Archive: September 30, 2024

Fuelling progress: AES advises local industry on how best to benefit from biofuels

The local manufacturing and industrial sector is showing increasing interest regarding switching to biofuels as a fuel source. However, the biomass fuels market is mostly still in its infancy, making it extremely challenging for South African companies to make the right decisions when moving away from traditional fossil fuels.

“Quite often the available information on biofuels is varying and it can be difficult to get the facts – based on experience – to support a decision. Therefore, a local energy optimisation partner’s knowledge can be invaluable,” says Dennis Williams, Commercial Director of Associated Energy Services (AES), a leading operations and maintenance service provider to the steam and boiler sector.

“In AES’s case, clients benefit from our hands-on experience and knowledge of fuel sources and thermal energy options. The final decision depends on individual clients’ needs and their short-, medium- and long-term objectives,” Williams explains.

‘Chipping in’ on the biofuels debate

Although the drive for a switch to biofuels is the reduction of emissions, Williams says carbon accounting can be a contentious topic, with the view that biomass is carbon neutral, resulting in the promotion of the use of biomass, even though more carbon dioxide is emitted than the same energy plant would using coal: “This is because the actual stack CO2emission per unit of thermal energy is higher.  However the CO2 emitted from biomass combustion is deemed to be absorbed by biomass that grows to replace that which has been used,” he points out.

In practical applications, it should also be considered that the chemical composition of wood includes alkaline metals such as sodium, potassium and high chloride levels. Chemical interaction between the fuel components and the furnace refractory lining at high temperatures increases corrosion levels, elevating maintenance costs.

“Furthermore, biomass is can be contaminated with sand, grit and dust. Silica-based, this interacts with the biofuel components inside a furnace, resulting in fouling and slag formation,” points out Ray Lund, Operations Director of AES.

Lund advises that biofuels also present ethical challenges to some companies: “When asking clients which operate on biomass why they had strict and narrow policies when sourcing fuel, we learnt that they wanted to ensure they were sourcing ‘genuine waste’ as fuel – rather than residue that was produced by cutting down trees specifically for fuel.”

One prospective client presented AES with a sliding scale of the most appropriate to least desirable choices of biofuels. Going forward, Lund believes that blue chip companies will increasingly drive ethical sourcing and require biomass to be certified as a fuel.

Even then, due to the quantum of energy required for the thermal process, larger industry has limited choices of fuels which can support the significant level of energy supply required.

“An added consideration is the ability of biomass-fuelled boilers to respond to changes in load or steam demand. “Solid biofuels, in general, respond slowly. If you have a very erratic steam profile on a pressure-sensitive process, solid biofuels are less suitable,” points out AES Projects Director, Gavin Evezard.

‘Green’ not always easy

Then, there is also a misconception that because it is widely regarded as ‘green’, biomass combusts easily.

“Current biomass-supplied steam combustion requires high levels of on-site skill and could potentially result in downtime should problems arise. Most biomass technologies have been developed on other continents and are not necessarily suited to local conditions. Global shareholders also often decide on a worldwide shift to biofuels – without fully appreciating different markets’ responses to the added costs,” Evezard remarks.

Furthermore, as the energy density of biomass is low compared to that of fossil fuels – not only is additional storage space needed on site, but more equipment is required to move up to four times the volume of feedstock to the plant.

Notwithstanding its inherent challenges, Evezard notes that there is a definite place for biofuels and, as a fuel-agnostic partner to industry, AES is ideally positioned to assist manufacturers to navigate any potential obstacles.

Williams advises: “Before embarking on a biomass journey, you need to look at what plant and equipment you require, get an idea of the costs and, simultaneously, look at fuel sourcing. If significant capital expenditure is required, you must ensure there is an available – and affordable – fuel source for the duration of the life of the plant. So, entering into negotiations with potential suppliers and concluding long-term supply agreements, including potential year-on-year price escalations is imperative.”

Evezard warns that one of the major frustrations is that biomass suppliers are not necessarily willing to enter into long-term agreements: “Some suppliers want to leverage the value of a commodity that currently has limited value and no pricing track record, knowing that it might gain value within a short period. Those that move early and manage risk properly can benefit. As one of the first, resources will be readily available and affordable. Those who enter the biomass market later may have to spend more and carry more risk.”

