliver consistent, maintenance-free
larly useful for materials reclamation, “We have built up a population of performance to keep electrical systems
as the environment is protected and, spin filters in mining and industry that functioning reliably,” he says.
at the same time, valuable fines are includes MCC rooms, control rooms,
recovered that would otherwise be lost transformer rooms, machinery spaces Environmental benefits
and workshops, to name but a few. “The benefits of the spin filter system
This technology has also proved effec- are almost endless. Return-on-invest-
tive for the cooling of variable speed ment is rapid due to a substantially
drive installations,” says Fraser. smaller spend on filtration maintenance
and replacement – not to mention the
Unlimited capacity ongoing reduction in equipment break-
He explains that the spin filters are down and support costs,” he explains,
constructed in modules that can adding that “environmental benefits are
be built up into large panels, sized also considerable, due to the reduction
to match required air flow, offering in undesirable emissions”.
“an unlimited capacity” on engineered “Without filtration, many processes
systems. would literally grind to a halt and pollu-
“The smallest available unit, con- tion and unhealthy working conditions
taining one Inertial spin filter module, would be greatly increased. Inertial
handles from 1 200 to 2 500 Nm3 spin filters have succeeded, even dur-
Spin filter units are a high-efficiency application of
per hour with ease, and upper range ing depressed economic conditions,”
cyclone technology. Air flow is induced to spin by fixed
vanes at the entry to the vortexes, and centrifugal capacity is only determined by the he says, adding, “They keep on saving
force then drives the dirt particles to the outside of application, and the available space.” time, labour and money long after they
the vortex. Fraser says that spin filters pro- have paid for themselves.” q
14 Mechanical Technology — February 2014⎪ Proactive maintenance, lubrication and contamination management ⎪
New range of cylinder covers launched
With the official launch into South Africa of a range of Seal Saver protective cylinder covers
in 2013, wear control specialist, Filter Focus, has introduced a breakthrough in preventative
maintenance tools to the African marketplace.
F
ilter Focus COO, Craig FitzGer- the rod seals. “Once in the system, plemented with success-
ald, says that the new Seal these tiny particles can act as a lapping ful results in numerous Craig FitzGerald, COO
at Filter Focus.
Saver range is designed to compound, causing wear to valves and industries worldwide,
extend the life of hydraulic cyl- pumps, and eventually damaging the and he is confident of achieving similar
inders and hoses. “It is a simple solution entire hydraulic system. Seal Saver success in the African market.
to a variety of hydraulic and air cylinder helps to stop the influx of contaminants, “Continued investment in Africa has
rod maintenance issues because of its to ensure the hydraulic system remains prompted the need for better quality
excellent resistance to heat, oil, chemi- clean and operational, saving equip- products. Given the international track
cals and water,” he explains. ment owners time and money in repairs record of Seal Saver, I am optimistic
According to FitzGerald, the Seal and unexpected downtime.” that it can add value to some of the
Saver range is available in ballistic Seal Saver is manufactured in the most demanding environments in
nylon, Kevlar or silicon models, which USA, where it has developed a ‘tried Africa, including construction; mining;
can all withstand temperatures up and trusted’ reputation over the years. waste management; refineries; mari-
to 1 000°C. “The Velcro closure and FitzGerald adds: “The solution has nas; recycling; wind turbines;
wrap-around design makes installation been proven to extend the life of the concrete; and oil and gas,” he
quick and easy, with no disassembly of cylinders, as it prevents harmful dust concludes. q
the cylinder required. Once installed, and debris from damaging the cylinder.
the Seal Saver opens and closes like When a cylinder needs to be replaced,
an accordion as the cylinder works.” Seal Saver can be reused on the new
FitzGerald adds that the Seal Saver cylinder for up to 25 years.”
range also prevents silt-sized particles FitzGerald says that more than The Seal Saver range for
from entering the hydraulic system via 50 000 Seal Saver units have been im- hydraulic cylinders and hoses.
Mechanical Technology — February 2014 15⎪ Materials handling and logistics ⎪
Complex design of chute systems
at Assmang’s Black Rock Mine
Using its proprietary Weba Chute systems, M&J Engineering has
completed the complex design for ten chute systems comprising
two for the tilt conveyors, four for the silo discharge and four
for the crushing circuit at Assmang’s Black Rock Mine, about
80 kilometres north-west of Kuruman in the Northern Cape. The
challenging design on an additional contract for four diverting chutes
on top of the silos has also been completed. The tilt conveyor and silo
discharge chutes have been approved for manufacture and will be delivered
to the mine by the end of the third quarter of 2013.
