Steinmüller Africa integrates advanced technologies at Mondi’s Boiler Erection Project Vuselela

Steinmüller Africa is leading the project at Mondi’s Richards Bay mill. The 18-month undertaking showcases a powerful blend of engineering excellence and cutting-edge technology. It marks a major milestone for the paper and pulp sector – and for Africa’s broader industrial progress.

Engineering excellence meets innovation

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

Thousands of metres of continuous welding are being executed on-site, using various welding methods, which includes 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 2-3 times while maintaining weld integrity. This methodology is projected to cut welding time by at least 50%.

“By strategically reengineering proven technologies, we’re achieving a perfect balance of speed and quality,” says Friedrich Schwim, Senior Welding Engineer, Steinmüller Africa. “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 via aerosol spray, which allows for continuous protection of cleaned steel without affecting weld quality. The product has been extensively tested, including 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 by feeding gas to up to eight welding machines from a central manifold and multi-cylinder pack. This setup ensures a continuous gas supply, greater control, and enhanced safety in compliance with Mondi’s stringent site standards.

Driving industrial lifecycle extension through R&D

Beyond the boiler project, Steinmüller Africa is pioneering new lifecycle extension technologies for Eskom’s high-pressure heaters (HP heaters), which preheat water before it enters boilers. These heaters often develop tube leaks that previously required manual plugging, with limitations on plug size.
Now, through a two-year research and development (R&D) process, Steinmüller Africa has developed and qualified a non-standard explosive plugging process. This method allows for the sealing of larger tube diameters, which was previously unfeasible. As the only supplier in South Africa – and likely in Africa – offering this solution, Steinmüller Africa is enabling its client to extend the life of components valued at up to R50 million each, without replacement.

Towards a more resilient industrial future

“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, laying the foundation for Africa’s industrial resilience.”

With the next major milestone in the project expected in May 2025, Steinmüller Africa continues to lead with purpose, innovation, and precision – delivering value through every weld, lift, and engineered solution.