MechChem JAN-FEB 2026 AFRICA
VIS: optimal inventory management for bulk materials
This month: WARMAN ® DWU: the dirty water workhorse
Ceramat retractable sensor fittings
Ventilation-on-demand and the Venetia Underground Project
Towards greater screening productivity
A partnership that is enabling the advancement of greener, low-carbon industrial spaces in South Africa Sustainable Industrial Spaces Programme
Industrial spaces are catalysts for economic growth and vital enablers of sustainable industrial development.
The National Cleaner Production Centre (NCPC) is leading national efforts to catalyse sustainable industrial development within SA’s industrial spaces. Together with the Department of Trade, Industry and Competition ( the dtic ), and the United Nations Industrial Development Organization (UNIDO) the NCPC supports these economic hubs to reduce environmental impact, develop sustainable energy models and support the national vision of a low-carbon economy.
The four high-impact, donor-funded projects implemented by the NCPC and UNIDO, at varying stages of implementation.
Visit: www.ncpc.co.za to view Sustainable Industries 2025 conference sessions
Ekandustria
Wadeville
Highveld IP Vaal SEZ
Phuthaditjhaba IP
Isithebe IP
Umbogintwini Industrial Complex
Global Eco-Industrial Parks Programme (GEIPP) Sustainable Energy Systems for Industrial Development Project (SESID) Global Clean Hydrogen Programme Low Carbon and Positive Energy in Industrial Spaces (TBC)
East London IDZ
Atlantis SEZ
Coega SEZ
Funding partners
26
06
16
40
MINERALS PROCESSING AND MATERIALS HANDLING 6 MATO’s high-performance belt cleaners Benjamin Sibanda, managing director of MATO, highlights the expanding range of high-performance belt cleaners, which are ideally suited to coal, diamond, copper, and platinum conveying operations. 9 Chute systems deliver at Palabora 10 Multotec redefines screening media attachment 11 Sandvik Rock Processing strengthens footprint POWERGEN, PETROCHEM AND SUSTAINABLE ENERGY MANAGEMENT 12 WEG Turbine Services: the long-term service offering MCA visits the Benoni facilities of WEG Turbine Services for an introduction to WEG’s comprehensive steam turbine-related supply, installation and long-term service offering now available to operators across Africa. 14 Unlocking Investment to close Africa’s energy gap 15 Condensate return and waste heat recovery WATER, WASTEWATER AND PUMPING SOLUTIONS 16 Weir’s WARMAN ® DWU: the dirty water workhorse The WARMAN ® DWU (dirty water unit) is a high-head hybrid pump for mine dewatering applications that combines the efficiency of a clear-water pump with the robustness of a WARMAN ® slurry pump. Marnus Koorts of Weir highlights the features and niche uses of this locally manufactured workhorse.
Published bimonthly by Crown Publications (Pty) Ltd Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: mechchemafrica@crown.co.za www.mechchemafricamagazine.co.za Editor: Peter Middleton e-mail: peterm@crown.co.za Advertising: Elmarie Stonell e-mail: elmaries@crown.co.za Design: Katlego Montsho Publisher: Wilhelm du Plessis Circulation: Brenda Grossmann The views expressed in this journal are not necessarily those of the publisher or the editors.
18 Integrated Pump Technology redefines dewatering 20 Maximising dewatering efficiency at extreme depths
21 Osmotic Engineering’s landmark year HYDRAULICS, PNEUMATICS AND AUTOMATION 22 Ceramat retractable sensor fittings: the solution for extreme conditions Henning Springer of Mecosa presents the key advantages of using Knick Ceramat fittings to protect and manage process control sensors in harsh, corrosive, abrasive, toxic, sticky or fibrous processing applications. 24 AI-led mine shaft scanning takes centre stage 25 Practical skills for real opportunities in Africa’s automotive sector MAINTENANCE SOLUTIONS AND ASSET MANAGEMENT 26 SEW-EURODRIVE’s expanding gearbox repair and refurbishment services SEW-EURODRIVE is addressing the lack of OEM support in the South African market. MD Raymond Obermeyer highlights what is to come after the 2026 move to the new service and repair facility. 28 KSB SupremeServ: SA’s comprehensive aftermarket pump service HEATING. VENTILATION AND AIR CONDITIONING 30 Ventilation-on-demand and the Venetia Underground Project MCA talks to Russell Hattingh, MD of BBE Consulting, about the role of advanced ventilation-on-demand in helping Venetia to deliver the mine’s enhanced air quality and operational efficiency. 32 HVAC solutions enhance operator safety and compliance 33 Liquid cooling in African data centres ENVIRONMENTAL MANAGEMENT 34 Babcock Africa partners with NCPC-SA to unlock sustainable gains As part of its plans to reduce environmental impacts, Babcock Africa has partnered with the National Cleaner Production Centre South Africa (NCPC-SA) to conduct resource-efficient and cleaner production (RECP) assessments. INNOVATIVE ENGINEERING 36 Towards greater screening productivity Duncan High of Haver & Boecker Niagara, highlights the advantages of adopting advanced vibrating screening technologies, including double eccentric screening with shear rubber mounts to improve screening performance and productivity. REGULARS 2 Peter’s comment: 2026: reasons for optimism 4 On the cover: VEGA Inventory System: VEGA’s Inventory System (VIS) is transforming material-flow operations in the process industries. 38 Products and industry news 40 Back page: 140 MW San Kraal wind farm advances Koruson 1 project
