http://www.engineeringnews.co.za
  SEARCH
Login
R/€ = 13.48Change: 0.08
R/$ = 11.46Change: 0.05
Au 1228.13 $/ozChange: -10.36
Pt 1231.50 $/ozChange: -11.50
 
 
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?








Start
 
End
 
 
And must exclude these words...
Close Main Search
Close Main Login
My Profile News Alerts Newsletters Logout Close Main Profile
 
Agriculture   Automotive   Chemicals   Competition Policy   Construction   Defence   Economy   Electricity   Energy   Environment   ICT   Metals   Mining   Science and Technology   Services   Trade   Transport & Logistics   Water  
What's On Press Office Tenders Suppliers Directory Research Jobs Announcements Contact Us
 
 
 
RSS Feed
Article   Comments   Other News   Research   Magazine  
 
 
Sep 28, 2012

R4.5m baghouse for aluminium producer completed

Back
Construction|Engineering|Wattville|Africa|Explosives|Industrial|Mining|PROJECT|Projects|PSY Systems|Systems|Tager Engineering|Water|Welding|Zimalco|Africa|South Africa|Chemical Processes|Electricity|Energy|Energy Costs|Explosives|Gas Costs|Manufacturing|Secondary Aluminium Producer|Service|Systems|Underground Mining|Bob Stone|Neels Van Niekerk|Rail|Water|Willie Willemse|Pollution Control|Process Control
Construction|Engineering||Africa|Explosives|Industrial|Mining|PROJECT|Projects|Systems|Water|Welding||Africa||Energy|Explosives|Manufacturing|Service|Systems||Rail|Water||Process Control
construction|engineering|wattville|africa-company|explosives|industrial|mining|project|projects|psy-systems|systems-company|tager-engineering|water-company|welding|zimalco|africa|south-africa|chemical-processes|electricity|energy|energy-costs|explosives-industry-term|gas-costs|manufacturing|secondary-aluminium-producer|service|systems|underground-mining|bob-stone|neels-van-niekerk|rail|water|willie-willemse|pollution-control|process-control
© Reuse this



The construction of a new R4.5-million baghouse for secondary aluminium producer Zimalco has been completed.

Air pollution control company About Air Pollution built the baghouse, which will enable the producer to maintain a continuous improvement of its air quality to fully comply with the new Air Quality Act, which came into effect in 2010.

The baghouse project was started in November 2011 and completed in July. The baghouse filters and cleans the emissions from the melting process, ensuring the final emissions comply within the limits set in the new Act.

Meanwhile, Zimalco engineering manager Neels van Niekerk tells Engineering News that the producer has also installed a new reverberatory melting furnace, which was commissioned in April.

This furnace has enabled Zimalco to save substantially on electricity and gas costs incurred during melting, and combat the escalating energy costs experienced over the last few years that are also expected in the coming years.

Engineering company Tager Engineering undertook the structural work for the furnace installation, while industrial process control specialist PSY Systems installed and commissioned the controls and burners.

“We did the bricklaying and used the opportunity to give inexperienced furnace bricklayers on-the-job experience. “The industry is under pressure in terms of furnace construction, as there are not many skilled furnace bricklayers in South Africa.

“We used our own in-house bricklayers, which helped us to save costs while providing invaluable training and cost saving in the process. “We also saved R500 000 on manufacturing and labour costs by doing the majority of the work ourselves,” Van Niekerk says.

The company will not divulge exactly how much it spent on the furnace but realised significant savings when comparing it with a turnkey furnace, which would have cost up to R7.5-million. Being able to plan and manage the project in-house resulted in these substantial cost savings, he notes.

Energy Saving
Meanwhile, Zimalco sales and marketing director Bob Stone says the use of aluminium powder for various applications has started to increase.

