We offer valves for precision processes - and demanding applications.
Our valves fulfill the highest of standards and are designed for many years of safe and reliable operation. Our service specialists regularly check, monitor and maintain all relevant system components - depending on what has been agreed. Our modular framework agreements offer you individual service and spare parts concepts. And we even go one step further. We additionally check systems for efficiency in order to reduce operating costs and increase productivity. For example, with the SES System Efficiency Service.
Inline
Sulzer
Verder strengthens its dosing pumps range with Spanish acquisition
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On the cover
Pipes, Pumps & Valves Africa
Managing Editor: Surita Marx
Tel: +27 (0) 87 700 9834
Cell: +27 (0) 83 281 5761
Email: info@pumpsandvalves.co.za
Web: www.pumpsandvalves.co.za
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Production Manager: Xane
Rely Precision Castings: driving change with innovation and expertise
Fueled by its new shareholders and a bold strategic overhaul, Rely Precision Castings is set to redefine the manufacturing industry. The company is committed to cuttingedge technology, sustainable practices, and unparalleled quality and is ready to tackle new challenges and seize emerging opportunities. Pipes, Pumps and Valves Africa finds out more.
It has been a busy few months at Rely Precision Castings, a company that has operated since the 1950s. Renowned for producing high integrity precision castings producing highintegrity castings to exact specifications, it is a business that has stood the test of time.
This resilience has been proven once again as the company survived 14 months of business rescue, thanks to the unwavering support of its clients and suppliers. This challenging period culminated in a successful buyout by a consortium of successful investors. The takeover by the new group of shareholders has placed the casting company on a new trajectory course.
Remarkably, all of this was accomplished within an election year in South Africa, which is historically challenging for business.
“Over the past 12 months, there has been a lot of change at Rely, and we have managed to emerge stronger than ever,” says Giancarlo Carrozzo, Director of Strategy and Commercialisation. “The journey to date has reaffirmed our resilience and proven that even when faced with challenges, this company delivers quality and reliability to its customers.”
Rely is one of the three investment casting foundries in South Africa. Situated in Boksburg, Gauteng, the foundry was originally established as a sand casting facility in the fifties. In 1973, investment casting capabilities were added.
According to Ian Barratt-Gibson, Production Director, the company is the largest precision casting manufacturer in Africa and the Southern Hemisphere, in terms of weight thanks to its ability to cast anything weighing only a few grams up to castings of 84kg.
“We are ISO 9001: 2015 SHEQ accredited, and we specialise in manufacturing investment castings produced according to individual customer requirements. All grades of air-melted alloys, including steel, copper, nickel, cobalt, aluminium, stainlees steel and other non-ferrous metals are poured in our foundry.”
Delivering success
According to Carrozzo, following the takeover, the company has embarked on a market expansion drive. “Growing our footprint is at the top of the agenda. We have a strategy in place that will see us invest not only in our facilities and technology but also in our staff. Skills development is important, and we continue to invest heavily in training, making sure we have the best team on board to service our customers.”
The company services a wide variety of industries, including transport, logistics, mining, power generation, water and sanitation, and general engineering. Its goal is to be a leading manufacturer in South Africa and the continent and to expand to the United States and Europe.
According to Barratt-Gibson, much of the company’s strength lies in its investment casting capabilities. “The benefits of investment casting are well-documented,” he says. “Not only can it be used to cast various ferrous
and non-ferrous alloys, but the parts require minimal if any, machining after finishing. We also achieve excellent surface finishes and can produce highly complex designs. Additionally, we can incorporate intricate design features such as logos.
“While slightly more cost-intensive upfront, investment casting proves more cost-effective in the long run. Yet, many companies still don’t realise its benefits. This process begins with a wax pattern coated in a refractory ceramic material. After drying and hardening the ceramic coating, we melt out the wax, leaving an internal cavity shaped like the final product, after which we pour in the chosen material. Once solidified we knock off the casting and perform minor fettling to create the finished product,” he explains. “Investment casting produces precise components with minimal material waste and energy consumption, virtually eliminating the need for machining.
“Moreover, we can rapidly develop prototypes that don’t require the upfront cost of a die and manufacture any quantity of components—from just a few to thousands— as per customer requirements. Not only do we work with various air-melted alloys, but we meet international standards.”
Wealth of knowledge
While investment casting minimises the need for machining, Rely prides itself on its advanced range of service offerings including machining, painting, heat treatment and polishing. “Our team is highly trained and skilled, capable of delivering bespoke solutions that meet every customer’s needs,” says Carrozzo.
The in-depth knowledge of the investment casting process is complimented by the team’s extensive application
experience and above average metallurgical applications expertise.
“Our technical team boasts over 120 years of combined knowledge, supported by a collection of over 6000 dies in our foundry.”
Ongoing investments in skills and technology underscore Rely’s commitment to establishing the foundry as a worldclass facility. “Our processes are efficient and reliable,” Barratt-Gibson emphasises. “While it takes six to eight weeks to initiate production, once underway, customers can order any quantity of their product weekly. We are not limited by production capacity in terms of personnel or volume.”
Quality remains paramount at Rely, with everything in our foundry meets world-class standards. “Our facility’s scalability allows us to adjust output as needed,” adds Carrozzo, highlighting how this flexibility benefits customers by minimising stock requirements. “We collaborate closely with each customer, delivering tailored solutions that precisely meet their requirements rather than offering a one-size-fits-all approach.”
Carrozzo encourages clients to engage directly with the Rely team regarding their needs. “As a flexible business, our agile approach enables us to deliver solutions that align with the customer’s requirements.”
Seal-less pumps for reverse osmosis water treatment
Demand for effective water treatment points to reverse osmosis.
Water is an essential substance to sustain life and one of the most valuable resources a nation can possess. Most of what is available, however, is of little use in its natural state. Water seems readily obtainable since it covers more than 70 percent of the Earth’s surface, but clean, fresh drinking water comprises barely a fraction of all available water. In fact, 97.5 percent of the world’s water is saline. Of the remaining 2.5 percent, 70 percent is locked up in the polar ice caps, and 30 percent resides in underground aquifers.
Demand for fresh water increases steadily, and researchers including Surendra N. Kulshreshtha of the University of Saskatchewan predict that half the world’s population could face water vulnerability by 2025 [1]. It is no surprise that the United Nations devotes much attention to the issue of safe, fresh water, particularly in places that have been underserved in the past. The UN released a new report in March 2009, Water in a Changing World, which is the third in series.
Equally concerning is ensuring that harmful toxins and contaminants are removed from water that manufacturing processes release in the environment. Wastewater from factory production often has levels of chemicals, pharmaceutical byproducts and other pollutants that can pose a significant risk to human beings and other life. Water and other liquids can be filtered and purified in many ways. One of the most effective methods is simple and straightforward: reverse osmosis (RO) filtration.
Design Principle
In RO filtration, liquid is forced through a semi-permeable membrane at high pressure, producing purified liquid. The contaminants are concentrated in a portion of the liquid that does not pass through the membrane and are discharged in a reject stream. Efficient RO systems employ positive displacement diaphragm pumps with a seal-less design and high pressure capability to purify large volumes of water or liquid at a time. The seal-less principle is
appealing because of its design simplicity, low maintenance and operating efficiency. Bill Wanner, CEO of Wanner Engineering, Inc. (Minneapolis, Minn.), explained how this design simplicity makes these pumps easy to operate and inexpensive to maintain. A seal-less design “removes the most maintenance intensive element compared to many other type pumps,” he said. “This not only permits the pump to operate in severe environments such as chemical treatment, but allows it to run dry indefinitely without damage, thereby avoiding a situation where operator error causes an equipment breakdown.”
Wanner added that the relatively small footprint of these RO membrane pumps is a tremendous advantage in mobile water treatment systems, such as those used by emergency management teams, offshore oil platforms and even in submarines, where space is at a premium. Due to its unique design, the seal-less, high pressure pump boasts a far more compact package than can be achieved with other pump technologies, such as multistage centrifugal pumps.
Energy Consumption
Energy usage is a major factor in the operational cost of water purification systems, so companies and organizations that rely on water treatment are extremely conscious of efficiency. It is not only important to keep costs low, but electrical power is also extremely coveted in certain environments. Oil platforms, desert desalinization plants and mobile treatment facilities are prime examples of how remote locations rely on efficient energy usage.
Manufacturers are likewise under increasing pressure to find efficiencies in energy usage, not only from their accountants, but from the general public. Going “green” is not just sensible for the bottom line, but is also smart PR. “We engineered [our pump] to operate so that a customer can use a smaller, lower wattage motor to acquire the same treatment capacity as other, less efficient types of pumps,” said Wanner. Wanner points to a number of
case studies demonstrating energy savings. In one such example, a single 12 kW seal-less PD pump replaced a pair of multistage centrifugal pumps totalling more than 18 kW, but with the same pumping capacity. The total energy savings was more than 50,000 kWh/year. Proportionate savings were shown in smaller applications, as well.
Since the seal-less, high pressure pump for RO is a positive displacement system, the flow rate remains constant even as pressure increases. This reduces the cost-per-gallon of water, the critical measuring stick when gauging efficiency. To stretch efficiency further, many customers are now incorporating energy recovery devices as well.
Reliability and Longevity
Approximately 80 percent of typical pump maintenance, according to Wanner, involves the replacement of leaking seals and packing. A seal-less design is an advantage in maintenance and downtime. In addition, these high pressure RO pumps feature a hydraulically-balanced diaphragm, so they are capable of handling virtually all particulates. According to Wanner, the pumps can handle solids of up to 500 microns, while other pump types may require the expense of a filter to prevent particulates larger than 10 microns from damaging the pump.
“We always tell our customers our Hydra-Cell positive displacement pumps handle the really miserable fluids and abrasives that destroy other pumps,” he said. “Our design enables charged and dirty liquids to be processed without the need for fine filtration to protect the pump. This reduces maintenance and allows the pump to operate continuously at high pressure.”
Wanner notes that most of these RO pumps can operate at any pressure from less than 40 psi up to at least 1,000 psi, with some models capable of operating at up to 2,500 psi. By comparison, rotodynamic pumps need to be started with 750 psi of pressure to avoid damaging the pump. When compared to piston and plunger pumps, seal-less RO pumps offer total separation of the pumped liquid from the lubricating oil, extending the life of the oil by a factor of four and reducing breakdowns.
“Axial piston pumps internally driven by water need five microns of absolute fine filtration,” Wanner added. “The filters typically cost around $500, and the elements, which should be changed every 15 days, cost about $180 each,” he said. “Those maintenance costs add up quickly, and failure to maintain the filter means very costly breakdowns.”
