The latest edition of the Sassda magazine is here and focuses on Sassda's celebration of its 60 years of helping to sustain the South African stainless steel sector. We announce the launch of our 2024 Sassda Columbus Stainless Steel Awards and look at the hot topic of desalination in South Africa’s water scare environs and the role that stainless steel can play in boosting the development of these much needed plants and enhancing South Africa’s future water security.
ISSUE 1 2024
THE SASSDA AWARDS ARE BACK BETTER THAN EVER!
STAINLESS WORTH ITS SALT IN SA’S DESALINATION DRIVE SASSDA CELEBRATES 60 YEARS OF SUSTAINABILITY IN 2024
Headline Sponsor
Contents
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SASSDA Perspective Sassda celebrates 60 years of sustainability & growth Market Intelligence Round Up The Best of the GPS eNewsletter Global News It’s time to move away from the global plastic addiction to sustainable stainless Stainless Steel Awards The Sassda & Columbus Stainless Steel Awards are back & they’re better than ever! State of the Stainless Steel Nation A critical juncture for local stainless Focus Feature Desalination Stainless is the ‘salt of the earth’ when it comes to desalination Professsional Profile Nthabiseng Sebelebele: Leveraging engineering expertise for innovation
SASSDA News Francis Le Roux - A fond farewell Regional Profile West Africa’s economic boom sparks global competition Country Profile A focus on Côte d’Ivoire Technical Profile Laser Welding - Shining a light on precision Membership Benefits Members make our industry great - this is how we can help you! Member Profile Fabrinox - The hallmark of a sector leader SASSDA News Eastern Cape golf day a clear winner Membership News A day of learning and immersion into the origins of stainless steel
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Adverts Columbus Stainless • Fastenright • NDE
Advertorial Novametal South Africa
association perspective
SASSDA celebrates 60 years of sustainability
TELEPHONE NUMBER 011 883 0119 Contact us
EMAIL info@sassda.co.za WEBSITE www.sassda.co.za
and growth This year will be a special one in the history of the South African stainless steel industry. Our industry
Sassda
MICHEL BASSON Executive Director michel@sassda.co.za FRANCIS LE ROUX Head of Administration francis@sassda.co.za
celebrates the 60th anniversary of its official establishment in July 1964. Since the beginning of the stainless steel industry in Southern Africa, Sassda has been recognised as the official voice of the industry - a role the association still plays. In 1912, the Krupp company patented the first austenitic stainless steel. This was not publicised broadly and in England, Harry Brearly was trying to improve the durability of gun barrels by adding chrome to alloys. He did not succeed, but his work paid off when he became the first person to produce stainless steel products. These took the form of cutlery made from martensitic stainless steel. This material was subsequently developed in America and led to the ferritic grades being produced in the 1930s. The last major development was the duplex grades produced in Scandinavia during the 1940s. South Africa and its neighbours have major reserves of the minerals that are instrumental in the production of stainless steel and the first stainless steel was produced in Middelburg in 1966. At that stage, local production capacity was 36 000 tonnes per year.
CALLUM SUTHERLAND Members & Communication callum@sassda.co.za MANKABE MORE Education & Training mankabe@sassda.co.za
TEBOGO NKWE Market Intelligence & Lobbying Tebogo@sassda.co.za KIM STEVENS Events, Email Marketing and Website kstevens@sassda.co.za
JOSE HERON Accounts jose@sassda.co.za
LUISE ALLEMANN Content, Social Media and PR luise@mediaink.co.za
Stainless steel is published triannual and is distributed to stockists, distributors, fabricators, specifiers, consulting engineers, architects, mining, petrochemical and chemical industries, food beverage and pharmaceutical industries, consumer outlets, end-users, educational institutes and provincial and government departments. Sassda makes every effort to ensure the accuracy of the contents of its publications, but no warranty is made as to such accuracy and no responsibility will be borne by the publisher or Sassda for the consequences of any actions based on information so published. All opinions, views and expressions contained in this publication are not necessarily those of the management of Sassda. The contents of this publication enjoy positive protection under the Copyright Act and therefore copyright thereof is expressly reserved. Any copying, publication and distribution of part or whole of the publication is prohibited unless consent is granted by Sassda.
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association perspective
Columbus Stainless rises During the early 1980s, there was further investment in strip rolling bringing the local capacity to 150 000 tonnes per year. The Columbus Joint Venture was formed, with the IDC, Samancor, and Highveld Steel as the major stakeholders. During the early 1990s production grew to 500 000 tonnes per year. In 2002, Acerinox acquired a 64% shareholding, and this investment gave birth to Columbus Stainless and increased production to just under 750 000 tonnes per year. During the last sixty years, Sassda has grown to an association covering the complete stainless steels value chain with just under two hundred members in the southern African region. However, it was not all plain sailing and over the last 60 years the association has had to adapt to a changing market and economy, as well as the dwindling economic growth of the country over the last two decades. Sassda is one of the oldest stainless steel development associations in the world and over the past 60 years, Sassda and the local industry have made their mark on the global arena with quality products and innovation and our “Cross and Ball” logo is world renowned.
also celebrating the return of the Stainless Steel Awards in 2024. The brief was that the event should recognise and applaud exceptional achievements within the
stainless steel industry during the recent past. However, it
is also aimed at celebrating the resilience of the South African stainless steel industry and its ability to weather a range of storms over the past 60
years. It’s now time to celebrate the tenacity, resilience, and teamwork in our industry that is, in effect, a celebration of the sustainability of an industry, the Association and its members. It is an event where the positive side of the past six years will be highlighted as motivation for the future that still is not looking all that bright. The awards will celebrate the material which builds our industry and society, and which is constantly improving life for all. It is to honour the people that keep the wheels turning in our industry, adding to economic growth, job creation, and a better environment for generations to come. It is the event that will again emphasise the fact that South African stainless steel has been simply brilliant for sixty years and that the intent is to remain brilliant for the sixty to come.