“Aluminium powder in South Africa is mainly used in the explosives industry. It is used in packaged explosives, instead of bulk explosives, mainly for underground mining and rock-blasting purposes. It is also used in the manufacture of flocculants, in chemical processes to purify South Africa’s drinking water, in drain cleaners and in exothermic welding of railway lines,” Stone notes.

“Aluminium thermic welding is used to join rail lines together to create one continuous rail. Aluminium powder is mixed with iron oxide and other elements, with the aluminium acting as the energy source when ignited, to melt the iron oxide and the rail, forming a seamless joint,” he explains.

Stone adds that the exothermic property of aluminium is also used in the production of ferro-alloys as an alternative to using large amounts of electricity.

He adds that in addition to the use of aluminium powder in the production of ferroalloys, such as ferrotitanium and ferrovanadium, it is also used to generate heat when ignited. This replaces the heat that would be required from other sources, such as electric arc furnaces, to melt the iron- and titanium-ore material to form the ferroalloy.

“This is one of the reasons why aluminium scrap is in high demand worldwide and it is something our government does not realise, as it continues to allow the free export of aluminium scrap out of South Africa.

“We are therefore exporting not only a strategic raw material and, by implication, many jobs, but also a massive store of potential energy,” Stone states.

Zimalco MD Willie Willemse says, although the use of aluminium powder to substitute other forms of energy in such applications is not new to the market, it is most viable now, because electricity costs are so high and increasing yearly.

“Owing to aluminium’s property of burning thermites at 2 700 °C, it is an ideal substitute for other forms of energy in the production of ferroalloys and reduction of oxides.

Willemse adds that, owing to the high cost of electricity, people are currently experimenting with this concept and other uses of aluminium, more than before.

“Where electrical energy was not available, there was a trend in South Africa to export primary ore and metals without beneficiation. “As a replacement for that energy, companies are using aluminium powder in various fraction sizes to beneficiate the ore by reduction into metal for local use and, also, before it is exported,” he says.

Social Responsibility

As part of Zimalco’s social responsibility initiatives, the company takes students from various universities and learning centres who would otherwise not have had the opportunity of being introduced to the industry, and gives them exposure to practical training to compile their portfolios of P1 and P2 towards their final qualification.

“We have taken in engaged apprentices, as well as mechanical, electrical and chemical engineering students for in-service training. The feedback has been positive and the trainees have achieved a great pass rate on their P1 and P2 certification,” says Willemse.

He adds that, as part of the company’s social and rural development responsibilities, Zimalco works closely with Kgothalang Primary School, in Wattville, Benoni, where it has implemented many projects to improve the school’s facilities.

“We recently roofed a section of the school that is used for assemblies and as a recreation area. “The new roof protects the learners from the harsh sun and rain during lunchtime and gatherings,” says Willemse.

The company plans to further upgrade the school’s facilities, including the ablution blocks, in the near future.

Zimalco has ISO 9001, ISO 14001 and OHSAS 18001 certification as audited by the South African Bureau of Standards. It was recently certified as a Level 8 broad-based black economic- empowerment-compliant company.

Edited by: Chanel de Bruyn
© Reuse this Comment Guidelines (150 word limit)
 
 
 
 
 
 
 
 
Other Metals News
Global crude steel production rose 1.2% year-on-year to 1.66-billion tonnes in 2014, the World Steel Association (worldsteel) revealed on Thursday. While crude steel production in the European Union (EU), North America and Asia expanded by a modest 1.7%, 2% and 1.4%...
Black-economic empowered diversified industrial holdings company, the Southern Palace Group (SPG), reported on Monday that it had entered into an arrangement to buy 100% of Macsteel Service Centres South Africa (MSCSA). MSCSA is a leading supplier of value-added...
Outgoing AMSA CFO Matthias Wellhausen
Matthias Wellhausen has resigned as CFO and executive director of ArcelorMittal South Africa (AMSA), effective March 15, to pursue other opportunities outside of the ArcelorMittal group. AMSA group controller Gerhard van Zyl would step in as acting CFO in March until...
More
 
