“Anything that we can do to help manage inflationary pressures, and to ensure a manufacturer can get their products to market cost-effectively – so that their customers can affordably access what they need- is always a good thing,” says Associated Energy Services (AES) Commercial Director, Dennis Williams.

“As one of South Africa’s leading operations and maintenance service providers, with a 30-year track record of providing cost-effective energy-efficiency to the chemical manufacturing sector, AES understands the important role which chemicals play in the manufacture of everything from very technical, application-specific products to commonly used, everyday consumables,” Williams explains, adding that – by advising and supporting local chemical manufacturers in the optimisation of their energy plant operations and maintenance – AES contributes to greater productivity and cost-savings, with a positive knock-on effect for industry and the economy as a whole.

A track record of good chemistry

AES began working for its first client in the chemical sector 3 decades ago, in Pretoria during the 1990s. The company supplied super-heated steam for a steam turbine. Steam was also used in the by- products recovery plant at the same manufacturer, where wash oil was heated to drive off the tars – benzene, toluene and xylene – which could then be beneficiated. The cleaned gas was then returned to the coke oven battery for use as a fuel.

AES’s role in the chemicals sector then evolved, with various manufacturers which became clients. In 2003, AES worked on a dehumidifier regeneration steam supply project for a large pharmaceutical manufacturer in KwaZulu-Natal. Here, AES’s thermal system drove hot air through a humidifier filled with an industrial desiccant to remove moisture from the production plant.

An even more recent project for a large chlorine manufacturer saw AES installing four gas-fired boilers. Since installation was completed in June this year, the company has been working closely with this particular client to optimise and improve steam production, and contain their thermal energy costs.

Steam for the people

“In the current economic climate, efficiencies across all business areas are critical. One of the significant challenges for local chemical manufacturers is global chemical producers, which make chemicals very cheaply. Local manufacturers risk having their products displaced by more affordable (but not necessarily better or safer) imported chemicals – which has massive implications,” says Williams.

He adds that the best way to manage thermal energy – and production costs as a whole – is by giving chemical manufacturers the best possible chance to maximise production efficiencies and reduce the amount of steam used.

“Although it may seem contradictory, it is in our interests to give clients the best quality thermal energy supply, and enable them to keep their demand for steam from AES to a minimum. This makes them stronger and more competitive – and that gives AES longevity on site – even though we may be producing smaller volumes of energy, he explains.

“For example, when you think of chlorine products which are used in the treatment of water, you realize that these are supplied to every municipality. Any cost or availability issue will impact on every person in South Africa, as everyone drinks water, and uses it for domestic, agricultural, manufacturing and many other applications. Therefore, the knock-on effect of AES’s energy efficiency management impacts not only on those chemical producers – but also on their supply and export chains – and even the person in the street. Think every day consumables such as washing powder, shoe polish, almost any consumable one can think of,” he says.

Steam and sustainability

The next area where AES can make a difference is by developing a client’s thermal energy efficiency plans, and also by looking at how to replace their so-called ‘dirty’, carbon-intensive fuels – such as coal – with ‘greener’, less carbon-intensive ones, to address their carbon footprint and sustainability goals.

Williams notes that the European Union recently (in October 2023) introduced stringent carbon border tariffs. Consequently, companies wishing to export chemicals must prepare to meet these strict requirements, and a specialised auditor is required to oversee the regulatory process.

AES can advise on adjustments to client’s energy plant and operations to ensure compliance. “For instance, we can offer alternative, less carbon-intensive fuels, or advise on renewable energy sources – such as biogas or biomass – or provide a sustainable energy mix. We can furnish the operational data for the client to submit to their auditors too, ” he explains.

However, it is not as simple as flipping a switch, he advises: “Typically, chemical plants are frequently very energy-intensive, featuring legacy operational footprints and equipment. Traditionally, South Africa’s large thermal energy users have relied on coal or heavy residual fuels due to cost and availability. Despite these factors, there is still an opportunity for plants to be optimised to reduce carbon intensity and improve efficiency. This is where AES facilitates the application of plant management methodologies and oversights to reveal generation benefits for the client.”

When it comes to a fuel change, AES has 3 decades’ worth of technical knowledge and experience. The company operated a biomass power station for almost 10 years with 6MWe capacity, and has also executed several technical solutions in this space.

