Projects

1. Saftronics 100kW Induction Furnace for Melting of ferrous and Non-Ferrous Metals

Saftronics completed the installation and commissioning of a 100kW Induction furnace in February 2021. The unit will be used to melt uranium contaminated metals for decontamination.


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  • Complete with water cooling and gas take off system. 
  • Induction Furnaces are the most cost effective and efficient furnaces to run.
  • We also added Power Factor Correction to assist bad power factor during a cold start
100kW Induction Furnace Project
 

2. Saftronics Medium Voltage Variable Speed Drive Commissioning.

Saftronics certified Engineers have been commissioning Medium Voltage VFDs since 2003.

From Senegal to South Africa, we have more than 50 completed installations, ranging from 1.6MW to 15MW, in the Oil, Mining and Process control industries. 



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  • In a natural occurring lake just 80Km from Dakar (Senegal), Grande Côte Operations SA decided to open up a Minerals mine, which, over an expected mine life of at least 20 years, is anticipated to produce on average approximately 85ktpa of zircon and 575ktpa of ilmenite (and small amounts of rutile and leucoxene) when in full production.

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    The mining process at the mine is very simple, a dredge travels through the dunes and utilizes the area’s shallow water table. It mines sand from the front of the dredge pond and pumps slurry to the floating concentrator. Sand is then washed through spirals, separating the heavy mineral concentrate from lighter quartz sand which is sprayed out the back of the pond restoring the landscape.

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    Saftronics Qualified Robicon Engineers were on site to commission 14 various Robicon drives, varying in size from 800kW – 4.5MW.

  • The Robicons’ are situated in a Substation in various locations onboard the dredge and concentrator, and are responsible for controlling motors with various applications whether it be for pumps or on winches that are used to maneuver the plant around the pond.
 

3. Saftronics Energy Division Power Factor Correction Panel

As the power factor load at maximum demand was registering at 0.65 lagging , a power factor correction panel rated for 850KVAr was installed. The panel consisted of oil filled capacitors and detuning reactors to protect the capacitors against harmful harmonic currents. Subsequent to the installation our client is enjoying a lower maximum demand charge due to a system that is now running at an acceptable power factor. The financial savings gained from this installation means that the payback period on this project is.


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  • Built for the global market and specifically engineered for harsh conditions
  • Full Stainless Steel Construction
  • Power Ratings at 22MW
  • Custom built starters can be designed for specific applications, based on two decades of research and design experience
 

Project 2:

Crossing Boarders for Service Excellence.

Saftronics supplied a Siemens GH150 – 800 Kw Containerised VSD to a mine in Africa. The container was built in a record time of 4 weeks. With a full client witnessed factory acceptance test before dispatch. This VSD is to supply a critical 800 Kw circulation pump on a SX plant. Due to the site conditions a 96 BTU air conditioner was supplied in the container to keep the temperature within the VSD specifications. All equipment was once again specified to be Siemens from the incomer, feeder panel and VSD.

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  • Built for the global market and specifically engineered for harsh conditions
  • Full Stainless Steel Construction
  • Power Ratings at 22MW
  • Custom built starters can be designed for specific applications, based on two decades of research and design experience

Project 3:

Saftronics took on a Turnkey project for one of the world’s leading pump.

Manufacturers. The project involved the supply and commissioning of a Saftronics Emperor MV Variable Frequency Drive, rated at 4,000kW, 6,600Volts. As well as building a 4m High steel platform capable of holding the weight of the MV Emperor VFD, a LV VFD (700kW 690V) and all associated Switchgear, cabling and Junction Boxes, for their pump test facility in South Africa. The Saftronics Emperor MV Range of frequency inverters are tailor made to suit most MV motor applications, from single permanent installations, to special cases where more than one motor is to be used or tested. The Emperor MV VFD is versatile enough to solve the most challenging installations and requirements out there. The pump test facility, which is now rated as one of the largest pump test facilities in the Southern Hemisphere, is able to regulate the speed of an AC Motor from (0-80Hz) at 3.3kV or 6.6kV and from 1MW to 4MW. The Emperor MV Drive is a Multi-Level Cascade Cell type controlled unit, and is capable of reducing the output voltage for smaller and lower voltage rated motors, eliminating the need for step-down transformers. The motor specifications are individually programmed into the Emperor MV VFD and the output frequency regulated to suit test requirements, even larger and higher rated motors above the rating of the MV Drive can be tested (up to 4 MW of maximum load) using this type of speed control. With the introduction of the Emperor MV Drive, no more inrush currents are recorded on start-up’s, and no more exceeding peak current as experienced on prior direct on line (DOL) starting. The Emperor MV Drive saved the client on excessive energy peak usage and expensive power utility fines.