Promoting sustainable growth and development
An aspect that has never changed is Sassda’s mandate to provide a platform for its members to collectively promote the sustainable growth and development of the industry with the main emphasis on stainless steel converted within the local economy. This is achieved by supplying the industry with world-class training, education, and technical support. There is a strong drive to collaborate with peer organisations to market the local industry and members by lobbying at a high level and creating networking opportunities for members. The association is simultaneously building on its illustrious past and looking to the future for opportunities to actuate the mandate in new and innovative ways. We are
Michel Basson Sassda Executive Director
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Issue 1 – 2024
market intelligence
The best of the GPS e-newsletter Each month Sassda rounds up a selection of global and local market intelligence articles that are sent to our members in an easy-to-read package of content. They’re designed to highlight pockets of potential growth in demand for stainless steel. Here are some of the best articles from the last few issues...
No charges for environmental crimes - NPA won’t prosecute Karpowership case The Director of Public Prosecutions in Pretoria has declined to bring charges against the environmental consultants who helped Karpowership SA bypass environmental regulations. A case was opened in May 2021 by the Environmental Management Inspectorate (aka Green Scorpions) which investigates environmental crimes. It relates to Karpowership’s 2020 attempt to bypass the complex process of obtaining environmental permits. At the time, the country was in the grip of the Covid-19 pandemic and Karpowership’s environmental consultants claimed that this “emergency” was a good reason to grant Karpowership an exemption under Section 30A of the National Environmental Management Act (Nema)… Read more
Inept African ports miss chance as Red Sea attacks reroute ships Africa’s inefficient and ageing ports are hampering the continent’s chances of capitalising on a surge in ship traffic that’s avoiding attacks by Houthi rebels through the Red Sea, logistics experts said. The number of vessels sailing around the southern tip of Africa is up 85% from the first half of December 2023, when the Iran-backed, Yemen-based terrorists intensified their attacks on ships, according to Clarksons Research. Some of the biggest beneficiaries are ports in South Africa, Madagascar, Mauritius, and Namibia, all of which have seen volumes rise… Read more
Gardens of Stainless Steel Located outside the Chinese city of Nanjing, the Jiangsu Garden Expo
recreates famous classical gardens from across Jiangsu province. The 3.5 km park is an outstanding example of regenerating a degraded environment into a living museum furnished with hotels, restaurants, and entertainment. Stainless steel features prominently throughout the Expo… Read more
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market intelligence
Transnet’s plan to attract rail investment misses the mark Transnet’s draft ‘Network Statement’, which is intended to ready the logistics provider for private investment, has received a lukewarm reception from the transport sector. Off-the-record discussions are more frosty, in part because Transnet appears intent on retaining its monopolistic control of rail and setting tariffs that could lump miners with a 65% increase in rail transport costs, according to some estimates… Read more
Canyon Coal to develop new R1.4 billion mine in Mpumalanga Canyon Coal is constructing a new coal mine in Hendrina, Mpumalanga. Production is expected to start in the second half of 2023, with the first phase of the Gugulethu project on track to be completed in eight to ten months and expected to produce 1.2 million tons a year. Formerly known as De Wittekrans, Gugulethu is a greenfield project located south- east of Hendrina that Canyon bought out of business rescue. Phase 1 of the project holds an economically mineable reserve of 14.3 million tons of run-of-mine (RoM) coal. It comprises three pits, one of which has been specifically designed to gain access to the underground reserve as part of Phase 2… Read more
Improved infrastructure can help SA escape low growth Infrastructure challenges in South Africa are mounting in what is turning out to be a perfect storm of power cuts, water shortages and potholes that are all too common. The South African Institution of Civil Engineering (SAICE) highlighted these challenges in its 2022 State of Infrastructure report that revealed that South Africa is at risk of becoming a “failed state”. The report assessed 32 different infrastructure segments and found only 15 to be “satisfactory” or above (graded C or above), with the remaining segments falling into being at risk of failing’ (D) or ‘unfit for purpose’ (E). South Africa’s overall infrastructure rating was a D, indicating that infrastructure is not coping with normal demand and is poorly maintained… Read more
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market intelligence
Koeberg nuclear fuel supplies in trouble after US-South Africa pact ends South African power utility Eskom is examining how the suspension of a pact that enables it to import nuclear fuel components from the US, will affect its sole atomic plant. The Agreement for Cooperation in Peaceful Uses of Nuclear Energy between the US and South Africa expired on December 4. That resulted in Westinghouse Electric losing its license from the US Nuclear Regulatory Commission to export fuel-assembly components to Eskom’s Koeberg plant near Cape Town. “Eskom is exploring the implications of the withdrawal of the US NRC approval for Westinghouse and what is needed to enable them to continue supplying fuel,” the utility said in a reply to questions… Read more
SA steel industry needs level playing field says Amsa’s Kobus Verster Writing in IOL.co.za, ArcelorMittal South Africa CEO Kobus Verster says the South African steel industry needs a level playing field through the establishment of a conducive operating environment and a level ecosystem to allow it not only to survive but to flourish. He stated; “As we enter another election season, there is much discussion about ‘saving’ the local steel industry. ‘Saving it’ is, however, a misguided narrative, and one that needs addressing” ... Read more
Looming industrial gas crisis, government called upon to make haste Against the backdrop of a looming supply crisis, Industrial Gas Users Association of Southern Africa Executive Officer Jaco Human reported that the South African gas sector employs 70 000 people and contributes significantly to the manufacturing sector to the extent of about R500-Billion a year. Speaking during a Moneyweb podcast, he reported there are no feasible or discernible alternatives for energy to run these plants at this particular point in time… Read more
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ADVERTORIAL
Novametal S.A. (PTY) Ltd, (formerly WPSSP) based in Wadeville, Germiston, has evolved to meet the demand of the South African market with ample local stockholding and International support from our Mill in Europe.
