R/€ = 15.16Change: -0.03
R/$ = 13.35Change: -0.02
Au 1156.06 $/ozChange: -2.88
Pt 981.00 $/ozChange: 2.00
Note: Search is limited to the most recent 250 articles. Set date range to access earlier articles.
Where? With... When?

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 Letters About Us
RSS Feed
Article   Comments   Other News   Research   Magazine  
Sep 28, 2012

R4.5m baghouse for aluminium producer completed

Construction|Engineering|Wattville|Africa|Aluminium|Explosives|Export|Gas|Industrial|Installation|Mining|PROJECT|Projects|PSY Systems|rail|Systems|Tager Engineering|Training|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|Willie Willemse|Pollution Control|Process Control
Construction|Engineering||Africa|Aluminium|Explosives|Export|Gas|Industrial|Installation|Mining|PROJECT|Projects|rail|Systems|Training|Water|Welding||Africa||Energy|Explosives|Manufacturing|Service|Systems|||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
Creamer Media Senior Deputy Editor Online
© Reuse this Comment Guidelines (150 word limit)
Other Aluminium News
ACCELERATING TREND The amount of aluminium used in vehicles is expected to increase by about 100% or more in North America and globally
The automotive industry’s shift from manufacturing vehicle body panels in steel to manufacturing them in aluminium is a trend that is expected to significantly accelerate, says aluminium industry representative body the Aluminium Federation of South Africa (Afsa)....
SMOOTH PRODUCTION Consistent flatness is required to feed the material into downstream processing lines
Metallurgical plant and rolling mill technology provider SMS group has identified the automotive industry as a crucial target market for the company, where its aluminium rolling technology can be applied, says SMS group Technical Services South Africa executive VP...
FULL OFFERING AC Exports' product range, including a spool of U-clips on the far righ
Durban-based precision aluminium components manufacturer AC Exports will receive a new machine for manufacturing small aluminium sausage clips this month, AC Exports chairperson Jens Reuning tells Engineering News.
Latest News
South African Airways (SAA) has enhanced its partnership with the airline’s in-flight duty-free concessionaire Tourvest Inflight Retail Services (TIRS), enabling Voyager members to earn miles when buying duty-free products and spend their miles when shopping for...
South Africa's new visa regulations are having an adverse impact on the country's tourism industry without proof that they are making any impact on child trafficking, according to Hussein Dabbas, International Air Traffic Association (Iata) regional vice-president...
The Council for Scientific and Industrial Research (CSIR) has developed a semi-autonomous solution for early pothole detection to potentially replace the often time-consuming expensive manual road inspection. Showcasing the Visual Surveying Platform (VSP), CSIR...
Recent Research Reports
Liquid Fuels 2015: A review of South Africa's liquid fuels sector (PDF Report)
Creamer Media’s Liquid Fuels 2015 Report examines these issues in the context of South Africa’s business environment; oil and gas exploration; fuel pricing; the development of the country’s biofuels industry; the logistics of transporting liquid fuels; and...
Road and Rail 2015: A review of South Africa's road and rail sectors (PDF Report)
Creamer Media’s Road and Rail 2015 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 infrastructure and network, the funding and maintenance of these respective networks, and...
Defence 2015: A review of South Africa's defence sector (PDF Report)
Creamer Media’s Coal 2015 report examines South Africa’s coal industry with regards to the business environment, the key participants in the sector, local demand, export sales and coal logistics, projects being undertaken by the large and smaller participants in the...
Real Economy Year Book 2015 (PDF Report)
There are very few beacons of hope on South Africa’s economic horizon. Economic growth is weak, unemployment is rising, electricity supply is insufficient to meet demand and/or spur growth, with poor prospects for many of the commodities mined and exported. However,...
Real Economy Insight: Automotive 2015 (PDF Report)
Creamer Media’s Real Economy Year Book comprises separate reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, gold, iron-ore and platinum sectors.
Real Economy Insight: Water 2015 (PDF Report)
Creamer Media’s Real Economy Year Book has been divided into individual reports under the banner Real Economy Insight and investigates key developments in the automotive, construction, electricity, road and rail, steel, water, coal, gold, iron-ore and platinum sectors.
This Week's Magazine
BUSINESS LEADERS PANEL Adam Craker, Ivor Chipkin, Alan Hosking and Allon Raiz at the 6th IQ Business Active Growth conference
At the sixth IQ Business conference held in Sandton last month, a panel of business leaders and academics advocated that business reclaims the initiative to spur growth in South Africa amid fragmented and haphazard political direction. Management consulting firm IQ...
The building industry is an essential component of the South African economy as it contributes about 15% to the gross fixed investment that drives the economy. However, with the country’s economy going through a tough time currently, this, in turn, reflects on the...
The recipients of the 2015 South African National Energy Association (Sanea)/South African National Energy Development Institute Energy (Sanedi) Awards were announced at a ceremony and banquet in Sandton last month. Sanea chairperson Brian Statham named Exxaro CEO...
ASHER BOHBOT EOH’s corporate goals were originally aspirations, but the company is relevant and is making a difference in the territories it operates in
As South African information technology (IT) firm EOH posted another full year of strong growth, CEO Asher Bohbot, known for his frank words, people-centric management style and stoic humanism, attributed the company’s continued South African and African growth to...
International heavy-equipment engine manufacturer Cummins’ regional distribution centre (RDC) in Woodmead, Gauteng, has halved the average logistics distribution time for clients in Southern Africa and allowed for critical or long-lead stock to be kept closer to...
Alert Close
Embed Code Close
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
Engineering News
Completely Re-Engineered
Experience it now. Click here
*website to launch in a few weeks
Subscribe Now for $96 Close
Subscribe Now for $96