Steam turbines provide a valuable opportunity for many industries in South Africa to self-generate more of their own power requirements, often from alternative fuels produced as a byproduct of their processes. According to manager of Steam Turbine Energy Systems, Rudolf van Pype, this technology offers benefits that include energy cost reductions, a more stable supply of power and a lower carbon footprint.
A leading South African firm taking advantage of these opportunities is Sappi Saiccor. Its mill at Umkomaas in KwaZulu-Natal is one of the world’s largest producers of dissolving pulp for viscose staple fibre. This is used mainly in the production of textiles, but also in other household, industrial, and pharmaceutical applications. Gas produced from this process represents a fuel source which generates steam for electricity production. “A 45 MW extraction backpressure steam turbine from WEG will be adding to Sappi Saiccor’s energy generating capacity at its MgO3 plant,” says van Pype. “The power generated will be used for internal consumption.”
He explains that steam turbine technology is also becoming increasingly versatile to accommodate the specific requirements of different facilities. At the Sappi Saiccor mill, for instance, there is the need to have 15 different load points served by the turbine, where in the past it was usual to have just two or three load points.
“It is now possible to provide many more load points, each one with its own inlet steam flow conditions,” he says. “The steam turbine design can cater for a steam flow range that varies considerably. For the new unit at Sappi Saiccor, this range will be from 75 to 300 t/h.”
As the leading manufacturer of steam turbines in Brazil, WEG has supplied a number of units of this turbine model to customers in the market there. The company’s factory in Brazil will design and manufacture the new unit bound for South Africa, and WEG will conduct the installation, commissioning and ongoing maintenance next year. The Sappi Saiccor mill will also use a 50 MVA, 11 kV; WEG alternator, which will be coupled to the steam turbine.
Van Pype highlights that there is significant interest in steam turbine technology among South African companies who produce steam as part of their industrial processes – especially those who have alternative fuel sources. He notes that loadshedding has limited the productivity of many firms, and they are now looking for longer-term solutions.
“We receive regular enquiries from companies who operate boilers for their operations, looking for opportunities to reduce their operating costs, while raising their production levels through a more reliable supply of electricity,” he says. “We are able to conduct an assessment of their steam flows and pressures to advise on the most suitable turbine size and the amount of energy they could generate internally.”
He adds that WEG also has a depth of local expertise and supporting infrastructure to service steam turbines of various makes, and can provide maintenance contracts to give customers peace of mind. In addition to this, WEG offers its customers access to a complete set of spare parts, all of which promote high equipment availability levels.
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