Steam generation and high-pressure piping solutions company Steinmüller Africa is leading the boiler erection initiative called Project Vuselela at multinational packaging and paper group Mondi’s Richards Bay mill.

The 18-month undertaking showcases a “powerful blend of engineering quality and innovative technology”. It marks a major milestone for the paper and pulp sector, and for Africa’s broader industrial progress.

Contracted to erect the new boiler, Steinmüller Africa is assembling imported boiler components and sections. With a site workforce of about 130 to 200 skilled professionals, the company’s project scope encompasses full mechanical installation – including steel structures, pressure parts, fans, flue gas ducts, tanks and critical systems, such as the air preheater and flue gas damper.

Thousands of metres of continuous welding are being executed on-site, using various welding methods, which include conventional stick and tungsten inert gas (TIG) methods. Recognising the scale and complexity of the welding scope, Steinmüller Africa has implemented Regulated Metal Deposition (RMD) – a modified pulse arc welding process that increases productivity by up to two to three times while maintaining weld integrity. This methodology is projected to halve welding time.

“By strategically reengineering proven technologies, we’re achieving a perfect balance of speed and quality,” says Steinmüller Africa senior welding engineer Friedrich Schwim. “This level of efficiency is crucial for fast-paced, large-scale projects like the Mondi boiler.”

Technology Integration in Challenging Conditions

Richards Bay’s high humidity poses significant welding challenges, particularly rust accumulation. To mitigate this, Steinmüller Africa has deployed laser cleaning technology to remove surface contaminants swiftly without compromising weld integrity. This non-abrasive method is vital for preparing steel in coastal environments.

Additionally, the team is using a weld prep primer, applied through an aerosol spray, which allows for continuous protection of cleaned steel without affecting weld quality. The product has been extensively tested, including in underwater immersion simulations, and has proven successful in maintaining weld integrity in high-moisture conditions.

Steinmüller Africa has also addressed on-site safety and gas handling efficiency by installing portable gas handling systems. This innovation eliminates the need to manually transport gas bottles across elevated areas, instead feeding gas to up to eight welding machines from a central manifold and multicylinder pack. This setup ensures a continuous gas supply, greater control, and enhanced safety in compliance with Mondi’s stringent site standards.

Driving Life Cycle Extension

Beyond the boiler project, Steinmüller Africa is pioneering new life cycle extension technologies for State-owned power utility Eskom’s high-pressure heaters, which preheat water before it enters boilers. These heaters often develop tube leaks which previously required manual plugging, with limitations on plug size.

Now, through a two-year research and development process, Steinmüller Africa has developed and qualified a non-standard explosive plugging process. This method enabled the sealing of larger tube diameters, which was previously unfeasible. As the only supplier in South Africa – and likely in Africa – that offers this solution, Steinmüller Africa is enabling its client to extend the life of components valued at up to R50-million each, without replacement.

“Our ability to reengineer technology, adapt to environmental realities and deliver under pressure defines who we are,” says Schwim. “We are building more than infrastructure, [we are] laying the foundation for Africa’s industrial resilience.”

Steinmüller Africa notes that it continues to lead with purpose, innovation and precision, “delivering value through every weld, lift and engineered solution”.