 
Latest News
JSE-listed Hudaco Industries’ share price climbed nearly 16% on Friday afternoon as the company announced that it would bring an end to a years-long tax challenges with the South African Revenue Service (Sars). In a trading statement to shareholders, Hudaco revealed...
President Jacob Zuma
South Africa was open for more investment and the country offered investment opportunities that no “wise” businessperson should miss, President Jacob Zuma told captains of commerce and industry during the yearly Business Interaction Group meeting on the sidelines of...
The Department of Trade and Industry (DTI) has rejected claims by black economic-empowerment (BEE) advisory firm EconoBEE that there is likely to be a delay to the scheduled May 1 implementation of the revised BEE Codes of Good Practise. “We are on track for the May...
More
 
 
Recent Research Reports
Liquid Fuels 2014 - A review of South Africa's Liquid Fuels sector (PDF Report)
Creamer Media’s Liquid Fuels 2014 Report examines these issues, focusing on the business environment, oil and gas exploration, the country’s feedstock supplies, the development of South Africa’s biofuels industry, fuel pricing, competition in the sector, the...
Water 2014: A review of South Africa's water sector (PDF Report)
Creamer Media’s Water 2014 report considers the aforementioned issues, not only in the South African context, but also in the African and global context, and examines the issues of water and sanitation, water quality and the demand for water, among others.
Defence 2014: A review of South Africa's defence industry (PDF Report)
Creamer Media’s Defence 2014 report examines South Africa’s defence industry, with particular focus on the key participants in the sector, the innovations that have come out of the sector, local and export demand, South Africa’s controversial multibillion-rand...
Road and Rail 2014: A review of South Africa's road and rail infrastructure (PDF report)
Creamer Media’s Road and Rail 2014 report examines South Africa’s road and rail transport system, with particular focus on the size and state of the country’s road and rail network, the funding and maintenance of these respective networks, and the push to move road...
Real Economy Year Book 2014 (PDF Report)
This edition drills down into the performance and outlook for a variety of sectors, including automotive, construction, electricity, transport, steel, water, coal, gold, iron-ore and platinum.
Real Economy Insight: Automotive 2014 (PDF Report)
This four-page brief covers key developments in the automotive industry over the past 12 months, including an overview of South Africa’s automotive market, trade figures, production and the policies influencing the sector.
 
 
 
 
 
This Week's Magazine
BRUCE BRADFORD The 3D printers have a clear upgrade path to eventually print in wood, ceramics and metal-alloys
Three-dimensional (3D) printers being sold in South Africa by electronics distributor Rectron currently print in two types of plastic, but have a clear upgrade path over the next five years to eventually print in wood, ceramics and metal-alloy materials, says Rectron...
The world’s two dominant commercial aircraft manufacturers, Airbus of Europe and Boeing of the US, both recently announced that they had made record aircraft deliveries in 2014. Boeing set a global record for the industry with 723 commercial aircraft delivered, while...
The Western Cape is shifting further into the renewable-energy space with the official opening of a factory specialising in solar inverters, a key component of solar photovoltaic (PV) plants. The investment in the manufacturing facility in Cape Town aims to boost the...
Business Leadership South Africa (BLSA) last month welcomed Cabinet’s establishment of a technical team war room to undertake various interventions to improve electricity supply security over the short- and medium-term, but added that the private sector also had a...
Despite a rapid rise in mobile connections and the economic and social benefits of such connectivity, more than half of the world ended 2014 unconnected. For this reason, industry commentators believe the biggest impact of mobile technology is still to come –...
 
 
 
 
 
 
 
 
 
Alert Close
Embed Code Close
content
Research Reports Close
Research Reports are a product of the
Research Channel Africa. Reports can be bought individually or you can gain full access to all reports as part of a Research Channel Africa subscription.
Find Out More Buy Report
 
 
Close
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks