Energy

Rolls-Royce powers Sibanye-Stillwater mine

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Delivering power to Rustenburg mine in South Africa. (Image source: mtu solutions)

Rolls-Royce in Africa has supplied and commissioned four 2500kVA prime rated containerised mtu Series 4000 generators to mining group Sibanye-Stillwater

The generators have been deployed at the K4 shaft in Rustenburg, South Africa, to provide critical back up power for underground mining operations.

“The project was a follow-up project of the first project at K3 Shaft which indicates satisfied repeat client,” mtu solutions said in an update on social media.

After the latest installation, it means Sibanye now owns a total of eight the same generators.

“The generators were specifically designed to withstand inrush current and other poor power quality events caused by mine shafts and hoists,” the statement added.

“Furthermore the containers were designed to withstand [a] high heat and high dust environment.”

Rustenburg is a shallow to intermediate level platinum gold metals (PGM)) operation, with surface sources and concentrators located northeast of the town of Rustenburg in North West Province, 120 km north-west of Johannesburg.

The site has more than 14,000 employees and contractors working on it.

It marks the latest successful installation for the Rolls-Royce brand in Africa, after commissioning 10 mtu gas gensets for the Egyptian Wood Technology Company’s (WOTECH) production plant at the start of the year.

The plant, in northern Egypt, produces medium-density fibreboard (MDF) from rice straw for use in furniture and buildings.

As the facility has no access to the public grid, it relies on the 20-cylinder mtu gas gensets which have a collective output of 25MW.

In June, Rolls-Royce officially opened a new headquarters and training facility in Johannesburg to support its Power Systems division.

The new centre will support the growing fleet of Power Systems’ mtu mobile and stationary power solutions across critical sectors such as energy, technology, mining, transportation and oil and gas.

Cobus Van Schalkwyk, director global mining and managing director, Rolls-Royce Solutions Africa, said at the time that the new facility “is a clear signal of our confidence in Africa’s growth and our commitment to being closer to our customers.”

The new training centre is designed to support between 100 and 150 trainees annually with a wide range of training engines, including mtu 2000 and 4000 series, used for power generation, mining and rail applications.

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Everllence to supply new Mauritania power plant

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Martin Chmiela, head of power, Asia Pacific, Everllence, and Mian Sun, deputy GM of the 5th Engineering Department, CNEEC, at the contract-signing ceremony in Beijing. (Image source: Everllence)

China National Electric Engineering Co. Ltd. (CNEEC) has awarded a contract to Everllence for the supply of dual-fuel engines for a new Mauritanian power plant

Everllence, formerly MAN Energy Solutions, announced in a statement that it will supply four high-efficiency 18V51/60DF engines for the power plant in Nouakchott, Mauritania’s capital.

The value of the contract was not disclosed.

With a total power output of 74 MW, the new power facility is set to play a key role in closing the existing gap in the country’s electricity supply.

“Everllence is making a vital contribution to stabilising Mauritania’s energy supply with this power plant,” said Ghassan Saab, head of power, MEA region at Everllence.

“We have been a trusted partner for energy projects across Africa for over half a century." Saab added.

"Everllence has realised power plants in more than 30 African countries, contributing over 2.5 GW of installed capacity to the continent.”

Under the latest contract, each engine will deliver 18.5 MW of electric power for the new plant, which will be operated by SOMELEC, Mauritania’s national power utility.

The state power firm also plans to build additional facilities to gradually meet the country’s growing electricity demand, the Everllence statement noted.

For its latest project, Everllence said production planning at an early stage and close collaboration with both the EPC contractor and end user will enable exceptionally short delivery times, with commissioning scheduled to be completed by late 2026.

“We’re proud that CNEEC is relying on our technology to strengthen the power supply in Mauritania,” said Martin Chmiela, head of power, Asia Pacific at Everllence, who signed the contract with CNEEC in Beijing recently.

“Our dual-fuel engines offer maximum fuel flexibility. Depending on availability, the engines can seamlessly switch between fuels without compromising performance, ensuring reliable power-generation at all times.”

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Maxion Wheels new solar project at Joburg plant

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Maxion Wheels investing in solar energy. (Image source: Maxion Wheels)

Maxion Wheels, a leading producer of wheels for passenger and commercial vehicles, has completed a 2.9 MWp solar project at its Johannesburg manufacturing plant

The move reflects a shift in the commercial and industrial (C&I) energy market to renewables and away from traditional thermal based power solutions.

Terra Firma, a South African C&I solar and storage solutions provider, worked on the project, timed which was timed with Maxion Wheels South Africa’s 60th anniversary event.

“Integrating renewable energy into our operations marks a significant milestone in our Roadmap Zero strategy towards net-zero emissions by 2040, and reinforces our position as a global leader in advanced manufacturing,” said Milos Despotovic, managing director, Maxion Wheels South Africa.

The carport and ground mount solar installation will supply approximately 20% of the manufacturing facility’s annual energy needs, reducing Maxion’s reliance on the national grid and providing protection against energy-related tariff increases.

It will also reduce greenhouse gas (GHG) emissions by approximately 5,100 tonnes per year.

A second phase of additional rooftop solar capacity is scheduled for completion in Q1 2026, with the possibility of integrating a Battery Energy Storage System (BESS) for energy arbitrage and backup power.

