As the demand for raw material continues to surge, the spotlight has turned to the mining sector, bringing both greenfield and brownfield mining projects into focus.

Ensuring these ventures are efficiently executed without compromising on time or budget necessitates a tailored strategy. Often, this means relying on the expertise of an Engineering, Procurement, and Construction Management (EPCM) contractor.

Successful partnerships

David Claassen, Managing Director of Trafo Power Solutions, firmly believes in the importance of partnering with adept EPCM professionals and says the key to successful partnerships lies in comprehending the EPCM domain. Established in 2017, Trafo Power Solutions specialises in dry-type transformers and has established robust collaborations with EPCM contractors globally, especially across South Africa, Africa, Australia, and Canada.

According to Claassen, Trafo Power Solutions’ consistent successes hinge on several principles, which include understanding project complexities, fostering effective communication, flexibility in adjusting to evolving project scopes, access to proven technology and products, and delivering timely results.

“It’s vital to understand that each project has its uniqueness, and our team successfully navigates this by adopting an “understanding strategy”, emphasising the importance of collaboration to manage the complexities,” he says. “Our deep comprehension of the project process helps us pinpoint and provide the most suitable solution tailored to customer needs.”

EPCM contractors handle intricate tasks such as detailed engineering and design. Trafo Power Solutions contributes by suggesting alternate solutions, ensuring efficient procurement, avoiding redundancy and ensuring the best outcomes for every project.

Communication is the cornerstone of successful project execution. With various EPCM entities employing different communication tools and software, Trafo Power Solutions prides itself on its adaptability. “Our flexibility allows us to mesh with any project team, irrespective of their chose software,” Claassen notes. He emphasises that this adaptability optimises project management processes, contributing to each project’s success.

Integrity and collaboration remain at the core of Trafo Power Solutions’ operations. Their dedication to understanding project requirements and prompt responses ensures minimal risks and streamlined operations. As Claassen aptly puts it, “The collective goal of stakeholders is the successful execution of a project. “Trafo Power Solutions, in partnership with TMC Transformers from Italy, offers top-tier dry-type transformers, emphasising quality and reliability. As the world shifts towards rapid infrastructural developments, such collaborations and expertise will only become more invaluable,” Claassen concludes.

Long regarded as a leading brand in abrasive slurry applications, KREBS® Technequip® knife gate valves now allow less stockholding of spares through the enhanced interchangeability of components.

Most of the components are standard across the range, explains Herman Britz, Regional Product Line Manager for Pumps, Cyclones and Valves at FLSmidth. The upgrade of the legacy products has ensured that customers need to keep a smaller variety of parts in their inventory.

“While the bodies of the flange-type valve and the wafer-type valve will differ, for instance, other components like the gate, actuator and wiper blades are standard,” says Britz. “This means that the components for a 200 mm flange valve, for instance, will also fit on the 200 mm wafer-type valve.”

This benefits the supply chain and helps customers to reduce their stockholding. With an extensive footprint in mineral processing, the KREBS® Technequip® valves are used across a range of commodities and materials – from phosphates to the platinum group metals.

Design

“The focus of our design was for harsh, abrasive applications – where these valves have proved their worth globally,” he says. In sizes from 50 mm up to 1,3 m in diameter, the valves match the pipe sizes in the market and are designed to deal with a wide range of pressures and process conditions. He highlights the ‘full port’ nature of the valve, reflecting that the valve’s inside diameter will be the same as the pipe when the valve is fully open.

“This reduces any pressure loss as the material passes through the valve, and ensures that there is no turbulence, which also reduces the wear rate,” he explains. “The gate removes itself completely from the flow of material, which is a key differentiating factor.”

He also points to the valves’ push-through or self-cleaning design. This is essentially a self-flushing function which eliminates the need for a packing gland. As the gate closes during actuation, material is ejected out of the bottom of the valve, ensuring that there is full closure of the gate and a reliable seal is created. Another vital contributor to the valves’ durability and performance is the internal wear sleeve.

“The wear sleeves on our knife gate valves are the only surface that is in direct contact with the slurry,” says Britz. “By protecting the other parts from wear and tear, the sleeves reduce the need for replacement of parts.”

A bubble-tight seal ensures that there is no spillage, whether the valve is open or closed. Importantly, the sleeves can also be replaced in the field, so there is no need to take the valve to a specialised workshop.

