CSH efficiently carries out R5m factory automation in Northern Mozambique

In a deal valued at over R5 million, JSE-listed CS Holdings` mining and manufacturing systems division, CS Systems Integration, has been awarded the factory automation contract for the Marromeu Sugar Mill in Northern Mozambique by John Thompson Africa (JTA), the contractor for the boiler project.

JTA designs, manufactures, project manages and constructs a broad range of industrial boilers. The company has been serving the South African industry for over 40 years and has established an international reputation, with exports to Sub-Saharan Africa, Mauritius, Europe, the Middle East, South America and China.

Situated on the banks of the Zambesi river some 300 kilometres North of Beira, the Marromeu Sugar Mill was badly damaged in the Mozambique war. After the withdrawal of most of the Portuguese settlers from Mozambique after September 1974, and during the civil war in 1982, the Marromeu Sugar Mill was abandoned and left for years in a dilapidated state. Today, Mauritian-based Companhia de Sena owns it. The area where the mill is situated is considered excellent for growing sugar and cane has already been planted ahead of the construction project, which aims to see the mill in operation for this year`s crushing season.

"Our contract involves the refurbishment and upgrading of the mill and boilers, including all instrumentation requirements, networking, PLC, SCADA, and the engineering and commissioning thereof," says Steve du Preez, product specialist of CS Systems Integration. "The system to be used in the factory automation is based on the latest Siemens control system, PCS7, Profibus PA and ASI bus. The system`s modern design and architecture permits the cost-effective design and economical operation of a plant throughout its lifecycle, including planning, engineering, commissioning, training, operation and maintenance, as well as future extensions.

"The system will control the entire sugar mill, from the raw materials handling of the sugar cane to the finished product," Du Preez continues. "The production process will be controlled from one control room, allowing the engineering staff to configure the Simocode motor protection and the Profibus PA instrumentation from a central point."

"Having worked together on other projects with CS Systems Integration, they were the preferred choice for the boiler contract, as they are already familiar with JTA`s automation systems and philosophies," says Quintus Engelbrecht, electrical and instrument engineer at JTA. "Additionally, they have an excellent track record and extensive experience in the sugar industry. Over the years, we have come to know and rely on CS Systems Integration`s capabilities."

According to Du Preez, once the boiler is operational, it will supply power to not only the mill, but the town as well. "The bagasse (a byproduct of the sugar cane) is used as a feed to the boiler, allowing it to be self-sustainable," he says.

Engelbrecht says the remote location of the mill makes for very difficult working conditions. "CS Systems Integration has had to contend with severe flooding," he relates. "The area is also infested with malaria and roads are virtually non-existent. Equipment has to be transported to the site on a 1 600-ton barge from Beira, along a lengthy sea and river route."

"Nevertheless, CS Systems Integration is dealing with these circumstances extremely efficiently, and the plant is scheduled to commissioned at the end of August," Engelbrecht concludes.