Novametal S.A. offers clients local partnerships and only the highest levels of service. Our trained staff are fully committed to offer the South African market the highest quality product and satisfaction without losing sight of each customer’s specific requirements. With constant research and development at our mill our range of stainless steel, nickel and aluminium wire will continue to evolve and offer the South African market new grades and products that covers a multitude of applications. Our products include but not limited to: Mig, Tig and Sub-arc welding wire available in a range
of different grades for example: 308LSI, 309LSI, 316LSI,310, 410nimo, nicrmo3, nicrmo4, nicr3, NI1 etc. Sizes available in Mig range from 0.8 to 1.2dia and Tig rods /Sub-arc from 1.6dia to 3.2dia in stainless steel, high nickel alloys and aluminium welding wire. We also stock general wire in grades 304 and 316 in sizes ranging from 0.9dia up to 8dia in half hard and soft condition. Other grades can be supplied upon request. Partner up with Novametal S.A. today to benefit and experience the quality, service and competitive pricing available to the local market.
Website : www.novametalgroup.com • Tel: +27 (11) 824-7600 / 824-1528 • 152 Haring Road, Wadeville, Germiston
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Issue 1 – 2024
global news
It’s time to move away from the global plastic addiction to sustainable stainless Given that the theme of Sassda’s 60th Anniversary is celebrating sustainability this article looks at the excellent work our global associate World Stainless is doing to champion the message that stainless steel is a viable alternative to plastic and should be used to ensure an environmentally eco-friendly product.
Choosing stainless steel for an application ensures that it will be produced responsibly, with an extremely low life- cycle inventory (also known as the life-cycle greenhouse gas emissions profile). Furthermore, stainless steel products have low, or close to zero, maintenance costs during their long life, and stainless steel can be reused indefinitely because they are easy to recycle without any loss of quality or material integrity. In line with this, worldstainless.org has reiterated its support for the Zero Waste initiative (www.zwia.org) which focuses on; “The conservation of all resources using responsible production, consumption, reuse, and recovery of products, packaging, and materials without burning, and with no discharges to land, water, or air that threaten the environment or human health”. This initiative underscores the urgent need to reevaluate material selection practices, highlighting the superior environmental credentials of stainless steel over traditional options like plastic. This comes as a response to escalating environmental concerns and the pressing need for industry-wide action.
With mounting evidence of the detrimental impact of plastic pollution on ecosystems worldwide, advocating for the adoption of stainless steel as the preferred choice for various applications, it’s clear that this is the most responsible and sustainable to make. A plastic addiction Sassda Executive Director Michel Basson comments; “We cannot afford to continue down the path of plastic dependency. The environmental consequences are dire, and it’s time for industries to take responsibility for their choices. Stainless steel offers a viable solution - one that prioritises sustainability without compromising on performance.” Indeed, the superior life-cycle strengths of stainless steel make it an ideal candidate for a wide range of applications. Unlike plastic, which contributes significantly to environmental pollution and resource depletion, stainless steel boasts low to zero maintenance costs throughout its long operational life.
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global news
This durability not only translates to cost savings for consumers but also reduces the need for frequent replacements, thereby minimising waste generation and conserving resources. Stainless steel’s inherent recyclability further solidifies its position as a sustainable material choice. Unlike plastic, which often ends up in landfills or oceans, stainless steel can be recycled indefinitely without any loss of quality or material integrity. This closed-loop approach to material utilisation, not only reduces the environmental burden associated with disposal but also presents economic opportunities by minimising the demand for virgin materials. Earlier this year The United Nations established Zero Waste Day to draw public attention to the need to address the global waste problem and promote sustainable practices aimed at achieving zero waste. In line with this, stainless steel microwave-safe food containers can help by reducing food waste and the waste streams of single-use food containers. Traditionally, metal food containers have been prohibited from being used in microwave ovens due to electrical arcing inside the ovens. Today it is easy to find microwave-safe stainless steel food containers in a variety of selling outlets, including popular online selling platforms. Most stainless steel food containers are made of 304 grade (18/8 stainless), and new microwave-safe containers have had their corners specially designed,
Basson emphasises; “Plastic cannot be the default choice anymore. We need to shift towards materials that prioritise sustainability and longevity. Stainless steel offers a viable alternative - one that is not only environmentally responsible but also economically sound.” Currency weaknesses and debt burdens are other factors to consider. These issues can lead to defaults, project cancellations, and payment difficulties for imports. Therefore, businesses must be aware of these factors and utilise Exim facilities wherever possible.