Maintenance cost is not the only concern. When one pump goes down for maintenance, it reduces the overall
treatment capacity. This means that additional pumps are required in large treatment facilities for redundancy. In smaller applications, it means two pumps are required when one maintenance free pump would have sufficed.
Application Flexibility
Although we tend to associate RO with water desalinization plants, it is also being used for innumerable applications in industries worldwide:
• Treatment of wastewater streams from food plants and industrial plants
• Treatment of waste solvent streams from chemical and pharmaceutical plants
• Treatment of recycled water for reuse
• Treatment of water used in boiler feed applications to prolong system life and efficiency
• Treatment of final rinse water in carwashes and in cleaning processes to aid drying and improve final result
• Disaster management water purification
Since pump seals deteriorate in the presence of corrosive chemicals, a seal-less design is often considered a necessity in everything from normal to severe-duty applications.
The Tides of Need and Demand to Rise
As the need for fresh water continues to rise and more laws regulating the treatment of wastewater are enacted, the demand for economical, energy efficient water treatment will increase. Part of this trend, driven by the rising cost of fresh water is toward localized treatment plants and units. Given the significant advantages of reverse osmosis filtration, it is no surprise that Wanner predicts this market will grow by 68 percent during the next five years.
Prime gearbox solutions from I-MAK tailored to meet pump applications
I-MAK, one of the premium global brands in the stable of bearings and power transmissions specialist, Bearings International (BI), has led the global market with a wide portfolio of gearbox and drive solutions for over 50 years.
With more than 1 000 000 references and hundreds of different product lines, I-MAK’s unique power transmission solutions cater to a large scale of applications in virtually all industrial segments. I-MAK gearboxes are widely used for diverse pump applications in the oil & gas and food & beverage sectors around the world.
I-MAK’s IR Series of Helical gearboxes is perfectly adapted to meet the stringent demands of pumps and transfer technologies which represent key applications across a broad range of industries. “The IR Series is available in twelve different sizes ranging from 90 Nm to 18 000 Nm and is ideally suited for gear and lube pump machinery,” says Kobus Groenewald, BI Product Leader: Gears. Fitted with either an input shaft or a direct IEC motor coupling and a standard foot configuration, these easy-to-mount and dismount gearboxes minimise downtime and scale up production, subsequently offering key cost-related advantages for end-users.
As a preferred supplier for thousands of crude oil producers, refineries and engineering companies, I-MAK is a key purveyor to Middle Eastern and North American oil & gas industries. The company is actively involved in several major oil & gas projects in the UAE, Qatar and Saudi Arabia. SIPCO-I-MAK in Houston, Texas, serves the US oil industry with a dedicated team of experts.
All I-MAK products are available in ATEX configuration to meet sector standards in the North American market as well as the needs of technological partners.
I-MAK has enhanced its product offering to the food & beverage industry over the past few years with the addition of several key features to meet this segment’s strict hygiene and food security demands. The application of special easy-to-wash paint and coatings on I-MAK gearboxes limit material deposits and rust, subsequently contributing to the maintenance of top hygienic standards at customers’ sites. Moreover, optional food grade oil and resistance to high temperatures and aggressive environments, reduce the potential risk of oil leakage.
“Innovation, quality and precision are woven into the fabric of I-MAK’s world-class quality, affordable, two-yearwarranty products which are backed by specialist local and international support,” says Robert Sillis, General Manager: Product Management at BI. Our strategic partnership with I-MAK therefore presents the backbone of our blueprint to provide superior quality, reliable solutions that are uniquely tailored to meet the diverse needs of a raft of industrial applications. The very high local added value of all I-MAK products aligns perfectly with our mission to enhance production uptime and efficiency, delivering our value proposition of keeping our customers ‘in motion’.”
IPR showcases rental as answer to dewatering, slurry and sludge
Cost effective and agile rental solutions for dewatering will take centre stage at IPR’s (Integrated Pump Rental) exhibition stand at Electra Mining Africa this year, as well as its quality range of slurry and sludge pumping equipment.
“Showcasing our growing range of rental pump dewatering options, we will also be celebrating our partnerships with world leading pump OEMs Atlas Copco and Toyo,” says Lee Vine, Managing Director at IPR. “The past year has seen us grow our formal collaboration with Atlas Copco and the great results are there for all to see.”
Featuring strongly at IPR’s stand will be the range of Atlas Copco diesel self-priming pumps and submersible units, says Vine, which the local market has embraced for its quality and performance. Also on show will be the range of Toyo heavy duty slurry pumps, and IPR’s in-house designed SlurrySucker dredging unit.
“There has never been a better time for mines, industry and other sectors to rent their pumping solutions from IPR,” he explains. “Pump rental allows companies to conserve their capital, and avoid high interest rates when borrowing for equipment purchases. Other key advantages are that customers incur no overhead costs with rental, and can rely on us to keep everything running smoothly.”
Vine emphasises that IPR has continued to grow its fleet in partnership with its OEM partners – whose own experts will be joining IPR’s technical and sales team at the Electra Mining Africa exhibition stand.
Steve du Toit, Sales Manager at IPR, points out that the event remains an important forum to engage with the market face to face – and to share insights and experience to improve customers’ business efficiency.
“Having a selection of our exciting products on the stand, combined with our depth of expertise, helps to facilitate valuable discussions and problem-solving with visitors,” says du Toit. “The presence of our OEM partners reinforces the strength of our partnerships – which benefit the customer through quality, performance and rapid support.”
He also highlights IPR’s in-house design and engineering capability, which underpins its customised solutions for specific challenges that mines face. This capacity is well proven through its pioneering SlurrySucker dredging unit; equipped with a Toyo heavy duty submersible pump, IRP recently upgraded its SlurrySucker to a Mk III model.
“We expect high levels of interest in water management challenges among Electra Mining Africa visitors, as we have seen how regulations are becoming more stringent,” he continues. “As retention ponds silt up over time, for example, mines face a growing risk of spillage which can cause environmental damage. There are similar problems facing wastewater treatment plants and other industrial sectors.”
Vine says that visitors to the exhibition will be impressed by IPR’s range of pumping solutions – with diesel units mainly for remote and opencast sites with no power supply and submersible electrically-powered units for underground and plant applications.
“We welcome visitors bringing their on-site challenges to us,” he says. “With our world class products and OEM partnerships, we have the hardware and experience to know what will work best for them.”
Visit IPR (Integrated Pump Rental) at stand number – YE13 IPR, +27 (0) 87 759 8654, admin@pumprental.co.za, www.pumprental.co.za
Inline pumps for space-saving applications
Pump manufacturer KSB Pumps and Valves has introduced its latest EtaLine range of inline pumps including the advanced EtaLine Pro for diverse applications such as HVAC, industrial recirculation and heating systems.
The single stage volute casing pump requires a smaller footprint while maintaining high outputs as required in tight industrial applications where space is at a premium.
The standard range of dry installed EtaLine pumps range in outputs from 1400 litres per minute to 3000 l/min making them suitable for a wide range of applications in tight quarters where performance and reliability are key.
The EtaLine pumps are engineered to excel in air conditioning, heating systems, water supply, heat recovery, industrial recirculation and cleaning circuits with key features including space-saving inline design allowing for vertical or horizontal installation, ideal for environments with limited space such as roofs or attics. Unlike traditional long-coupled pumps, the EtaLine pumps eliminate unnecessary space requirements while maintaining exceptional performance.
Despite their compact design, the EtaLine pumps boast impressive efficiency, delivering reliable performance without the need for balancing valves. This efficiency is further enhanced by the integration of a Variable Speed Drive (VSD) in the EtaLine Pro model, produced in Germany, providing users with unmatched control and energy savings.
“Our EtaLine pumps represent the pinnacle of fluid management technology,” says KSB Pumps and Valves market area manager, Dylan Mitchell. “With the innovative design and advanced features, our pumps offer
unparalleled performance, flexibility and efficiency for applications in industrial pumping solutions.”
In addition to the advanced design of our standard EtaLine pumps, the EtaLine Pro pump incorporate advanced intelligence features, including a VSD with remote capabilities and our user-friendly flow manager App. These features enable users to have greater control over their pumping systems, simplifying operation and maintenance processes from remote locations if required.
Intelligent settings available allows the pumps to adapt to the conditions for optimal performance regardless of demand and flow rates and allows vastly enhanced efficiency as a result. These pumps are designed for efficiency and longevity from the bottom up and contribute to sustainable manufacturing practices by reducing material usage and weight, aligning with global efforts to minimise environmental impacts. Their Carbon Neutral production process reflects KSB’s commitment to sustainability and corporate responsibility.
With a focus on local manufacturing, KSB aims to expand its market share and solidify its position as an industry leader in fluid management solutions.
KSB Pumps and Valves South Africa, +27 (0) 11 876 5600, annett.kriell@ksb.com, www.ksb.com
Sulzer brings motors back online and minimizes lost production
Carrying out routine maintenance can be a chore, but failing to complete regular checks on important pieces of machinery can result in unexpected downtime and lost productivity.
Sulzer’s service center in Colton, CA, recently completed an urgent repair on a 700 hp (522 kW) motor, caused by a failed bearing, that could have been easily avoided.
A minerals processing company in the USA relies on many large motors to power essential pieces of equipment such as water pumps, pulverizers and vacuum pumps. To minimize the spares inventory, they use similar motors where possible to minimize downtime.
Keeping spares on-hand
For example, seven pieces of equipment are powered by 700 hp medium voltage motors that are now around 20 years old. Aside from the essential spare parts, there is also a complete motor that is used to replace assets that are removed for overhauls every three or four years. However, some of the maintenance routines are a little sporadic.
Sulzer has regularly carried out planned maintenance and overhauls of rotating equipment for the minerals company, including the 700 hp motors, which are interchangeable between different applications. When one of the motors failed unexpectedly, it was removed from service and sent to Sulzer’s Colton Service Center for inspection and repair.
When the motor was disassembled, the inspection showed the drive-end bearing had overheated and failed, allowing the rotor to contact the stator, which damaged the windings in both the stator and the rotor as well as the bearing cap. The motor had been overhauled by Sulzer three years previous, so all the technical details of the asset were on record. This made ordering new windings much quicker, expediting the repair process.
Repeat failure
In the meantime, the rotor and stator were stripped out before checking for any defects in the laminations. In this case, some minor machining enabled any hot spots to be removed and the core loss tests achieved a satisfactory result. At the same time, a new bearing cap was manufactured in-house, ready for reassembly.