Transparency You Can See Average circulation April to June 2025 ABC 10 702 Printed by: Tandym Print, Cape Town
Cover story: VEGA Contact: Miguel Petersen Tel: +27 11 795 3249 Email: info.za@vega.com Website: https://www.vega.com/en-za
January-February 2025 • MechChem Africa ¦ 1
2026: reasons for optimism
Peter Middleton
Addressing the Joburg Mining Indaba in October last year, when gold first surged above US$4 000 per ounce, the South African mining veteran Duncan Wanblad la- mented missed investment opportunities in the mining sector. He pointed out that South Africa's mining po- tential has not been fully explored due to unsupportive exploration policies over the past 20 years. Exploration is a critical part of the mining life cycle, he explained, and it typically takes 17 years to get a de- posit permitted, ramped up and into full production. A generation has been sacrificed through these restrictive exploration policies. Today, South Africa's deeper, older shafts cost more to operate than those of competitors in Africa, Australia and Canada, he noted, while policy uncertainty, infra- structure problems and labour unrest continue to pre- vent investment in exploration and mine development. It is hard to believe our economy or the South African mining industry is in a good place, but there are some positive signs. Unit 6 of the Kusile Power Station entered com - mercial operation in September last year, marking the conclusion of Eskom's ‘new-build’ programme, albeit more than a decade later than planned. The Eskom grid has begun 2026 with an additional 4 400 MW of avail- able capacity compared to this time last year. Eskom says the current resilience of the power system reflects significant improvements in its generation fleet and the success of its Generation Recovery Plan, which is driving stronger operations and securing the country’s energy future. The year-to-date availability factor (EAF) has further increased to 64.66%, and the fleet has now achieved or exceeded the 70% EAF mark on 55 occasions, “…rein- forcing energy security and grid stability,” according to Eskom’s Media Statement of Friday, 16 January 2026. On the mining side, gold and platinum continue to set price records, following an easier 2025 year for the mining sector. PWC’s SA mining report for 2025, entitled ‘South African mining sector shows resilience and recali- brates for sustainable future’, revealed that the mining in- dustry recorded a 28% increase in market capitalisation, driven by record gold prices and a rebound in platinum group metals (PGMs). Although revenue remained flat, free cash flow improved on higher operating cash flow and lower capital investment. The 2025 year was characterised as a dynamic mix of challenges and progress for South Africa’s mining sector. Despite infrastructure constraints, policy uncertainty and rising operational costs, the industry maintained its contribution to GDP at approximately 6%, reaffirming
its critical role in the national economy. The World Bank, in its Global Economic Prospects report for Sub-Saharan Africa, said that the region’s growth picked up to an estimated 4.0% during 2025, up from 3.7% in 2024, driven by moderating inflation and higher-than-expected commodity prices, particularly for gold, other precious metals and coffee. Among the region’s three largest economies, Nigeria's growth edged up to 4.2%; Ethiopia’s eased to a still-robust 7.1%; while South Africa’s economy strengthened to just 1.3 %. For 2026, the World Bank projects that Ethiopia and Nigeria are likely to achieve growth rates of 7.2% and 4.4%, respectively. South African growth will increase to 1.4% in 2026 and 1.5% in 2027, driven by continued reform momentum, particularly in the energy and logis- tics sectors, and rising public investment. In response to the World Bank’s outlook, the South African Government said it affirms that “sustained re - forms are beginning to yield positive results,” and that “Government will continue to work with social partners, the private sector and international development insti- tutions to strengthen reforms, unlock investment and build a resilient, inclusive and sustainable economy.” The lead HVAC feature in this issue of MCA highlights the role of advanced ventilation-on-demand in helping realise the Venetia Underground Project expansion, which aims to extend the life of this De Beers Group diamond mining operation by 25 years. Construction began on this project in 2013, with the first production being achieved 10 years later, in October 2023. The full production capacity of up to 4.5 million carats of diamonds per year from this highly mechanised, modern mine is expected to be realised between 2026 and 2028. And this development has been achieved despite a difficult decade in South Africa. Looking forward from an energy perspective, the Integrated Resource Plan 2025 (IRP 2025) signals a shift to cleaner solar, wind and nuclear energy sources, for the first time displacing fossil fuels as our primary energy source. In addition, the highly successful Renewable Energy Independent Procurement Programme remains central to addressing energy security issues. There is no doubt that deep-seated challenges remain unresolved. But the outlook seems better. We are on a gradual recovery path. If we remain resilient, keep up the pressure for meaningful reforms, take the opportunities available to us, and focus on true economic and environmental sustainability, we may yet emerge as an investment-friendly, modern and prosperous African country.
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2 ¦ MechChem Africa • January-February 2025
VEGA Inventory System transforms supply chains This article highlights the role of the VEGA Inventory System (VIS), which seamlessly integrates VEGA’s advanced instrumentation with secure, cloud-based inventory management software to transform material-flow operations in the process industries.
system allows users to monitor live levels, detect deviations immediately and trace their causes. This kind of transparency minimises the financial impact and ensures that the cause of the discrepancies is quickly identified and avoided in future. The architecture of modern inventory control The architecture of the VEGA Inventory System is built around the seamless integra- tion of VEGA’s advanced instrumentation with secure cloud-based software. At its core, the process unfolds in a straight- forward sequence: sensors collect data, gateways transmit it, the data is securely hosted, and users can visualise the results. First, VEGA level transmitters, designed for both liquids and bulk solids, measure levels in vessels, silos or storage tanks. These readings are then transmitted to the VIS portal at regular intervals via gateways or wireless instruments. Once received, the data is securely stored on VEGA’s serv- ers in dedicated installations or on client premises, using end-to-end encryption and robust authorisation management. Users can access this information via a web browser or mobile app and view their inventory data in several real-time modes. The system offers four distinct viewing options, each tailored for specific monitor- ing needs. The chart view displays key nu- merical data, such as stock levels, available space, timestamps, and, for many liquid in- ventories, daily consumption and coverage. The graphic view provides an at-a-glance visual representation, using colour-coded
Developed by VEGA as a holistic solution for inventory monitoring and control, VIS integrates three pillars: precise measurement technology, cloud-based software and streamlined logistics planning.
I n modern process industries, the con- sequences of poor inventory manage- ment are significant. Excess inventory consumes valuable capital and storage space, while shortages can bring operations to a grinding halt and lead to costly last-minute deliveries. For efficient and safe manufactur - ing and logistics in Africa, having real-time visibility and the ability to anticipate material needs are non-negotiable. This is precisely the advantage offered by the VEGA Inventory System (VIS). Developed by VEGA as a holistic solu- tion for inventory monitoring and control, VIS brings together three pillars: precise measurement technology, cloud-based software and streamlined logistics planning.
On paper, this may read as ‘just another au- tomation tool’, but in practice, it represents a paradigm shift: operators and suppliers shift from reacting to stock events to an- ticipating them. At VEGA, data acquisition, precise visualisation and efficient logistics are considered core elements of successful automated inventory control. Why visibility matters In chemical plants where raw material silos are manually inspected once a day, late deliveries, inaccurate readings and unsynchronised transport are realities. Each one of these creates risk. But with VIS, the inventory status of tanks and silos is captured and visualised in real time. The
VEGA level transmitters, designed for both liquids and bulk solids, measure levels in vessels, silos or storage tanks.
4 ¦ MechChem Africa • January-February 2025
⎪ Cover story ⎪
The AIR line of VEGS instruments offers self-powered, wireless measurement solutions ideally suited to hard-to-reach or off-grid environments.
This shift involves comprehensive training, process adjustments and buy-in from all stakeholders. To support users through this transformation, VEGA provides consultancy services, training sessions and ongoing technical support to ensure smooth imple- mentation and adoption. When considering return on investment, the cost of installing the VIS, including hard- ware and hosting, is modest, especially given the substantial savings it delivers. By reduc- ing the need for urgent deliveries, enabling more efficient route planning, minimising excess inventory and decreasing the likeli- hood of production stoppages, companies benefit from rapid investment returns. Local users have reported that these benefits are realised quickly, underscoring the system’s effectiveness and value. The future is NOW! Industrial operations are becoming increasingly interconnected, and data- driven systems like VIS represent the next generation of inventory management. The term ‘inventory’ no longer means static stock in boxes in a warehouse or bulk solids in a silo; it means dynamic, predic- tive, and networked resources, especially in the African manufacturing and supply chain environment, where disruption, logistics complexity and cost pressures are daily realities. A shift towards a digital inventory system is not just beneficial; it’s becoming essential. For industrial players seeking to trans- form their material-flow operations, the VEGA Inventory System offers more than technology; it provides a mindset: see everything, act before the alarm and optimise continuously. The move from reactive to proactive supply-chain insight is no longer optional; it is the competitive edge. VIS brings to- gether instrumentation, IoT, analytics and logistics into a single platform. As the saying goes, ‘what gets mea- sured gets managed’. With Vega’s VIS, what gets measured is visible, actionable and optimised. www.vega.com/en-za Users can access VIS information via a web browser or mobile app and view their inventory data in several real-time modes.
indicators to show stock status, ranging from ‘Reorder’ to ‘Safety stock’, and includes alarm thresholds for immediate awareness. For organisations with operations across multiple sites, the map view provides a geographical overview, showing facility and storage container locations and their colour-coded inventory statuses. This fea- ture is particularly valuable for managing plants, depots or remote silos. The trend view enables users to review both his- torical and current data in a chart format, making it easier to identify usage patterns, forecast consumption and plan deliveries accordingly. A familiar traffic-light colour scheme un- derpins the user interface: green for healthy levels, yellow for caution, and red to high- light the need for replenishment. Users can further refine their view by applying filters based on location, product type, inventory level status, alarm levels, and more, ensuring the system remains intuitive and adaptable to a wide range of operational requirements. VIS goes beyond just ‘visibility’ and includes logistics planning tools. With the dispatcher module, users can plan delivery schedules: which driver will take which product, from which tank, to what location and when. The system also draws on histori- cal consumption data to forecast future us- age and support optimised delivery routes. The “dynamic web map” gives a current overview of tank locations and statuses. Two application scenarios: internal and supplier-managed VIS offers two principal deployment models, each delivering distinct advantages. In the internal inventory monitoring approach, a company utilises VIS to track its stock levels across various locations, including production plants, external manufacturing sites and storage depots. This model pro- vides immediate access to up-to-date and historical consumption data, which supports economic production planning and supply chain management. As a result, companies benefit from greater operational efficiency and achieve cost savings by optimising their logistics processes. The second model is Vendor-Managed Inventory (VMI), in which the supplier is
responsible for monitoring and replenishing stock. Through the VIS portal, suppliers re- ceive real-time visibility into tank or silo lev- els at the customer’s site, enabling proactive planning. This arrangement gives suppliers swift access to customer consumption data, thereby enhancing production planning, im- proving logistics efficiency, and increasing client retention. Customers, on the other hand, gain as- surance of a consistent supply, experience fewer urgent orders and production inter- ruptions, reduce administrative workload, and can focus more on their core business with increased confidence in their inven- tory levels.