Learn more here or contact info@worldstainless.org for more information.
so they do not cause problems when used in a microwave oven.
The main advantages of stainless steel microwave-safe food containers are: • Eco-friendly: A resilient, reusable and recyclable product that does not harm our environment or humans. • Food safe: A completely safe material that meets all global food hygiene standards. • Versatile: Innovative product that can be used in every appliance in your kitchen including microwave ovens!! • Convenient: Lightweight, portable and easy to use - just clean and reuse ... over and over again. • Economical: Damage resistant and extremely long- lasting, meaning no need to re-purchase.
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Issue 1 – 2024
stainless steel awards
The SASSDA and Columbus Steel Awards are back and they’re better than ever!
New look awards offer eight key categories and an enhanced digital entry mechanism
As Sassda proudly celebrates its 60th Anniversary in 2024, it has also announced the highly anticipated return of the Sassda & Columbus Stainless Steel Awards supported by title sponsor Columbus Stainless and category sponsors Euro Steel, Macsteel, NDE, & Novametal South Africa. Centred around the theme, ‘Sustainability: A Legacy of Brilliance’ the awards will take place on 19th September 2024 and will honour the enduring strength and durability of stainless steel, while recognising the resilience of the local stainless steel industry in navigating the current challenges it faces. Sassda Executive Director Michel Basson comments; “We have stated that the intent of the event is to recognise and applaud exceptional achievements within the stainless steel industry during the recent past. However, it is also to celebrate the resilience of the South African stainless steel industry to weather a range of storms over the past 60 years. He points out that Sassda is one of the oldest stainless steel development associations in the world and over the past 60 years Sassda and the local industry have made
their mark on the global arena with quality products and innovation the world renowned “Cross and Balls” logo. Explaining the reason for the awards’ long hiatus Basson explains; “ The last global storm the South African industry had to face came in the form of a pandemic that brought the world to its knees. This also temporarily halted our tradition of the awards as a showcase event every second year. “The world has undergone countless changes since our founding but through it all, Sassda has remained a pillar of support and innovation for the stainless steel industry, and we are therefore proud to host these sought after awards. They are a vital opportunity to reflect on the resilience of our members and underscore the critical role stainless steel plays in shaping a sustainable future.” Basson adds that this year’s awards represent a fresh new take on an old classic given that the number of categories has been streamlined to eight and the digital entry mechanism has been made as user-friendly as possible.
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stainless steel awards
The award categories are:
Sponsored by:
Sustainability recognises a sustainable innovative new product or project featuring an impact on either energy use, environmental improvement, recycling, material use or life-cycle costing. Duplex Stainless Steel The use of this specific grade of stainless steel in an application which demonstrates innovation and life-cycle cost effectiveness. Entries will cover both projects and products. Ferritic Stainless Steel in a product or project that demonstrates innovation, life-cycle cost effectiveness, substitution, and growth potential. Austenitic Stainless Steel in a project or product with an application in this grade of material that shows innovation, life-cycle cost effectiveness, substitution, and growth potential. Export Achievement recognition of significant growth in export sales through innovation, quality and effectiveness (volume, value or both) Business Excellence will recognise businesses for building a sustainable, long-term, thriving business that has demonstrated innovative use of stainless steel in the design and development of products, to become a leader in the field of excellence. Lifetime Achievement awards a person or persons that have made an outstanding contribution to Sassda and the stainless steel industry.
Overall Winner the most successful and outstanding winner from all the categories.
In terms of entry criteria, the awards are open to individuals and companies (locally and abroad) that participate in the design, production, conversion, distribution and use or specification of stainless steel. Entrants do not need to be a member of Sassda. Entries for the awards close on 8th July 2024 and will be adjudicated by an independent panel of judges drawn from recognised professionals, representing all sectors of industry. The winners will be announced at a banquet dinner to be held on the 19th of September 2024 at The Indaba Hotel, Fourways, Johannesburg.
Click here for more information and to enter
CLICK HERE
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state of the stainless steel nation
A critical juncture for local stainless steel
How would you categorise the performance of the South African stainless steel sector in the last three years? The local decline in production and consumption, which was also experienced globally, was mainly caused by a decline in economic activity due to the pandemic as well as global logistical issues. As the shutdown regulations were eased we expected a spike in stainless steel demand for re-stocking. This took place worldwide, and it was, we believe, the main driver for the growth of more than 20% in local consumption during 2021. Although this was expected, it was also understood to be short lived as stock levels started to stabilise and the industry returned to normality. The domestic market continued with this growth trend and increased by more than 3% in 2022. This was significant, in light of the impact of the nickel price volatility during the early parts of 2022. It was also encouraging that the rate of growth in local consumption of stainless steel showed an increase of more than 300% compared to the South African GDP growth during the first post-pandemic year.
