IWC, African leaders in water cooling technology, will be showcasing their dynamic GRP Pipe System (“Glass Reinforced Polyester” Pipe System) at the Water Show Africa 2015, happening from 24 - 25 March 2015 at the Sandton Convention Centre in Johannesburg. IWC’s GRP pipes are extremely corrosion resistant, very lightweight and have a low friction loss coefficient, providing a massive saving in energy costs for pumped water applications, or a higher "q" value for gravity flow. With an infiltration and exfiltration free coupling system, no water is lost from the source up to the end user. Says Roger Rusch, IWC CEO, “Our GRP pipe system is the leading technological solution to large water applications due to its resistance to galvanic and electrolytic corrosion. This resistance to corrosion makes it ideal for municipal water applications as well as transfer pipelines for potable water, sewerage, seawater, desalinated water, power plant cooling water, chemicals, industrial waste water, and irrigation. Once installed, there should be little need for maintenance on the piping for over 50 years, making it the most cost effective life cycle investment available.” To construct their GRP pipes, a dense laminate is created using two primary raw materials: resin and glass-fibre roving. The manufacturing process is described as the “discontinuous helical filament winding process”. This helically wound glass reinforcement, impregnated with resin, ensures simultaneous hoop and axial structural strength for each pipe length, with the cured resin providing the ‘plastic’ corrosion resistant component. A third component, sand, is sometimes added as a layer to gain stiffness while maintaining the low mass ratio typical of GRP pipes. For extremely corrosive conditions, typically for industrial chemical uses, a high quality resin known as ‘vinyl ester’ can be used to enhance the corrosion resistance level of the piping. IWC typically supplies pipes in lengths of 12m which use . . .
In copper production, heat generated during extraction processes can be harnessed and transferred back into the system using heat exchangers, resulting in significant energy savings and unparalleled yield. “Compact heat exchangers, such as gasketed and welded plate heat exchangers, as well as spiral heat exchangers, are the most efficient technology for heat transfer,” says Roger Rusch, CEO of Industrial Water Cooling (IWC). “Their close temperature design, high internal turbulence and large heat-transfer areas combine to recover up to 25% more energy when compared to conventional shell-and-tube heat exchangers. This excess energy can be recycled and used in other applications within the copper processing plant.” During the initial copper extraction process, plate heat exchangers are used to control chemical temperatures within the autoclave where crushed copper ore is leached with sulphuric acid to produce impure solutions of copper sulphate. Spiral heat exchangers are then incorporated to recycle the rich acid’s low-grade heat, which is then used to pre-heat the lean acid coming back from solvent extraction. Another area where plate heat exchangers deliver optimum heat recovery is during the electrowinning process where copper ions are extracted from the copper sulphate. The electrowinning cell consumes nearly 80% of total energy required for the production of copper. Here, steam is used to heat rich electrolyte before it enters the electrowinning cell. Gasketed plate heat exchangers reduce net consumption of energy in the plant by recovering low grade heat during the process and using it to preheat the rich electrolyte. “Plate heat exchangers are low-cost and low-maintenance and are up to 90% smaller than the equivalent shell-and-tube heat exchangers. By replacing costly and bulky shell-and-tube units with compact heat exchangers, copper processing plants are recycling megajoules of wasted energy each year,” says Rusch. Author: Nissin Laby from . . .