“On our flange-type valve, a technician can simply remove the retainer flange and take out the sleeve, replacing it with a new part and returning the retainer to its position,” he says. “This is certainly a stand-out feature when compared to most products on the market, and helps our customers avoid undue downtime.”

Tailings, the waste products from mining, can be liquid, solid or a slurry, and may contain toxic substances. To avoid these substances from contaminating water sources or polluting the environment, mines contain them in tailings dams and are required to maintain and monitor them to ensure they remain safe.

When tailings dams fail, the consequences can be lethal, which is why it’s important that drainage systems remain operational and function efficiently. High-pressure jetting equipment can be used to ensure this is the case.

“The way most tailings dams work is that a slurry of mining waste is piped into the dam, and the solids then settle to the bottom. The water is recycled to be used in the separation process again,” explains Sebastian Werner, MD of Werner Pumps, leading manufacturer of high-pressure jetting equipment in South Africa.

“Aside from ensuring that the dam walls are sound, it’s also important to monitor drainage. If the drainage system gets blocked, it can pose major safety risks.”

If the drainage system gets blocked, it causes flow restriction and can affect safety factors such as the degree of saturation in the dam, and phreatic surface levels. Blockages can be caused by anything from algae build-up to mineral deposits.

“To avoid or deal with blockages, regular jet-rodding is recommended,” says Werner. “This entails using high-pressure water jetting equipment to scour the walls of the drainage system to allow water to flow freely by unclogging the pipes. It can also assist in identifying damaged pipes.”

Werner Pumps supplies trailer-mounted high-pressure jetting units, which can be used for cleaning domestic sewer lines, as well as water sandblasting. The units are high-quality, 100% locally manufactured, and customisable for every customer’s specific requirements, with models available for every need. They range from 8 litres per minute to 500 litres per minute, with pressures from 50 Bar to 2800 Bar and power from 2.5kW to 500kW, while the ultra-high-pressure units (such as those used in the tailings cleaning applications) offer 1000 Bar and are also suitable for applications such as rubber and scale removal.

Extras available include a Werner low-water inlet switch, high-pressure jetting hose (20m, 30m or 50m), a high-pressure gun with lance, nozzle holder and fan nozzle, and the Werner small hose reel for smaller diameter hoses, for cleaning of household lines.

“We initially designed the trailer units for domestic applications and smaller sewerage clearing operators and municipalities who were looking for a more cost-effective option than investing in a truck unit, but we’ve found that because they are so easy to transport, they are much lighter and they can get into tight spaces, they are ideal for other niche applications,” says Werner. “We have a customer who uses one of our trailers not only for tailings dam maintenance on the mines, but also for clearing out piping in the boreholes they drill too. The trailer-mounted unit continues to be one of our most versatile offerings.”

About Werner Pumps

For over 30 years, Werner South Africa Pumps & Equipment (Pty) Ltd. has been designing, manufacturing, supplying and maintaining specialist high-pressure jetting equipment. The company has built a reputation as a local industry leader through its focus on delivering high-quality, low-maintenance, 100% South African manufactured products that last, all while considering clients’ budgets.

Aside from its in-house manufacturing capabilities, Werner Pumps specialises in the supply and maintenance of high-pressure jetting equipment, German high-pressure pumps, high-pressure sewer cleaning hoses, Swiss-engineered Nozzles by ENZ, and high-pressure guns, lances and cleaning equipment.

Despite their envisaged benefits, adopting Clean Coal Technologies (CCTs) in new coal-fired power entails bearing a significant cost burden. Are organisations willing to bite the bullet?

By Nick Barnes

“To keep global warming to no more than 1.5°C – as called for in the Paris Agreement – emissions need to be reduced by 45% by 2030 and reach net zero by 2050.”

This is the pledge by the United Nations’ Net Zero Coalition on Climate Change.

It is a clarion call for everyone to play a part in reducing greenhouse emissions from their respective activities.

However, there is a huge burden on industries that utilise huge volumes of fossil fuels, as they are classified as the biggest producers of emissions.

Coal-fired power plants

Coal-fired power plants are one of the biggest producers of greenhouse gases. Greenhouse gases emitted by coal-fired power stations include but may not be limited to SOx, NOx, CO2, and particulate matter (PM). And so, industries that utilise or own coal-fired power plants should adopt measures to reduce emissions.