Practical considerations for implementation
VEGA has designed the VEGA Inventory System (VIS) to be highly compatible, en- abling integration of measuring instruments from other manufacturers, provided they can connect to VEGA’s signal-conditioning instruments. This means that up to 15 sensors can be linked via HART multidrop to a single VEGASCAN controller, making upgrading existing systems straightforward and efficient. Data security is treated with the utmost importance, with cybersecurity require- ments considered non-negotiable. For example, in South Africa, the VIS portal has undergone thorough auditing. It is certified to the IDW DS 951 SOC 2 standard, provid- ing users with confidence in the system’s integrity and compliance. Connectivity is also a key consideration, particularly for remote sites where tradi- tional network infrastructure may not be available. To work around this, VIS supports mobile network options such as NB-IoT and LTE-M, as well as satellite connections, ensuring reliable data transmission regard- less of location. The AIR line of instruments further enhances this flexibility, offering self-powered, wireless measurement so- lutions ideally suited to hard-to-reach or off-grid environments. Transitioning from manual stock checks to a fully digital inventory management system requires more than just new tech- nology; it demands organisational change.
January-February 2025 • MechChem Africa ¦ 5
MATO’s high-performance belt cleaners Benjamin Sibanda, managing director of MATO, a Multotec Group and MATO International Group company with operations in South Africa since 1987, highlights the expanding range of high-performance belt cleaners, ideally suited to coal, diamond, copper and platinum conveying operations.
M ATO, South Africa’s only manufacturer of lacing clips for mechanical conveyor belt fastening systems, supplies an extensive, high-quality range of belt prod- ucts and services to large-scale mining and materials-handling operations in Africa. “We have recently introduced new designs of our belt cleaners, including primary, sec- ondary, and diagonal cleaners that are splice- friendly and offer improved performance,” begins the company’s MD, Benjamin Sibanda. “When I first joined the company in 2005, we were predominantly known for belt fasteners and lacing equipment, mainly for underground collieries. Mechanical fasteners are generally not preferred in process plants because belt joints are not fully sealed. Fast forwarding to 2015, 2016, with the world starting to worry more about coal's impact on the environment, we were asked to start look- ing at other applications and products that we could add to our basket,” Sibanda explains. In addition to its core lacing system of- fering, MATO manufactures and designs belt
cleaners, also known as belt scrapers. “We don't scrape a customer’s conveyor belts, though. We remove carryover material to improve belt performance and extend wear life. And we can now offer a complete range of conveyor belt cleaners that are designed to suit the conveyors for a broad range of miner- als processing plants,” he tells MCA , adding that the new range is suitable for all types of belts, rubber belts with vulcanised joints and textile belts, broadening the scope of MATO’s product offering to include diamond, copper, iron ore and platinum mining operations. “All conveyor belts carrying any mineral product need to be continuously cleaned, for underground and surface operations,” he says. For all belt types, Sibanda continues, in- dustry has been seeking a conveyor cleaning system that is splice-friendly. “Belt cleaner blades must always be kept just on or above the belt surface to prevent damage. So, in developing MATO blades for primary, sec- ondary or diagonal belt cleaners, we always had to keep our mechanical splice in mind to avoid damaging the blades or ripping the belt
joint. With that in mind, our Australian team began investigating designs suitable for any belt joint. “They came up with solutions for all three commonly used belt cleaners, primary clean- ers, secondary cleaners and diagonal clean- ers,” says Sibanda. MATO’s diagonal tail pulley cleaner To protect the tail pulley lagging, it is crucial to avoid entrapment of spilt material on the underside of the belt. “Here, we can deploy a V-plough or a diagonal belt cleaner, based on considerations, such as how much space is available; how the mine wants to capture the material that comes off, and how to minimise the amount of material that remains under the belt and the tail pulley. “The traditional plough arrangement tends to be better known and more popular, and
The primary cleaner on a conveyor belt sits on the drive pulley beneath the discharge stream and handles about 90% of carry-back material.