South Africa’s automotive industry contributes 5.3% of GDP and supports over 500,000 jobs across the value chain.

However, the sector is under increasing pressure due to global trade barriers, growing competition and decarbonisation requirements.

For manufacturers such as Maxion Wheels, where electricity is one of the largest input costs due to energy-intensive processes, managing energy spend is critical to maintaining competitiveness.

Solar power offers a solution that enables firms to reduce and manage costs, improve resilience and reduce climate impact.

As the world's leading manufacturer of steel and aluminium wheels, Maxion Wheels produces approximately 50 million wheels per year across its 31 locations on five continents.

The Johannesburg plant produces high-precision aluminium wheels for major automotive OEM customers in South Africa.

Given its intensive industrial processes, continuous uptime is mission-critical.

The plant relies on extensive machinery including various robots, integrated foundry systems and automated conveyor networks operating around the clock.

For Terra Firma, the project meant ensuring continuous power supply while meeting strict health, safety and operational standards at every step of the deployment.

Under a comprehensive medium-term Power Purchase Agreement (PPA), Terra Firma financed, designed, engineered and installed the project, and will manage and maintain it for its lifetime.

The PPA delivery model offers the cost and GHG emission reduction benefits of solar power, without the capital expenditure or risks of ownership, according to said Grant Berndsen, CEO, Terra Firma.

“We thank Maxion Wheels for entrusting Terra Firma as their energy partner to bring this project to life,” said Berndsen.

“Together, we’re demonstrating how solar power helps enable long-term sustainability, resilience and global competitiveness for South Africa’s automotive manufacturing sector.”

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Mondi advances energy independence at Merebank mill

Mondi’s Merebank mill boosts self-sufficiency with new turbine and flood-proofing projects, driving MAP2030 sustainability goals. (Image source: Mondi Merebank)

Mondi, a global packaging and paper leader, has reached a key sustainability milestone at its Merebank mill in Durban, South Africa, through the installation of a new turbine at the site’s power plant

With this development, the mill can now generate 60% of its own electricity, reducing reliance on grid power and enhancing efficiency.

The upgrade features a condensing steam turbine, new cooling towers, piping, and control systems, designed to harness excess steam from the mill’s boiler.

Highlighting the project’s significance, Donovan Naidoo, operations director at Mondi Merebank, said, “By generating power on site, we reduce our dependency on external electricity supply, reduce costs and take a step towards energy independence, climate resilience and long-term operational stability. Once the cooling tower upgrade is completed, the new turbine will produce more electricity than the mill consumes – a significant milestone in our journey towards self-sufficiency.”

Beyond greater energy independence, the turbine also supports a lower carbon footprint for the mill.

In parallel, the mill has finished two flood-resilience projects aimed at reducing risks from natural disasters. These include the installation of flood gates and inflatable flood barriers, enabling the rapid creation of water-catchment dams. These initiatives safeguard operations and surrounding communities during extreme weather, ensuring continuity.

Both the turbine generator and flood-defence projects align with the Mondi Action Plan 2030 (MAP2030) sustainability commitments.

Hitachi Energy powers up Geita gold mine

Tanzania’s Geita gold mine gets connected to the national grid. (Image source: Hitachi Energy)

Hitachi Energy has completed a project to connect Tanzania’s leading gold producer, Geita Gold Mine Limited (GGML), to the national grid, displacing the use of traditional thermal gensets for energy

In a statement, Hitachi Energy said the project replaced 80% of the fossil-fuel gensets used by GGML for power generation and is expected to reduce the site’s carbon emissions by at least 50 kilotons (Kt) CO2 per annum.

Tanzania’s national grid is currently estimated to be made up of around 45.5% renewable energy sources.

“We are proud to support Geita Gold Mine Limited in this landmark achievement,” said Mohamed Hosseiny, managing director at Hitachi Energy in Africa.

AngloGold Ashanti, the owner of GGML, collaborated with the Tanzanian government, power utility Tanzania Electric Supply Company (Tanesco), and Hitachi Energy to execute the project.

As part of the deployment, Hitachi Energy delivered a state-of-the-art power electronic converter that stabilises the mine’s connection to the grid, featuring a PCS 6000 STATCOM system.

The system’s performance is further optimised through MicroSCADA, which provides crucial real-time monitoring and control.

The PCS 6000 STATCOM system was pre-assembled, tested to the highest standards, and shipped as a containerised package for fast installation on-site.

Its compact design and adaptability to harsh mining environments make it a “compelling solution” for industrial and remote grid applications, according to Hitachi Energy.

“Electrification solutions, like the STATCOM system, are vital to accelerating the global energy transition,” a statement read.

“By delivering innovative technology to high-impact markets, Hitachi Energy empowers the world’s energy system to be more sustainable, secure, resilient, and affordable.”

During the project execution, the company engaged with local partners, providing supervision and training to contractors and skills development.

Hosseiny added that it underlined the industry’s commitment to improving its environmental footprint.

“AngloGold Ashanti’s unwavering commitment to sustainability and climate resilience across their business, value chain, and communities sets a remarkable standard in the industry,” he said.

“It is reassuring that our pioneering technologies and solutions are advancing a sustainable energy future for all.”

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