Project will be the world’s first large-scale carbon capture facility for cement production
Growing population and rapid development around the Municipality and Johannesburg are some of the challenges faced by the Department of Water and Sanitation in South Africa. The over utilized capacity of Sebokeng Wastewater Treatment Works, part of Sedibeng Regional Sewer Scheme, had its capacity increased from 100Ml/d to 150Ml/d with the addition of Module Six (6).
This scenario identified the drivers for improvements and upgrading; and presented new opportunities for WEG as a manufacturer of electrical solutions.
Zest WEG’s team of specialists in partnership with PCI Africa, one of Africa’s leading purification systems designers and contractors of water and waste water solutions for the municipal and industrial markets, joined skills and supplied many solutions for the entire wastewater treatment works. WEG motors are installed in all major processes, from screening, sand removal, primary sedimentation, reactors, fermentation of raw sludge, final clarification, waste sludge thickening up to dewatering.
After many years of unforeseen delays Module Six (6) portion at Sebokeng – Emfuleni has finally been commissioned.
The project is located approximately 50 km south of Johannesburg, in South Africa, and involved the demolition of existing water tanks, earth-moving operations, excavation for terracing purposes, and concrete works for the rehabilitation of the Sebokeng wastewater treatment plant – Module 6, leading to an overall capacity of 150 Ml/day.
The scope of supply included several low voltage W22 electric motor solutions ranging between 3kW and 280kW, suitable for applications all over the entire WWTW works consisting of the following:
• 2 off 50Ml/day screw pumps fitted with 280kW motors.
• 4 off front rake screens and hydro conveyors.
• 2 off compactors.
• 2 off 30m PST half bridges with 2 recycle pumps per tank.
• Bioreactor consisting of 1 mixer and 21 aerators varying from 30kW to 90kW.
• 6 off A recycle pumps and 4 off R recycle pumps.
• 3 off 30m half bridge SST’s each with 2 off RAS pumps.
• 2 off WAS pumps feeding to the dewatering holding tanks.
• Chlorine dosing system for dosing from 1-ton drums c/w dosing pumps.
Sludge Treatment Process
• 2 off sludge holding tanks with floating aerators.
• 6 off turbo drain presses feeding into 6 off dewatering presses.
• All the necessary pumps and associated equipment.
This project reinforces WEG capacity of supplying innovative and quality products to the Water Segment, and confirms that the company is in line with customers’ needs by improving energy efficiency, reliability of plant operation performance and reducing the environmental footprint. Also, the involvement of Zest WEG local branch expertise was critical for the good relationship with the integrator’s team.
WEG has just announced the construction of a new electric motor factory in Santo Tirso, Portugal. The company intends to invest 23.5 million euros to build 22,600 m² of manufacturing facilities on the same area where WEG already has a 16,300 m² low voltage industrial motor factory.
WEG´s plan with the new unit is to expand the production of large electric motors and transfer its factory located in Maia to Santo Tirso, centralizing all operations in a single manufacturing site.
“We are not only making investments to increase production capacity, but also improving our operations in Portugal. In addition to moving the production of medium and high voltage, explosion-proof motors, electrical panels, automation solutions and service support to Santo Tirso, we are also planning to increase electrical motors range for larger sizes in the country”, says Alberto Kuba, Managing Director of WEG Motores – Industrial Business Unit. As stated by Alberto, this is a strategic investment and represents a very important step for WEG’s business expansion in the European market.
The new factory in Santo Tirso should start operating in the first quarter of 2024 and will allow creation of around 100 new jobs.
WEG started its own operations in Portugal in 2002 with the purchase of an electric motor factory in Maia. In 2015, the company started the construction of a new electric motor factory in Santo Tirso, 24 kilometers away from Maia. This unit was inaugurated in 2018 and incorporates a verticalized production line that counts on machining processes, rotor manufacturing, winding, assembly and dedicated electrical testing laboratories. Currently WEG employs more than 700 people in Portugal.
The largest manufacturer of electric motors in Latin America and one of the largest in the world, WEG is always seeking new technologies that increase the reliability and safety of its products. For that purpose, WEG now has a new laboratory specialized in testing motors for high temperatures—up to 500 ºC. In this environment, it is possible to submit motors from the Smoke Extraction line to conditions similar to those of the application, conducting development and pre-certification tests in accordance with the requirements of EN 12101-3 Standard.
Ensuring safety in business and industrial installations is one of the main concerns when designing the structure of places with great concentration of people. The W22 Smoke Extraction motor was developed to ensure air circulation in closed environments and emergency situations, withstanding operations at high temperatures and ensuring quick extraction of smoke and heat.
The Smoke Extraction motors ensure the safety of subways, underground streets, tunnels, parking garages, airports, manufacturing plants, airports, among other small and large facilities, with the efficiency and reliability of WEG products.
With the pre-certification tests carried out in WEG’s new laboratory, it is possible to develop and test motors with new insulating materials produced with new technologies capable of withstanding high temperatures. In addition to all new product development tests, the laboratory is used to test motors that will be submitted to certification. Before going for certification, an additional unit from the same manufacturing lot is tested to ensure that the design will be approved in the certification process. In the development of new lines, the laboratory enables the use of new technologies, guaranteeing the quality of the products.
Figure 1. Air flow inside the oven
The new laboratory can test up to three motors per day, from frames 80 to 225, under the rated electrical and mechanical loads and air speed conditions. It is possible to validate computer models, speeding up the development of technologies and virtual prototyping. This ensures that the motor is suitable for the application conditions, avoiding delays in the lead time or the need to reschedule new certification tests.