Lund emphasises that a local partner such AES should be part of the process from the outset.

“We can provide support and overcome any of the challenges which we have outlined – however the fundamentals must be right. The technology needs to be suited to the fuel and the fuel must work with the design of the plant,” he concludes.

Gals in Hard Hats: building a future for women in construction and infrastructure

‘Curiosity has no gender’: a pertinent observation from Palesa (Ntuku) Mokwena, a fourth year Bachelor of Science (civil engineering) student from the University of the Witwatersrand. Raised in a family that encouraged resourcefulness and discouraged gender stereotypes, Mokwena is fascinated by the diversity of civil engineering.

Mokwena is one of 60 young women from the universities of Pretoria, Johannesburg and the Witwatersrand who attended Gals in Hard Hats, an innovative Women’s Month and youth development initiative hosted by Colossal Concrete Products (CCP) at its Brakpan manufacturing facility, which included a site tour to give students and other guests insight into ‘construction in action’.

The event was co-hosted and co-sponsored by two of Colossal’s suppliers, construction chemical company Chryso Southern Africa and AfriSam, a leading supplier of cement, construction materials and technical solutions.

“The tours enabled us as students to see everything that happens behind the scenes. If you have that all in mind and you see where you want to work, the path to get there is much easier,” comments Thea Giliomee, who is studying water resources engineering at the University of Pretoria.

Colossal Concrete Products Chief Executive Officer, Gwen Mahuma-Madida, says that her company’s close relationship with its suppliers often leads to discussions about collaborating to improve their industry: “In this instance, it developed into the Gals in Hard Hats event. We gave the ‘gals’ a taste and view of the different construction and infrastructure-related avenues that they can follow. Our speakers ranged from university lecturers to manufacturing business owners and a metallurgist – representing the wide spectrum of the potential careers there are in these sectors.”

Where the challenge ‘STEMs’ from

According to the University of Stellenbosch, women make up approximately 13% of STEM (Science, Technology, Engineering and Mathematics) graduates. Only 7% of engineers registered with the Engineering Council of South Africa (ECSA) are women.

Colossal Concrete Products Chief Operating Officer, Mmapitso Kiewiet, believes that any women-focused development initiatives should not only highlight careers in STEM, but showcase women as trailblazers: “We need to start amplifying our voices as women, and not be shy of our successes, so that young women can see what is possible! STEM must be introduced during girls’ formative years, so this can spark their interest – and the confidence to pursue it.”

Student attendees admitted that there was a huge stigma attached to STEM subjects at schools, and that these are typically regarded as being ‘only for boys’.

Event speaker Dr Grizelda du Toit, Project Professional at AfriSam and mother of a young son and daughter, points out that more effort is required from schools and universities to raise awareness about the importance of STEM subjects. However, a change in attitude and mind-set should begin at home, with parents encouraging girls to develop technical skills and also set the example.

When asked how she would advise school leavers wishing to follow in her footsteps, Sandra Onyeka, currently in her third year studying civil engineering at the University of Johannesburg and specialising in transport, replied: “Do not be intimidated, or go in with preconceived notions that this is a male-dominated industry. It can only change if you want it to change!”

Fellow student Mokwena adds that one’s background should not stand in the way: “I heard a quote along the lines of: ‘do not let your background put you back on the ground’. A lot of us did not attend the best schools, and only saw a computer when applying for university. As hard as these circumstances are, they should never stop one from achieving one’s goals.”

Managing the workplace

According to the latest report from the Engineering Council of South Africa (ECSA), more than 70% of professional women who graduate leave their chosen professions because of the workplace climate.

Nelisiwe Simelane, a physical metallurgist and key account manager at Mitak – and one of the speakers at the event – says it is sad that, despite regular debates about women’s empowerment, the salary disparity between male and female professionals still needs to be addressed.

Simelane identifies three things that are needed to retain skilled women in the South African workplace:

  • The vast stereotypes around race, gender and age to be challenged and addressed
  • The creation of networking platforms or opportunities that are inclusive. Networking is a very powerful tool for success and growth – however, the opportunities need to be more inclusive
  • The development and implementation of mentorship programmes. Newcomers should encounter those who have walked the same road and are prepared to pay it forward

“Many leave the workplace because of a lack of guidance – and insufficient insight into the career path that they have chosen,” she comments.