6 ¦ MechChem Africa • January-February 2025
⎪ Minerals processing and materials handling ⎪
Left: The first and most significant advantage of Mato’s diagonal tail pulley cleaner is that it is easy to install. Right: MATO Unique (MU) secondary cleaners are located beneath the belt, behind the primary, to remove stubborn material from the underside of the belt.
these are a part of our offering. But we believe our new diagonal design is often a better solu- tion,” advises Sibanda. The first and most significant advantage of our diagonal tail pulley cleaner is that it is easy to install. “It is mounted on the channel beams. An installer uses a hydraulic punch to drill two holes on either side of the channel sections of the structure before bolting the cleaner into place. The diagonal blade then rests on the belt under its own weight. The blade floats up and down to accommodate a splice or mechanical belt joint, allowing the cleaner's diagonal blade to continuously re- move material from the underside of the belt, channelling it to one side of the conveyor,” explains Benjamin Sibanda. The system does not require tensioning; it is corrosion-resistant; provides even wear when correctly sized; and includes adjustable limits that engage when the polyurethane blade material reaches 85-90% of its wear life, preventing belt damage from direct contact with the blade's mounting plate. Primary cleaners The primary cleaner on a conveyor belt, which sits on the drive pulley beneath the discharge stream, handles about 90% of carry-back ma- terial. Correct positioning of this belt cleaner is critical. It must sit against the pulley below the main material flow to redirect any carry- back material into the discharge stream. “A primary belt cleaner is typically mount- ed at 15 degrees below the centre on the drive pulley, to protect the blade and to ensure op- timal angle of attack is achieved, but we have developed templates to ensure that installers can position them optimally,“ says Sibanda, adding that on an enclosed transfer chute, a cut out hole on both sides may be required to pass the cleaner shaft through for position- ing, installation and inspection purposes. An installation manual with templates makes it
very clear where the chute needs to be cut, where the blade must be and the required angle of attack. The blade is made from poly- urethane material with proprietary additives that are self-lubricating and outperform any other cleaner blades on the market, in both wet and dry conditions,” says Sibanda. “For underground conveyors, we supply these as overlapping segmented blades 150 wide with a range of different heights, making it easy to install a blade to match any pulley diameter. In addition, for primary cleaners on surface conveyors, we manufacture solid blades in lengths from 450 to 2 100 mm. “The other nice thing about our MATO blades for primary cleaners is the slide-on, slide-off replacement feature, which signifi - cantly reduces downtime. By removing one pin, the blade can be slid off, and a new one slid into its place,” he says, adding that the blade-shape design offers high performance, particularly for belts with mechanical connec- tors or splices. Self-adjusting contact with the belt is achieved using either a tension or a compres- sion spring, depending on the client’s needs. Compression springs offer longer life, though, because repeated blade contact with joints can subject tension springs to cyclic fatigue.
for all types of splices, thanks to a secondary cleaner design that prevents hard contact with raised connections. “Our MUS series has a slide-on cushioned blade for easy installa- tion and maintenance to minimise downtime, while ensuring that all blade alignments are 100% true across the entire conveyor belt width,” he adds. While Mato can offer all traditional bolt-on blade types, from MCS 2 to MCS 6, Sibanda is particularly proud of two unique types: the MATO Unique Secondary 2 and 3 (MUS2 and MUS3). “The MUS2 secondary cleaner, for exam - ple, has a unique parallelogram designed into the cushion that gives the cleaner flexibility to float just above the belt while maintaining a constant blade attack angle. This gives auto- matic adjustability for when the belt thickness varies and for belts with mechanical fasteners, particularly when a tungsten impact blade is used,” he explains, adding that the MU2 with a tungsten blade offers excellent performance on vulcanised belts. Additionally, MATO’s patented M-Track mounting system offers the same simple slide-on, slide-off method for replacing the one-piece cushioned blade on the crossbeam. “Belt cleaners enhance safety, reduce belt maintenance requirements, and extend equip- ment life. Drawing on our experience with mechanical fasteners, we have now designed a high-performance range that outperforms traditional solutions. We also offer compre-
MATO Unique (MU) secondary cleaners
Secondary cleaners are located beneath the belt, behind the primary, to remove stub- born material from the underside of the belt. “There is a lot of vibration in these areas; the conveyors can be huge, typically running at very high speeds. Our secondary cleaners are designed to handle these conditions due to their heavy-duty construction, providing an extremely high level of cleaning,” notes Sibanda. Most notably, the blade shape, even with a hard-metal blade, is belt connector-friendly
hensive on-site assessment services for conveyor belts of any kind, which we call MATO CAALC, to make the benefits of our solutions clear to operators,” con- cludes Benjamin Sibanda. www.multotec.com/ en/mato-conveyor-belt- cleaners
Click here to watch a video that shows how Mato belt cleaners work.