“We are solutions-, technology- and fuel-agnostic, so we can generate steam using multiple fuels. For example, we have clients where we can generate steam using their own by-products which, under other circumstances, would simply have been disposed of, often at cost. We increase the efficiency of the overall thermal energy process for our clients,” Williams points out.

Sustainability is also an ever-changing space. “Shortages of natural gas are currently being predicted, which will see AES finding alternative sources of energy for our existing clients which utilise natural gas. This is where our accrued benefit of technical expertise and on-site industry experience really comes to the fore,” he says.

The cornerstone of steam

Williams admits that, in the chemical sector – where manufacturing is more complex and to an extent differs from other kinds – steam can either play a direct or an indirect role in the overall process, and AES works closely with its clients to arrive at the right solution.

“Thermal carriers are common to all chemical industries but, in our service level agreements, we include services which are operationally tailored to the individual client: some may have a continuous offtake which is constant and predictable; while others may operate in batches based on demand. We could have different processes running concurrently, with a lead-time for demand. We design thermal systems that are customised for the client, and often we can offer strategic input in their processes. What we have developed – which is an innovation for our industry – is a system which is applied where steam is provided from multiple boilers. Effectively, it is a load-balancing system across the boilers which has delivered significant improvements in efficiencies and visible emissions,” he says.

Overall, the AES’s competitive edge comprises technical know-how, experience, depth of institutional memory and wide-ranging ongoing research. The company is able to focus on steam production in a way that most clients would simply not be able to do if this remained under their own management.

Risky business

Notwithstanding these considerations, Williams adds that the crux of the matter will always be the provision of skilled human resources.

“We cannot get away from the importance of skills in energy efficiency management, however equally, we cannot ignore the prevailing shortage of technical skills in South Africa: not only when it comes to expertise, but also industry experience. The challenge is that these shortages can spill over into the substantial area of risk mitigation. The key part of what we do is to mitigate operational risks. We have, over 30 years, developed the baseline knowledge to successfully do this.

In fact, AES’s ISO 9 001, 14 001 and 45 001 certifications are specifically for plant operations and maintenance. Once we have the workflows set up, we make room for the inevitable project variants and we manage that risk. The chemical sector is broad field – there are fuel risks, flammable gases and liquids, emissions, hazardous chemicals, health and safety considerations and compliance requirements – right through to carbon tax.

Therefore, as a company, we invest heavily in our people, and in the training and development of staff on-site in the client’s energy plants. This is a crucial aspect of the value-add that we offer – particularly in a sector as dynamic and challenging as the chemical manufacturing industry,” he concludes.

As we prepare for another exciting Investing in African Mining Indaba in 2024, the theme of ‘positive disruption’ could not be more appropriate for the directions being forged in the field of mine blasting and explosives.

According to Ralf Hennecke, Managing Director of Omnia group company BME, mining has been facing the same winds of change that are impacting all sectors of the global economy, but has not just been adapting to new demands. Rather, the sector has been applying technologies that are taking safety and productivity to new levels.

“From our perspective as mining technology partners, BME can certainly attest to how mines are ‘Embracing the power of positive disruption’,” said Hennecke. “We have no doubt that this is a critical element of African mining’s bold new future.”

Sustainable ramp-up?

He highlighted that one of the many questions that will be posed at this year’s Indaba relates to how Africa will respond to the increased demand for battery minerals, and whether the continent can sufficiently ramp up production while sustainably managing environmental and social impacts.

“This is a challenge to be faced as much by the mining companies themselves as their entire value chain, and calls for long term partnerships dedicated to innovation and constructive problem- solving,” he said. “In the blasting space, we feel well-positioned to play our part – as our continuous improvement strategies have pushed the boundaries in terms of both sustainability and productivity.”

At the heart of what quality blasting is all about is to streamline downstream processes for mining customers. This invariably means efficiency, which has impacts on cost and carbon emissions.

Right fragmentation

In blasting, good rock fragmentation is key to unlocking the early stage efficiencies on mines, which are doubly significant because the loading, hauling and comminution phases that follow are among the mine’s most energy intensive. Making these functions smoother means that less energy is consumed, cutting costs and reducing the operation’s carbon footprint.