Gary Patton, Colton SC Manager, explains: “Under normal circumstances, the minerals company would have installed the spare motor and production would have continued unaffected. However, in this case, the spare had recently been shipped to us for repairs following a premature bearing failure, caused by a problem in the application”.
Unfortunately, in this case, the lamination stacks of the rotor and the stator could not be saved, so additional parts would be required, and this repair would have a longer lead time. This dual outage had a significant effect on the production volumes of the minerals processed, which dropped by 25 percent. It was essential that the latest failure was repaired as quickly as possible.
Saving a week in project time
Once the new coils were installed, along with new bearings and seals, the motor was reassembled and run on Sulzer’s in-house testbed before being returned to the customer. The expected project time was five weeks, but by expediting the coils and working two shifts, Sulzer was able to reduce this by a whole week.
Patton concludes: “On this site, we found that the vacuum pumps are located beneath another process, which means that the motor cooling ducts can become blocked with debris. Unless this is cleared regularly, the motor and bearings can start to overheat, as happened recently in this case. A simple maintenance process could have prevented repeated failures of these motors and saved time and money for the business.”
Industrial applications such as this need reliable equipment, but any repairs need to be of a high quality and delivered quickly, especially when productivity is reduced due to an equipment failure.
Sulzer has suggested the addition of a shelter for the motors to reduce the build-up of debris and enable the motors to operate reliably between planned overhauls. The addition of bearing temperature sensors could also alert maintenance staff to the issue before the bearing fails. In the meantime, Sulzer’s quick response and outstanding service has ensured that the motors have been returned to service at the earliest opportunity.
Proud suppliers to the: Civil, Irrigation, Mining & Industrial Markets
Tsurumi Pump highlights solutions suitable for small wastewater systems
At this year’s show, the company will display a series of recent additions to Tsurumi’s AVANT® line of FM approved products.
Tsurumi Pump will reaffirm its commitment to serving the unique needs of water and wastewater systems at this year’s NYRWA 45th Annual Technical Training Workshop and Exhibition, which will be held from May 20 to 22 in Verona, New York. The company will occupy booth #75 at the Turning Stone Resort & Conference Center.
Small-scale water and wastewater systems present distinctive challenges, demanding solutions that prioritize accessibility, efficiency, and durability. Tsurumi is proud to offer a range of products specifically designed to address these challenges and enhance the operational efficiency of rural water systems.
“Accessible products are at the heart of Tsurumi’s offerings. With readily available inventory and personalized customer service from knowledgeable experts, we ensure small municipalities get the equipment they need when they need it,” said Chris Bristol, municipal product sales manager at Tsurumi. “Our commitment to accessibility extends to Tsurumi’s FM certified, explosion-proof MQ Series, providing customized solutions to each system’s unique requirements.”
Within the AVANT line of FM approved products, the MY and MQ series of pumps can be found. The MQ series is an engineered product built to specification to satisfy the unique challenges faced by lift stations. Additionally, the MY series of pumps is an in-inventory option that includes the MYCZ submersible chopper pump. The MYCZ chopper pump is a multi-channel open impeller solution that is suitable for liquids containing large-sized solids. Tsurumi is determined to offer quality products with a diverse range of options.
Sewage and Wastewater Solutions
Tsurumi’s sewage and wastewater solutions are comprised of three segments:
• AVANT FM approved pumps and mixers product line
• Process Equipment
• Other non-FM approved Tsurumi pumps
As described above, the AVANT line includes the MQ and MY Series, but it also includes the FM approved MMR series of mixers. The AVANT MQ and MMR series include premium-efficiency IE3 motors. This means overall efficiency and energy-savings improved over standard pump offerings. With greater efficiency in both the hydraulics and motor designs, Tsurumi can help improve operations costs over the pump’s life cycle. Tsurumi’s process equipment is effective not only in stabilizing processing and increasing treatment speeds but also in reducing costs and conserving energy. Processing equipment includes mixers, aerators, bar screens, scum skimmers, and dehydrators.
Additional Tsurumi sewage and wastewater pumps feature non-clog submersibles, high-head options, and various impeller types. The widely favored C Series cutter pump is offered with and without a guiderail for additional versatility.
Expert guidance
Municipalities interested in learning more about Tsurumi’s solutions can expect expert support and guidance from both the sales and engineering teams. Tsurumi’s staff is skilled with the knowledge to educate current and prospective customers on the company’s products’ features and benefits. Providing training to an external audience will give municipalities the knowledge necessary to make informed decisions and optimize their water and wastewater systems.
“We recently introduced the FF type series flow switch which has applications specifically suited to the water, oils, gas, food and beverage sectors as well as in general industry where pump protection is required. Its 200-bar pressure and piston valve seat design makes it a unique flow switch for a variety of industry applications” says Jan Grobler, MD, Senseca SA.
The simple mechanical operating principle of the piston valve seat design is space-saving and can be used and installed economically for high unit counts. The design of the flow meter FF is practically maintenance-free across all applications.
The volume flow raises a piston (fitted with a magnet) out from a valve seat against a spring force. The stroke causes a change in the magnetic field, where a hermetically isolated Reed switch is actuated and an electrical signal is generated. With spring-assisted stabilisation of the piston, use in all installation positions is possible. The vertical positioning of the Reed switch, adjusted at the factory, enables recognition of flow rates from approx 2% to 60% of the recommended maximum volume.
Largest value selection
Jan says the Senseca FF Flow Switch offers the largest switching value selection as well as the widest housing spectrum with a valve seat design. It is a cost effective and low maintenance flow switch which delivers improved system safety. The FF flow switch series consists of housing sizes for nominal pipe widths from DN8 to DN50 and
freely selectable switching values from 0.41 l/m. The swift reaction times of less than 100ms supplies a rapid actuation time for applications. An additional highlight of the flow switch is the high switching value repeat accuracy with a minimal pressure loss of less than 0.1 bar.
High pressure cleaning
“The FF series of flow switches suit high pressure cleaning technology applications as they are available in various housing sizes and are in fact suitable for applications within any sector where water, oils and gas are processed” comments Jan.
The simplistic design of the piston valve seat reduces maintenance substantially making it a preferred choice for applications where flow measurement is required. The FF flow switch offers a space saving solution for high unit counts, high efficiency and has a tamper proof switching value offering high system safety.
Filtration
When applied in process water in industrial systems, frequent contamination situations arise due to sediments and other ordinary content in the water. The filtration is a recommended design feature. The FF flow switch enables horizontal flow through the housing where the vertical functional design is highly resistant to water contaminants. This results in the filtration efficiency of the overall system being supported delivering enhanced safety and functional reliability throughout the application.
“Your order, we adjust”
The flow switch FF can be ordered to meet specific customer requirements. There is no switching value drift with the FF flow monitor, an advantage in flow monitoring for heat exchangers in cleaning technology applications with hot water systems.
“You order, we adjust. Senseca assures you that your application runs exactly the way you want it to. Individual and tamper-proof. Many industrial applications will benefit from the flow switch FF series. It is uniquely flexible, highly accurate with low costings, making it a preferred choice for flow monitoring applications” Jan concludes.
Senseca SA, +27 (0) 74 459 0040, Jan.Grobler@senseca.com, www.senseca.com
Underpinning mining operations in Africa with pumping solutions
Integrated Pump Technology is significantly enhancing mining operations across South and sub-Saharan Africa through its innovative pumping solutions and strategic distributor partnerships.
The company has established itself as the go-to source for durable, high performance Grindex pumps since its inception as the official distributor in 2014.
With a keen focus on mine drainage and slurry applications, Integrated Pump Technology has expanded its reach beyond South Africa, ensuring that mining operations throughout the continent have access to toptier pumping solutions. This expansion is largely attributed to the company’s unique approach to distributorship, which emphasises local support and technical expertise.
Central to Integrated Pump Technology’s success is its dedication to building a skills-based distributor network. This initiative ensures that each major mining area is supported by specialists capable of providing localised assistance. “Our strategy involves integrating technically trained sales representatives who understand the unique challenges and needs of their respective regions,” explains Jordan Marsh, Managing Director at Integrated Pump Technology.
From its headquarters near OR Tambo Airport in South Africa, the company extends advanced support, empowering distributors to offer comprehensive aftersales service, maintenance and technical support.
The company’s commitment to local empowerment extends to its support for B-BBEE initiatives and adherence to the Mining Charter’s localisation requirements. Integrated Pump Technology is proactive in providing onsite technical training to both distributors and end-users, aiming to enhance local skills and employment prospects.
Grindex pumps, renowned for their reliability and efficiency, are at the heart of Integrated Pump Technology’s product offering. These world class submersible pumps are designed to withstand the demanding conditions of African mines, featuring built-in smart devices for enhanced operational safety. Marsh says that Grindex pumps are backed by a 30-month warranty, highlighting the confidence that mining engineers place in these pumping solutions.
The well-respected Godwin range of diesel-driven pumps was recently added to the company’s product offering, and Jordan explains that these pumps are ideal for use by customers wanting to deploy a robust pumping solution in locations where electricity is not available
Integrated Pump Technology’s expertise extends beyond standard offerings, with a dedicated engineering team capable of designing custom solutions to tackle complex dewatering challenges. This flexibility and commitment to excellence have positioned the company as a leader in the dewatering pump sector, ready to support mines through performance efficiency improvements. “As Integrated Pump Technology looks to the future, our own team as well as our strategically placed distributors are identifying numerous opportunities for growth and development” Marsh concludes. “Our extensive sales and support network stands ready to meet the evolving needs of the mining industry across Africa.”
Xylem’s innovative solar water solutions provide adaptability for dependable underground or surface water access. They are designed to:
• Meet all agricultural needs
• Protect you from energy cost fluctuations
• Provide rapid return on investment.
This system satisfies all your agricultural needs, including watering crops and livestock, along with household water demands on your farm or ranch.
Dependable access to underground or surface water resources can be challenging. As demand for safe, sustainable, cost-effective solutions grows, Xylem – in partnership with Lorentz –has provided an answer.
Discover our complete range of sustainable solar solutions.
It’s all a question of dose
A new stepper motor-driven pump improves the dosing of aggressive chemicals.
Gentle and low-pulsation dosing of aggressive chemicals without pressure peaks and with minimized dead time. This is made possible by MEMDOS SMART, a new type of stepper motor dosing pump that Lutz-Jesco will be presenting at Achema, the world’s leading trade fair for the process industry, held from 10 to 14 June 2024 (Hall 8, Stand K86). The Industry 4.0-compatible dosing pump can be operated as easily and reliably as a smartphone via its full-colour touch display.