The 2022 performance is even more impressive seen against the backdrop of a weak economy, floods, unrest, and the lack of electricity experienced by industry during the period. This momentum and the gains made in our work with the Steel Master Plan indicated a solid starting point for continued growth in the years to come. Overall, since 2018 stainless steel exports from South Africa declined from around 450 000 tons per annum to just under 150 000 tonnes in 2023. This had a similar influence on the local production of stainless steel since local production is mainly driven by the export market. Local production nearly halved over the period bringing production figures to 218 000 tonnes. Bear in mind that the local production capacity is more than three times the current level. The result of this is a decline in the local conversion of stainless steel of around 16% during 2023.
How is Sassda championing the growth of the local stainless steel sector?
Sassda’s growth strategy within the framework of the Steel Master Plan is dual faceted. Our mandate speaks about the
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state of the stainless steel nation
the structural profiles to the required standards. The announcement of the closure of the AMSA long products, put a damper on this strategy, since these plants were identified to produce structural profiles. Sassda therefore participated in industry discussions and supported the work and efforts done by ISF, SAISI and BUSA amongst others to be able to postpone or delay the closure date for 6 months. What is Sassda’s stance on the proposed closure of ArcelorMittal’s long steel operations in South Africa? AMSA is a significant supplier of long steel products to the South African manufacturing industry supplying approximately 450 000 tons a year of product that cannot be supplied by the local mini mills due to capacity, capability, and quality constraints. The resulting steel shortages will lead to the almost immediate closure of industries that are reliant on the supply of long steel from AMSA. Automotive steel components are typically safety critical. The automotive industry bodies advised that any change in the supply chain requires substantial time for approval
promotion of stainless steel use with an emphasis adding local value which will create tonnage and sustainable jobs. Localisation or import replacement of stainless steel products with high labour intensity such as the local production of beer kegs and cooking products would be able to create jobs with an increase of locally used tonnage of around 250 000 tonnes as a target. The strategy of driving higher tonnage in the local manufacture of electrical transmission towers and rural bridge infrastructure in the utility ferritic grades such as 3CR12 for corrosive and other sensitive regions of deployment. These industry initiatives to create more locally converted tonnage are currently under threat with the Arcelor Mittal South Africa (AMSA) announcement regarding the closure of its long product facilities. The plants earmarked for closure were set to produce many of the profiles and products identified for these projects. This means that 2024 will once again be a tough year for the local stainless steel industry. Most of our fabricating members work in carbon steel as well and the developments regarding AMSA would take its toll on our current industry activities. What are some of the key projects flowing from the Steel Master Plan that Sassda is working on? • Hollowware: Sassda and its partners in the demand side structures in the Steel Master Plan have completed an investigation and a report on the local manufacturing capacity for hollowware. This will now be presented to major retailers to gain possible commitment for potential demand. It has also been noted that the enforcement of SABS standards can be beneficial to local producers by restricting the imports of sub-standard goods. As such, Sassda is currently contemplating a repeat of the investigation done a decade ago regarding the quality of hollowware available from retailers in South Africa. The study entails the purchase of a range of stainless steel items available in retail stores. This will be followed by tests for material quality, against the SABS Standard 998 which specifies the technical aspects of acceptable hollowware. The results of such a study would potentially highlight serious discrepancies in quality and identify possible dumping practices. It would also have the effect of encouraging the public to purchase local stainless s teel products. • Structural profiles: We remain committed to getting 3CR12 included in the national standards for electrical transmission towers and rural bridges. This will open additional markets for structural profiles and possibly exports. Whereas kegs and hollowware can be regarded as job creators, structural use will be tonnage generators. However, this strategy was largely dependent on the local carbon steel industry’s capacity to roll form
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state of the stainless steel nation
and typically takes more than a year. This could cause a halt in auto production or at least a very uncompetitive scenario. The direct job losses at AMSA are quoted as 3 500, industry experts estimate the immediate indirect job losses at 30 000 which includes service providers to the AMSA plants. The following quantitative impact analysis was submitted by the auto industry: • Local steel tonnage loss: +- 70 000 tons p.a. plus SAAM35 volumes forecast at more than 100 000 tons.
• Cost increases due to importation: 25% to 35%.
• Knock on effect to losses of related sub & full assemblies: More than 7% resulting in an estimated R35-billion p.a. • Suppliers at risk: Approximately 17 suppliers will be directly affected (Domestic OEM suppliers plus exporters). • OEM & Supplier Profitability Erosion due to loss of localisation: No longer qualifying content for the Automotive Production Development Program. • Short-term jobs impacted: +- 30 000 including suppliers and backward linkages, growing in the medium to longer term. Against this challenging background how does Sassda see 2024 playing out for the local sector? A key part of Sassda’s role is to identify potential avenues for localisation and increases the local tonnage converted. However, the bottom line for the growth of the stainless steel sector in terms of employment figures and tonnage consumed would be the local socio-political environment and improvement of service delivery with a major focus on improving the consistency of electricity supply, rail transport and port efficiency. We are also acutely aware that this is an election year that brings a lot of uncertainty and volatility. The immediate future does not have a positive slant, but we trust that in time our industry will shine again because stainless steel remains simply brilliant.