January-February 2025 • MechChem Africa ¦ 7
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8 ¦ MechChem Africa • January-February 2025
Chute systems delivers at Palabora More than a decade after installation, Weba Chute Systems’ custom-engineered transfer chutes at the Palabora Copper Mine continue to perform reliably with minimal maintenance, thanks to an innovative design tailored to high-impact underground conditions. ⎪ Minerals processing and materials handling ⎪ H ighlighting the company’s dominance in engineered flow control solutions that prioritise durability, efficiency and opera- to be helping mines around the world shift from reactive maintenance to engineered reliability.” https://webachutes.com/
minor spares required. “Our 2025 site inspection confirmed the Weba Chutes at PMC are still in excellent condition,” he says. “The customer feedback has been outstanding, and they have report- ed significantly reduced spillage and dust, improved flow control and no unplanned downtime from chute failure.” This performance has not gone unnoticed in the mining sector. Weba Chute Systems is actively leveraging the PMC success story to support new underground projects, espe- cially in block-cave mines, where controlled material flow and long-term reliability are critical. Through technical presentations, case studies, and field demonstrations, Weba Chute Systems continues to expand its footprint across commodity industries, including gold, platinum and iron ore. “PMC is a notable benchmark project for us,” Baller notes. “It proves that when you engineer for the application, perfor- mance and longevity follow. We are proud
tional sustainability, the custom-engineered transfer chutes supplied by Weba Chute Systems for Palabora Mining Company’s (PMC) Copper Mine continue to operate with virtually no maintenance. Located in Limpopo Province, South Africa, PMC’s underground block-cave operation required a specialised approach to materials handling. The original scope of supply needed Weba Chute Systems to design and install transfer chute systems capable of handling coarse copper ore up to 220 mm after crushing within a high- capacity conveyor network operating at belt speeds of 3 to 4 m/s. The systems were specified for a throughput of around 5 000 t/h, servicing 20 production cross- cuts and 320 drawpoints in a compact min- ing footprint 650 m below surface. The Weba Chute Systems solution was unique due to its alignment with the site’s operating realities. “We didn’t just supply chutes,” Mark Baller, Managing Director at Weba Chute Systems, says. “We deliv- ered an engineered flow control solution. We carefully analysed the fragmentation profile, belt speeds, spatial constraints and impact zones, and designed systems that optimised flow while protecting infrastruc- ture,” he explains. At the heart of Weba Chute Systems’ success is its patented ‘super tube’ design, which controls the direction, velocity and impact of material as it flows through the chute. Unlike conventional chutes, so of - ten generic in design and prone to wear, blockages and dust, Weba’s transfer point solutions are engineered using Discrete Element Method (DEM) simulations to model and optimise flow behaviour. This reduces turbulence, prevents build-up and dramatically limits wear on liner surfaces. Durability was further ensured through strategic material selection. High-impact zones were lined with high-chromium cast iron and ceramics, while structural compo- nents were fabricated from high-strength steel using precision welding and advanced surface treatments. The result, Baller says, is a system that has withstood over a decade of harsh underground operation with only
A conveyor-on-conveyor transfer chute installed by Weba Chute Systems at Palabora Copper Mine (PMC), which is still operating efficiently more than a decade after installation.
A Weba Chute Systems field advisor inspects a conveyor transfer point in operation, underpinning the company’s ongoing commitment to ensuring optimal material flow and performance across all installations.
January-February 2025 • MechChem Africa ¦ 9
Multotec redefines screening media attachment To help address risk and remove potential safety hazards, Multotec has developed a range of hammer-less screening media attachment systems that significantly reduce the amount of hammer blows traditionally required when installing or removing screen media.
D esigned for faster, easier change- outs while lowering the number of hammer blows needed, these systems not only make the pro- cess quicker and easier for maintenance, but also significantly improve operator safety, reducing the risk of injuries, fatigue and un- planned downtime in demanding mining environments. “Safety is at the heart of every innovative solution we design," says Denzyl Macauley, Screening Support Manager at Multotec. “By reducing hammer use during panel changeouts, we are directly addressing one of mining’s most common safety hazards and helping reduce the number of hand injuries on site,” he adds. Conventional attachment systems require repeated hammer blows to fasten modular screen panels to support frames on mineral processing equipment such as trommels and vibratory screens. Each panel typically re- quires multiple hammer blows per pin, along with additional tools such as screwdrivers and crowbars. The removal process is also a two- step process, which increases both time and risk. These tasks are often carried out in con- fined and ergonomically challenging spaces. For maintenance personnel, this creates multiple safety hazards: from hand and finger injuries caused by missed hammer blows, to pinch points when holding pins in place dur- ing hammering and repetitive strain from repeated, forceful exertion. In some cases, hot work such as flame cutting is required, which introduces additional burn and spark risks. In today’s mining industry, where safety is non-negotiable, such risks not only endanger personnel but also lead to unplanned stop- pages and productivity losses due to extended installation times. Delivering safety and productivity simultaneously As an alternative, Multotec’s hammer-less attachment systems for screen media simplify static and vibrating screen media changeouts, making them faster, safer and more efficient. Instead of repeated hammering, panels can be clipped or snapped into place using just a few light hammer blows or simple hand leverage. This minimises the force required, reduces the number of moving parts compared to conventional systems, and lowers overall maintenance effort and cost. “By simplifying the process and reducing
Multotec's Adaptable, Cost-effective, Ergonomic (ACE) fixing solution is engineered for unparalleled security and features a robust dual locking mechanism that ensures maximum reliability.
hammer blows, our latest attachment systems make screen panel changeouts faster, easier and safer,” explains Jean Laurens, Screening Support Engineer at Multotec. “That means fewer injuries, greater efficiency and less disruption to production,” he adds. Furthermore, Multotec offers several latest-generation hammer-less systems for use on modular runner-type screens that ac- commodate interlocking, standardised screen panels. These can also be retrofitted to any existing screen decks or systems currently in operation. The ERX system, designed for extremely heavy-duty applications, secures modular interlocking polyurethane or rubber panels using fixed clamping strips and a top locking strip. This eliminates the need for multiple bolts and nuts and eliminates hot work, such as grinding or cutting, during changeouts. The Y-LOK system is specifically tailored for Multotec trommel screens, where modular polyurethane or rubber screen panels attach via a snap-on mechanism along a Y-shaped groove rail system, enabling quick and secure installation with minimal hammering. For general screen attachment needs, the CCX and HALO systems provide versatile clip-in and snap-on solutions suitable for ap- plications ranging from sizing and dewatering to media recovery. These systems reduce reliance on tools, enabling single-person chan- geouts by hand while remaining compatible with all screen media materials.