What do wastewater treatment plants, power stations and car washes have in common? They all need to dose aggressive chemicals on a daily basis – wastewater treatment plants have to dose flocculants into the water, power stations have to dose rust inhibitors to their piping and car washes are required to dose detergents to their cleaning brushes. These substances are often introduced via dosing pumps equipped with a diaphragm in its dosing head. The backwards movement of the diaphragm generates negative pressure in the pump head, which draws liquid in. If it moves forwards, the fluid is expelled from the pump head.
It is a simple and reliable principle with just one downside: conventional models available on the market usually work with standard motors running at a constant speed that maintain equal diaphragm stroke times during priming and ejection. This is disadvantageous because fluid delivery stops during the vacuum generation phase. These constant interruptions not only reduce efficiency, but also lead to a phenomenon known as “pulsation”, which can cause pressure fluctuations in the lines that impair the accuracy of the dosing and, in the worst case, result in damage and outages. “Pump operators often have to buy expensive accessories such as pulsation dampers in order to manage this detrimental effect,” says Steffen Roth,
Head of Development at Lutz-Jesco GmbH. “An economical alternative that we will be presenting at Achema 2024 is our new generation of diaphragm dosing pumps called MEMDOS SMART.”
A stepper motor enables the gentle and low-pulsation dosing of aggressive chemicals
At the heart of the new diaphragm dosing pumps from Lutz-Jesco is a drive with a microprocessor-controlled stepper motor. Unlike standard motors, however, the motor can be run asynchronously. In other words, the dosing pump can operate at different speeds for the suction stroke and pressure stroke. This enables operation of the motor at a higher speed during suction, thereby creating negative pressure which draws in the fluid more quickly. The vacuum phase, a dead time with standard motors, is reduced to a minimum. After priming, the stepper motor can then operate at a slower speed to expel the fluid in a controlled and even manner without an abrupt increase in pressure. A slow mode is available for highly viscous media.
“The stepper motor enables an almost constant supply stream, which permits the gentle, low-pulsation dosing of aggressive chemicals without pressure peaks and with minimized dead time,” emphasizes Roth. The repetitive accuracy of the MEMDOS SMART series diaphragm pumps is +-1 per cent across the entire dosing range. “We are convinced that stepper motor-driven diaphragm dosing pumps will dominate the market for high-precision and reproducible industrial dosing applications.”
The MEMDOS SMART is available in eight performance levels, with delivery rates ranging from two litres per hour at a pressure of 20 bar up to 180 litres per hour at four bar. There are also four different versions to cover all market requirements.
Easy to install, Industry 4.0-compatible and as easy to operate as a smartphone via a touch display
Lutz-Jesco has designed the pumps of the MEMDOS SMART series to be so compact that they require minimal installation space and can be integrated into compact dosing systems. For example, the models with delivery rates of between two and 30 litres per hour are just 280 mm long, 130 mm wide and 220 mm high. The pumps have a removable base for quick wall mounting, thereby minimizing the installation effort. The fullcolour 3.5-inch touch display can be integrated into the right-hand, left-hand or rear side of the housing, depending on the version, thereby ensuring flexibility for different installation situations. A version is also available with a ring cable. “Users can mount the cable-connected displays of several pumps next to each other on the wall and control the devices centrally from a single location, thereby saving time” says Roth.
other market players. It makes for significantly faster and less error-prone pump control”. At the same time, users can integrate the devices into a higher-level control system via a BUS interface. “In the Industry 4.0 era, this enables seamless integration of the dosing pump into larger industrial automation systems. If desired, the pumps of the MEMDOS SMART series can even control the entire system with valves, sensors, flow meters and other dosing pumps.”
According to Roth, the operation itself is as intuitive as that of a smartphone. “Users can understand and perform all functions immediately without the need for operating instructions. This combination of a full-colour touch display with operation similar to a smartphone sets us apart from
NETZSCH Pumps: Customized and sophisticated solutions for almost any application
Discover the world of NETZSCH pumps, where decades of experience meet stateof-the-art technology. Our portfolio of positive displacement pumps not only offers you highest quality and reliability, but also a customized pump solution for your application. You have the application, we have the pump.
From precise dosing in the pharmaceutical industry to the transfer of large quantities of crude oil – NETZSCH Pumps & Systems offers you the solution for smooth pumping and lasting satisfaction. We will show you how to benefit from using NETZSCH pumps.
Highest quality thanks to years of experience
Highest quality and maximum reliability this is what NETZSCH pumps stand for. We draw on more than seven decades of experience developing, manufacturing and selling pumps. Our in-depth expertise in producing rotary positive displacement pumps enables us to offer customized solutions for even the most demanding applications – from the smallest dosing pumps to large pumps for the oil, gas and mining industries. Every NETZSCH pump is the result of years of research and constant innovation. By using only high-quality materials, we ensure the longevity of your system. This enables us to guarantee you Proven Excellence and outstanding performance in all areas.
Advantages offered by NETZSCH pumps
NETZSCH pumps offer many advantages to meet the requirements of the most diverse applications. The high adaptability of our products ensures optimum solutions for pumping even complex media in the most
demanding environments. In addition, the robust design of NETZSCH pumps ensures a particularly long service life and minimizes maintenance requirements. This leads to a reduction in your operating costs in the long term.
Compared to models from other manufacturers, NETZSCH pumps are straightforward to maintain, thanks to their innovative design. We continuously set new standards in efficiency and performance to ensure your processes always run smoothly.
Applications where to benefit from NETZSCH pumps
As a global specialist in handling complex media, NETZSCH ensures efficient and reliable application processes. In the chemical and pharmaceutical industries, for example, they enable precise dosing and safe handling of sensitive, aggressive or highly viscous media. In the food and beverage industry, NETZSCH pumps offer you contamination-free and hygienic pumping. They also play a decisive role in the oil and gas industry and mining when pumping raw materials under extreme conditions. Our pumps are also characterized by high reliability and robustness in environmental technology, such as wastewater treatment or sludge processing. These characteristics are also indispensable in the field of battery production, for example, when pumping lithium sludge.
Regardless of the industry, NETZSCH pumps guarantee optimum results.
Everything from a single source
The NETZSCH pumps portfolio includes various pump technologies for multiple industries. With the NEMO® progressing cavity pumps, TORNADO® rotary lobe pumps, NOTOS® multi screw pumps and PERIPRO® peristaltic pumps, NETZSCH offers a wide range of solutions customized to your individual needs and the specific requirements of each industry. Our range is completed by grinding systems, dosing technology and accessories designed to increase the efficiency and reliability of your system. Every product in our portfolio is characterized by innovation, durability and the highest quality standards to ensure optimum performance and satisfaction.
Benefit from the all-round carefree package of NETZSCH pumps
The all-around carefree package of NETZSCH pumps offers comprehensive care and support beyond purchasing a pump. You benefit from a holistic service that includes preventive maintenance, fast spare parts supply, and customized training courses. This ensures optimum performance and longevity of your pump systems and minimizes downtime and operating costs in the long term.
In addition, our dedicated team of experts is available around the clock to provide technical support and advice to ensure complete control and peace of mind in your operations. Choosing a NETZSCH pump ensures technical excellence and the highest operational efficiency and satisfaction.
Original spare parts for NETZSCH pumps
Using original spare parts is crucial for the performance and longevity of NETZSCH pumps. All our spare parts are manufactured to the same high standards as our pumps to ensure seamless compatibility and maximum performance. Using original parts ensures your pump always works efficiently, minimizing the risk of breakdowns and costly repairs. Whether you need to carry out scheduled maintenance or short-term repairs, with original spare parts from NETZSCH, you ensure long-term operational reliability and value retention for your investment.
NETZSCH pumps: In the region for the region
In the region for the region – that is NETZSCH’s motto. By setting up production facilities and service centers on all continents, we ensure we respond quickly to your requirements. Every region has its unique requirements. For this reason, we have established teams of experts around the world who not only speak the local language but also have an understanding of the cultural and marketspecific conditions. This regional presence enables us to work closely with you and develop customized solutions meeting local and global requirements.
As your reliable partner in conveying complex media, NETZSCH combines global reach with a local commitment to offering a service knowing no borders. Let our local experts advise you and benefit from NETZSCH’s decades of experience and innovative solutions.
Verder strengthens its dosing pumps range with Spanish acquisition
Verder Group, a global leader in industrial pump solutions, has further fortified its dosing pumps range through a strategic acquisition of a majority stake in ITC, a prominent Spanish company renowned for its expertise in developing and manufacturing dosing pumps for agricultural and water treatment applications. This acquisition further strengthens Verder’s dosing pump pillar and its ability to support crucial water treatment facilities in Africa.
Water security concerns are increasingly pressing, particularly in regions like South Africa that has been grappling with water delivery challenges in major metros like Johannesburg for some time. By incorporating ITC’s cutting-edge dosing pump technology into its portfolio of innovative dosing pump solutions, Verder Liquids can play a pivotal role in supporting infrastructure upgrades through the provision of high-quality dosing pumps.
“Wastewater management stands as a critical challenge globally, encompassing various sources such as household drainage, industrial effluent, stormwater, and agricultural runoff. Despite the potential for recycling and treatment, a significant portion of wastewater (approximately 80% according to the UN) is discharged into the environment without proper remediation. This poses severe risks to freshwater sources, exacerbating contamination and jeopardising the availability of safe drinking water,” says Darryl Macdougall, Managing Director, Verder Pumps South Africa.
Innovative dosing pump solutions
Verder’s dosing pump solutions are comprehensive, encompassing an array of solutions tailored to meet
diverse dosing requirements which are further bolstered by the Microdos and ITC ranges. From electromagnetic solenoid-powered diaphragm pumps to peristaltic pumps and motor-driven piston and diaphragm pumps, the portfolio encompasses a versatile suite of products designed to deliver precise and controlled chemical dosing across various applications. These pumps are indispensable in industries such as municipal water treatment for wastewater and drinking water, industrial wastewater management, chemical manufacturing, laboratory research, the food industry, landscaping, and agriculture where accurate dosing is imperative for operational efficiency and safety.
“Hose pumps, a fundamental component of our dosing pump range, offer a simple yet effective pumping mechanism ideal for wastewater treatment applications. By employing a re-enforced rubber hose subjected to compression and relaxation cycles, hose pumps ensure the contained medium, such as lime or flocculant, remains isolated from the pump’s moving parts. This design minimises downtime and maintenance costs associated with traditional pump types, offering a cost-effective and reliable solution for dosing applications. Moreover, hose pumps boast advantages such as compact size, energy efficiency, continuous operation, and reduced risk of leakages, contributing to enhanced operational efficiencies
and environmental sustainability,” says Macdougall. Supporting infrastructure and environment
The integration of advanced dosing pump technology not only enhances industrial processes’ efficiency but also holds profound implications for environmental conservation and water resource management. By facilitating precise chemical dosing and wastewater treatment, Verder’s dosing pumps play a pivotal role in safeguarding freshwater sources, mitigating pollution, and ensuring the sustainable use of water resources. As water scarcity looms as a global challenge, investments in innovative pump solutions emerge as a critical imperative for ensuring water security and fostering socio-economic progress.
