webvic-c

Read the Digital Magazine

Top Stories

Grid List

WEG Africa offers in-house access to specialised facilities including a labyrinth rolling machine for sealing strips. (Image source: WEG Africa)

Energy

Steam turbines represent mission-critical equipment for a range of industries from sugar and paper to steel and petrochemicals, but there is now greater opportunity among these sectors to generate more energy to sell into South Africa’s national grid, according to WEG Africa

Traditionally, companies using steam turbines have usually consumed all the energy they produce in their processes – with a range of benefits such as supply reliability and cost savings. As the country struggles to keep up with power demand, however, there are more opportunities for the private sector to produce excess electricity for sale into the grid.

According to Alastair Gerrard, executive energy systems at WEG Africa, this trend is already advanced in Brazil – the home of holding company WEG. Many steam turbine users in Brazil have capitalised on these opportunities by increasing their boiler efficiency.

“While it may be common in South Africa’s sugar industry, for example, to use medium pressure boilers, the Brazilian market uses high pressure boilers up to 140 bar – and gain significant efficiencies with these higher pressures,” said Gerrard. “This allows these sugar producers and other users to upgrade their facilities and considerably augment their revenues through the sale of electricity, while also paying off their capital investments much quicker.”

He points to the government’s strategic direction in establishing the National Transmission Company of South Africa, a key step in transforming the country’s electricity industry. This will open doors for more private companies to ‘export’ excess electricity into the grid, helping to stabilise supply and strengthen the foundation for economic growth.

“This has been successfully achieved in countries like Brazil, and it is exciting to see that we are making progress on this journey in South Africa,” Gerrard added. “We believe that WEG Africa has an important role to play in this endeavour – through our long experience in this field and our full service offering for steam turbine users.”

A comprehensive offering

Cobus van Eeden, WEG turbine services manager at WEG Africa, highlighted that the company offers customers a turnkey capability. It sizes steam turbine solutions according to the specific operating parameters of the customer’s application, and supplies a bespoke thermal power system. The service also includes installing the machines, commissioning and ongoing after-sales servicing and maintenance.

“As an OEM of steam turbines, gearboxes and generators, we can even help customers to assess their current equipment – whether these are WEG products or from other OEMs – and provide strategic options and recommendations,” surmised van Eeden. “In addition to our depth of engineering expertise for repairing such equipment, we can also analyse the potential for enhancing operational efficiency and increasing power output capability of the equipment.”

The company provides long term service level agreements, including contracts for preventative maintenance. WEG Africa also works with customers on their forward planning, which may include considering the transition to electricity exporting.

Unrivalled customer support

Gerrard pointed out that this approach is built on its commitment as an OEM to stand alongside customers throughout the lifecycle of the equipment supplied. He noted that, while there has in the past been some acceptance of third-party support in this field, WEG Africa favours in-house OEM support for its solutions through service level agreements that give customers confidence in the total lifecycle cost of their purchase.

“Our field service technicians – active in many African countries and offshore – are on site with customers, developing a thorough understanding of their equipment and requirements,” he explained. “We integrate this information within our various functions to deliver the most valuable response and guidance on maintenance scheduling.”

Van Eeden outlined WEG Africa’s extensive engineering capability which includes machine servicing on customers’ sites – from gearboxes and turbines to generators and control systems. Equipment requiring more intensive work can be transported to the company’s 1,200 sq m workshop east of Johannesburg, which prides itself on quick turnarounds.

“Our facility includes full engineering capabilities, including the repair and manufacture of turbine bearings as well as the ability to conduct aftermarket engineering and optimising of numerous components,” he said. “We achieve this through our skilled machinists and technical staff, working with sophisticated scanning and engineering tools.”

In-house access to specialised facilities such as a labyrinth rolling machine for sealing strips, as well as a sandblasting booth for preparing components, further underpins the quality of workmanship and efficiency – thereby minimising downtime for customers.

This article was authored by WEG Africa.

An updated H120 GC hammer. (Image source: Cat)

Construction

Caterpillar has updated several of its GC hammers, turning them into more durable and high-performance pieces of equipment

The versatile GC hammers are designed with large hammer tool diameters and deliver high-impact power in order to quickly break through tough materials encountered in a range of application such as road construction, trenching and demolition. The updated Cat H130 GC, H140 GC, H160 GC and H180 GC hammers feature powerful hydraulics and quick access to maintenance areas to increase productivity, improve uptime and reduce costs, according to Cat.