The timespan covered by the graph indicates various sector activities and acts as a snapshot of the COVID-19 and post-pandemic unfolding of events. The negative historic growth rate continued and accelerated during 2020 when the industry experienced severe COVID lockdown conditions. To some extent, this was mitigated by Sassda’s work to get the dtic approval for the stainless steel to run at a 50% capacity compared to the 30% required for other industries.
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focus feature
Stainless Steel the ‘salt of the earth ’ when it comes to desalination
Desalination has become a popular talking point over the past decade in South Africa. During recent droughts along the Southern and Eastern Coastline desalination played an important part in supplying communities with drinkable water. Unfortunately now that the critical need for alternative water sources has been alleviated, the desalination systems until the next crisis. However, reality dictates that the water crisis is already upon us and that water sources will remain under escalating pressure with an increase in populations in and around the major coastal cities. Whilst the water crisis is spread over the Southern African region due to climate changes and increased demand for water in industry and rural development, desalination is a potential solution to water supply in the coastal regions only.
Cape Town’s proposed new desalination plant has the potential to use 900 to 1000 tons of stainless steel that would be used to construct the desalination unit, connecting pipework, other equipment such as pumps and valves for the unit, and its auxiliary systems and general infrastructure. In this issue’s Focus Feature, we take a deep dive into the concept of desalination and the potential for its use in this vital project…
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focus feature
for up to half of a plant’s production cost. In South Africa, we do not have a constant or consistent energy supply available to see this process as a final solution. Membrane technology makes use of semi-permeable membranes to separate salts from water. In the Cape Town area, the emergency desalination plants used reverse osmosis, which uses high pressure and a semi-permeable membrane to filter salt and other impurities from water. In reverse osmosis, water from the ocean is forced through thousands of tightly wrapped, semi-permeable membranes under extremely high pressure. The membranes allow the smaller water molecules to pass through, leaving salt and other impurities behind. Desalination processes are still developing and there are a number of other technologies available as alternative solutions. One of them would be so-called multiple effect distillation (MED) which uses heat and electricity to produce
A complex process Desalination, in any form, is based on simple principles but highly complicated in practice. It is the process of removing salt and other impurities from seawater to make it drinkable. The two most common methods for desalination are thermal and membrane technologies. The thermal technology involves heating saline water (seawater) to produce water vapour, which is then condensed and collected as fresh water. This process is called distillation, which involves boiling seawater in a still, collecting steam, and condensing it to obtain fresh water. Distillation is the most obvious method for removing salt, but it consumes large amounts of energy whcih can account
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focus feature
potable water. The water to be treated passes through a set of evaporators in series. The steam from one cell is used to evaporate the water in the following, while the primary energy input is to the first stage. Typically, MED systems have multiple chambers and hot steam from a nuclear power plant is carried into the chamber through pipes, repelling seawater on the pipes. Another method would be electrodialysis (ED) in which an electric field is used to separate any dissolved salts from water. The process involves the use of ion- selective membranes that allow either positive or negative ions to pass through while retaining the opposite ions. Electrodialysis has many applications, including desalination, table salt production, wine stabilisation, whey demineralisation, and pickling bath recovery. What does a desalination plant for a city look like? Spain is the world’s fifth largest producer of desalinated water, with 770 large-scale desalination plants, 99% of which are high capacity installations. A good example would be the Valdelentisco Desalination Plant in Murcia, Spain, which uses pumps to move water from the raw water tank to sand filters. The water is then passed through cartridge filters made of rubber-coated carbon steel, which filter the water through polypropylene ore size 5µm. In Sydney, Australia, seawater is drawn from the Tasman Sea through four intake pipes on the seabed, about 25 m below the water level. At full capacity, the intake pipes
deliver about six hundred million litres of seawater daily to the plant via a 2.5 m diameter concrete tunnel. Drum screens are used to remove any large materials that may enter through the intake tunnel. The plant’s pre- treatment filter system removes any solid material, such as algae and small dirt particles to get the seawater as clean as possible before the reverse osmosis process. The seawater is filtered through layers of filter coal and sand to prepare it for the reverse osmosis process. The clean filtered seawater passes through 36 000 reverse osmosis membranes so any
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focus feature
regarded as medium sized in global terms. The stainless steel would be used to construct the desalination unit, connecting pipework, other equipment such as pumps and valves for the unit, and its auxiliary systems and general infrastructure. Stainless steel in reverse osmosis systems The temporary plants used around Cape Town were of the reverse osmosis types. In reverse osmosis plants, there are much lower pressures and thus a high use of PVC and other plastics. The use of stainless steel is limited to the pumps, valves and tubes working at higher pressures. These plants require far less stainless steel than thermal desalination plants; for example, a plant producing 1500m3/h of permeate requires about 30-40 tons of the aforementioned materials. Conclusion Desalination is already widespread in some water-stressed areas, like the Gulf region, where Kuwait gets up to 90% of its drinking water from desalination, where Kuwait gets up to 90% of its drinking water from desalination 42% of the United Arab Emirates’ water needs. While desalination is a reliable process used by over three hundred million people worldwide, it has some negative environmental impacts: • Fossil fuels - Desalination is energy-intensive and uses fossil fuels contributing to global warming. • Toxic brine - The brine produced by desalination plants can pollute coastal ecosystems. • Waste and chemicals - Desalination plants produce waste and toxic chemicals that can harm wildlife. • Greenhouse gas emissions - Desalination plants that use diesel produce greenhouse gas emissions. • Temperature difference - The temperature of rejected brines is often 10 to 15 degrees Celsius higher than that of ambient saltwater, which can be harmful to marine ecosystems. • Marine life - Desalination surface water intakes are a huge threat to marine life. For example, the sodium metabisulphite discharged from desalination plants can negatively impact seagrass habitats. It is clear that desalination is expensive and has significant environmental sideeffects but in an arid country such as South Africa what would be the alternatives? Additional reading 1. https://sassda.co.za/wp-content/uploads/2024/03/ ISSF_Desalination_in_Stainless_Steel.pdf 2. www.dailymaverick.co.za/article/2023-12-03-cape- town-set-to-purify-treated-sewage-water-for-drinking- purposes