Verder’s strategic acquisition of ITC and the expansion of its dosing pumps range underscore the company’s
VERDER
proactive approach towards addressing pressing water security challenges. By leveraging advanced dosing pump technology, Verder is poised to support infrastructure upgrades, enhance operational efficiencies, and contribute to environmental sustainability, thereby safeguarding freshwater resources for future generations.
“Not only can the right dosing pump solution go a long way to addressing environmental sustainability but can also spare us from the nightmare scenario of running out of the precious resource that is drinkable water, which is absolutely indispensable to our health, recreation and social and economic progress,” concludes Macdougall.
Verder Pumps South Africa, +27 (0) 11 704 7500, info@verder.co.za, www.verderliquids.com
The difference between RSV Gate valves and Wedge Gate valves
These valves are robust and usually have a long service life. But, they suffer some disadvantages:
• The valve is often over-tightened to ensure a good seal. This makes it difficult to reopen. If leverage poles are used to apply extra force the valve can be damaged.
• The groove in the bottom of the body traps dirt and can stop the valve from closing properly.
• Anti-corrosion coatings near the valve seats are prone to damage, leading to corrosion of the valve body.
The resilient seated gate valve (RSV) was designed to overcome these problems. The gate has a rubber coating which makes for a better seal without needing excessive force or a body seat.
Early RSVs weren’t as good as those available today. Manufacturing quality was poor and the rubber lining sometimes detached from the gates. Today the rubber lining is moulded to the gate at high temperature and pressure leading to an excellent long-term bond. Some manufacturers now offer replacement guarantees of up to 20 years.
The strong bond between the gate and rubber makes the RSV a good choice in scour applications where high velocities might have torn the rubber in the past.
The manufacturing process, and economies of scale, have made these valves both cheaper and more readily avaiable than wedge gate valves. Fusion Bonded Epoxy (FBE) coating applied to the body and bonnet resist corrosion.
Other benefits include:
• Better sealing performance.
• Lower opening and closing torque.
• Resilience to particles in the water. There is no groove at the bottom of the valve to trap dirt.
• Reduction in water hammer due to the rubber absorbing some of the impact of a pressure spike.
Ultra Control Valves, +27 (0) 11 452 6514, Peter@ultravalves.co.za, www.ultravalves.co.za
The stuff dreams are made of
The booming hydrogen market promises brilliant prospects for environmental protection and investments running into the billions. It will transform the electricity, heat, and mobility sectors, and permanently transform entire industries. Valves, actuators and automation are set to play a key role in this. The innovative components involved support the rapid growth of the H2 industry.
However, the hydrogen market is very demanding. Systems must be able to handle a wide range of pressures, and temperatures as low as minus 253 °C. The high explosiveness requires the highest standards of sealing.
In addition, H2 plant operators expect products from the valve industry that are designed for a long service life and require little maintenance.
The valve industry is also adapting to this: As the hydrogen market scales up, the systems become larger and the pressures involved increase – and thus the dimensions of the valves also change. There’s no doubt about it that companies are facing big challenges...
Solutions for the entire value chain
Challenges for which companies are already offering solutions – along the entire H2 value chain from generation by electrolysis, through storage, transport, and conversion, all the way to the end application. With highquality materials and special geometries, as well as digital and automated products, the valve industry is proving itself to be catalyst for the hydrogen revolution. Leak testing and material suitability tests assure the end user of the safety that is particularly important for H2 systems.
All of this will ensure that hydrogen becomes so much more than the stuff dreams are made of. You can discover the trends and highlights from the valve industry at VALVE WORLD EXPO from 3 to 5 December 2024 in Düsseldorf. www.valveworldexpo.com
Cathode Isolation Valve for fuel cell systems
Reliable sealing of the stack is a top priority for the safe operation of fuel cell systems. The new Cathode Isolation Valve (CIV) from Purem by Eberspaecher meets the strict requirements for seal-tightness and prevents premature aging.
The use of hydrogen as an energy carrier plays a major role in the decarbonization of industry and mobility. Depending on the application, hydrogen-based fuel cell systems are a sustainable operating alternative, for example, for heavy duty commercial vehicles, passenger cars or stationary applications. The heart of a fuel cell is the so-called stack, in which the chemical energy of hydrogen is converted directly into electrical energy through an electrochemical reaction. Balance of Plant components guarantee safe functioning and efficient operation. The special requirements include sealing the cathode path to prevent leakage and therefore premature aging.
Longer service life
The Cathode Isolation Valve (CIV) from Purem by Eberspaecher is used in the cathode air path of the fuel cell system. The reliable sealing concept hermetically isolates
the stack when the entire system is shut down, preventing premature stack wear and extending operating life. At the same time, the conditions inside the fuel cell remain constant, enabling faster restarts. A fail-safe function of the Cathode Isolation Valve guarantees that the fuel cell stack is closed quickly and reliably in the event of a fault within the system.
The component is also adapted to the specific installation spaces of fuel cell systems: Their compact dimensions and customer-specific connections allow them to be designed for different applications.
Advanced material design
With its expertise in the field of materials science, Purem by Eberspaecher has designed the CIV for the specific requirements. The product is made of special materials that are insensitive to hydrogen. Another focus is on the use of suitable alloys that are resistant to attack by ultrapure water, which is a by-product of the chemical reaction and can lead to corrosion of metals.
Continuous control
The electric actuator of the CIV allows the cover position to be continuously adjusted in order to individually regulate the mass flow and pressure within the fuel cell stack and thereby optimize operation. This additional functionality ensures lower counterpressure and has been developed in cooperation with experienced partners. When developing Balance of Plant components, the exhaust and acoustics specialist draws on its Clean Mobility experience in exhaust technology and utilizes synergies from valve development. The Cathode Isolation Valve was tested in close cooperation with existing customers in order to further develop the first sample components for rapid series production.
New Emerson high-flow solenoid valve increases plant reliability and operating efficiency
ASCO Series 327C solenoid valve features direct-acting, high-flow design for superior flow control performance and operational certainty.
Emerson has introduced the new ASCO™ Series 327C solenoid valve, which features a direct-acting, highflow design that provides superior flow-to-power ratio compared to similar valves. The Series 327C design features a balanced poppet construction that permits high flows at minimum power levels, making it ideal for use in power plants, refineries and chemical processing facilities.
Facilities like these can have hundreds, even thousands, of valves installed throughout their processes and systems. Even one malfunctioning valve can disrupt critical gas and fluid flows, impacting process quality and forcing unscheduled downtime and extra maintenance.
The ASCO Series 327C incorporates features that combine reliability and durability to increase operational efficiency and improve process certainty. The valve features a unique, two-layer dynamic seal technology that provides low friction and excellent stiction resistance, helping ensure reliable valve operation in environments with temperatures ranging from –60 to 90 degrees Celsius. In addition, the valve is SIL (Safety Integrity Level) 3 Capable, demonstrating a high level of performance integrity and a very low risk of failure over the valve’s projected lifecycle.
“Facilities such as power plants and refineries have demanding, high-flow gas and fluid delivery processes and need valves that are efficient, reliable and easy to maintain across thousands of hours of operation,” said Anne Sophie Kedad, director of marketing with Emerson’s discrete automation group. “The ASCO Series 327C solenoid valve provides the reliable performance these facilities require, helping improve operational efficiency by minimizing unnecessary maintenance trips and extending the intervals between proof tests.”
The ASCO Series 327C valve can help streamline supply chains and simplify specification complexities for global industrial users by providing a single, globally approved solution for high-flow solenoid valve applications. The valve also offers a unique electrical test connection to minimize field commissioning time and prevent moisture ingress in storage.
Emerson, +27 (0) 11 451 3700, www.emerson.com
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CCUS supporting clean energy transition
Carbon Capture, Utilization and Storage (CCUS) is the process of capturing carbon dioxide (CO2) formed during power generation and other industrial processes and storing it to avoid emission into the atmosphere.
In cases where it is not utilized at the capture site, the CO2 is compressed and transported for use in a range of applications such as conversion to fuels or chemicals, or injection into depleted oil and gas reservoirs, saline formations, or other geological reservoirs where the CO2 is trapped for permanent storage.
CO2 capture has the potential to grow from 40 Mt CO2 in 2021 to 1.8 Gt CO2 by 2030 and 7.6 Gt CO2 by 2050, according to the International Energy Agency (IEA). CCUS infrastructure will need to grow throughout the energy transition to support this increase, stemming from global climate goals and emerging CO2 applications.
One expert choice to help with your CCUS processes
Flowserve is not just an equipment supplier. We’re your ideal partner with the right products, engineering prowess, services and expertise to help companies across industries identify opportunities to enhance process efficiency and cost-effectiveness.
What’s more, Flowserve offers the following unique advantages that can enable your company to achieve its energy transition objectives, including:
• The most complete portfolio of flow control equipment
designed to work as a system and optimize CCUS processes.
• An end-to-end internet of things (IoT) suite of solutions that can:
• Increase process and operational efficiency with remote monitoring of assets.
• Utilize predictive analytics to anticipate equipment failures before they happen.
• Enable operators to take preventive measures to avoid process disruptions.
• A single point of contact for:
• Project planning with engineering, procurement and construction (EPC) consultants and company project managers.
• Commissioning and operations with plant managers and technicians.
• Unparalleled service and technical support expertise backed by a global network of Quick Response Centers (QRCs)
A comprehensive flow control portfolio
With unrivaled expertise in developing and implementing
flow control systems for capturing, transporting and storing carbon dioxide (CO2), Flowserve is uniquely qualified to be the primary flow control partner for customers endeavoring to reduce their carbon emissions.
We understand how pumps, valves and seals should work in complete systems. As a result, Flowserve can help you engineer, design, commission and maintain end-to-end solutions so they perform optimally.
In 1984, Flowserve pioneered the use of pumps for highpressure CO2 pipeline and injection service and later became the first company to use dry gas seals in densepha se CO2 pumps. Flowserve also can demonstrate unsurpassed experience in pumping the many solvents used to capture CO2. Similarly, our valve and automation solutions provide unmatched reliability in carbon capture, transportation and storage applications.