“Earlier this year, we updated the H110 GC and H120 GC models, and they have been well received by our customers,” explained Tom Munch, senior product consultant. “Expanding these feature upgrades to the H130 GC through H180 GC models gives customers a full range of durable and reliable hammer work tool solutions fully validated and matched to machines from the 10- to 55-ton class sizes.”

Durable, effective and easy to maintain

To increase production and efficiency at the jobsite, Cat has aimed to combine power with fast impact frequencies. The new hammers have large tool diameters from 155-185 mm and have high impact power.

Moreover, durability is ensured through the standard high-vibration adapter alongside power cells made of high-quality alloy steel enabling a two-stage heat treatment process. Hydraulic components are also shielded from damage by heavy-duty side places to boost reliability.

Besides durability, Cat has also taken pains to improve and simplify the way maintenance is performed on the equipment. With quick and easy access to maintenance areas already hallmarks throughout the GC hammer line, the new models now feature a slip-fit and 90-degree rotatable lower brushing for easy replacement in the field. These help to reduce service time and extend service life.

Daily tool inspection and grease points are accessible from ground level with the hammer mounted on the machine. According to Cat, this enhances safety and reduces the time for routine maintenance. Finally, reinforced connecting hardware and easy bolt tightening help to provide strong, durable joints to extend the hammer life.

Cat has also made headlines recently for introducing its new Dynamic Energy Transfer solution the can transfer energy to both diesel-electric and battery-electric large mining trucks while they are operating. Learn more in the recent issue of African Review available now.

Deployment of the Concorde Cell Plant Unit is safe and rapid, resulting in faster return on investment. (Image source: Metso)

Mining

Metso, a provider of end-to-end solutions for the aggregates, minerals processing and metals refining industries, has unveiled the modular Concorde Cell Plant Units to expand its flotation portfolio

The company outlined how the new solution consists of prefabricated and pre-installed containerised units to streamline the setup process and minimise installation work on-site.

“Concorde Cell Plant Units feature a complete sampling and automation portfolio, along with a modular basic design that conveniently accommodates add-ins,” remarked Tatu Miettinen, product manager, flotation and thickening at Metso. “This flexibility allows for tailored solutions that meet the diverse needs of our end customers and EPCMs alike.”

The new solution builds on the Concorde Cell flotation technology for efficient fine and ultra-fine particle recovery for complex ore bodies that was launched in 2021. According to Metso, this technology subsequently set a benchmark in high-intensity pneumatic flotation, reducing plant operating costs and contributing to operational sustainability through minimised energy and water consumption per ton of metal produced.

The newly-introduced Concorde Cell Plant Units reportedly offers a comprehensive solution encompassing test work and the complete plant unit as well as maintenance and service. The compact unit design integrates pre-designed components, such as connecting launders, pipes, and pump sumps, to ensure a seamless operation and enables reduced footprint and lower plant height, which facilitates easier integration into existing facilities. With this new approach, a shorter order-to-operation timeline can be achieved, allowing for more workshop hours and less site work and ultimately leading to a quicker return on investment.

The announcement comes hot on the heels of a major contract award for Metso on the continent. Click here to learn what solutions and services Metso will provide for Barrick in Zambia.

AGL received the recognition at the Invest in African Energy Awards 2024. (Image source: AGL)

Logistics

At the Invest in African Energy Awards 2024, organised as part of the Africa Energy Week (AEW), Africa Global Logistics (AGL), a leading multimodal logistics operation in Africa, received the Service Provider of the Year award

AGL provides tailor-made solutions to meet the complex requirements and unique needs of energy industry projects on the continent. It has an investment strategy of EU€500mn (approx. US$535mn) per year, allowing it to support Africa’s major transformation with the objectives of connecting the continent to the global market, supporting intra-African trade and reducing the environmental impact of its logistics activities.

According to AGL, it is this commitment to the development of innovative and sustainable logistics solutions for the energy sector in Africa that has earned it the prestigious awards. Mohamed Diop, regional director, AGL Senegal, explained, “This award is a testament to our unwavering commitment to innovation, sustainability and operational excellence. We are honored by this recognition and remain committed to supporting our customers and partners with world-class logistics solutions, serving Africa's sustainable development.”

The company is involved in large-scale projects across Africa and supports strategic initiatives such as the GTA project in Mauritania and Senegal, the development of the Tilenga CPF, and the management of Sasol's land base in Pemba, Mozambique. AGL also supports the implementation of modular and integrated solutions, adapted to the different phases of energy projects, from exploration to production.