Derived from the ERX series, Multotec's Adaptable, Cost-effective, Ergonomic (ACE) fixing solution requires zero hammer blows, eliminating the risk of impact injuries during screen panel changeouts. The ACE panels lock in place with just hand pressure, so there is no impact risk and no pinch points. Once in place, ACE is engineered for un- paralleled security and features a robust dual locking mechanism that ensures maximum reliability. When paired with the top locking strip, it becomes virtually fail-proof, staying securely in place even where other fastening solutions have failed, making the system the most reliable solution on the market. When the time comes for removal, ACE re- quires no screwdrivers or pry bars. Multotec’s engineered, battery-powered tool makes panel removal simple, fast and safe. These advanced attachment systems dem- onstrate Multotec’s focus on putting person- nel safety first while streamlining changeouts. Reducing risks and simplifying installation, decreasing operator fatigue, and improving alertness and morale result in a safer working environment, faster maintenance, greater plant availability and improved productivity. Available through Multotec’s global branch network, these attachment systems reflect the company’s strong commitment to innovation and safety, helping reduce injuries, improve working conditions, and increase productivity. https://www.multotec.com
10 ¦ MechChem Africa • January-February 2025
⎪ Minerals processing and materials handling ⎪ Sandvik Rock Processing strengthens footprint In support of West Africa’s growing mining sector and Sandvik Rock Processing’s equipment offering, the company is strengthening its footprint with a robust multi-tiered service offering that includes on-site engineering, parts warehousing, training and condition monitoring.
W ith a strong focus on uptime, safety and productivity, Sandvik Rock Processing continues to in- vest in local resources to ensure rapid responsive support for its crushing, feeding, screening and rock-breaking solutions. West Africa has long established itself as one of the continent’s most exciting regions for exploration and mining, and Sandvik Rock Processing continues to build on a strong tech- nical support footprint for its product offering, which includes stationary crushers, screens and feeders, mobile crushers and screens and rockbreakers. From on-site engineering services to parts warehousing, training and condition monitoring, the company has built a responsive multi-tiered support system designed to ensure smooth, reliable operations for its customers. “We understand the pressure in the mining sector for increased operational uptime, safety and productivity,” says Michael Okunola, Service Manager for Sandvik Rock Processing West Africa. “As supply partners to the industry, this can only be achieved through our continued investment in human and material resources on the ground: close to customers for rapid response.” As part of the company’s suite of support services, Okunola highlights the various levels of its on-site engineering support programme. Customers can select from a range of offer- ings, including having Sandvik Rock Processing engineers on-site at the mine 365 days a year. Dependingonhowremotethemine’slocationis, management may prefer an engineer to visit the site monthly, bi-monthly, quarterly or annually. “Our services are completely tailored to cus- tomers’ needs,” he emphasises, “but the primary focus is generally the same: to closely monitor the condition and operation of equipment on site, to ensure proactive maintenance and to optimise performance.” He explains that the company’s local service technicians are the first responders to custom - ers’ needs, providing on-site diagnostics and troubleshooting, as well as emergency work and routine maintenance. Sandvik Rock Processing also has after-market engineers who can com- mission equipment and conduct visits in line with customer preferences. Parts availability Effective maintenance means having the nec- essary parts available when needed, he points out. Sandvik Rock Processing therefore offers
Service support for Sandvik Rock Processing’s mobile crushing and screening equipment forms a key component of the company’s comprehensive localised support offering for rock processing operations across West Africa.