According to an EPRI (Electric Power Research Institute of the US) study more than half of all unplanned power outages are due to corrosion, which generally corresponds with other studies that half of all failures in industry are corrosion related. Studies in different countries indicate that 25% to 30% of water supply is lost in the supply chain due to leaks resulting from corrosion. Approximately 50% of all carbon steel produced is used to replace existing corroded steel work. The cost of corrosion accounts for more than 5% of South Africa’s GDP, which is estimated at over R130 million. The mining industry presents one of the harshest environments, pushing process equipment to the extreme. Using corrosion-resistant glass-fibre reinforced polymer (GRP) as an alternative to carbon steel will dramatically reduce the need for repairs or replacement, saving mining operators millions of Rands. “Pipes are considered the arteries of a mining operation, which means they need to be built to withstand a variety of extreme operating environments, including metal extraction where process chemicals reach temperatures of up to 90°C. Carbon steel or even most stainless steel alloys are not recommended for use in these aggressive environments. Glass-reinforced plastics display exceptional resistance to corrosion and the use of GRP in these applications is well documented,” says Roger Rusch, CEO of Industrial Water Cooling (IWC). GRP piping, for example, can be used throughout solvent extraction processes as this material has low permeability making it compatible with wet acid gases and recovered acids across a wide spectrum of concentrations and pH levels. GRP is also used to produce liners for electrolytic and electrowinning cells and for the construction of storage and processing vessels. “Material selection boils down to lifecycle cost and with its low cost, low maintenance and high abrasion resistance, GRP is the ideal solution for effective corrosion-control in . . .
Labelled the ‘pipe of the future’, corrosion-resistant, glass-reinforced plastic (GRP) pipelines can save mining companies millions on reoccurring pipeline breakdowns due to corrosion. Fiberglass-reinforced plastic pipes are now considered exceptionally advantageous in the mining industry where highly-resilient materials are required to withstand corrosive chemical used and harsh environmental conditions experienced in the mining process and in particular metals processing plants. Roger Rusch, CEO at IWC, experts in GRP manufacturing and installations in South Africa and Africa, says “GRP pipes are well-priced, do not require maintenance and are designed to have a lifespan of around 50 years, which is a huge saving on the life cycle cost over a 50-year period, especially in the mining industry where conditions are harsh.” In response to the growing demand for fibreglass equipment and piping, in 2012, Industrial Water Cooling, IWC, officially launched a glass-reinforced plastic (GRP) manufacturing facility in Isando, Ekurhuleni, which is one of only two GRP plants of this kind in South Africa. Before IWC launched its GRP facility, the biggest local supplier of industrial fibreglass was based in KwaZulu-Natal. “Our facility offers a range of services and products including on-site GRP piping repair work as well as the manufacturing and design of corrosion resistant linings and fittings for pipeline systems.” says Rusch. IWC’s GRP manufacturing facility undertakes the design, manufacture and installation of GRP piping and fittings from 25mm up to 2500mm in diameter Polypropylene; PVC and HDPE vessels and piping; and GRP corrosion resistant linings. Fiberglass-reinforced plastic is constructed by weaving together individual strands of fine glass fibre to form a flexible fabric, which is then placed in a mould and combined with resin. This process is then repeated in order to create many layers of the fibre glass and resin, which then becomes a high . . .
PRESS RELEASE August 31, 2014 Intertek Sub-Saharan Africa promotes Management System Integration Johannesburg, South Africa - Intertek, a leading quality solutions provider to industries worldwide , hosted a Management System Solution symposium in Johannesburg from 21-22 August 2014, addressing management system challenges and integration. Integrated management systems can be implemented by organizations in any sector and of any size. Organizations may consider this step to lower costs and simplify their maturing management systems by fully or partially integrating the requirements of different audit criteria with a single set of documentation, policies, procedures and processes. Integrated audits can bring many benefits to your organization, such as lower certification costs, fewer interruptions to the organization, reduced documentation, streamlined processes, and more consistent objectives across multiple systems. The symposium included presentations by industry specialists, who addressed the benefits and practicalities of integrating multiple management systems, as well as individuals who had been involved in the integration of multiple management systems within their companies. The event also featured professionals who currently serve on the international committee developing the new ISO 9001: 2015 revision, and who are actively involved in the review of the ISO 14001 and OHSAS 18001 international standards. The proposed changes to the ISO 9001 and ISO 14001 standards, prior to their expected release in mid-2015, as well as the impact of the High Level Structure on the ISO range of standards was of great interest to attendees. Delegates were also provided with the opportunity to engage in working group sessions which addressed generic global and local non-conformances as well as those specific to the SHEQ, CSR and Food schemes. Intertek will continue to keep the sub-Saharan marketplace abreast of the changes affecting management systems, and to . . .