Event speaker Adele Wentzel, AfriSam Sales Manager Cement Manufacturing agrees that more competitive compensation and benefit packages are needed – together with more flexible and supportive work environments – to help female employees to establish a healthy work-life balance.

Concrete opportunities

Mahuma-Madida notes that Colossal Concrete Products has worked hard to grow its female workforce: “Besides being highly skilled, we find that women also bring a different dynamic to the organisation, so including them in our team has benefits far beyond their roles.”

Wentzel concurs: “Women are typically empathetic, patient and have great instincts. We are also very direct and transparent in our communication. We listen to others and value their opinions. This leads to unique ideas and increases creativity and innovation.”

The event participants all agree that, despite the difficulties, more women are entering engineering, construction and infrastructure-related professions and roles, with companies creating opportunities through training and internships. For example, Du Toit remarks that she has noticed more female artisans, electricians, fitters, boilermakers and engineers on site – as well as women working in safety and quality management.

Michelle Fick, Business Unit Development Manager: Concrete Aesthetics at Chryso Southern Africa, a leading construction chemicals company, Saint-Gobain subsidiary and co-sponsor of the event, says: “Chryso is committed to create real prospects for career advancement and fulfilment – especially for women – empowering our staff to grow and lead within the industry.” Fick also highlights how new opportunities are emerging in Building Information Management (BIM) and other IT-related disciplines, reflecting increasing innovation in the construction industry.

“There was a definite ‘golden thread’ key message which attendees took away from Gals in Hard Hats event: in a nutshell, for women entering industry and business today, there will be challenges, uncertainties, setbacks and even disappointments. However, perseverance, hard work and self-belief is key – as the guest speakers highlighted.

Furthermore, the response – not only from the female students but also from customers attending the event – was overwhelming! It was so inspiring,” Wentzel adds.

“Our co-sponsors, as well as many of the attendees agree that – while national Women’s Month in August is a great initiative – there is a need in the industrial sector, for many more opportunities such as this.

As a result, we are proud to announce that Gals in Hard Hats will be repeated next year, this time at an AfriSam operation, with Colossal Concrete Products and Chryso Southern Africa co-hosting and co-sponsoring the event,” Mahuma-Madida concludes.

Bolt and Engineering ‘bolted’ to great suppliers and servicing a wide range of industry sectors

Bolt and Engineering Distributors (B.E.D.) continues to solidify its position as a leading provider of comprehensive industrial solutions.

At the recent Electra Mining 2024 tradeshow, B.E.D’s strategic partnerships with exhibiting suppliers such as Fronius, Milwaukee Tool (represented locally by Upat), and Bolt Torque took centre stage, demonstrating how these suppliers leverage B.E.D.’s strong nationwide footprint and access to pivotal industries such as mining, general engineering, fabrication and agriculture.

B.E.D. ensures that customers across diverse industry sectors receive the right machines and tools for the right application, backed by technical expertise, thorough product training and excellent customer service.

Commitment to safety, quality and customer support

Mike Giltrow, CEO of B.E.D. emphasises the importance of selecting the right suppliers as a cornerstone of the company’s success across a wide range of vertical sectors: “We believe that our suppliers are as important as our customers. We work with established international and local brands that not only offer outstanding products but also share our commitment to quality, safety and long-term customer satisfaction.”

In line with this, B.E.D. carefully evaluates supplier relationships to ensure that these align with its values and customer requirements: “Choosing the right supplier goes beyond product quality. We look for partners which provide strong technical support, ongoing training and innovation. Our suppliers do not just sell products: they collaborate with us to deliver comprehensive solutions tailored to each customer’s requirements, irrespective of the industry sector.”

Bolt Torque: more than just ‘torque’

A recent addition to the B.E.D. supplier portfolio, Bolt Torque offers cutting-edge torqueing and tensioning technology, for industries such as wind power, ship repair, and oil and gas. Angus Houston, Global Sales Manager at Bolt Torque states: “B.E.D. provides essential on-site support, ensuring our torqueing solutions are well understood and properly implemented.”

