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African Petrochemicals Jan/Feb Edition 15_1 {2018}

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characterised by low

characterised by low levels of inclusions, oxides and discontinuities and the weld hardfacing closely mimics the corrosion resistance of the equivalent monolithic alloy. Most critically, the careful control of heat input makes it possible to control weld dilution to less than 5%, which is critical for many high-performance alloys. Thermal spraying provides increased resistance to high temperatures and oxidation, traction, cavitation, chemicals and corrosion as well as wear resistance (resulting from erosion, abrasion and sliding wear). Thermal spray is the method of spraying materials onto a prepared substrate material by heating particles in the stream of a heat source to create a semi-molten state. Particles are then propelled by high velocity onto a prepared substrate where they adhere to the base surface via a mechanical bond. Particles then continue to build until a specified thickness is attained. On completion of all repairs, NDT was done by a third party inspector to ensure that there were no coating defects. Final assembly work was done at Thermaspray. Each valve was tested and signed off by the responsible engineer from the power station. Thermaspray also refurbished the valve spares to a standard set of dimensions to ensure interchangeability if required. These sizes were developed together with engineers from the power station and Van Wyk confirms that they have proven to be successful. All processes at Thermaspray adhere to the applicable international standards and are done according to a quality control procedure which is dated, signed and noted when any of the processes are performed. Non-destructive testing is performed by the power utility’s accredited service providers. On completion of the valve refurbishments, a data pack was created consisting of all the inspections, signed QCP document, NDT testing certificates, material certificates, Weld Procedure Specifications, material analysis and relevant photos. Thermaspray, in a joint venture with Cape Town-based Surcotec, offers an extensive portfolio of engineering and thermal spray coating solutions that extend component life cycles to assist OEM and end-user clients across southern Africa in reducing costs and increasing production. The companies’ worldclass quality wear- and corrosion-resistant thermal spray coatings, Plasma Transferred Arc (PTA) cladding and Polymer coatings (in partnership with Plasma Coatings USA and Diamant Metallplastic Germany) are augmented by a host of specialised allied services. Contact Tel: +27 (11) 316 6520/8/9 Fax: +27 (11) 316 7527 Web: Blog: YouTube: About Thermaspray Thermaspray, headquartered in Olifantsfontein, Johannesburg, has close to 20 years’ experience in wear- and corrosion-resistant thermal spray coatings. In addition to providing a comprehensive range of support coating finishing technologies in the bespoke finishing shop, Thermaspray also refurbishes industrial components damaged by wear and corrosion. The company’s in-house, metallurgical laboratory is the only dedicated facility of its kind in Africa’s thermal spray industry and is equipped to undertake world-class developments and quality control. Thermaspray is a DQS ISO 9001 Quality Management and Eskom level 1 certified company. About Surcotec Surcotec is the oldest established thermal spray coating company in the Western Cape. The company has a wealth of experience in thermal spray coatings and mechanical component refurbishing. Surcotec’s coating services are supported by a fully equipped engineering workshop and an on-site machining division. A level 1 B-BBEE company, Surcotec is TNV ISO 9001 Quality Management certified and is certified as a level 2 nuclear supplier to Eskom. Verderflex hoses stand apart from competitors Verderflex pumps stand apart from their competitors- reliable, innovative, high performance peristaltic pumps that pump difficult products in tough conditions. Verderflex pumps are renowned for providing top-quality solutions to an array of problems, within process industries around the world. Used in Original Equipment Manufacture (OEM) as custom solutions that can be incorporated wherever accurate dosing is required such as in vending machines. The Smart and Scientific models are easily programmable tube pumps and ideal for use with chemicals or in a laboratory setting. This range is complimented by the industrial tube pump range. Specifically designed to be used in hazardous areas, they provide a compact pumping solution for automated systems as standalone pumps or as part of OEM. These pumps have multiple power options and quick and easy tube change features. A range of tube materials are available to handle a range of different chemicals as well as hygienic options for food and beverage dispensing. The Dura and VF hose pumps reliably pump the toughest fluids and are often found pumping slurry with high solid content from the mining industry to water plants. The hose is the most important feature of any hose pump and Verderflex has designed its hose to be the longest lasting in the market, capable of withstanding corrosive and abrasive applications. The Verderflex hose can also be used in many other peristaltic pumps on the market, for more information visit the hose page. Due to the more often than not hazardous nature of the products pumped by Verderflex hose pumps, the range had been designed to provide maximum safety to the workforce and environment. Both the VF & the Dura’s hose connection is disaster-proof, totally containing the hose inside the pump casing – unlike other peristaltic pumps, eliminating any danger. Verderflex pumps are incredibly accurate at dosing: they offer repeatable accuracy of ±1% without any slip. They also have a vacuum capability of 95% or a 9.5m / 31’ lift of water. Our largest peristaltic hose pump can pump 90m3/hour or 390 US GPM at pressures up to 16 Bar or 230 PSI. About Verder Pumps South Africa The Verder Group comprises Verder Liquids and Verder Scientific, specialising in products and services for fluid handling and laboratories respectively. The Verder Liquids division comprises in-house Verder pumps, systems and services distributed by local Verder suppliers. Manufacturing in-house allows the Verder Group to maintain the highest standards over the design, build and testing procedures, which reduces risk and costs to the customer. This provides the customer with a high-quality product at a great price. 21