IWC, Africa’s leaders in industrial water cooling solutions, will join the continent’s heavyweights in mining, industrial, construction, engineering and related industries at the Electra Mining Africa 2014 exhibition, taking place from 15 – 19 September 2014 at the Expo Centre Johannesburg. Electra Mining Africa 2014 is one of the most prominent mining, industrial machine tools and electrical trade shows in Southern Africa, attended by over 850 manufacturers, suppliers and service providers who will be showcasing their latest products and cutting-edge innovations. South Africa is estimated to have the world’s fifth-largest mining sector in terms of GDP value. The notable mineral resources of the country include gold, iron, phosphates, diamonds, manganese and platinum and the nation’s total reserves remain some of the world’s most valuable, with an estimated worth of R20.3-trillion ($2.5-trillion). Although production in the South African mining sector was marred by labour unrest in the previous financial year, the industry still adds significant value to the country’s economy with regards to GDP contribution, employment, tax and export revenues. Company MD Roger Rusch says, “South African mining companies are key players in the global industry and account for a significant portion of world production and reserves. IWC keenly looks forward to participating at Electra Mining 2014 to provide mining heavyweights with effective and competitive cooling solutions.” IWC designs and manufacturers a type of forced draft counter flow cooling tower, known as a slurry cooling tower, that can withstand the severe conditions of deep-level mining. These dual composite cooling towers are able to operate in high temperature environments amidst the harsh chemical compositions of slurry, which is a by-product of the pressure-leach process used in cooper mining. The segmented, modular design of IWC’s slurry cooling towers allows for easy assembly and cost-effective . . .
IWC, leaders in industrial cooling tower systems in Africa, have recently become the official Southern Africa distributor for SATI Filters, and for good reason. They are tough, highly versatile and best of breed. An effective water filtration system is crucial to the smooth running of industrial cooling tower operations and ensures optimum efficiency. Filtration systems prevent corrosion and reduce the risk of growth of the deadly Legionella bacteria and other microbes. An effective filtration system minimises downtime due to scheduled or unscheduled maintenance and reduces unnecessary loss of water. SATI is an Italian-based manufacturer of a unique line of water filtration systems that are able to meet all industry-specific needs. SATI’s filtration systems cover the entire field of normal filtration from 5000 up to 1 micron. Their products include manual filters, semi-automatic filters, self-cleaning screen filters, pleated cartridges and membrane filters. Unlike most of the major manufacturers, all SATI Filters are constructed with a stainless steel body, which is ideal in an industrial water cooling environment due to steel’s higher resistance to wear and tear, its ability to work under harsh operating environments and a longer lifespan. The main models, such as the SATI Rotor, have been designed to work in very aggressive conditions and are available in Duplex stainless steel or stainless steel coated with a special paint. IWC supply a number of SATI Filter models to fit industry-specific cooling water filtration requirements. These include: Self-cleaning filters: ? Aquaspeed is a self-cleaning water filter system with a patented pressurized water jet that cleans the cartridge, ensuring low water consumption and short stops of the outlet flux during the cleaning cycle. It is suitable for use in pressurized systems with a small flow rate (< 40m3/h) and is supplied with valves, pressure gauges and an electronic controller. This is the only . . .
IWC’S forced draft counter flow cooling towers, which have been designed and manufactured for the specific pressure-leach process used in copper mining, excel at cooling slurry with high levels solids, extreme temperatures and highly aggressive chemical compositions. IWC’s forced draft cooling tower is typically octagonal in shape and consists of a number of field assembled, dual composite GRP panels. These structural panels have polypropylene liners with the structural laminate made from high quality vinyl ester resin. The panels also have a conductive carbon tissue that acts as a corrosion barrier. This carbon tissue also preforms non-destructive “spark testing” of the internal polypropylene panel seal welds to establish the integrity of the weld during the whole life of the slurry cooling tower. The cooling tower comes complete with a rubber lined stainless steel basin which is designed to prevent clogging. IWC’s forced draft counter flow cooling tower is installed with a fibreglass fan reinforced with vinyl ester resin making it suitable for hostile industrial environments. The forced draft fans have a 16 degree blade angle and have a recorded operational efficiency of 97.85%. The slurry cooling towers are also fitted with corrosion-resistant Grade 316 stainless steel distribution pipes, distribution pipe sprayers and drift eliminator spray pipes to ensure durability and thereby reduced downtime for maintenance. Advantages of IWC’s slurry cooling towers The segmented, modular design of IWC’s slurry cooling towers allows for easy assembly and cost-effective maintenance. The forced draft fans and removable spray lances can be conveniently accessed from an external walkway. IWC’s slurry cooling towers have no fill, which eliminates the possibility of fouling and corrosion within the cooling tower and the risk of growth of microbes such as the deadly Legionella bacteria. Despite having no fill, the forced draft counter flow slurry cooling tower . . .