Houston also emphasises how B.E.D. facilitates Bolt Torque’s entry into various markets: “Our collaboration with B.E.D. ensures that end-users, many of whom may not be aware of the advanced torqueing and tensioning solutions available to them, can access the right tools for the job. Through B.E.D.’s extensive footprint and network, we are able to showcase the benefits of our high-quality Plarad tools. We also offer a rental option, meaning less of a capital outlay for customers.”

The partnership also provides B.E.D. customers with access to Bolt Torque’s SANAS-certified calibration laboratory, ensuring the proper maintenance of torque tools. “This service is critical across sectors where safety and precision are key, such as energy and infrastructure projects,” Houston adds.

Milwaukee Tool: ‘powering’ many industry sectors

Milwaukee Tool, represented by Upat locally, has significantly expanded its vertical sector reach thanks to B.E.D. Wayne Weber, COO of Upat, explains the effectiveness of this collaboration: “Through our partnership, we leverage B.E.D.’s sales team to bring Milwaukee Tool closer to customers and close the gap between the product and the customer.”

Milwaukee Tool’s M18 Platform – known for its extensive range of versatile tools such as drills, saws, and impact drivers – and the MX FUEL Platform, which focuses on heavy-duty equipment such as concrete cutters and power generators – cater to a wide range of industries. Powering this innovative product portfolio is Milwaukee Tool’s distinctive Red Lithium cordless battery technology, as well as machine learning and advanced operational safety features.

“Upat and B.E.D. work together to introduce Milwaukee Tool’s unique technology to customers. We are proficient in all technical aspects of these tools, and B.E.D.’s team ensures that mining and and other customer relationships are nurtured, helping us close deals and providing ongoing support. B.E.D. offers excellent after-sales service, which is key in ensuring long-term customer satisfaction.”

Mike Giltrow shares his enthusiasm for Milwaukee Tool’s technology: “We have always wanted to align with a quality supplier at the forefront of battery-powered technology, and Milwaukee Tool is a leader in this field. Their products offer ease of use, portability, efficiency and durability, making them a perfect solution for mining, construction and many other sectors.”

Fronius: advanced welding solutions

B.E.D.’s partnership with Fronius spans over 15 years, and it has played a pivotal role in delivering top-tier welding solutions to multiple industries. Edric Van Der Walt, Fronius Welding Specialist for Africa at Fronius South Africa, highlights the importance of this collaboration: “Our advanced welding systems, including the iWave and TransSteel Pulse series, are designed for versatility and high performance. B.E.D. ensures these solutions reach a broad market, helping customers to get the best results.”

Fronius’s innovative welding systems, including the TransSteel, TPSi, iWave, Ignis and AccuPocket offerings, are well suited to challenging environments. Van Der Walt adds: “The partnership with B.E.D. enables us to provide sales support and technical expertise. Their team of Area Sales Managers and experienced welding specialists ensure that our products are used accurately, meeting each sector’s specific demands.”

Andres Loaiza-Espinosa, Fronius Export Sales Manager for Africa and Latin America, also emphasises the importance of innovation and collaboration: “Fronius and B.E.D. share a common ethos – ours expressed in our tag line ‘unleash your welding potential’ and B.E.D.’s in theirs – ‘it’s our business to know your business’. We introduce advanced welding technology which provides significant advantages to customers across many different sectors. Together, we work closely to understand vertical sector-specific needs and tailor our solutions accordingly.”

He believes that B.E.D. has played a pivotal role in expanding Fronius’ presence and market penetration across the region: “Through our collaboration and synergy with B.E.D., we are able to reach customers in critical sectors such as mining, renewable energy, fabrication and petrochemicals. B.E.D. ensures that our products and solutions – supported by expert training and technical service – meet the unique needs of South African businesses. As such, we are not only motivating customers to engage with welding at a whole new level, but jointly contributing to the country’s growth and development, by providing the technology and support which drive industrial success.”

The power of partners

“We are proud of the many leads which these key suppliers, working together with our Area Sales Managers, generated during the recent Electra Mining exhibition – and we are confident that our B.E.D. team will ensure these bear fruit.

We are fully committed to building on the strong collaborative relationships we have cultivated with our suppliers and customers. Our goal is to continue expanding our reach, not just in mining and agriculture, but in every industry where our products can make a difference.”