Modular solutions for small chlorine plants from thyssenkrupp thyssenkrupp Industrial Solutions’ modular skid mounted chlorine plants offer a cost-effective and practical solution to industries on the African continent who require small chlorine alkali plants for applications such as water treatment and mineral processing. 22 Bruce Bassett, Process Industries Senior Manager for Special Projects at thyssenkrupp Industrial Solutions South Africa, explains why their modular chlorine plants with a 15 and 45 ton capacity are particularly suited to the African market: “Many African countries import chlorine and caustic but the quantities are not large enough to sustain chlorine alkali plants. Due to the vastness of the continent, getting these products up to African countries from South Africa for example, present tremendous logistical challenges which can increase the cost of the products four fold, simply making it economically unviable.” While on-site chlorine production presents a better alternative to import, Bassett warns that setting up a chlorine plant presents its own challenges. Construction costs can sink a project and this is where our modular approach presents the simplest, fastest and most cost-effective solution for facilities that are remotely located and have limited engineering capabilities and staff resources. Chlorine is produced through the process of electrolysis (the passing of an electric current through brine (sodium chloride (NaCI) or common salt dissolved in water), with salt as the feedstock. Two co-products that result from chlorine production are caustic soda (sodium hydroxide, NaOH) which is an alkali and hydrogen (H2) which is a combustible gas. In the modular solution, electrolysis is built on multiple skids that fit into 40 foot containers that can be easily, quickly and cost-effectively transported to site. Construction and assembly is also fast and easy, needing only a small team, leaving only the non-modular plant sections to be stick built. Rapid project implementation and plant start up time result in substantial savings in terms of construction time and costs. “Our modular engineered solutions have innovated processes through simplification,” comments Bassett. Designed and manufactured by thyssenkrupp Uhde Chlorine Engineers of Milan, Italy, skid mounted chlorine plants are made of a different functional skid groups such as brine filtration, brine super purification, and sodium hypo production. In addition to new plants, these group modules can be installed in existing facilities for modernisation and debottlenecking. Pre-testing, quality control and quality checks are done at the workshop in Europe during pre-assembly of the skid units, mitigating construction risks and reducing testing activities in the field. Mechanical connections, electrical wiring and, where possible, pressure tests are all performed in the workshop. Tolerance testing in the workshop also guarantees trouble free field installation. thyssenkrupp combines global technology with local knowledge to offer a complete turnkey EPC solution – from feasibility studies and plant design including geotechnical information and civil works, through to all necessary infrastructure, construction commissioning and O&M. “Plants also need power and here too we can assist. Instead of being vented into the atmosphere, we capture the excess hydrogen in fuel cells, a co-product resulting from chlorine production, to produce energy. This method can generate up to 0.8 megawatt of power.” “Once a plant is operational, we continue the partnership with our customer through our full service offering that includes ongoing training and after-sales support,” concludes Bassett. Today there are skid mounted chlorine plants in operation in Europe and South America, and Bassett confirms that they are currently working on a feasibility study for the development of a plant in South Africa. About us: The Industrial Solutions business area of thyssenkrupp is a leading partner for the engineering, construction and service of industrial plants and systems. Based on more than 200 years of experience we supply tailored, turnkey plants and components for customers in the chemical, fertilizer, cement, mining and steel industries. As a system partner to the automotive, aerospace and naval sectors we develop highly specialized solutions to meet the individual requirements of our customers. Around 19,000 employees at over 70 locations form a global network with a technology portfolio that guarantees maximum productivity and cost-efficiency. For more information visit:


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