The reality

In an ideal world, industries should ditch coal and adopt the cleaner options of renewables and nuclear. Nonetheless, the reality is that coal constitutes a big part of the current sources of electricity (currently 29 of the world’s electricity sources).

Based on the state of affairs, coal will remain a significant source of electricity in the foreseeable future. This is not least in South Africa where coal-fired power plants supply baseload electricity.

On the role of coal, the World Coal Association could not have put it more perfectly by stating: “It is not the use of coal but the way coal is used that should be the focus of attention.“ In other words, the world has to use coal responsibly with minimal impact on the environment.

It is now or never.

Currently, in many countries, South Africa being one of them, coal-fired plants are approaching the end of their life about to be decommissioned. As a replacement, new plants will be developed. Thus, there should be more urgency.

Clean Coal Technologies (CCTs)

Thanks to recent advances, in new coal-fired power plants Clean Coal Technologies (CCTs) can be incorporated, where applicable, to minimise emissions. In the power generation context, CCTs refer to technologies that meet the need for a maximum amount of energy with minimum waste production while increasing the overall plant efficiency.

But the question is: Are industries willing to go the extra mile for the sake of achieving the collective good in the long term? Would economics allow them?

First of all, it is important to analyse the options available, and the commitment to adopting them entails.

Available CCT options

So far, three main CCTs deployed and operational globally are High-Efficiency, Low-Emission, or HELE, pollution abatement, and carbon capture utilization and storage (CCUS) technologies.

1. HELE

The scope of ‘clean coal’ has been extended to include supercritical and ultra-supercritical coal-fired plants. Also known as High-Efficiency Low-Emission (HELE) plants, characteristically, these are without CCTs and run at 42-48% thermal efficiency.

Compared with a subcritical unit, typically, HELE plants typically cost more than a subcritical unit on average. For instance, the capital cost of ultra-supercritical (USC) HELE technology is 20-30% more than a subcritical unit.

However, this is offset by higher efficiency which reduces emissions and fuel costs to about 75% of subcritical plants. Usually, a supercritical steam generator operates at very high temperatures and pressures (above 22Mpa). This is a stage where the liquid and gas phases of water are no longer distinct.

Countries that demonstrate that supercritical and ultra-supercritical plants are workable are South Korea and Japan. In these countries, about 70% of coal-fired power comes from supercritical and ultra-supercritical plants.

2. Abatement

There are several techniques employed in the abatement of coal. These include:

• Washing coal

Cleaning coal by washing aims at reducing emissions of ash and sulfur dioxide when burning coal.

• Electrostatic precipitators and fabric filters

Electrostatic precipitators and fabric filters can remove 99% of the fly ash from the flue gases

• Flue gas desulfurization

The process of Flue gas desulfurization aims to reduce the output of sulfur dioxide to the atmosphere by up to 97%. This is dependent on the level of sulfur in the coal and the extent of the reduction.

• With Low-NOx burners

With Low-NOx burners, coal-fired plants can reduce nitrogen oxide emissions by up to 40%. When used together with re-burning techniques, Low-NOx burners can reduce NOx by 70%. Furthermore, when used with selective catalytic reduction, low NOx burners can clean up 90% of NOx emissions.

• Integrated gasification combined cycle (IGCC)

Integrated gasification combined cycle (IGCC) and pressurized fluidized bed combustion (PFBC) enable higher thermal efficiencies still up to 50% in the future.

• Pulverised coal Ultra-clean coal (UCC)

Pulverized coal Ultra-clean coal (UCC) from new processing technologies reduces ash below 0.25% and sulfur to very low levels. This implies that pulverised coal might be used as fuel for very large marine engines, in place of heavy fuel oil. So far, there are at least two UCC technologies under development. However, wastes from UCC are likely to be a problem.

3. Carbon Capture Utilisation and Storage (CCUS)

Carbon Capture Utilisation and Storage (CCUS) encompasses gasification and sequestration.

Using steam and oxygen, gasification, including underground coal gasification (UCG) in situ, turns the coal into carbon monoxide and hydrogen.

Sequestration refers to the disposal of liquid carbon dioxide, once captured, into deep geological strata.

Cost burden

It is tempting to ask: Why doesn’t industry go all out in embracing these CCTs considering the urgency?

Well, as with any business, in adopting the CCTs, the first consideration is cost and benefit – The board would be thinking: “What impact will it have on the bottom line? What is in shareholders Return On Investment?”