Labchem (Pty) Ltd has become the latest member of the Chemical & Allied Industries’ Association (CAIA) to sign the Responsible Care (RC) Public Commitment, thereby committing the company to implementing its guiding principles. Labchem (Pty) Ltd, which operates from Johannesburg, was established in 1983 with the objective of becoming a leading laboratory supplier in South Africa. Offering extensive ranges of standard and specialised chemicals, laboratory glassware, general consumables and basic laboratory instrumentation, the company has established strong ties with renowned international and local chemical manufacturers. “In 2005, Labchem obtained ISO9001:2008 certification and succeeded in maintaining this ever since. In 2012, we moved into our new premises with extended warehousing to better accommodate our growing company and customer demands. We have built a new, modern chemical store to enable us to store hazardous chemicals safely. With on-going determination to improve operations in a holistic manner, Labchem’s recent, voluntary membership of CAIA and the signing of the Responsible Care Public Commitment will help guide the company in current and future aspects of chemical safety and product stewardship. It is our company’s expectation that the implementation of the Responsible Care principles will be of benefit to the company employees, customers and the environment in which we operate.” said CEO Derek Stott. “By signing the RC public commitment, Labchem (Pty) Ltd pledges to conduct all its operations in a safe and environmentally sustainable manner and to incorporate the Responsible Care ethics and requirements into its business strategy, management system and daily operations," says Louise Lindeque, Responsible Care Manager at CAIA. One hundred and fifty nine companies are signatories to the RC initiative in South Africa, which shows that the initiative is more than a set of principles and declarations. Through the sharing of information . . .
South African leaders in cooling towers and cooling solutions, IWC, announced today that is has acquired Tektower, a South African cooling tower manufacturer and related services provider. Tektower, formerly known as Suzler Cooling, has been providing innovative cooling solutions for 40 years completing projects in South Africa and on the sub-continent including Sudan, Kenya, Zambia, Nigeria, Mozambique and Mauritius. Currently based in Spartan, Gauteng, Tektower will be relocating to the IWC company premises in Isando, retaining its brand name and operating as an IWC subsidiary. While existing management of Tektower will remain the same, joining the board of directors at Tektower is Mr. Pooven Reddy, current Financial Manager of IWC who will take over as Financial Director of the new IWC subsidiary, and Mr Roger Rusch, Managing Director of IWC, who will assume the role of CEO. Mr Rusch says, “The strength of the Tektower brand and their expertise in the South African market as well as their impressive track record in Africa offers an added advantage to IWC’s existing service and product offering.” Industrial Water Cooling (Pty) Ltd (IWC) are a specialist water cooling company, with specific strength and focus on evaporative cooling systems and cooling towers in particular. IWC was founded in 1986, specialises in evaporative water cooling for numerous applications. Some industries in which we are involved are: • Power Generation • Mining • Petrochemical • Sugar • Steel & Aluminium • Food & Beverages • Air-conditioning, Refrigeration and many other applications. For many years IWC has been a member of the CTI, Cooling Technology Institute, based in the USA. This association has as its member’s consultants, designers, constructors as well as end users of cooling towers. Due to IWC’s extensive experience in the refurbishment of cooling towers it has undertaken in excess of 80% of the Natural Draught refurbishment work conducted in . . .