salt and other minerals can be removed. The water is pushed at high pressure (60bar) through the semi-permeable membranes, which function as a filter for the salt and minerals and only allow fresh water to pass through. The freshwater produced by the reverse osmosis process requires minerals to be added before it is fluoridated and chlorinated, in line with Australian Drinking Water Guidelines and NSW Health requirements. Two large pumps transfer the water from the drinking water storage tank into a pipeline to the end-users. Approximately 58% of the water used during the desalination process is returned to the ocean. This water is known as seawater concentrate (effectively saltier seawater) and is transported back to the ocean via an outlet tunnel and specially designed outlet dispersion nozzles. These nozzles make sure the water mixes rapidly and returns to normal seawater salinity and temperature within a short distance of its discharge point so as not to harm the local marine environment. How much stainless steel is used in desalination? One should distinguish between the desalination processes when trying to determine the quantities of stainless steel used in such applications. The tonnage would also depend on the plant’s capacity. The types or grades of stainless steel used in desalination would also be noble or with higher alloying content to protect against harsh conditions in the process. Since desalination is not common in South Africa, we have no real data on local projects. South Africa is only beginning its feasibility studies on the suitability for such a facility and currently, a study is being finalised for a proposed plant near Cape Town. If this report shows that such a project is feasible, this will be the first permanent installation with this level of capacity in Southern Africa. Stainless steel in thermal desalination It would seem that empirical data from the proposed Cape Town project shows that a thermal desalination plant, which produces about 1500 m3/h of distillate, requires 900- 1000 tons of stainless steel . A plant of this capacity will be
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Issue 1 – 2024
professional profile
Nthabiseng Sebelebele: leveraging engineering expertise for innovation Air Liquide Lead Business Developer Nthabiseng Sebelebele a Chemical Engineering graduate from Wits University, pursued a Masters Degree focusing on energy optimisation. Her passion for engineering, drivenby a fascination with science, drives her commitment to large-scale projects in the stainless steel sector. With experience in the explosives and gas industries, she now excels in strategic business development at Air Liquide, leveraging technical expertise for innovation...
“Stainless steel is an indispensable component of our nation’s prosperity. Preserving and supporting this industry is imperative for the well- being and growth of our country. We must take action to ensure its continued resilience in our society.”
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Issue 1– 2024
professional profile
Why did you decide to study engineering and what is it about the discipline that attracted you to this field of study? I completed my undergraduate studies in Chemical Engineering at Wits University. After I graduated, I decided to continue my academic journey by pursuing a Master’s Degree, where I directed my focus towards heat integration and the optimal utilisation of energy resources. My attraction to engineering stems from my exposure to science during my school years. As I progressed into high school, I was captivated by the field of engineering, which amplifies the principles of science from laboratory experiments to large-scale applications. This transition fascinated me; from conducting small experiments to envisioning and designing vast industrial plants capable of mass production. It was the prospect of contributing to significant projects that directly impact our daily lives that truly ignited my passion for engineering. “It was the prospect of contributing to significant projects that directly impact our daily lives that truly ignited my passion for engineering.”
thermodynamics - one of the most difficult university courses - we were able to calculate the varying gas consumption rates under different conditions. This included accounting for temperature differentials during hot summer days versus cooler winter months, to estimate potential losses accurately. This exercise was instrumental in implementing cost savings.
What was your first company and your position there?
My first job was with AECI Mining, a company specialising in manufacturing explosives for the mining sector that awarded me a bursary for my tertiary studies. During my time at AECI, I engaged in various efficiency enhancement projects and continuous improvement initiatives within the plant.
In your current position, how would you describe a typical day and what it entails?
I am responsible for business development within our bulk and on-site division. My role involves spearheading the expansion of our business by identifying new opportunities and sectors for growth. When visiting a client, I assess their needs and requirements. Subsequently, I return to the office to analyse the gathered information. I identify potential solutions from our product and service portfolio that align with a client’s needs. Crafting a compelling business case is important because the proposed solution must be financially viable for the client and our company. Therefore, I present the proposed solution and its benefits. This includes a breakdown of costs, potential savings, and the value it brings to their business. Collaboration ensues, with adjustments made, as necessary. My role entails extensive interaction across various sectors, with steel remaining a primary focus. Technical expertise, combined with a deep understanding of customer processes and our offerings, is key. What is your view on the looming industrial gas crisis? How are you working to solve that problem for customers? We don’t handle natural gas; that falls under Sasol’s domain. Our focus lies primarily on gases such as nitrogen, oxygen, and argon. While we don’t operate in the natural gas sector, we remain open to engaging with customers who utilise it, exploring ways to support their needs. However, it’s not within our current scope of work. That being said, Air Liquide is known for its innovation and proactive approach to problem solving. We continuously assess the challenges we encounter and explore potential solutions. However, at present, bridging the gap for natural gas isn’t feasible for us.