The fact: based on evidence from projects, well-meant efforts to implement the CCTs may not always have the much-desired end. The World Coal Association notes this in its review: “Some of these (CCTs) impose operating costs and energy efficiency loss without concomitant benefit to the operator.“

Specifically, there is concern that in the quest to adopt the CCTs, the cost of achieving low, near-zero emissions would negate the economic competitiveness of coal. Generally, CCT technologies are both costly and energy-intensive.

Slow uptake

Small wonder, in its Energy Perspectives, the International Energy Agency (IEA) laments the slow uptake of CCS: “CCS is advancing slowly, due to high costs and lack of political and financial commitment.“

Meanwhile, as the world dithers to adopt CCTs, coal emissions worsen global warming. Unquestionably, the sooner commercial-scale technologies are embraced, the better.

Realistic option

Accordingly, the IEA urges timely interventions, especially the available CCTs.

While owners of coal-fired power plants doubt the commercial viability of adopting CCTs, the IEA sees a realistic option in CCUS. The body hopes to see owners of coal-fired power plants embracing CCUS to put the world on the path to net-zero emissions. In a report on CCUS in its Energy Technology Perspectives 2020 series, it explains: “It is the only group of technologies that contributes both to reducing emissions in key sectors directly and to removing CO2 to balance emissions that cannot be avoided” (i.e. including direct removal of CO2 from the atmosphere).“

Enabling environment

More importantly, governments have to play a pivotal role by creating an enabling environment for industry to fully embrace CCTs. One of the options is through tax breaks. To offset the financial losses due to the perceived liability of compliance, governments can incentivise industries by providing tax breaks for companies adopting CCTs.

The importance of correct bearing installation is paramount in industrial machinery. And this is particularly important where major plant is subject to arduous and continuous use in demanding industries, including food, beverage, primary processing, timber, sugar, mining, energy, and oil and gas.

All these industries cannot afford downtime caused by 16% of all bearing failures, which specifiers attribute to incorrect installation. Maintenance specialists say this is likely to be a big contributor to shorter service life and maintenance safety hazards, says hydraulic tensioning specialist, Technofast Americas.

But an obstacle to eliminating bearing setting problems in recent times has been restricted supply of proven, cost efficient bearing setting equipment, either because it is not available because of production lapses in the industrial gearing up following Covid, or because delivery has been delayed in stretched supply lines, says Technofast Americas Founder and CEO John Bucknell.

In response to these challenges, the company has boosted its capabilities to meet tight maintenance deadlines globally, while also lowering the competitive cost of the wider range of bearing setters it is producing to meet demand for cost efficient proven product.

“The big plus of a specialist and agile company like ours it that we can respond to changing market conditions and needs sooner and better than slower older suppliers. This is winning us more markets for our proven technology, including Technofast EziTite bearing setters, which we can manufacture to all sizes for precisely mounting or dismounting typical elements such as bearings, shaft couplings, through to specialist items such ships’ propellers, and rudder pintles,” says John Bucknell.

“When a new bearing is incorrectly mounted – be it by way of poor fitting, brute installation force, or incorrect tools – it can lead directly to premature and sometimes very swift bearing failure,” says Bucknell. A poorly installed bearing is not only a pending production liability in terms of service life, but also in terms of expensive downtime and the OH&S factors involved in getting the worn part out again when it fails prematurely,” he says.

“Crude approaches may be quick, but they can be nasty and dangerous, risk damage to machinery shafts, and make subsequent bearing failure analysis either difficult or impossible,” says Bucknell, whose safety-engineered and money-saving hydraulic tension solutions are used in time-critical fastening and service applications.

Bearing sleeve withdrawal example

These same qualities of speed, precision and avoidance of downtime while ensuring worker safety were demonstrated in service with a bearing sleeve withdrawal operation when assembling a new mobile crusher and conveyor. It was being commissioned on-site to make road-base gravel for applications such as new highways and worksite infrastructure.

The newly imported machine – purpose-built to be assembled where needed for immediate service – required precision technology that was demonstrably superior to old methods such as using a hand-made jig laboriously fabricated for the purpose, with no way of determining if the process was accurate.

The EziTite ® Bearing Setter employed its high-pressure hydraulic oil feed (at 700 bar) to compactly, powerfully, and precisely to complete the process in a controlled and carefully governed process.

