BMG recently played a key role during the annual shutdown at Mhlume Sugar Mill in Swaziland. “The project involved the design, manufacture and supply of diffuser chains, shaft and sprockets, as well as housings and bearings. BMG was also responsible for the refurbishment of the Zollern Dorstener gearbox and the supply of quality components, including fasteners, tooling and lubricants,” says Stan Truby, BMG’s technical manager.
BMG imported all stainless steel components for the diffuser chains from Tsubaki Japan for the local manufacture of link plates. This involved forging, multiple heat treatment procedures and machining. A modified design of the shaft at the mill was developed by BMG’s technical resources team, forged by Arcelor Mittal and machined by Elgin Engineering. Elgin was also responsible for manufacturing the sprockets and their assembly onto the shaft in accordance with BMG’s specifications. The housings and specialised sealing arrangements for the shaft were designed by BMG. NSK bearings and BMG housings were assembled onto the diffuser shaft at Elgin Engineering in Durban by BMG.
The Zollern Dorstener gearbox, with a capacity of over 4 million Nm of torque, was designed especially for this application. It was installed in 1978, providing 35 years of service with minimal spares required. Earlier in the year, it was removed by BMG’s field service teams and sent to the company’s engineering hub for complete refurbishment. This involved input bearing changes, gearbox seal changes and final gear settings. Special logistics were needed to transport the 5,8 m long shaft, 14 ton gearbox and the diffuser chain safely to site.
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