Technical support and services
Detect, diagnose and quickly respond to equipment and system issues. Successful CCUS projects will need more than engineered-to-order (ETO) systems. In addition to providing the industry’s most complete flow control solutions portfolio, Flowserve introduced RedRaven, an end-to-end IoT solution encompassing sensors to cloud architecture, condition monitoring and predictive analytics services.
CCUS operators can use RedRaven to monitor thousands of assets over sprawling facilities reliably and cost-effectively. With real-time RedRaven monitoring, plant personnel and Flowserve technicians can view aggregated data to make decisions on-site. Our monitoring center along with our team of service and support personnel can provide you with insights, alerts and recommendations.
Our commitment to energy transition At Flowserve, our approach to energy transition begins and ends with our purpose - to make the world better for everyone. We understand that when we enable our customers to tackle climate change and address increasing energy demands through our innovative flow control solutions, we can make the world better – now and for generations to come. Our approach is threefold. We are diversifying, decarbonizing and digitizing to support the global energy sector’s transformation toward low-carbon sources.
Diversification
Our innovative portfolio of flow control solutions and services will support energy systems around the world to diversify the energy mix and adopt cleaner sources of energy.
Decarbonization
We will support the reduction of energy-related CO2 emissions across the mix of energy sources through our innovative portfolio of flow control solutions and services.
Digitization
We will enable improvements in efficiency, productivity, sustainability and safety of energy systems around the world through our digital solutions and services.
Enza Civils’ crucial role in shaping SA’s infrastructure future
Enza Civils, a division of Enza Construction, is strategically positioning itself to play a pivotal role in addressing South Africa’s pressing infrastructure needs in the water, transport, and energy sectors.
As the country grapples with significant infrastructure challenges, Enza Civils stands at the forefront, ready to provide essential solutions. Coen Naicker, Divisional Director at Enza Construction, along with Civils Contracts Directors Riaz Cassoojee, Ian Ferguson, and new team member John Hopewell, shared key insights into the company’s future, outlining an optimistic long-term outlook.
Together, they provided a comprehensive overview of the civil engineering industry and Enza Civils’ strategic direction, highlighting the company’s readiness to tackle the nation’s infrastructure demands.
In the recent budget announcement, South African Finance Minister Enoch Godongwana committed R943.8 billion to public infrastructure over the next three years. T his investment is poised to rejuvenate and expand the nation’s infrastructure, with allocations of R486.1 billion from state-owned enterprises, R224.8 billion from provincial and national governments, and R213.8 billion from municipalities.
Key focus areas include energy, water and sanitation, transport, digital infrastructure, human settlements, and agriculture. The government’s strategy includes a transformative approach to infrastructure financing and delivery, emphasising public-private partnerships (PPP)
and innovative institutional frameworks to attract private investment. A consolidated entity will streamline the financing, preparation, and execution of large projects, collaborating directly with private financial institutions and various governmental bodies.
Building more than just roads – building a future
Founded with a mission to specialise in bulk earthworks, roadworks, and the installation of essential services such as water and sewerage, Enza Civils has spearheaded numerous large-scale infrastructure projects across South Africa. Under the leadership of Coen Naicker, who joined Enza in 2016, the division has experienced significant growth and diversification, positioning itself as a key player in the industry.
“South Africa’s infrastructure, energy and water challenges are well-documented,” says Coen. “There is quite a lot of concern in the industry about whether or not, as an industry in South Africa, we have the resources and capacity to execute the work that’s coming and the work that is already out there.”
Coen’s deep understanding of these challenges has guided Enza Civils to consistently surpass expectations, ensuring the company is ready to address the nation’s changing infrastructure demands. His strategic vision and dedication to quality have played a crucial role in the division’s
accomplishments, cementing Enza Civils’ reputation as a reliable partner in South Africa’s development efforts.
Tackling water challenges
Starting with the water challenges in South Africa, Coen discussed the ambitious Lesotho Highlands Water Project (LHWP), which involves the construction of the Polihali dam and the connecting tunnel to the Katse dam.
“The LHWP is a monumental endeavour, aiming to create a reservoir on the Senqu and Khubelu rivers to bolster South Africa’s water supply from the Katse Dam to the Integrated Vaal River System, serving Gauteng and its neighbouring regions,” he explains. “Given Lesotho’s limited resources for such a project, much of the needed expertise and materials must be sourced from South Africa and abroad, including Europe and China.”
As part of the LHWP, numerous bridges are being constructed to maintain road access, particularly where existing low-level bridges will be submerged once the Polihali Dam is operational. Among these, the Senqu Bridge project stands out, stretching 825 meters in length and reaching a height of 90 meters. Awarded in August 2022, the construction contract for this bridge was granted to the WRES joint venture (JV), consisting of Webuild S.p.A, a prominent Italian construction firm, in collaboration with South Africa’s Raubex Construction, Lesotho’s Sigma Construction, and Enza Construction.
Roads and infrastructure development
The imperative of maintaining and enhancing South Africa’s road network is widely recognised, with SANRAL embarking on numerous projects, including the upgrade of the N2 / N3 freeways in KZN. While some projects are already in progress, others are yet to be put out for tender.
In October 2016, seven construction sector companies entered into an agreement called the Voluntary Rebuilding Programme (VRP) to drive transformation in the industry.
This initiative entails mentoring and nurturing smaller contractors while contributing to a construction fund for socio-economic development, as part of an industry settlement agreement with the government.
Under the VRP, Raubex committed to mentoring two partners, one of which was Enza Civils, with the objective of helping them reach 25% of Raubex’s South African turnover.
Coen elaborates on the collaboration with Raubex, stating, “Through our partnership, we have successfully completed three road rehabilitation projects in Kimberley, the Bakwena Platinum Corridor Upgrade, which added 32km of carriageway, and the widening of the N4 bridge over the Crocodile River to accommodate a dual carriageway. Additionally, we undertook a 30km partial upgrade of the R23 national road near Standerton in Mpumalanga. This included the construction of 4km of dual carriageway, a pedestrian crossing, traffic circles, and the completion of six bridges and sections of the R23 highway, with the project being delivered on 26 April 2023.”
Riaz, Contracts Director for the project, notes, “Upon commencing work in 2021, we were advised that this project might face challenges due to community concerns. However, SANRAL’s protocol mandated the initial three months of the contract to engage with the community and establish liaison structures. We prioritised transparency and local resourcing wherever feasible, fostering a positive working relationship with the community.”
Future transportation
projects
Looking ahead, Enza Civils is poised to expand its footprint in the transportation sector. John Hopewell highlights the potential opportunities: “Over the next two to three years, we are considering re-entering the road space, depending on SANRAL’s awarding and releasing of tenders. We see huge opportunities in upcoming road projects issued by the KwaZulu-Natal Department of Transport.”
Additionally, Enza Civils is exploring partnerships for large contracts emerging from TRANSNET’s rail infrastructure projects and the Durban Ports Authority.
Large-scale construction in the energy sector
Riaz explains, “Among our significant energy-related endeavours is the second phase construction of the Combustion Waste Facility at Kusile Power Station, a venture secured through a joint venture with Grinaker LTA.”
“The facility spans over 1,080,900 square meters and comprises an HDPE-lined storage area for ash residue from the coal-fired boilers. Our contract encompasses the construction of access roads, drainage systems for both contaminated and clean water, as well as pollution control measures such as dams and drains, in addition to the storage dam.”
Renewable energy ventures
Through its partnership with Tractionel Enterprise, Enza Civils has entered the renewable energy space. Their collaboration is currently focused on the Ummbila Emoyeni Renewable Energy Project in Mpumalanga. Tractionel serves as the EPC contractor for grid connection, while Enza Civils takes charge of civil and building work for the main transmission station. Owned by Seriti Green,
Ummbila Emoyeni represents a commitment to sustainable wind turbine and solar energy solutions. Enza Civils is poised to solidify its position as Seriti Green’s preferred contractor for future projects, marking a significant step toward a greener, more sustainable future.
Growing capability and expertise
Looking ahead, Enza is strategically focusing on various areas of business development, particularly in the energy sector where Tractionel Enterprise plays a leading role. By leveraging Enza Civils’ expertise in engineering and construction, the company aims to excel in energy-related projects. Additionally, Enza is committed to enhancing its presence in the water infrastructure sector. The transportation sector remains another key focus, with a specific emphasis on road and rail projects.
Coen emphasises the value of the Voluntary Rebuilding Programme (VRP) partnership with Raubex, which has diversified Enza’s portfolio, enabling independent tendering for projects. With a CIDB grading of 9CE, Enza can now tender for projects of any size, although it remains prudent and open to joint ventures for larger endeavours.
Continuously enhancing capabilities is a priority for Enza. Recently, the company acquired a significant shareholding in Post Tensioning and Structural Solutions (PTS-S), specialising in post-tensioning, construction hydraulics, and structure repair. This strategic move aligns with Enza’s diversification strategy and aims to bolster its specialist capabilities.
Under the leadership of PTS-S directors Gary Williams and Paul Heymans, Enza expands its client base across infrastructure, mining, commercial, and building sectors. Leveraging their extensive expertise in post-tensioning, stay cable, heavy lifting, bridge jacking, and incremental launching, PTS-S has already achieved positive outcomes. Notably, it secured subcontracts for various projects, including the Senqu Bridge, EB Cloete Bridge, and N2-N3 upgrades known as Key Ridge.
Commitment to skills development
Enza has long been acknowledged as a construction group recognised for its strong work ethic and unwavering commitment to quality, alongside its inclusive policies.
This reputation is upheld through the firm belief that its people are its greatest competitive advantage.
Enza prioritises skills development and retention as core business imperatives. Demonstrating its dedication to industry advancement, Enza is steadfast in nurturing and enhancing its workforce. The Learnership and Graduate Development Programmes serve as vital entry points, attracting young talent to the business. Recently, Enza introduced a Foremen Development Programme tailored for experienced foremen lacking formal qualifications in the industry. This initiative involves a year-long mentoring process, acknowledging their expertise while facilitating the attainment of formal qualifications.
Enza’s Graduate programme targets construction management, engineering, and quantity surveying graduates, offering specialised training. The application window for the 2025 programme opened in May 2024, and typically draws between 4,000 to 6,000 applicants annually. Enza typically welcomes between 15 to 20 graduates each year, with 14 graduates joining the 2024 intake.
Looking ahead
Coen Naicker is optimistic about the future, not just for Enza Civils but for the industry. “While South Africa faces numerous challenges, including water supply issues and deteriorating infrastructure, these problems present opportunities for Enza to provide solutions,” he says.