“It has been a long journey towards improving fragmentation,” he said. “While BME entered the South African market in 1984 as a pioneer in cold emulsion explosives, this was followed by decades of investment in emulsion technology and our range of electronic and digital solutions – as well as equipment and accessories.”

Electronic detonation

This allowed the company to constantly leverage its offering with emerging technologies over time, which it embraced by building in-house expertise and capacity. Among BME’s most valuable lines of development was electronic detonation, which continues to enhance blasting outcomes through its safety, accuracy, reliability and flexibility.

By allowing milli-second delays between detonations, and by lengthening our firing window, mines are now able to design increasingly intricate blasts to suit their geological conditions and production requirements. Mines have also been able to initiate ever larger blasts, thereby limiting their pit disruptions and blast-related downtime.

“Underpinning this capability has been BME’s own electronic initiation system – AXXIS – which is steadily evolved by our dedicated team of engineers, technicians and operators,” said Hennecke.

Software has of course been central to the positive disruption in the blasting space, and a key application has been in the planning of blasts. Today, mines can use blast planning programs like BME’s Blastmap to prepare each blast to the finest detail of complexity – then even simulate the results.

Safe blasting

A non-negotiable in Africa’s mines is the prerogative of safety, he pointed out. A high point for BME was its recent dual safety innovation in our flagship AXXIS Titanium system, where testing can be conducted at a lower voltage than detonation.

“Expanding our operations into Africa, we have applied our safety commitment to the same global standard,” he said. “As an active member of Safex – the international industry body focused on the safe application of explosives – BME applies the highest standards across our operations. This is reflected in our zero recordable case rate (RCR).”

BME has even made our contribution beyond the technical arena, and into explosives-related regulatory development in Africa. As a blasting pioneer in Africa, it was the first explosives company to be licensed in countries like Mauritania and Sierra Leone. Its experience meant it could assist government authorities there in drafting legislation that would pave the way for the responsible application of explosives.

Preventing oil hazards

In addition to supporting the mining sector’s drive towards lower carbon emissions, it has also been vital for mining stakeholders to protect the environment in every way possible. Where innovatively applied, he explained, these efforts should also lead to positive social impacts – a key element of the environmental, social and governance (ESG) priorities that are growing in importance. “BME has managed such an achievement with our used oil initiative,” he said. “By systematically and responsibly collecting used oil from customers and other sources, we remove this hazardous substance from the economy and prevent possible contamination of water and land.”

By embracing the circular economy approach, BME treats and re-uses this oil as a fuel agent in its quality emulsions, ensuring that it is safely disposed of during our high energy blasts. The benefits extend further, as the company has designed the collection network to include small businesses in local economies around mines. This assists the social responsibility efforts of mines as they work towards promoting economic diversity and livelihood resilience in their host communities.

Innovation in blasting

To support the global move towards lower emmissions, BME’s parent company Omnia Holdings has entered into a partnership with Swedish-based Hypex Bio Explosives Technology, which is at the forefront of innovative and sustainable civil explosives solutions.

“Hypex Bio has developed a ground-breaking emulsion using hydrogen peroxide (HP). This first-to- market non-nitrate explosive emulsions reduces the carbon content of blasting by 90% over traditional sources. This technology has the potential to completely change the explosives supply industry,” said Seelan Gobalsamy, CEO of Omnia.

Bold future

“It is well accepted that the bold new future for African mining cannot be business as usual,” argued Hennecke. “While companies like BME root their success in an operational foundation of secure supply chains and reliable delivery to customers across the continent, we also embrace the need for innovation and change.”

This certainly applies to services and solutions, but also to how companies create the waves of success that generate opportunities for African economies all the way down the supply chain. “With Africa as our base, BME demonstrates what the continent has to offer other mining regions of the world,” he concluded. “Africa is responding actively to the revitalised search for minerals critical to the energy transition, and can leverage a more sustainable future from this opportunity.”

Submersible pumps have long been a staple in the world of fluid handling and pumping, with their presence becoming more pronounced, especially in particular applications like sump pumping, wastewater management and numerous industrial processes.