What was the most challenging aspect of it?
University life operates at a significantly faster pace compared to high school. I have always held myself to high standards, so experiencing failure on my first university test was a jolting experience. It’s common for thee types of setbacks to affect one’s self-esteem, potentially leading to self-doubt. In such moments, it becomes imperative to believe in yourself, to rise above the challenges and to persevere with determination. How did the first years of your career build on what you learnt during your tertiary education but in a more practical setting? What were the key lessons you’ve learnt during this time? I was fortunate in the early years of my career to work with individuals who were highly engineering-oriented and were therefore supportive and knowledgeable. It made it easier for them to bridge the gap between my academic background and the practical applications required in our work. Those initial years were when I found myself applying the calculations learned in university. For example, in my current role within the gas industry, understanding the dynamics of gas flow is crucial, especially in terms of identifying losses within our operations. Gas, being invisible, presents a challenge in pinpointing these losses. However, by leveraging the principles of
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Issue 1 – 2024
professional profile
What is the most exciting project, innovation, or growth strategy that you’re working on at present and what lessons has it taught you? In our line of work, we primarily supply air gases like nitrogen and oxygen to our customers. An innovative focus for us is diversifying how we deliver these gases. Traditionally, we’ve provided them in cylinders, similar to the gas cylinders used for LPG. We also supply our gases in bulk form (which is the liquified state of oxygen, nitrogen, etc.) using road tankers into storage tanks at customer sites. Additionally, we offer the option of constructing either small to medium plants on, or near, the customer’s premises, from which we can supply the gases directly. This approach presents an exciting opportunity, particularly for eligible customers, as it eliminates the need for gas transportation via trucks. By reducing reliance on trucking, we not only decrease our CO2 emissions but also enhance supply reliability. This is especially significant in regions like South Africa, where protests and roadblocks are common, leading to delays in gas deliveries. Having a local plant ensures uninterrupted supply, circumventing logistical challenges associated with road disruptions. It is important to note that this approach isn’t suitable for all customers and depends on factors such as usage volume and other considerations. However, for eligible companies, it can significantly transform their operations, offering a reliable and sustainable solution to their gas supply needs. “We are confronted with numerous challenges, and the most pressing one affecting everyone, whether on a large or small scale, is load shedding. For businesses in industries like steel, ensuring operational continuity amid such uncertain power conditions is key” What do you feel are the biggest challenges facing South Africa’s stainless steel sector at present and how can these be overcome? As South Africans, we are confronted with numerous challenges, and the most pressing one affecting everyone, whether on a large or small scale, is load shedding. For businesses in industries like steel, ensuring operational continuity amid such uncertain power conditions is key. While government has the ultimate responsibility for ensuring sustainable power, businesses also have a role to play. Even small to medium initiatives, such as exploring solar energy options, can make a difference. At Air Liquide, for instance, we have entered into power purchase agreements in partnership with Sasol and various suppliers who will establish solar plants across the country. This
not only contributes to decarbonisation but also helps alleviate the strain caused by load shedding. However, the challenges extend beyond power issues. The sustainability of companies in South Africa, particularly in industries like steel, is crucial. ArcelorMittal, for example, cites factors like production costs and load shedding as threats to its sustainability. To remain competitive, the local manufacturing sector must address these challenges and ensure competitiveness against imports. Why do you feel that stainless steel still has such an important role to play in growing South Africa’s economy? I would like to reiterate the significance of the stainless steel industry, as it is deeply intertwined with various aspects of our society. From construction to medical applications and across all industries, stainless steel plays a vital role. Its collapse would pose a significant challenge for our country. For South Africa to prosper, we rely heavily on steel in our daily lives and economic activities. Moreover, the steel industry is a substantial contributor to our GDP. It sustains livelihoods, enabling people to put food on their tables, access education, and pursue employment opportunities. Stainless steel is an indispensable component of our nation’s prosperity. Preserving and supporting this industry is imperative for the well-being and growth of our country. We must take action to ensure its continued resilience and relevance in our society. What do you consider as the most exciting innovations/product developments happening in stainless steel right now and what sectors hold the greatest potential for the use of stainless steel in the future e.g. aerospace? Personally, a topic that resonates with me is decarbonisation. As a parent, I’m driven by the desire to leave behind a healthy planet for my daughter. Therefore, I am particularly passionate about companies that prioritise this agenda and seek ways to transition towards greener practices, including the concept of green steel. Ensuring that steel production becomes more environmentally friendly while remaining competitive is essential. By embracing green steel initiatives, we not only enhance competitiveness but also contribute to the larger ecosystem of our world. It’s inspiring to witness discussions and actions taking place within the steel industry in South Africa, such as the developments in Saldanha with ArcelorMittal. I’m genuinely excited about the potential impact of these initiatives. They have the power to revolutionise the steel industry and play a significant role in preserving our planet for future generations. I see green steel as not just an industrial advancement but also a crucial step towards environmental sustainability.
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