WEG, recognized for the excellence in reliability and safety for various applications, offers the market numerous high performance solutions to bring more innovation, technology and dependability for industrial processes worldwide.
The use of a ball mill in the grinding process is a traditional technique widely used for particle size reduction or for mixing materials, used in various industrial works, such as mining companies. In this sense, because it is a more severe environment, it is necessary to use a motor with greater resistance and protection.
With efficient solutions in the mining sector, WEG supplied a slip ring motor from the M Mining line, frame 560, 1,300 kW, 3,300 V, 4 poles, 50 Hz to drive the ball mill of a mining company in Argentina. The applied motor makes the process more efficient, ensuring greater operational security, in addition to having simple and reduced maintenance.
WEG motors of the M Mining line were specially developed with electromechanical characteristics that provide durability, resistance and robustness, ideal for operating in harsh environments in the mining and cement segment. The big difference in this project is that to reduce the need for field adjustments, WEG adapted the manufacturing process to scale the solution according to the customer’s needs.
This supply consolidates WEG as one of the main suppliers of motors for the mining segment in Latin America, in addition to reinforcing the company’s flexibility in meeting the specific needs of its customers. For the customer, it increases reliability in operation and reduces downtime for maintenance.
The new brush lifting system is the evolution of the already established WEG brush lifting system, with the incorporation of the operating logic, fault investigation capabilities, operation monitoring via HMI simplifying and reducing the costs of motor installation, operation, and maintenance. In order to carry out the operation logic in a simpler way, its operation is via PLC. The monitoring of the operation and eventual faults is available via the integrated PLC’s display so that the user has full control over the performance of this system.
The need for maintenance compared to a fixed brush system reduces considerably, due to the brushes being lifted after the motor starts, in addition to allowing the elimination or reduction of several variables, such as:
The lifting set has a gearbox driving the operation, adding robustness, reliability, and simplicity to the system. The brush holder works with constant pressure springs and has three inspection points, allowing agility and visibility in preventive, predictive or corrective maintenance. The internal position of the lifting mechanism is read by means of inductive sensors and they have a system that indicates their operating status.
WEG has just opened a new Commercial Operation in Istanbul, Turkey.
With the strategy of increasing its market share in the country by selling all the company’s products, the Operation will also be the gateway to a new low-voltage electric motor factory, which has started to be built in the city of Kocaeli, around 80 kilometers from the Bosphorus Strait on the Asian side of Turkey.
Expected to come into operation in the first half of 2022, the new factory will count on 7000 square meters of facilities, which in addition to the manufacture of electric motors will also be used for support services, engineering, product development and application, sales and technical service for customers.
As stated by Alberto Kuba, Managing Director of WEG Motors Business Unit – Industrial, the new factory will allow WEG to expand the business of low voltage electric motors in Eastern Europe along with increasing the company´s market share in Turkey´s local market, where there are major business opportunities. “All Eastern Europe countries, particularly Turkey, offer great potential for WEG Motion Drives solutions. Counting on a factory in the country, we will have the possibility to increase our production portfolio and strengthen our distribution capacity in the region”, says Kuba.
Similar to other WEG manufacturing sites, the layout of this unit will have modular design, which allows for the gradual and continuous increase of production capacity as well as the manufacture of other product lines so as to meet the company’s future expansion.
“Our strategy is to gradually expand our product portfolio in the country, in addition to implementing local verticalization, creating more opportunities for our suppliers and contributing with the economy development of Turkey, a country that we greatly appreciate for its history background and economic potential,” explains Kuba.
There is no doubt that one of the major water problems facing the world today is the provision of drinking water. Water scarcity was listed in 2019 as one of the biggest global risks in terms of potential impact over the next decades.
Through a team of engineering specialists dedicated in the Water Industry, WEG has always been at the forefront of supplying electrical solutions for the Water Industry worldwide. This time WEG products are chosen as part of the Keppel Marina East Desalination Plant (KMEDP) project in Singapore. In this specific project, WEG’s motors are installed in it.
The KMEDP is an innovative large-scale desalination facility; and is also the world’s first dual-mode desalination plant. Its innovative capability can treat both freshwater and seawater, depending on weather conditions. The plant will produce 137.000 m3/day of clean water, which is enough to fill 45 olympic-size swimming pools and 7 percent of Singapore’s daily water demand.
For this project, WEG Singapore collaborate with Torishima, a pioneer in pumps for seawater desalination, to supply the high efficiency motors for their Reverse Osmosis (RO) system package.
In desalination systems, from small to large capacities, energy savings is always concern, it’s usual therefore, to consider energy recovery devices (ERD) to achieve best operation conditions and high energy savings. This device combined with the ERD Booster pumps and high-pressure pumps will drive cost savings and emission reductions.
There are two types of pumps used in RO system High Pressure Pump and ERD Booster Pump.
The WEG’s motors scope of supply from Nantong Factory was:
Motors for the use in desalination plants are required to operate in harsh climates 24/7, highly durable, with special painting plant against corrosion from seawater and high efficiency to minimize energy consumption.
WEG is very proud to be part of the Keppel Marina East Desalination Plant project, with the supply of special designed products to attend customers’ needs. This project is another WEG step towards Water Industry and Driving Efficiency and Sustainability.
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