Providing specific infrastructure and skills for logistics bases, supply chains and energy construction projects, AGL also offers advanced logistics services (4PL), renewable energy solutions, and rigorous compliance systems that ensure safety, regulatory compliance, and environmental compliance for large industrial projects.

Samaila Zubairu and Saad Al-Khalb signing the Mou. (Image source: AFC)

Finance

The Saudi Export-Import Bank (Saudi EXIM) and Africa Finance Corporation (AFC) have signed an MoU to collaborate on initiatives aimed at enhancing exports in the Kingdom of Saudi Arabia and AFC member companies

“The MoU with the Africa Finance Corporation comes as part of the bank’s commitment to enhancing international economic and trade relations,” remarked Saudi EXIM CEO, H.E. Eng. Saad Al-Khalb. “The agreement will cover several areas of cooperation, including exploring opportunities to support joint projects between companies in the Kingdom and the member countries of AFC, by providing credit solutions that support companies and institutions of all sizes and activities. It will also pave the way for local investors to benefit from promising investment opportunities in Africa, thereby enhancing the flow of non-oil Saudi exports to expand into various African markets, in line with empowering the non-oil national economy and creating a diverse and inclusive economy in line with Saudi Vision 2030.”

Confirmed on the sidelines of the 2024 IMF/World Bank Annual Meetings, the MoU will also promote the exchange of information, technical expertise and knowledge sharing between the two organisations.

Samaila Zubairu, president & CEO of AFC, added, "Strategic partnerships are vital for economic transformation, and in today’s world, no nation can tackle sustainable development alone. As such, AFC is pleased to partner with the Saudi Exim Bank, marking a major milestone in strengthening ties between Africa and Saudi Arabia. Leveraging our collective expertise and resources, we aim to contribute significantly to driving industrialization, facilitating trade and creating jobs for a dynamic economic ecosystem that benefits both regions.”

The ALPLArecycling division will produce up to 35,000 tonnes of rPET per year. (Image source: ALPLA)

Manufacturing

ALPLA, an international plastics manufacturer and recycler, has cut the red tape on its new state-of-the-art recycling plant in South Africa, marking its entry into the country’s PET recycling market

The new plant is located in KwaZulu-Natal and has been completed following an investment of around US$60mn and approximately 18 months of construction.

Once all processes have been qualified and the flakes and pellets have been approved by the customer, the facility will begin production in 2025 and will help ALPLA to produce up to 35,000 tonnes of recycled PET (rPET) flakes and food-sake rPET pellets annually in the country. Located on a 90,000 sq m site, the plant will increase the supply of rPET in the national market.

According to Dietmar Marin, managing director of ALPLA recycling, country’s beverage industry will benefit from this by receiving high-quality material and be able to meet the legal requirements. Currently, South Africa’s EPR regulation requires PET drinks bottles to contain 10% recycled material since 2022, and this will double to 20% by 2026.

The recycling plant is designed to increase the proportion of pellets and can accommodate a second extrusion line to promote the circular economy in South Africa. An additional 30,000 sq m of space is available at the site for further expansion. ALPLA will process the high-quality recycled material into PET preforms for the production of drinks bottles at the Lanseria plant, which opened in 2022.

Safe, affordable and sustainable packaging

The opening of the new facility was market by a ceremony with around 180 guests in attendance. This guest list included representatives from the South African Ministries of Trade, Industry and Competition and Forestry, Fisheries and the Environment, as well as those from the province of KwaZulu-Natal, the eThekwini Metropolitan Municipality, the iLembe District Municipality, and Austria’s Ambassador Romana Königsbrun.

Together, the guests celebrated the opening of the state-of-the-art plant that will process rPET produced at the plant in Lanseria back into safe, affordable and sustainable packaging.

“South Africa is a strategically important market for us and one in which we want to continue to grow,” commented ALPLA CEO Philipp Lehner. “Together with our customers and partners, our aim is to provide safe, affordable and sustainable packaging solutions to our customers and to continue improving standards of living. With our investments in Ballito and before that in Lanseria, we have laid the foundation for a successful future.”

Sihle Ngcamu, CEO of Trade & Investment KwaZulu-Natal, added, “ALPLA’s involvement does not only accelerate the industrialisation of iLembe District Municipality, but ensures investing in projects that support UN Sustainable Development Goals, attracting other companies along the value chain and creating several thousand jobs in the collection infrastructure.”

Most Read

Latest news