Ruaan Venter, Rental Development Manager at IPR, says that while engineers have various solutions at their fingertips submersible pumps often stand out especially when compared to vertical spindle pumps. So, what gives these submersible devices their edge?

“First and foremost, submersible pumps are known for their superior energy efficiency,” Venter says. “This elevated efficiency not only makes them outperform their vertical spindle counterparts, but it also leads to significant cost savings in the long run.”

Space is often at a premium in many dewatering setups, and this is where submersible pumps have the upper hand. Their direct placement in the fluid they handle means there is no need for extended piping or additional external infrastructure. This innate compactness becomes a boon, especially in locations where space is tight.

Maintenance

Maintenance is also a recurring concern in any wastewater, mining or industrial environment and Venter says that submersibles come out on top here as well. With fewer moving parts than vertical spindle pumps, which often come with above-ground mechanical setups, submersible pumps are less prone to wear. This reduced wear translates into more dependable performance, ensuring a smoother operational experience.

Fluid handling is the core of any pump, and submersible pumps excel in this domain. Venter explains that due to their fully submerged operation, these pumps are essentially immune to issues like cavitation or airlocks, which sometimes plague vertical spindle pumps. This submerged state ensures a consistent and smooth pumping process, offering significantly enhanced reliability.

“But it’s not just about efficiency and reliability. Submersible pumps also promise a quieter operational experience. Their underwater functioning naturally dampens sound and curtails vibrations, offering a noise-free solution,” he continues.

Moreover, submersible pumps are stalwarts when it comes to reliability, even in challenging environments. Their underwater operation shields them from many external factors, ensuring they last longer and operate with unwavering reliability, even when conditions turn hostile.

But what if the fluid isn’t clear water? Submersible pumps have got that covered too. They are adept at processing an array of fluids, even those riddled with abrasive solids. This versatility makes them an excellent choice for varied tasks, be it sewage or other wastewater pumping applications or dewatering in intricate mining operations or sumps in buildings or other structures.

Safety is paramount, and submersible pumps dont skimp on this aspect either. Their positioning underwater diminishes risks linked with rotating parts and potential leaks, issues that are often more glaring with above-ground pumps.

In today’s age, where environmental consciousness is key, submersible pumps rise to the occasion. Many can be customised to avert fluid leaks, ensuring they operate with minimal environmental impact, adhering to contemporary ecological regulations and sustainability goals.

Lastly, their design boasts flexibility. Depending on the depth requirements, these pumps can be adapted, ensuring a fluid handling system that aligns perfectly with specific operational demands.

“The decision between submersible pumps and vertical spindle pumps really comes down to the unique demands of the application in question, but given the vast array of benefits submersibles bring to the table – from energy efficiency to environmental safety – they undeniably present a compelling argument for their widespread adoption across various sectors,” Venter concludes.

IPR is the master distributor for the full range of Atlas Copco submersible dewatering pumps, as well the Toyo range of heavy-duty slurry pumps. The company has an extensive reference base and offers its pumps for outright purchase or on a rental basis. Its skilled team can assess an individual application and propose the most appropriate solution that will ensure the lowest total operating cost for a customer.

urnKey Modular is a go-to Company specialising in off-site Construction. Recently, the company made a milestone in Sasol South Africa’s coarse ash dump project.

Prefabricated deployment, a construction process where building components are pre-built off-site in a controlled factory environment, is rapidly gaining popularity due to its many advantages over traditional on-site construction. Companies like TurnKey Modular are pioneering new fabrication methods for off-site construction and have extensive experience offering diverse prefabricated deployment solutions underpinned by technical innovation and a client-centric focus.

Sasol’s coarse ash dump project 

Recently, TurnKey Modular was tasked with designing and constructing a prefabricated solution for Sasol South Africa’s coarse ash dump project. The project required two modular structures, one of which is an 86-tonne building that is 8.5 meters wide by 20 meters long. “In terms of weight and area, it’s probably the biggest unit that we’ve done,” says Darrin Day, TurnKey Modular Operations Manager.

The building holds medium voltage and low voltage switching equipment, switching panels, DCDVs, and battery tripping units ACDB. Additionally, it has a segregated fire and explosion-resistant battery room to ensure optimal safety, as the oil and gas industry has stringent regulations which need to be adhered to. For instance, batteries in the room need to be “intrinsically safe”, which means that should there be a spark or flame, it’s all kept within an enclosure that won’t ignite any gases that may occur in the battery room. This is the third unit of its type designed by Turnkey Modular for Sasol South Africa.