“With our strategic partnerships and a diverse portfolio, we are well-positioned to deliver quality infrastructure solutions. Our CIDB grading of 9CE allows us to tender for any size project, and we look forward to what lies ahead.” Enza Civils is committed to being the infrastructure solutions provider of choice, leveraging its partnerships and expertise to address South Africa’s most critical infrastructure needs. The company’s focus on long-term projects in the water, transport, and energy sectors underscores its bullish outlook on the future.
Unearthing greater efficiency with AI in the African mining sector
The global mining industry is in a state of flux as unprecedented demand for resources clash with ongoing global economic volatility and geopolitical tensions, creating both immense challenges and opportunities.
From record-high gold prices to the stunning growth in renewables driving demand for minerals and the global transition to net-zero, the mining industry is currently in an era of intense reinvention and disruption.
Africa’s mining sector isn’t spared this volatility. The continent has more than half of the world’s reserves of platinum group metals and diamonds, and nearly half of manganese and cobalt reserves, both critical elements in the batteries powering the global transition to cleaner energy.
Searching for greater productivity
In the current business environment, mining companies are under intense pressure to increase efficiencies, reduce costs, and boost productivity.
Autonomous technologies have ushered in a broad range of economic benefits for the mining industry over the past decade. By leveraging automation to perform some of the more hazardous tasks, mining companies have minimised worker exposure to dangerous conditions and bolstered overall safety standards within their operations.
Recently, the emergence of digital technologies such as machine learning and artificial intelligence (AI) has introduced new gains in efficiency and productivity. One market estimate predicts that investment into AI by the mining sector will reach $7.264-billion by 2033, driven by a compound annual growth rate of 22.7%.
The ethics of AI in mining
While it’s undeniable that AI holds immense promise for the mining industry, the introduction of any new technology is typically accompanied by a number of ethical dilemmas.
In the context of mining, fears around AI range from the displacement of human labour by automation and the increased surveillance compromising data privacy and encroachments on autonomous decision-making.
One of the biggest fears of AI’s impact in the mining sector relates to the potential of the technology to displace workers by automating their job roles and essentially making them redundant. In the context of Africa, job fears will remain, especially considering the important historical role that the sector plays in employment creation, especially in markets such as South Africa.
There are also concerns over explainability, that is how AI decisions can be explained in a way that makes sense to human workers. For example, if AI is used in surveillance at mining sites to improve safety and security, questions may arise over how the algorithm determines which actions can be considered safety or security incidents.
Whilst AI has the potential to improve efficiency and safety in mining, its deployment introduces new risks that must be carefully managed. Mining companies, technology developers, and regulatory authorities must collaborate to
establish robust safety protocols, provide comprehensive training, and establish clear lines of accountability to mitigate the risks associated with AI use in mining operations.
Practical use cases
Despie the concerns, AI will unquestionably play a leading role in the mining sector’s success in the coming years. AI lends itself to a myriad of applications across the mining value chain, including:
Exploration
AI-driven prospecting mapping models are emerging that analyse geological, geochemical and geophysical data sets to pinpoint promising areas for mineral exploration. By amalgamating diverse data sources, these AI models can enhance the successful discovery of promising resource deposits.
Geotechnical monitoring
Geotechnical monitoring and analysis are crucial to ensuring ground stability and infrastructure stability at mining operations. Here, AI can be integrated with sensor networks to detect early signs of instability or failure, while predictive models can forecast ground behaviour and assess potential hazards. AI can also be applied to create detailed simulations of rock masses that can help guide the design of tunnels, underground layouts, and slope stability.
Mine planning & optimisation
AI technologies enable dynamic, data-driven decisionmaking to optimise mine plans and production schedules. Mining operations can leverage AI to predict performance
under various conditions, helping decision-makers identify optimal productivity strategies while minimising costs. Predictive maintenance systems can also optimise the performance of mining equipment, reducing downtime and improving overall operational efficiency.
Supply chain management
AI’s benefits extend beyond mining sites to bring improvements to supply chain management. Predictive inventory management leverages AI for a variety of tasks, including reducing inventory planning time, minimising costs, optimising repair schedules, and determining the optimal times for reorders. By using techniques such as time-series analysis and probabilistic modelling, mines can gain real-time visibility over their supply chain. This can help mining operations optimise their logistics operations, including transportation routes and distribution networks.
AI is a transformative force in the mining industry, introducing a broad range of innovative applications to solving complex challenges across various facets of modern mining operations. By embracing AI-driven innovation and collaboration, mining companies can pave the way for a more efficient, sustainable and responsible mining future.
Written by Shabir Ahmed, Industry Advisor: Energy & Resources at SAP Africa
Electra Mining Africa: where inspiration and innovation meet
From drones to the Cloud to AI, the world is progressing at the speed of light. It’s not always easy staying on top of the latest innovations in your field. But at Electra Mining Africa 2024, you’ll find all the latest cutting-edge technology on display, hear talks from trailblazers in the industry and meet hundreds of exhibitors across the areas of mining, electrical, automation, manufacturing, power and transport all in one place.
Taking place at the Expo Centre in Nasrec, Johannesburg from 2-6 September, this year’s event will be one of the biggest Electra Mining Africa exhibitions to date. The show will extend across 35,000+ m² of exhibition space and accommodate over 850 exhibitors, demonstrating the popularity of the show. It’s focus is largely on local industry suppliers and manufacturers with top brands participating, together with an international contingent from countries including the UK, USA, Canada, Australia, Italy, Germany, Switzerland, Taiwan, India and China.
As the largest trade show of its kind in Southern Africa and with its over five decades of experience, Electra Mining Africa offers an outstanding opportunity for both exhibitors and visitors, buyers and sellers, to connect face-to-face and develop long-lasting business relationships.
Hundreds of live demonstrations will bring machinery and equipment to life, with thousands of new products and innovations displayed throughout the five exhibition halls and extensive outside exhibit areas.
“We’re looking forward to this year’s show,” says Gary Corin, Managing Director of Specialised Exhibitions, a division of Montgomery Group. “The industry gave its full support to Electra Mining Africa 2022, which had just over 30,000 visitors through the gates. We’re expecting to exceed those numbers this year. Large organisations and SMMEs will be represented across the areas of
mining, electrical, automation, manufacturing, power and transport. Some have exhibited with us for over 50 years, with their businesses growing alongside the growth of Electra Mining Africa. What better way to bring a brand to life: on the floor of an exhibition where you’re engaging with your target market face-to-face. It’s a unique valueproposition to participate in an exhibition like this.”
The Electra Mining Africa Innovation and New Products Awards will be taking place again this year, following its success in 2022. Organised in partnership with the South African Capital Equipment Export Council (SACEEC),the awards recognise the outstanding levels of innovation at the show. Many entries are anticipated again this year.
Charlene Hefer, Portfolio Director at Specialised Exhibitions, spoke about the various attractions, citing the Forklift Driver competition and the focused automation hall as two of the exciting elements at this year’s show.
“The Forklift Driver competition organised in conjunction with Lifting Africa and LEEASA is back this year on a much bigger scale. It’s where exceptional forklift driver skills will be put to the test with Forklift operators competing for the coveted title of Forklift Driver Champion,” explains Hefer. “We’re also thrilled that the automation hall, a huge attraction in 2022, has received overwhelming support from industry again this year and will be filled with ground-breaking innovations. In addition, for the first time this year, Electra Mining Africa is incorporating the Local Southern African Manufacturing Expo.”
Education and learning is important to Electra Mining Africa. Industry experts will be delivering free-to-attend talks on latest trends and developments at the Seminar Theatre in Hall 9, hosted by the South African Institute of Mechanical Engineering (SAIMechE). Topics will be aligned with the show’s theme days of sustainability, women and skills development, , safety and lifting, innovation and South Africa day. The Lifting Equipment Engineering Association of SA (LEEASA) and the Southern African Institute of Mining and Metallurgy (SAIMM) will be hosting conferences alongside the show. Women in Mining South Africa (WiMSA) will be hosting a half-day women in mining workshop.
“Electra Mining Africa is going to be a great show and the innovation on display will be mind-blowing,” concludes Hefer.
Subsaharan Africa turns to local Electrolux (KWIKOT) industrial for water heating solutions
Electrolux (Kwikot) Industrial’s massive water heating tanks are making a name for themselves beyond local borders. The tanks, which vary in size from 500 to 30,000 litres and used in settings such as mines, hotels, lodges and student accommodation, are sought after as far afield as Mauritius, Angola, and Mozambique with new countries in the region set to come on board.
Murray Crow, Electrolux Managing Director (MD) for South Africa, says the latest green industrial heat pumps are a game-changer. They efficiently heat water, using much less electricity, making them a popular choice for industrial tanks. “The shift to heat pumps instead of traditional elements has resulted in substantial cost savings on electricity bills for industrial sites,” he says, adding that the company maintains stock ranging from 500 to 3,000 litres, “ensuring prompt supply to meet the demands of our diverse clientele”. Electrolux acquired the Kwikot Group for a total R3.18 billion a few years back.
General Manager, Harry Huyser, says Electrolux (Kwikot) Industrial specialises in the meticulous construction of geysers tailored to meet the specific requirements of these diverse industries. The business has over the decades also shown a remarkable stride towards innovation and efficiency, bringing a new era of excellence in the realm of industrial water heating solutions with tailored industrial geysers to meet varied needs. From mines, hotels, lodges, and holiday resorts to other large-scale facilities requiring copious amounts of hot water, the industrial department at Electrolux (Kwikot) delivers geysers built with precision and to customer specifications.
“We cater to anyone who needs a substantial supply of hot water, whether it’s for ablution blocks at mines, factories, hotels or any industrial setting,” says Huyser. Beyond geysers, Electrolux (Kwikot) Industrial is a one-stop solution for industrial water heating needs. The company supplies solar heaters, industrial heat pumps, and a full range of industrial valves and spares essential for installations. The industrial heat pump, a testament to new technology, offers significant energy efficiency and cost savings. Setting the company apart, Electrolux (Kwikot) Industrial proudly
emphasises local manufacturing. “Ninety percent of our tanks are locally manufactured in Benoni. From rolling the tank material to welding and assembly, everything is done locally according to customer specifications,” says Huyser. The company’s factory in Benoni is a hive of activity where domestic geysers and industrial tanks are produced under the same roof. Specialising in building stainless steel tanks, Electrolux (Kwikot) Industrial caters to unique needs, even constructing tanks for dairy farms where stringent hygiene standards are imperative. Electrolux (Kwikot) Industrial boasts an impressive track record of quality and durability. Tanks are commissioned on-site to ensure proper installation, covering their warranty. Huyser proudly reveals: “Our tanks have a track record of two-year and five-year guarantees. We haven’t had a guaranteed replacement in 16 years, except for cases of customer negligence,” says Huyser. The longevity and reliability of their tanks are underscored by the fact that replacements from 2010 are only occurring now, with tanks from 1996 still in operation.