The vibrating feeder discharge onto a
M
conveyor.
&J has a longstanding re- rial sizes, shape and throughput,” he
lationship with Black Rock continues. Above: The Nchwaneng II Plant at Black
Mine, having previously “M&J Engineering provides designs Rock Mine in the Northern Cape.
designed and manufac- and solutions that meet these needs
tured 29 of the mine’s chute systems. and furthermore ensures that the fin- for a tilting conveyor. Material is trans-
“We receive repeat business from our ished product is of the highest possible ferred from the tilting conveyors that
customer base for a number of reasons. quality to provide decreased downtime feed the silo and the crushing circuits.
Before any project is undertaken, we and wear, increased productivity and a These two chutes are required for
carefully and extensively consult with favourable return on investment. Our the material feed, which comes from
the customer regarding their specific team of highly experienced engineers is different sources.
needs,” says Mark Baller, managing available at any stage, before and after One chute handles lump sizes of
director of M&J Engineering. installations, to discuss any issues or up to (minus) 450 mm. These materi-
“It is important to factor in the queries with the customer,” he adds. als are conveyed and then transferred
direction of flow and velocity of the Ted Cruickshank, projects manager through the chute system. The capacity
calculated volume and type of material of M&J Engineering, points out that is 1 100 tph on an incoming 1 050 mm
in each application, while taking into the second contract required a unique wide belt running at 1,85 m/s. The
account belt width, belt speed, mate- design, as the transfer point had to cater outgoing belt, which feeds the crushing
16 Mechanical Technology — February 2014⎪ Materials handling and logistics ⎪
circuit, is 900 mm wide and travels
at 2,0 m/s. The second chute on the
tilting conveyors moves material with
a particle size of minus 150 mm to
the silo circuit on the identically-sized
incoming and outgoing belts.
“We had to accurately determine
the conveyor feed trajectory to elimi-
nate spillage and at the same time
minimise the wear and tear. During
our discussions on the design with the
mine personnel and their vendors, we
utilised FEA (finite element analysis) to
ensure that the transfer point solution
would optimally transfer material in
line with the mine’s requirement,”
Cruickshank states.
“It was critical at this point in
the project to not only acquire
approval on the verification
of the design from the mine
input, but also to construc-
tively utilise their feedback
Above: The plant feed head chute onto the conveyor at
in the process. While this Nchwaneng II Plant at Black Rock Mine.
portion of the contract was
Left: The bin discharge onto the feeder chute.
extremely onerous, it was also
very fruitful and will ensure a lenges such as the design on Black
benchmark transfer point for the Rock Mine’s chutes. By stretching the
mine,” Cruickshank says. capabilities of our engineers we are able
The design of the four chutes on top to benefit customers on future projects
of the silos was no less complicated. through this extended knowledge and
The silos are fed from tilt conveyors, lump sizes. The crusher discharge chute experience. Through the application of
with the material being transferred at a was designed for ease of maintenance, what the engineers have learned, we
maximum lump size of minus 150 mm, without affecting the requisite 500 tph are then able to provide a chute system
with a throughput of 900 tph and a bulk throughput of minus 150 mm crushed that is a plant enhancement, rather
density of 2,5. material,” Cruickshank continues. than a potential bottleneck,” concludes
“We had to cater for reversible “M&J Engineering embraces chal- Baller. q
conveyors by using shuttle discharge
boots to ensure that the material is
discharged in the direction of the outgo-
ing conveyor. As a specific requirement
in this instance, we had to ensure that
the tolerances were exact. This required
extensive design and engineering verifi-
cation during the design process.”
The four chutes which form part of
the upgrade on the crushing circuit will
supply a grizzly feed chute, a grizzly
oversize discharge chute to a crusher,
a fines discharge chute from the grizzly
(undersize), and a crusher discharge
chute.
“The maximum lump size feed-
ing into the crushing circuit is minus
450 mm and the oversize maximum
tonnage is 400 tph. The grizzly un-
dersize chute is designed to cater for
500 tph, with a maximum lump size
of 450 mm, while the oversize chute
feeding the crusher is designed to ac-
commodate 400 tph at minus 150 mm The conveyor head chute into the crusher.
Mechanical Technology — February 2014 17You can also read