Commitment to Safety

What also sets TurnKey Modular apart is its commitment to safety consciousness. The company conducts meticulous route surveys and uses engineering expertise to ensure that big loads are transported safely. For instance, on the CAD project, a D9 dozer was riding behind the truck just in case it began sliding. This level of safety consciousness was also evident in the design of the buildings, which were carefully assessed after being assembled in a fully operational state inside TurnKey Modular headquarters in Germiston, Johannesburg.

The beauty of off-site construction is that the buildings on-site in Secunda look exactly how they looked on the Turnkey Modular floor. “We stood it in the shop with all that handrails, walkways, legs, everything,” adds Day.

Before being loaded onto the truck, all the small components were removed and then sent separately on a truck. The substation is fully operational and tested before leaving the factory, and the only thing that needs to go in when it gets to the site is the cables that go in and out.

The Future of Construction 

Prefabricated deployment is the future of construction, and companies like TurnKey Modular are leading the way. They redefine what’s possible for off-site construction and ensure that every project they undertake is done with the utmost safety and precision. The CAD Project is an excellent example of their technical innovation and client-centric approach, and it’s no wonder that they’re quickly becoming the go-to company for off-site construction solutions in South Africa.

With the continued energy poverty being experienced in South Africa, motors and drives are set to play an ever more crucial role in industry’s energy solution strategy. The manufacturing and processing sectors, which include minerals processing plants, are energy-intensive industries, and finding ways to reduce energy consumption while increasing efficiencies is essential for both economic and environmental reasons.

This is according to Jaco Brits, Projects and Technical Manager at WEG Africa, who says that the company has the knowledge and expertise as well as the technology solutions to assist operations in reducing their operating costs and increasing their productivity while guarding their energy security.

“Electric motors and drives are used across industries to operate pumps, mixers, conveyors, vibrating screens and feeders, crushers, and other machinery including automated packaging systems,” Brits says.

“Advancements in motor and drive technology, underpinned by WEG’s extensive research and development, have seen substantial improvements in energy efficiency, both equipped with advanced control algorithms to optimise motor performance based on real-time conditions,” he explains. “These algorithms assist in ensuring motors operate at peak efficiency levels, even in complex processes.”

“By upgrading to newer technology and installing higher efficiency motors such as the WEG IE3 or IE4 electric motor, customers can significantly lower their energy consumption. In addition to this,” he adds, “by combining high efficiency motors with WEG variable-speed drives (VSDs), better control and optimisation of equipment can be achieved. This ensures that equipment operates at its most energy efficient speed and power level, and will reduce operating costs significantly.”

Commenting on the use of VSDs, Brits explains that traditional fixed speed motors run at a constant speed regardless of the actual load requirements. In contrast, VSDs are most effective in controlling the speed and torque of motors based on the actual load requirements. This level of precision facilitates the adjustment of the motor’s speed to match the load, thereby ensuring that equipment operates only as needed. VSDs also have faster reaction to load changes and better integration with equipment. “All these factors reduce unnecessary energy consumption during periods of low demand and enhances overall equipment efficiency and performance,” says Brits.

Unpacking advancements in drive technology, Brits points to the WEG CFW11 VSD line, which incorporates some of the most advanced technology in the world for alternating-current three-phase induction motors.

“Incorporating WEG Vectrue™ technology, these new generation WEG drives combine variable frequency, sensorless and closed-loop vector (with encoder) control techniques in a single product. This facilitates high torque and a fast dynamic response with the self-tuning function allowing automatic configuration of the drive to adjust it to the motor and load in vector modes,” Brits says.

With most industries looking at sustainable energy resources including renewables such as wind and solar, motors and drives will continue to play an important role in facilitating the integration of such systems. VSDs can be used to balance power supply and demand, and ensure stable operation in hybrid energy setups.

“Substantial efficiency improvements are possible by leveraging the latest motor and drive technology, and the significant savings in energy consumption more than justify the capital cost of replacing old technology equipment with higher efficiency technology,” Brits concludes.