“Use of the EziTite Bearing Setter was simple, with the assembly screwed into place and energized with a pressure pump. The internal pressure generated acted upon the internal annular piston to press against bearing’s inner race, driving the sleeve,” said Bucknell. Once the bearing sleeve operation was complete, the pressure was released, and the EziTite Bearing Setter removed.

Technofast’s EziTite hydraulic bearing setters are available in standard sizes, or they can be produced for custom applications in as little as two weeks, further reducing potential downtime, says Bucknell.

The principle of the EziTite Bearing Setter’s operation is similar in operation to the standard Technofast EziTite Hydraulic Nuts used globally – except the nuts don’t have the mechanical locking ring used on bearing installation tasks, says Bucknell. On these, a standard locking nut and washer are set to maintain correct operating preload.

Technofast’s ranges of EziTite, EziJac ® and CamNut products are proven globally in mission-critical applications where speed, precision and avoidance of downtime are paramount. They are easy to fit and remove with little physical effort, optimising safety, and minimising downtime.

About Technofast

Technofast Industries is a worldwide leader and specialist in Bolt Tensioning, providing innovative and effective technical solutions along with uncompromising customer service.

As the demand for raw material continues to surge, the spotlight has turned to the mining sector, bringing both greenfield and brownfield mining projects into focus.

Ensuring these ventures are efficiently executed without compromising on time or budget necessitates a tailored strategy. Often, this means relying on the expertise of an Engineering, Procurement, and Construction Management (EPCM) contractor.

Successful partnerships

David Claassen, Managing Director of Trafo Power Solutions, firmly believes in the importance of partnering with adept EPCM professionals and says the key to successful partnerships lies in comprehending the EPCM domain. Established in 2017, Trafo Power Solutions specialises in dry-type transformers and has established robust collaborations with EPCM contractors globally, especially across South Africa, Africa, Australia, and Canada.

According to Claassen, Trafo Power Solutions’ consistent successes hinge on several principles, which include understanding project complexities, fostering effective communication, flexibility in adjusting to evolving project scopes, access to proven technology and products, and delivering timely results.

“It’s vital to understand that each project has its uniqueness, and our team successfully navigates this by adopting an “understanding strategy”, emphasising the importance of collaboration to manage the complexities,” he says. “Our deep comprehension of the project process helps us pinpoint and provide the most suitable solution tailored to customer needs.”

EPCM contractors handle intricate tasks such as detailed engineering and design. Trafo Power Solutions contributes by suggesting alternate solutions, ensuring efficient procurement, avoiding redundancy and ensuring the best outcomes for every project.

Communication is the cornerstone of successful project execution. With various EPCM entities employing different communication tools and software, Trafo Power Solutions prides itself on its adaptability. “Our flexibility allows us to mesh with any project team, irrespective of their chose software,” Claassen notes. He emphasises that this adaptability optimises project management processes, contributing to each project’s success.

Integrity and collaboration remain at the core of Trafo Power Solutions’ operations. Their dedication to understanding project requirements and prompt responses ensures minimal risks and streamlined operations. As Claassen aptly puts it, “The collective goal of stakeholders is the successful execution of a project. “Trafo Power Solutions, in partnership with TMC Transformers from Italy, offers top-tier dry-type transformers, emphasising quality and reliability. As the world shifts towards rapid infrastructural developments, such collaborations and expertise will only become more invaluable,” Claassen concludes.

With every mine or quarry site needing to evaluate dewatering requirements at some point, it is important to determine the exact nature of potential water problems to inform the design of a fit- for-purpose dewatering solution.

Marnus Koorts, General Manager Pump Products at Weir Minerals Africa, advises that for every dewatering project it is important that the customer works with an original equipment manufacturer (OEM) that understands the environment, site conditions and specialises in dewatering solutions.

In any mining environment, water comes from several sources, with rain being the most prolific in some regions. However, other sources such as natural seepage and aquifers can yield a significant amount of groundwater, especially in underground mining operations which can lead to considerable disruption of operations with costly consequences.

Dewatering plan

A comprehensive, reliable and flexible dewatering plan is therefore essential to remove excess water from working areas in order to allow operations to continue while safeguarding operators and maintaining productivity.

Several factors are worth considering before selecting and installing a dewatering solution, and this should start with a thorough assessment to facilitate the design and build of a fit-for-purpose dewatering solution that is site-specific, cost effective and manageable.

