With a lofty goal of cutting its carbon emissions by 50% by 2030, minerals and mining technology solutions provider Weir is well ahead of meeting this target since introducing the initiative in 2019, says Weir safety, health and environment director for Europe, the Middle East and Africa (EMEA) Chris Mortimer.
He attributes this accomplishment to Weir measuring and monitoring sustainability like any other key performance indicator (KPI).
“Sustainability is measured and monitored, as with any other KPI. Every EMEA facility needs to reduce its carbon footprint by 50% by improving energy efficiency, limiting water consumption and reducing waste. This equates to about 6% a year, which is quite ambitious.”
Mortimer admits that this goal is more easily achieved at the company’s larger, energy-intensive facilities, such as Isando and Alrode in Johannesburg, Gauteng, and its Heavy Bay Foundry (HBF) in Gqeberha, Eastern Cape, than at smaller premises with minimal energy needs.
Every Scrap Counts
The use of scrap metals in Weir’s foundries is much more energy efficient and sustainable compared with sourcing new, unused metal. But, with significant demand for scrap metal exports from other countries, China particularly, it is a challenge to direct scrap metal back into Weir’s system.
“This is particularly true of high chromium cast iron, which we use for our wear parts,” explains Mortimer.
Therefore, Weir service centres collect scrap metal for the company’s foundries, with waste bins dedicated to the collection of old high chrome pump parts that are replaced during servicing.
“We’ve also started including scrap metal purchasing as part of our service level agreements with customers. We’ll buy their scrap directly at a better price than that offered by a scrap dealer. Even though we offer them more money than a scrap dealer would, we’re still not paying as much as we would if we sourced scrap metal from a third party.”
Weir’s customers also benefit from a circular waste cycle, lowering their carbon footprint.
Further, the company has invested in water harvesting at all its major facilities to supply water for gardens and the flushing of the toilets, for example. Weir’s smaller service centres are starting to do the same, particularly in areas where there is an abundance of rain.
“Rainwater is also collected and treated at our foundries to cool furnaces, with demineralised plants installed for each circuit.”
Weir drives energy efficiency by focusing on all energy forms – electricity, gas and fuel, says Mortimer.
A solar power plant was installed at its Isando facility about three years ago through a power purchase agreement with a third-party company which installed and maintains the system.
“Weir is assured of supply and a predictable electricity price for ten years, after which it takes ownership of the system,” he adds.
While this backup power supply cannot be used to operate the furnaces at the Isando foundry, it is sufficient to power the rest of the facility. Weir is now installing solar at its Alrode facility. The project is close to completion, with a battery energy storage installation planned in future.
The company also plans to install solar at HBF in the third quarter. This is in addition to HBF starting to draw sustainable, grid-based renewable energy in mid-2026 through a wheeling agreement with an independent power producer (IPP).
“Partnerships and collaboration with other industrial users and IPPs, particularly at HBF, are key to us being able to invest in sustainable energy solutions. We are actually the smallest of the industrial users being supplied through this agreement, even though we have a foundry,” shares Mortimer.
Before Weir can start drawing power, it must build a new substation that, once completed, will be owned by Nelson Mandela Bay municipality. Initially, HBF will be supplied 10% of its energy requirements, whereafter this percentage will increase incrementally every year. The agreement also enables Weir to budget for its energy costs more precisely, with yearly increases linked to the consumer price index.
Enabling Sustainable Mining
Weir’s products enable mining companies to produce the minerals and metals needed for the energy transition. The company is focused on providing miners with sustainable solutions that help them to reduce their carbon footprint.
“We take a holistic approach – looking at and analysing how what happens downstream impacts upstream equipment and processes and vice versa – when working with miners to help them reduce the environmental impact of their operations.”
For example, Weir’s ENDURON high-pressure grinding rollers with air classification can eliminate the need for water in the grinding process in some applications, while its CAVEX 2 hydrocyclone cluster delivers water and energy efficiency. This is in addition to the energy efficiency afforded by WARMAN pumps, particularly those with Wear Reduction Technology upgrades.
Weir believes that in reducing an operation’s impact on the environment, local communities are supported. Using less water and electricity means that more resources are available for others.
“The people who work for us generally come from the areas surrounding our operations and, therefore, we have a strong connection with these communities. Not only do we aim to use companies from surrounding communities to supply our service centres as much as possible, but we also engage community members to service our equipment on mine sites. This is in addition to an internship programme, through which 80% of graduates are employed by Weir directly,” says Mortimer. 