While quality comes at a price, Electrolux (Kwikot) Industrial ensures a spectrum of options to meet diverse budgetary needs. Prices range from R60,000 to R500,000, with stainless steel tanks commanding a premium. The company even manufactures electric panels locally, providing flexibility to cater to unique requirements. Electrolux (Kwikot) Industrial prides itself on a dedicated team of coded welders, qualified boilermakers, and skilled individuals with expertise in cladding and insulation. With nearly two decades of experience, the team’s collective knowledge ensures consistent excellence. “In our team, we’ve cultivated a culture of expertise, and our specialised staff ensures minimal staff turnaround. Our welders and boilermakers are highly qualified, bringing years of experience to their roles,” says Crow.
In an effort to integrate industrial water heating solutions from the design stage, Electrolux (Kwikot) Industrial actively collaborates with architects. Huyser encourages architects to factor in their boilers from the inception of building designs, emphasising the importance of early involvement to ensure seamless integration. Electrolux (Kwikot) Industrial is constantly meeting with role players to come up with new innovations in the industrial water heating systems.
Sigfox S.A. to enable South Africa move to smart water meters on 0G network
Sigfox SA, a robust and exceptionally low-power technology, was selected by the National Treasury as the network to underpin the new smart water meter ecosystem.
The tender, commonly known as “RT29” awarded to various System Integrators, will see existing meters adapted or replaced to become smart meters to improve revenue collection and service delivery. All the new meters will run on the nationwide Sigfox IoT network.
Greg Rood, CEO of Sigfox South Africa, says: “Water is a basic human right, and we are proud to be associated with provision of such essential services, supporting both revenue collections and provision. The fact that the National Treasury has entrusted Sigfox to monitor and support over 15,000,000 smart water meters in the country underlines how robust the technology is. We expect this to be a catalyst to further grow our local IoT and system integrator ecosystem.”
Rood explains that Sigfox was selected to support the smart water meters due to the extensive network coverage, robustness of the technology, low power consumption and the SLAs associated with Sigfox. Sigfox 0G is a preferred technology for utilities around the world, and has an established track record of supporting large commercial utility deployments in South Africa. The superior range and penetration of the advanced Sigfox ultra-narrowband (UNB) signal makes it the ideal connectivity choice to reach meters that are often installed in challenging environments.
“The Sigfox SA network already covers 91% of the South African population. Should there be a need to extend or densify the network, this can be achieved quickly and cost-
effectively,” he says.
Sigfox technology also overcomes potential power challenges – smart water meters typically lack access to external power and rely on batteries. Sigfox’s low power network technology – designed to support IoT at scale –means a device can run on the same battery for over 10 years.
Rood says: “The technology has an extremely low power reliance. The smart meter devices are sealed and waterproof, with batteries built in. Our devices will last for over 10 years at one reading a day, which far exceeds the three-year lifespan stipulated on the tender. Due to this extended lifespan, it’s practically an ‘install and forget’ scenario, which cuts costs and optimises resources. Sigfox’s benefits also include ease of installation, accuracy and reliability. And the fact that the network is independent means there is no reliance on Wi-Fi or fibre in the ground.”
He notes that Sigfox is the only mass coverage network underpinned by an SLA. “This enhances reliability and delivers unprecedented ROI for municipalities,” he says.
“The transition to smart meters supported by Sigfox SA will mean improved collections for municipalities, real-time and accurate billing for customers, and improved management of increasingly scarce water resources,” Rood says.
Sigfox SA, www.sigfoxsa.co.za
Getting value from smart water technologies
Smart water management will meet SA’s growing demands for cleaner and cheaper water.
Barcelona is a unique city, blending old monuments and cathedrals with a very modern and bustling metropolis. But it has a few things in common with South Africa’s towns and metros, notably a semi-arid climate with limited access to water. As water stresses increased, Barcelona’s authorities needed to make a plan—and they decided to use smart water technologies. The results have been incredible.
Smart tech to solve water challenges
Water providers across SA are struggling with growing demand, ageing infrastructure, and shifting weather patterns. Experts warn about water shortages as several major cities and towns have already implemented water restrictions. Meanwhile, major water infrastructure is breaking down in large metros such as Johannesburg and eThekwini, buckling under the dual strains of rapid population growth and underinvestment in maintenance. Though the situation looks increasingly dire, water utilities have a big opportunity. Innovation in engineering and digitisation has honed a range of smart water solutions that can help improve existing water systems without
massive replacements, giving sites time and space to scope their future improvements with the help of data-driven insights to improve efficiency, forecasting, and demand prediction.
“Smart water solutions have developed extraordinarily in the past twenty years,” says Chetan Mistry, Strategy and Marketing Manager at Xylem Africa. “They can deliver specific point solutions, large overhauls, or start collecting and analysing rich data for planning. One of the biggest advantages today is that you can tackle a specific problem with a smart solution, then use that investment to tackle the next problem. You can scale effort while keeping costs under control.”
Smart water technologies are fundamentally data-driven. They collect and leverage water performance data to improve results through better management and visibility. Examples include smart sensors that collect various data points, data analytics for planning and efficiency, predictive maintenance, integration of different infrastructures for improved performance, and comprehensive real-time visibility through interactive dashboards (accessible
anywhere via the cloud and an internet connection).
The ROI of Smart Water
These innovations have a lot to offer, and they are costeffective. But, like all infrastructure solutions, there are still investment concerns. What is the value, the return on investment, of a smart water solution? Utilities can jump into smart water systems only to get less return than expected. How can utilities invest in the right smart water technologies and start to get that momentum they can build on and modernise their sites?
The two crucial steps to realising healthy ROI from smart water are embracing a digital modernisation strategy and focusing on value beyond cost. Digital modernisation is neither a mere rip-and-replace strategy nor as simple as installing and linking a few sensors to software. To get good results, the vision must be more specific.
“Water sites already use technologies; they have sensors and software,” says Mistry. “Smart water systems take things to the next level because they enhance what you already have and introduce new methods and insights. This means you rely only on a technical or cost mindset. You should choose smart solutions that work for a site’s strengths and enhance the site’s requirements. Start with a plan, a vision, for the site, then look for specific opportunities to apply smart water solutions.”
For example, a site might already generate useful data, but the overall management tools are isolated. Collecting information requires considerable time before one can predict consumption levels or maintenance demands. In this case, water managers can unify water operations
through cloud platform dashboards that securely consume the data, analyse results, and deliver single-truth insights to authorised personnel wherever they are—on-site, at the office, or even on the road.
Modernisation with a plan delivers results
A municipality could recoup costs by reducing non-revenue water. To do so, they can use smart flow systems to measure water allocation and consumption, identifying where there are losses. They can employ smart leak detection to pinpoint problem areas without shutting down the water pipelines for inspections.
Every site has unique needs and priorities. Smart water succeeds when there is a mindset for modernisation and a strategy to support that vision. These needn’t be massive projects—there are many low-hanging fruits that water utilities can exploit to see quick gains.
With the right planning and partners, smart water delivers great returns on investment. Barcelona reduced overall water usage by a massive 25 percent while still finding more revenue through optimisation, cost savings, and better service to customers.
All of this was accomplished by adding smart technologies to the city’s sprawling (and often antiquated) water systems. Imagine what smart water solutions can do for South Africa’s struggling water infrastructure.
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Millions of tons of grease and oil flowing into our waterways annually
Shocking statistics reveal that approximately 50% of lubricants used on industrial machines and equipment eventually makes their way into the environment where just one litre of used oil has the capacity to poison about a million litres of water.
Significantly, the global market for lubricants is rising and in 2019 increased by 2% to more than 45 million tons showing how dire the consequences are becoming. These figures also indicate just how much needs to be done and changes made in order to reduce the amount of pollutants making their way into our water sources every day.
Solutions are hard to find considering the importance of lubricants in machines ranging from cars to tractors, ships and manufacturing equipment, almost every moving application that bears weight or creates friction needs lubrication to avoid abrasion and heat. Bearings, shafts, spindles and gears are just some of the items that keep the wheels of industry “working like a well-oiled machine” but there is hope with newer and better ways that have already been developed to mitigate the need for grease and oils.
At the forefront of these is world-leading motion plastics manufacturer, igus, who has embarked on a decades long development journey to produce thousands of different formulae of polymers that are tribologically designed with built-in lubrication to operate without oils and grease. As a result, polymers such as its iglidur and others are rapidly replacing steel in applications such as bearings, bushings, gears, robotics and is even used in tandem with steel in applications such as shaft linear guides, energy chains and other friction and abrasion applications.
With no requirement for lubrication these developments have quickly found favour in global clean room
applications, food and beverages, pharmaceuticals and other applications, while its applications in heavy industry, earthmoving, agriculture and some of the toughest environments have enjoyed a slower uptake thanks to its initial scepticism over plastic’s ability to withstand tough tasks. However, the skyrocketing cost of lubrication and the ongoing cost of maintenance in recent years has pushed the agenda and thankfully has steadily filtered through to the point where today the use
of plastic bearings is commonplace in the heaviest machines where they have proven to outlast other materials in a wider range of applications.
“One must remember that In earthmoving alone, a small 16-ton excavator uses about 60 litres of grease per year which is mostly destined to end up in the ground and ultimately in our rivers. Larger machines and industrial plants use proportionately much more and can often be replaced by our igus’ motion plastics solutions,” says igus South Africa managing director, Ian Hewat.
He adds that South Africa is rapidly catching up to global benchmarks and the uptake of its motion plastics solutions is gaining pace across applications in heavy engineering, chemical plants, agriculture and other tough environments, never mind the food and beverages and other “clean environments” who already enjoy the benefits if its lubrication-free products. In fact, several high-profile instances of its products outlasting other materials in bearing and anti-abrasion, noise reduction, as well as corrosion resistance applications, have shown local engineers and designers the value of polymers across all applications.
More recently the company even introduced a free-touse App for smartphones that automatically scrutinises photographs of machines or applications uploaded to the application to identify igus solutions to improve performance with solutions that also negate the use of lubricants. igusGO App is a cutting-edge solution that is free for anyone to download and use. Fortunately, wherever more complex solutions are required, igus’ team of polymer experts are at hand to advise users on applications and are able to call on its German and international laboratories and counterparts to find solutions for customers’ unique requirements.
igus South Africa, +27 (0) 11 312 1848, ihewat@igus.net, www.igus.co.za
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