ment services for key equipment, component rebuilds and routine preventive maintenance. He highlights that the company’s presence in these locations enables rapid response times, reduces delivery lead times, and generally en- hances customers’ operational uptime. Building local capacity Recognising the importance of skilled operators and technicians in West Africa, Sandvik Rock Processing invests heavily in skills development and training initiatives. These can be conducted on-site or remotely and include tailored mod- ules based on specific types of equipment, as well as technical refresher training to keep customers up to date with the latest technolo- gies and best practices. Among the most critical capacity-building offerings is operator maintenance training, which is most useful when conducted in a real- life, practical environment. When customised for specific mines, this training can focus on the actual equipment installed on the site. “We also run ‘train-the-trainer’ programmes which empower supervisors to share knowl- edge internally,” he says. “Trainees receive certificates of competence, strengthening their career development and enhancing local skills in the process.” Sandvik Rock Processing also supports apprenticeships as part of its local talent devel- opment initiatives. This includes internships and partnerships with technical schools. The company’s e-learning platform further expands its reach, allowing customers to access training on topics such as equipment operation, pre- ventative maintenance and safety procedures. “Our local technicians are well-trained, and benefit from continuous upskilling through regular visits to the company’s facilities,” says Okunola. “Our growth plans in West Africa are a clear signal of our commitment to the market in the region, ensuring that technical support is close at hand and fully resourced,” he concludes. https://www.rockprocessing.sandvik
support to mines through customised inven- tory management. Under a parts management agreement, the company’s team even visit mines to assess which inventory items have been used and which need replenishment. “Under our vendor-managed inventory (VMI) system, for instance, we monitor stock levels on behalf of the customer and ensure timely replenishment,” he explains. “We try as far as possible to help the customer to avoid running out of parts, which can lead to delays and downtime.” This may require moving critical spares onto customer sites as consignment stock so that they can be stored for immediate access. Okunola highlights that Sandvik’s SAM digital service plays a valuable role in facilitating op- erational excellence in the region’s crushing and screening plants. “Our SAM platform helps our technical personnel. and even the customer, to monitor the consumption of parts and facilitate procure- ment,” he explains. “Our technical teams use SAM to track the daily operation of our equip- ment, analysing data to diagnose issues before they become critical. We can then advise the customer what actions are required to ensure that machines are always running efficiently and at the lowest lifecycle costs.” Regional presence Underpinning its commitment to parts avail - ability is Sandvik Rock Processing’s strategi- cally located regional facilities, with a West African hub in Kumasi, Ghana. This includes a warehouse and workshop facility to support customers throughout the region. “We also have a facility with a warehouse in Bamako in Mali, and in Ouagadougou in Burkina Faso,” he says. “A recent addition to our footprint in the region is our warehouse in Abidjan in Côte d’Ivoire. Each of these sites has its own team to provide technical support and logistical coordi- nation to customers.” The workshop facilities provide refurbish-
January-February 2025 • MechChem Africa ¦ 11
WEG Turbine Services: the long-term service offering MCA visits the Benoni facilities of WEG Turbine Services to meet Alastair Gerrard, Executive for Energy systems, for an introduction to WEG’s comprehensive steam turbine-related supply, installation and long-term service offering now available to operators across Africa. F ollowing the February 2024 acquisi- tion by WEG of the Benoni-based service facilities of RTS, Rotating Technologies and Services, a leading
provider of engineering, maintenance and repair services for steam turbines, centrifugal and reciprocal compressors, gearboxes and other related equipment, WEG has estab- lished itself as an OEM and servicing provider for steam-turbine and generator solutions across the lifecycle of its own and other brands. “Before the acquisition, RTS was a local partner for servicing our WEG steam turbines for the sub-Saharan African region, and we worked closely with them to install, man- age and service WEG turbine installations. Incorporating RTS into WEG’s thermal energy business enables us to offer an expanded set of solutions for operators of steam turbine generator sets and mechanical drives across sub-Saharan Africa, from installation to long- term preventative maintenance and remote monitoring, followed by plant upgrades and replacements,” he adds. “What we've done here in Benoni is to con- solidate our steam turbine solutions offering, from supplying new WEG turbines, gearboxes and generators, to a comprehensive range of aftersales services, which are all now managed from this facility,” says Alastair Gerrard. Explaining the strategy underpinning the RTS acquisition, he says that WEG’s thermal energy business is made up of a solutions team, which deals with supplying new equip- ment designed according to a customer’s specification or need; and the turbine services side, which looks after the installation of new equipment, as well as the after sales servic- ing, either through service level agreements signed with customers, or on a quote, receive and order basis. “WEG in Brazil has a strong servicing back- ground. What we lacked here in Africa was the ability to do our own installations and our own servicing. We were offering the equipment and then working with third parties to deliver these services. But whoever manages servic- ing, not only controls the supply of spares, but also stands a far better chance of securing new
WEG’s turbine facility in Benoni consolidates the company’s steam turbine solutions, from managing the supply of new WEG turbines, gearboxes and generators to offering a comprehensive range of after-sales services.
they need to be brought down for a service intervention, though. “The first service, at about 12 months, is a simple inspection service, where we look at the emergency stop valve (ESV) at the front of the turbine where the steam comes in. We clean the ESV to ensure it's operating correctly, conduct an overall health check of the machine, and review the operator logs for incidents that may suggest further work is needed. “Then, after another 10 000 hours of op- eration, we do a minor overhaul that involves a little bit more. We use borescopes to inspect the turbine casing, the condition of the blades, rotors, and other internal components with- out opening the machine. This cycle repeats in years three and four, but in the fifth or sixth year, after about 40 000 hours of operation, we perform a major overhaul that involves opening the casing. “The timing of interventions depends on several factors, such as the quality of the steam that's been put through the turbine. If poor, then the period between interventions needs to be shortened. And if any problems are picked up, then we obviously need to in- tervene early to avoid potential catastrophic
orders for machines,” Gerrard argues. “By servicing steam turbines from any OEM, we develop knowledge of the client’s machines and applications. We can under- stand the environment and the challenges, and collect a history of machines across the market. When a turbine is no longer economi- cal to repair, service and usage data enable us to quickly put together a custom replacement solution that meets the client's specific needs. “This is why we decided to get into ser- vices: to access the market at a different level, to understand what's out there over time, and eventually, to look at replacing existing machines with WEG solutions. When we sell a WEG solution, we have the resources to offer industry-leading value-added services. We don't just dump and run; we reassure the client that we'll walk the road with them throughout the machine's lifecycle and be- yond,” he tells MCA. Lifecycles and turbine service needs Typical steam turbines, says Gerrard, are de- signed to operate continuously for 24 hours a day and 365 days a year. At least once every 10 000 operating hours (or 12-14 months),
12 ¦ MechChem Africa • January-February 2025
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