CRADLE TO GRAVE •
Traditionally , companies using steam turbines have usually consumed all the energy they produce in their processes – with a range of benefits such as supply reliability and cost savings . As the country struggles to keep up with power demand , however , there are more opportunities for the private sector to produce excess electricity for sale into the grid .
According to Alastair Gerrard , executive Energy Systems at WEG Africa , this trend is already advanced in Brazil – the home of holding company WEG . Many steam turbine users in Brazil have capitalised on these opportunities by increasing their boiler efficiency .
“ While it may be common in South Africa ’ s sugar industry , for example , to use medium pressure boilers , the Brazilian market uses high pressure boilers up to 140 bar – and gain significant efficiencies with these higher pressures ,” says Gerrard . “ This allows these sugar producers and other users to upgrade their facilities and considerably augment their revenues through the sale of electricity , while also paying off their capital investments much quicker .”
He points to the South African government ’ s strategic direction in establishing the National Transmission Company of South Africa , a key step in transforming the country ’ s electricity industry . This will open doors for more private companies to ‘ export ’ excess electricity into the grid , helping to stabilise supply and strengthen the foundation for economic growth .
“ This has been successfully achieved in countries like Brazil , and it is exciting to see that we are making progress on this journey in South Africa ,” he says . “ We believe that WEG Africa has an important role to play in this endeavour – through our long experience in this field and our full service offering for steam turbine users .”
Cobus van Eeden , WEG Turbine Services manager at WEG Africa , highlights that the company offers customers a turnkey capability . It sizes steam turbine solutions according to the specific operating parameters of the customer ’ s application , and supplies a bespoke thermal power system . The service also includes installing the machines , commissioning and ongoing after-sales servicing and maintenance .
“ As an OEM of steam turbines , gearboxes and generators , we can even help customers to assess their current equipment – whether these are WEG products or from other OEMs – and provide strategic options and recommendations ,” says van Eeden . “ In addition to our depth of engineering expertise for repairing such equipment , we can also analyse the potential for enhancing operational efficiency and increasing power output capability of the equipment .”
The company provides long term service level agreements , including contracts for preventative maintenance . WEG Africa also works with customers on their forward planning , which may include considering the transition to electricity exporting .
Gerrard points out that this approach is built on its commitment as an OEM to stand alongside customers throughout the lifecycle of the equipment supplied . He notes that , while there has in the past been some acceptance of third-party support in this field , WEG Africa favours in-house OEM support for its solutions through service level agreements that give customers confidence in the total lifecycle cost of their purchase .
“ Our field service technicians – active in many African countries and offshore – are on site with customers , developing a thorough understanding of their equipment and requirements ,” he explains . “ We integrate this information within our various functions to deliver the most valuable response and guidance on maintenance scheduling .”
Van Eeden outlines WEG Africa ’ s extensive engineering capability which includes machine servicing on customers ’ sites – from gearboxes and turbines to generators and control systems . Equipment requiring more intensive work can be transported to the company ’ s 1 200m 2 workshop east of Johannesburg , which prides itself on quick turnarounds .
“ Our facility includes full engineering capabilities , including the repair and manufacture of turbine bearings as well as the ability to conduct aftermarket engineering and optimising of numerous components ,” he says . “ We achieve this through our skilled machinists and technical staff , working with sophisticated scanning and engineering tools .”
In-house access to specialised facilities such as a labyrinth rolling machine for sealing strips , as well as a sandblasting booth for preparing components , further underpins the quality of workmanship and efficiency – thereby minimising downtime for customers . •
Source : supplied by WEG Africa
There are more opportunities for the private sector to produce excess electricity for sale into the grid . Many steam turbine users in Brazil have capitalised on these opportunities by increasing their boiler efficiency .
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www . africanmining . co . za African Mining Publication African Mining African Mining • January 2025 • 63