MechChem Africa May 2017

May 2017

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MechChem Africa

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Plant maintenance, lubrication and filtration

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Local green masterplan

for the environment

ne of the most rigorous and

specialised processes for the

mining, industrial, manufactur-

ing, and commercial develop-

ment sectors is environmental licencing and

compliance assurance, underwhich fall dust

suppression solutions, water solutions, en-

vironmental management services, carbon

solutions, agro-forestry products and fire

solutions. I-CAT Environmental Solutions

director, Lourens Jansen van Rensburg,

explains.

I-CATEnvironmental Solutions offers an

‘environmental masterplan’ in terms of the

resulting compliance, auditing, andmonitor-

ing requirements.

These environmental-compliance solu-

tions have a specific focus on the mining

and industrial sectors, as prescribed by

relevant national legislationand compliance

standards, “The current economic climate in

South Africa has resulted in companies cut-

tingdownonbudget allocation forminimum

environmental compliance, while recognis-

ing their obligations to account for their

activities impacting on the environmental

and to accept responsibility for them,” Van

Rensburg says.

I-CAT offers an Environmental

Masterplan solution whereby all external

environmental licencing, auditing, andmoni-

toring requirements are addressed within

its Environmental Solutions department.

Benefits include cost- and resource-savings,

as well as ensuring that all environmental

aspects are considered and assessed in an

integrated, holistic manner.

“Furthermore, we can assist our clients

with their sustainability and integrated

reporting requirements in line with the

relevant standard, covering reporting on

economic, environmental, social and gov-

ernance performance.

“We present our clients’ values and

governance models in a

holistic manner, while

determining the link

between their busi-

ness strategies and

commitment to a

sustainable global

environment,” con-

cludes Jansen van

Rensburg.

I-CAT is a lead-

ing environmental

solutions company with a primary focus

on supplying products and services that as-

sist industrial clients in various aspects of

environmental compliance. The company is

well positioned to assist all its clients’ needs

in environmental management regarding;

dust suppression solutions, water solutions,

environmental management services, car-

bon solutions, agro-forestry products and

fire solutions.

eading cement producer, PPC, recent-

ly commissioned ACTOM’s environ-

mental solutions specialist business

unit, JohnThompsonAPC, toupgrade

the dust collection system serving one of the

main production lines at PPC’s Dwaalboom

plant near Thabazimbi in Limpopo Province.

The turnkey contract, worth in excess of

R30-million, was awarded to JohnThompson

APC in May 2016 and completed in March

2017. The contract involved retrofitting

the original electrostatic precipitator (ESP)

system for the plant’s Kiln No.1 with a

reverse-pulse filtration system deploying

tubular bags to maintain dust emissions

below 20 mg/m

“The new system represents a substan-

tial upgrade on its predecessor. The lower

emission level it maintains is to meet stricter

environmental regulations which have come

into effect,” commented Raymond Hopkins,

John Thompson APC’s project manager on

the contract.

The pulsejet conversion, erected on the

roof of the former ESP system, contains over

3 600 tubular filter bags with a total air-

moving capacity in excess of 500 000 m

/h.

Thebaghouse is fittedwithglass-fibre tubular

Turnkey filtration system

for cement plant

bags capable of withstanding temperatures

of up to 260 °C.

The contract also incorporated the design

and manufacture of a centrifugal induced

draft (ID) fan for the baghouse comprising a

2 700 mm diameter aerofoil impeller driven

byamotorofover1.0MW,aswellasmaterials

handling equipment consisting of drag chains

and rotary valves discharging the collected

dust into an existing product conveyor.

ACTOM’s industrial and mining fan spe-

cialists TLT ACTOM, which John Thompson

APCsub-contracted toproduce thebaghouse

fan assembly, was also commissioned as part

of its scope of work under the contract to de-

signandmanufactureacustomisedkilnIDfan.

“This centrifugal ID fan, although it forms

part of the filtration system contract, is unre-

lated to thedust collection system,” explained

James Sole, TLT ACTOM’s sales engineer,

industrial and process fans.

“Its function is heat recovery, as it takes

the hot off-gas from the kiln for re-use in the

production process. It is designed to with-

standhighdust loads and temperatures and is

madeofexceptionallywear-resistantmaterial

due to the highly abrasivematerial towhich it

will be exposed.”

With a diameter of 3 600 mm, it is one

of the largest fans used in an industrial ap-

plication and is driven by a motor in excess

of 2.0 MW.

ACTOM (Pty) Ltd is the largest manufac-

turer, solutionprovider, repairer anddistribu-

torofelectro-mechanicalequipmentinAfrica,

offering awinning and balanced combination

of manufacturing, service, repairs, mainte-

nance, projects and distribution through its

40 outlets throughout Southern Africa.

The company is also a major local supplier

of electrical equipment, services and balance

of plant to the renewable energy projects. It

also holds numerous technology, distribution

and value added reseller agreements with

various partners, both locally and interna-

tionally.

A bird’s eye view of the reverse-pulse ESP

conversion developed and installed by John

Thompson Air Pollution Control at PPC’s

Dwaalboom cement factory near Thabazimbi.

ACTOM’s environmental solutions specialist business unit, John Thompson

Air Pollution Control (APC), recently developed and installed a reverse-pulse

electrostatic precipitator conversion as an upgrade to the existing dust collection

system at PPC’s Dwaalboom cement plant near Thabazimbi in Limpopo.