“Each operation’s dewatering requirements are different,” says Koorts. “Consequently, we believe that dewatering solutions should be customised to suit the site conditions. At Weir Minerals, we don’t supply a dewatering solution without first going to the site to assess the different parameters that determine an optimal solution for the operation.”

Another critical factor to consider is the head pressure required to pump the water out of the pit. Many of the pits are very deep, which means additional booster pumps are needed to overcome the large vertical lift. Based on the mine site configuration and whether an open pit or underground operation, these could be positioned at multiple levels to help raise the water.

“The characteristics of the water can have an impact on the final equipment and materials used. For example, the pH range, temperature, corrosive and abrasive content all play a critical role in selecting the equipment to transport water effectively. The presence of solids in the water, the specific gravity, size distribution and content percentage will determine the type of pumps required,” he says.

In addition, Koorts notes that there is an industry perception that dewatering is just about the pump itself. He, however, cautions that a pump is only one part of the equation with a dewatering systems comprising numerous critical components including pumps, drive units, priming systems, control systems, control valves and discharge piping.

“It is critical that the preferred dewatering system OEM be able to integrate all these various components into a single system. At Weir Minerals we have a large portfolio of in-house and external components that allow us to provide a fit-for-purpose dewatering solution and take responsibility for the entire system’s performance. These include multiple pumping solutions, drive units, pontoon barges, electrical control systems, hoses, discharge piping systems and hydrocyclone separators, amongst others,” concludes Koorts.

Tailings, the waste products from mining, can be liquid, solid or a slurry, and may contain toxic substances. To avoid these substances from contaminating water sources or polluting the environment, mines contain them in tailings dams and are required to maintain and monitor them to ensure they remain safe.

When tailings dams fail, the consequences can be lethal, which is why it’s important that drainage systems remain operational and function efficiently. High-pressure jetting equipment can be used to ensure this is the case.

“The way most tailings dams work is that a slurry of mining waste is piped into the dam, and the solids then settle to the bottom. The water is recycled to be used in the separation process again,” explains Sebastian Werner, MD of Werner Pumps, leading manufacturer of high-pressure jetting equipment in South Africa.

“Aside from ensuring that the dam walls are sound, it’s also important to monitor drainage. If the drainage system gets blocked, it can pose major safety risks.”

If the drainage system gets blocked, it causes flow restriction and can affect safety factors such as the degree of saturation in the dam, and phreatic surface levels. Blockages can be caused by anything from algae build-up to mineral deposits.

“To avoid or deal with blockages, regular jet-rodding is recommended,” says Werner. “This entails using high-pressure water jetting equipment to scour the walls of the drainage system to allow water to flow freely by unclogging the pipes. It can also assist in identifying damaged pipes.”

Werner Pumps supplies trailer-mounted high-pressure jetting units, which can be used for cleaning domestic sewer lines, as well as water sandblasting. The units are high-quality, 100% locally manufactured, and customisable for every customer’s specific requirements, with models available for every need. They range from 8 litres per minute to 500 litres per minute, with pressures from 50 Bar to 2800 Bar and power from 2.5kW to 500kW, while the ultra-high-pressure units (such as those used in the tailings cleaning applications) offer 1000 Bar and are also suitable for applications such as rubber and scale removal.

Extras available include a Werner low-water inlet switch, high-pressure jetting hose (20m, 30m or 50m), a high-pressure gun with lance, nozzle holder and fan nozzle, and the Werner small hose reel for smaller diameter hoses, for cleaning of household lines.

“We initially designed the trailer units for domestic applications and smaller sewerage clearing operators and municipalities who were looking for a more cost-effective option than investing in a truck unit, but we’ve found that because they are so easy to transport, they are much lighter and they can get into tight spaces, they are ideal for other niche applications,” says Werner. “We have a customer who uses one of our trailers not only for tailings dam maintenance on the mines, but also for clearing out piping in the boreholes they drill too. The trailer-mounted unit continues to be one of our most versatile offerings.”

About Werner Pumps

For over 30 years, Werner South Africa Pumps & Equipment (Pty) Ltd. has been designing, manufacturing, supplying and maintaining specialist high-pressure jetting equipment. The company has built a reputation as a local industry leader through its focus on delivering high-quality, low-maintenance, 100% South African manufactured products that last, all while considering clients’ budgets.

Aside from its in-house manufacturing capabilities, Werner Pumps specialises in the supply and maintenance of high-pressure jetting equipment, German high-pressure pumps, high-pressure sewer cleaning hoses, Swiss-engineered Nozzles by ENZ, and high-pressure guns, lances and cleaning equipment.

Smart collaboration between four of SKF South Africa’s business units has resulted in plant optimisation as well as the delivery of several sustainability benefits for key customer, Wilmar SA (Pty) Ltd, part of Wilmar International Limited.

Founded in 1991 and headquartered in Singapore, Wilmar International Limited is Asia’s leading agribusiness group, ranking amongst the largest listed companies by market capitalisation on the Singapore stock Exchange. Wilmar International’s business activities include oil palm cultivation, oilseed crushing, edible oils refining, sugar milling and refining, manufacturing of consumer products, specialty fats, oleochemicals, biodiesel and fertilisers as well as flour and rice milling. The local company’s consumer products include edible oils, rice, margarine, shortening and mayonnaise.

A Global Service Agreement for SKF Services was signed through the SKF Indonesia office. When this information was shared with SKF Global, SKF South Africa identified an opportunity for providing value added solutions and services for Wilmar SA’s Randfontein plant located on Johannesburg’s West Rand, in Gauteng.

Collaboration between the customer and SKF resulted in SKF offering the management of their rotating assets within the plant,” explains SKF Territory Sales Manager, Simphiwe Siwela. “They have always relied on reactive maintenance and in line with this form of maintenance practice, bearings and other related components would subsequently only be replaced once they have failed. As a result, the customer experienced frequent and unexpected machine breakdowns necessitating unplanned shutdowns which resulted in costly losses in production time and subsequent lost company capital.”

With the customer keen to introduce RCM in partnership with SKF. SKF conducted a site inspection, meeting with Wilmar SA’s technical team Led by Mduduzi Dube (Plant Engineering Manager) and Nhlanhla Maswanganye (Maintenance Planner) to gain a full understanding of the customer’s needs.

Following the site-walk, the SKF business units – CoMo (Condition Monitoring), MaPro (Maintenance Tools), MFS (Mechanical Field Services) and Lincoln (Lube Systems) – combined their collective experience, knowledge, and competencies to develop a best product and service solutions package for Wilmar SA.

“Our recommendations included on-site monthly vibration condition monitoring for critical plant equipment, proposing both on- and offline systems,” notes Siwela. “In addition to monthly lubrication inspections on existing Lincoln systems, SKF and Wilmar decided on the installation of new lube systems for additional critical assets.”

The SKF team further proposed that Wilmar’s technical personnel be equipped with SKF maintenance tools including quick data collection (QuickCollect sensors) and laser alignment tools (MaPro) to facilitate random equipment spot checks. Siwela adds that SKF’s proposal also included training to ensure the skilful, accurate and efficient use of the SKF maintenance products by Wilmar personnel to optimise tool performance.

Wilmar SA accepted SKF’s complete solutions proposal, signing a Service Level Agreement for monthly vibration condition monitoring and inspections of Lincoln lubrication systems over a twelve-month period as well as Mechanical Field Services on an ad hoc basis. A new lubrication system for the extractor machine at the Randfontein plant was successfully installed and commissioned by the Lincoln team. The customer also placed an order for an SKF TKSA71 Laser alignment tool and a CMDT 391-PRO-KS-SL QuickCollect sensor. Siwela affirms that Basic Condition Monitoring and Laser Alignment training has already been conducted with Wilmar SA technicians.

Siwela notes that as a direct result of this on-going project, plant operation has been optimised through significantly reduced unplanned shutdowns owing to increased equipment reliability and service life. He also points out that, most importantly, machine and operator safety has been enhanced.

SKF delivered several sustainability benefits that curtail costs and contribute to the customer’s green environmental goals. In addition to a reduction in the consumption of material, direct energy and emissions during use, indirect energy consumption from supporting systems has also decreased. This aligns with Wilmar International Limited’s strategy of embracing sustainability in its global operations, supply chain and communities.

To add further value, SKF approached the OEM who supplies most of Wilmar SA’s preparation plant’s equipment/machines, proposing collaboration in terms of the bearings supply for their machines. “Our proposal was successful and the company has become one of our OE customers who now purchases directly from SKF,” confirms Siwela.

“We consider this an extremely successful project, adding value for our customer through overall plant optimisation and subsequent increased production while increasing and fortifying collaboration across SKF’s business units,” concludes Siwela. /ends/

SKF is a world-leading provider of innovative solutions that help industries become more competitive and sustainable. By making products lighter, more efficient, longer lasting, and repairable, we help our customers improve their rotating equipment performance and reduce their environmental impact. Our offering around the rotating shaft includes bearings, seals, lubrication management, condition monitoring, and services. Founded in 1907, SKF is represented in approximately 129 countries and has around 17,000 distributor locations worldwide. Annual sales in 2022 were SEK 96,933 million and the number of employees was 42,641. www.skf.com

® SKF is a registered trademark of the SKF Group.

Laverick Media Communications t/a Laverick Ntuli Communications: +27(0)79 949 1090 sonia@laverickmedia.co.za / www.laverickntuli.co.za

NEO moves forward on site

Ten months after its „birth“ GHH´s latest LHD receives a
remarkable acceptance in the market: A significant number of
orders are in the books for the new LF-10 NEO, told the
manufacturer. And there is more to come.
At 2.5 m, the loader offers the highest tipping height on the market,
according to GHH. This means that every 30 ton dump truck currently
available worldwide can be loaded in the field. The LF-10 NEO also
offers the greatest operator ergonomics in the industry, with a large
footbox, excellent visibility and superior comfort. The manufacturer
attributes great importance to the human factor: a machine can only
provide the prerequisites – its ultimate productivity is brought out by the
performance of a satisfied operator in the cabin.
The NEO marks a turning point in the portfolio of the German
manufacturer. Gradually, the other product lines are to be upgraded to
the new performance standard. The LF-10 NEO made the start, as the
class with a payload of 10 tonnes is said to be the most in demand in
the industry worldwide. Some orders have already been delivered.
A considerable number of improvements, all of which can be
measured in terms of increased performance and productivity, have
gone into the NEO series, says GHH.
A lot of changes have also been made at the factory. For example, the
improved models feature a more modular design. On the one hand, to
be able to manufacture more cost-efficiently. On the other hand, the
vehicles can now be assembled much faster at the site of operation if
transport in one piece is not possible. Despite all the robustness and
simplicity for maximum reliability and safety, telemetry solutions and
technologies also go into the vehicles. For example, to be able to
monitor the fleet remotely with the “GHH inSiTE” software. An
important factor here is predictive maintenance in order to reduce
costs for the customer.
We are not reinventing the wheel, told GHH, but the actions taken are
so substantial that customers will receive a remarkable benefit when
compared to what is currently in the market.

The LF-10 NEO is the newest version of the LF-10, one of the most
requested product in the portfolio of GHH. “The high break out forces,
efficient boom and bucket motion times as well as the strong power to
weight ratio makes the LF-10 NEO one of the best in class”, says Ingo
Rath, Product Line Manager Loaders at GHH in Germany. With a
length of 9,6 m and an overall width of 2,6 m the LF-10 NEO is very
compact and versatile for excellent manoeuvrability in a mid-seam
underground mining environment.
The standard bucket holds 4,6 m3 or 10 tons, making loading and
unloading easier and more cost-effective. Customized bucket size for
different application is available. “GHH installs the water-cooled
Mercedes OM936 diesel engine with 240 kW which is the best in the
10 ton loader size class”, says Rath. “The large fuel tank also allows
for full shift operation with no worry for refuelling mid shift and losing
valuable production time”. Exhaust gas emissions complies with EPA
Tier 3 / EU Stage IIIA on the standard machine, while EU Stage V is
also optionally available. The low fuel consumption, ease of
maintainability and robust design as well as durability and reliability of
the product all add to the low operating costs.
The LF-10 NEO has a great operators’ compartment which boasts
excellent ergonomics, control layout and general arrangement within
the cabin. The large footbox gives the operator significant space and
comfort, while the excellent visibility rounds off an already well
designed cabin. In general, the loader now comes standard with useful
safety and maintainability features such as the Proximity Detection
System (PDS) interface, which allows the integration of third-party
equipment. And optionally the loader is also available with GHH
inSiTE, a digital analytics system, and automation ready.

GHH press office
Mr Bjorn Hoffmann
Phone +49 (0)521 – 260 2513
Mail ghh-newsroom@pressways.de
Pressways PR, Ecos Office Center
Herforder Str. 69, 33602 Bielefeld, Germany