HYDAC’s process filtration strengthens performance in Africa’s hydropower sector
Reliable filtration for efficient, sustainable hydropower.
HYDAC boosts hydropower efficiency in Africa with reliable, low-maintenance filtration and water treatment solutions.
HYDAC’s process filtration strengthens performance in Africa’s hydropower sector
Amid Africa’s dynamic energy transition, the demand for robust, low-maintenance technologies has evolved from a convenience into a critical necessity. As hydropower continues to gain momentum across the continent, the need for reliable, automated process filtration and water treatment systems has become central to maintaining operational efficiency and protecting vital infrastructure.
HYDAC responds to this demand with its AutoFilt RF3—an advanced, self-cleaning backflushing filter that stands as a flagship in a broader portfolio, which also includes the RF4, RF4W, RF5, and RF7, as well as a suite of pre-filtration systems. Each is engineered to optimise water quality and extend the life of key equipment in hydropower applications through effective process filtration and water treatment.
Leading HYDAC’s operations in the region are Justin Pick, Sales Manager for Southern African Development Community (SADC) and Kenya, and William Lahner, Technical Sales Manager. Their field-oriented, consultative approach ensures HYDAC technologies are not only delivered but seamlessly integrated into complex client operations across multiple sectors.
“With a focus on hydropower and mining, and growing interest from the marine and cement sectors, I spend much of my time visiting sites and working directly with clients,” says Mr Pick. “Understanding how our equipment is used in real-world conditions is key to delivering meaningful, reliable solutions.”
Driving process efficiency through intelligent filtration and water treatment
Among HYDAC’s filtration offerings, the AutoFilt RF3 plays a pivotal role in water-intensive operations such as turbine systems. These environments demand the continuous removal of solid particles from low-viscosity fluids to prevent premature wear and minimise operational downtime. In these scenarios, process filtration is not just helpful—it is mission-critical.
“The RF3 is a fully automatic, self-cleaning backflushing filter,” Mr Pick explains. “It removes particulate contamination from process water without requiring constant manual oversight. The reduced need for consumable replacements and the minimal water loss during cleaning cycles offer substantial operational and environmental benefits.”
Designed for reliability and ease of integration, the RF3 uses existing pressure differentials to trigger its cleaning cycle, allowing the system to remain online—even during backflushing. This intelligent approach is vital in energy environments where downtime equates to lost revenue.
Engineering excellence in action
The RF3 operates on a simple yet highly effective principle: fluid flows from the inside to the outside of conical filter elements. As contamination accumulates, the system initiates a backflush that sequentially cleans each element without interrupting filtrate flow.
Key features include conical filter elements; wedge wire options (50 to 3000 μm); super mesh wire (25 to 60 μm); pulse-aided backflushing; and isokinetic filtration. The unit’s flow-optimised housing, adjustable flange positions, and ready-to-operate design enable rapid, flexible deployment across a variety of systems.
A comprehensive portfolio of water treatment and filtration solutions
HYDAC’s filtration systems are designed with adaptability in mind, accommodating a range of operational and spatial requirements.
“We offer not only the RF3, but also the RF7, which operates in the same way but is configured horizontally to overcome space or height constraints,” says Mr Lahner. “For more compact installations, the RF4 offers a smaller footprint with similar performance.”
He explains that model part numbers correspond to filter size, with the RF3 and RF7 most commonly deployed due to their flexibility and proven performance across a range of field conditions.
The RF3 and RF7 sizes range from DN 50 to DN 900 standard connection sizes.
Proven performance across Africa
HYDAC’s expanding footprint across Africa is driven by the reliability and low-maintenance nature of its filtration technologies. Many systems have been installed through OEM partnerships during the construction of new power stations or turbine upgrade projects.
However, Africa’s river systems introduce unique operational challenges.
“Our rivers often carry significant debris—from tree branches and foliage to entire floating islands of waste,” notes Mr Pick. “Such large contaminants must be intercepted before they reach equipment.”
Strengthening protection with pre-filtration and water treatment
To address these challenges, HYDAC provides pre-filtration systems designed as a critical first line of defence. These solutions help protect the RF series filters from coarse debris, enabling long-term performance.
Reliable pre-treatment ensures uninterrupted process filtration and extends service intervals.
Mr Lahner highlights the HYDAC AutoFilt ATF TwistFlow Strainer and PRFS screen basket filter as highly effective pre-filtration options in these demanding environments.
“I observed basket filters installed on several lines at a hydropower complex—an essential safeguard during commissioning when large volumes of debris were diverted from the river,” he says. “The RF3 is not designed to handle that level of contamination. Systems developed for European rivers can struggle in Africa’s far more challenging conditions.”
These screen baskets—constructed from stainless steel or internally coated with epoxy—capture solid particles efficiently while offering straightforward maintenance. These components also support broader water treatment goals by minimising environmental discharge.
Bridging the skills gap
Despite their advanced automation, the performance of HYDAC’s filtration systems can be compromised when operators are unfamiliar with their use.
“Our filters are designed to operate autonomously once configured,” Mr Lahner explains. “But we’ve found that limited user knowledge often results in underperformance.”
This highlights the need for practical, on-site training. “Ensuring that operators are well-versed in both system operation and maintenance is critical to unlocking the full benefits of our technology,” he adds. HYDAC supports this through targeted training focused on process filtration system care.
Supporting legacy infrastructure
Much of Africa’s hydropower infrastructure dates back to the 1950s and 60s and is now in need of refurbishment. HYDAC plays a vital role not only in new installations but also in maintaining and modernising legacy systems.
“We don’t just sell new systems,” says Mr Pick. “We also support the existing installed base and explore ways to upgrade plants through brownfield installations.”
This support is built on a strong foundation of collaboration. “We work directly with clients to understand their technical requirements and tailor our solutions accordingly,” Mr Pick adds. “That consultative approach helps demonstrate the operational and economic advantages of solutions like the RF3.”
Beyond filtration: a system-wide approach
While process filtration remains central to HYDAC’s offering, the company is also expanding its support in oil and lubrication systems—helping clients build system-wide resilience, improve efficiency, and reduce total lifecycle costs across energy and industrial operations.
These enhancements support more comprehensive water treatment strategies
Reduce lifecycle costs
Improve efficiency
Looking ahead
From the Congo River to the Zambezi, HYDAC’s AutoFilt RF3 is helping redefine filtration standards in Africa’s hydropower sector. With a focus on self-sufficiency, energy efficiency, and intelligent design, HYDAC is not only addressing today’s challenges but also building a more sustainable, resilient future for power generation and water treatment across the continent.
