Zest WEG e-house solution powers large platinum hig mill
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One of the largest High Intensity Grinding (HIG) mills in the southern hemisphere is being powered using an E-House solution from Zest WEG
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Zest WEG is key supplier of motors and vsds for Kamoa-Kakula
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Zest WEG is supplying an extensive range of motors and variable speed drives (VSDs) for the second phase of the Kamoa-Kakula project, one of the world’s most exciting new copper developments, located on the Central African Copperbelt in the DRC.
Phase one produced its first copper concentrate on 25 May 2021, and is expected to produce 200,000 tonnes of copper in concentrate annually. Phase 2, now in the advanced stages of construction, will result in a doubling of production capacity. Future phased expansions will eventually see a mining rate set to process 19 million tonnes per annum.
For the first phase of the project, Zest WEG was also the key supplier for this electrical equipment. According to Joe Martins, mining sector specialist for Zest WEG, the mine’s scope of supply for the second phase is a repeat of the first. The first phase was supplied in 2020 with WEG medium voltage VSDs and WEG high voltage motors to drive the mine’s primary and secondary mills in the concentrator plant.
“We began to manufacture these long lead time items in 2019, and delivered two medium voltage VSDs and two 3,3 kV motors for the mine’s 7,000 kW primary ball mill and its 7,000 kW secondary mill,” says Martins. “Our high voltage motors and medium voltage VSDs were also selected to drive the two 1,200 kW high pressure grinding rolls (HPGRs) in the plant.”
WEG high voltage motors and automation solutions drive the underground ventilation fan applications, providing fresh air to the underground mine workings, he says.
All these large items are designed to specification, manufactured and tested in WEG’s Brazil facilities. Due to Covid-19 travel restrictions, the factory acceptance tests were conducted virtually, with special processes being developed to allow thorough inspection and comment online. The testing of the equipment for phase two – also conducted in a virtual environment – was completed in the third quarter of 2021.
Significantly, Kamoa-Kakula will be among the world’s lowest greenhouse gas emitters per unit of copper produced, and Zest WEG’s energy efficient motors and automation solutions will contribute to this.
The first phase order included over 700 WEG low voltage IE3 premium efficiency motors, supplied to various local and international original equipment manufacturers, and installed throughout the concentrator plant. These motors drive equipment such as the rock breakers, conveyor drives, flotation cells, thickeners, slurry pumps, winches and other mechanical OEM packages.
Where processes within the plant required variable speed control, WEG low voltage VSDs were selected to provide the speed and control necessary for this equipment. Martins explains that by selecting WEG low voltage VSDs in combination with WEG low voltage motors, Kamoa-Kakula will benefit from a 36 month warranty period.
“An important part of the energy efficiency strategy was for the plant to standardise on our IE3 premium efficiency motors – rated according to the IEC 60034-30 international standard,” he says. “With a class leading energy efficiency rating, this means reduced carbon emissions and greatly reduces operational energy costs.”
Additionally, Zest WEG is supplying the Kamoa-Kakula Project with a new 20 MVA, 33kV/11kV mobile substation, which is currently being manufactured in South Africa. The substation will provide stepped down power, and can be moved to supply power to different areas within Kamoa-Kakula’s mining footprint.
“Underpinning the performance of our equipment at the mine will be high levels of service and support from Panaco who is our Value Added Reseller (VAR) in the DRC,” says Martins.
Commenting on VARs, Martins says that those appointed by Zest WEG in this role are far more than simply distributors. “Panaco, as our VAR in the DRC, is a 100% locally owned business specifically chosen to promote and support the wide range of Zest WEG’s offering in the region. Its team includes technical specialists and the company’s operating methodologies and culture are closely aligned with ours, and will aid in supporting our current installed base, client network and growth expectations in the region.”
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Zest WEG supplies to new natural gas, helium project
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One of the two six-meter containerized substations being supplied to the Tetra4 onshore natural gas and helium project.
Developed by emerging producer Renergen, Tetra4 is the country’s first and only holder of an onshore petroleum production right. Located near Virginia in the Free State province, the natural gas in the deposit reportedly contains world-beating concentrations of helium – up to 12% compared to typical levels of around 0,5%.
The first phase of the project is advancing well, with the construction of the liquid natural gas (LNG) and helium plant scheduled for completion by the end of 2021 or early in 2022.
According to Lukas Barnard, Zest WEG’s sector specialist – oil and gas business development, the equipment ordered from Zest WEG is on track to be delivered and installed in the third quarter of this year.
“The transformers we have been contracted to supply are a 7MVA 33/11KV unit and two 1.5MVA 6.6/0.4KV units, being manufactured locally at our transformer facility in Wadeville,” says Barnard. “We will also supply the 33kV, 11kV and 6,6kV medium voltage switchgear, which will be installed into two six-meter containerized substations, being locally manufactured by Zest WEG at its Heidelberg facility.”
“The medium voltage switchgear will be installed in the modular substations in Heidelberg, where a factory acceptance test will be conducted before equipment is transported to site,” he says. “The complete package is managed with a single point of contact – a project manager – at Zest WEG, easing the customer’s administrative burden.”
Renergen says it wanted a supplier with the necessary experience and expertise, but more than that it needed a partner who could meet the tight delivery requirements, with enough flexibility to find solutions to the challenges related to a project of this nature.
“There have been many benefits working with local companies including additional flexibility and control, while allowing us to react quickly to changes and challenges that arise as we roll out the project,” says Nick Mitchell, Renergen Chief Operating Officer.
“Any support of local business has far reaching economic benefits for the communities in which they operate and this remains a critical balance for us to achieve in a project, where not all the components can be manufactured locally or available locally. It also reduces currency risk by minimizing our exposure to exchange rate fluctuations.”
Renergen also emphasizes the advantage of Zest WEG’s package solutions capability, especially in a project like this with multiple streams of work that need to be coordinated across multi-disciplinary teams. Barnard says this is where Zest WEG’s project manager added considerable value in terms of management, procurement and project flow.
“When multiple contractors and suppliers are involved, the project flow becomes very difficult and can generate significantly more risk,” he says. “Our project manager was able to work with the customer to mitigate these risks and streamline the roll-out.”
He also notes the advantages of the containerized and E-House modular substations in fast track projects. By manufacturing the units in a dedicated facility, Zest WEG provided an efficient solution while reducing the on-site responsibilities of the project developers.
“Building a brick-and-mortar substation means more personnel and activity on site over an extended period, with all the related health and safety implications such as inductions and medical checks,” says Barnard. “It is quicker and far more convenient to build it in a well-equipped facility such as ours where it is also possible to run factory acceptance tests before delivery.”
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