Mhlume Expansion project – Phase 2 Progress Update

The second phase of a four phase expansion project at the Mhlume Factory is currently underway. The scope for this phase is to increase the capacity of the factory’s boiling house by adding new pans and other new process equipment, but also upgrading existing ones.

Summary

The second phase of a four phase expansion project at the Mhlume Factory is currently underway. The scope for this phase is to increase the capacity of the factory’s boiling house by adding new pans and other new process equipment, but also upgrading existing ones.

    • Emineo is the EPCM contractor for the project, managing sub-contractors from Swaziland, South Africa, India, and Mauritius
    • Country: Swaziland
    • Contract period: 2017-2019

Engineering deliverables and progress to date

  • The following main equipment has been sized and modeled, and positioned on general layouts:
      • One 120m3 capacity « C » Continuous Vacuum Pan, complete with a new condenser and supported by a new structure.
      • One 75m2 capacity “A” Batch Vacuum Pan with a new condenser and a reinforced structure.
      • Three clear juice heaters of 550m2, with a new structure
      • One 225m3 new clear juice tank.
      • Two molasses tanks with a capacity of 10m3 each
      • One 35 t/h rotary sugar dryer, cascade type
  • Specification of all process, mechanical, electrical and instruments
  • 3D Modelling of existing plant areas affected by the project using 3D AutoCAD to build a Navisworks model to be used by all contractors on site
  • Drafting of general layout drawings, piping isometric drawings, structural guide drawings, civil guide drawings, electrical & instrumentation layout drawings

Procurement progress

  • Call for Tenders for a total of 26 packages, including equipment supply and site works packages, have been prepared and issued
  • Adjudication of offers received from suppliers/contractors from South Africa, India, and Mauritius
  • Tender awarding and contract drafting

Construction progress

Construction works are currently at 57% complete, and include the following scope:

  • Civil works
  • 105 tons of structural steel
  • 5 km of piping up to DN1400
  • Over 350 valves, up to DN900, including 20 with pneumatic actuators, installed
  • Management of sub-contractors (civil, mechanical, electrical, scaffolding, etc.), including quality as well as health and safety on site
  • Quality control management
  • Equipment shipped in modular form to be assembled and tubed on site
  • Storage tanks shipped in knock-down form to be assembled on site
  • Control loop and interlocks set-up and tuning during commissioning
  • Regular performance follow-up after commissioning, for first few weeks of crushing season with regards to teething problems
  • Weekly progress reports and planning updates issued to client up to completion of project

1st steam trial is currently planned for the 2nd week of April 2019.

First sugar at Tongaat Hulett new refinery in Mozambique

Emineo and partner SiVEST recently completed the commissioning of the new sugar refinery at the Açucareira de Xinavane Sugar mill (AdX), which is majority-owned by Tongaat Hulett Sugar South Africa.

Emineo and partner SiVEST recently completed the commissioning of the new sugar refinery at the Açucareira de Xinavane Sugar mill (AdX), which is majority-owned by Tongaat Hulett Sugar South Africa.

The 90,000 t/y plant was successfully commissioned in September 2018, 10 days only behind schedule, which remains a great achievement considering the fastrack nature of the project.

For additional details about Emineo’s scope and achievements, please read our full article here

https://www.emineo.mu/projects/xinavane-mozambique/

Omnicane 200tpd Refinery expansion project

Emineo completed the Omnicane refinery expansion works earlier this year, as the main contractor for the mechanical, structural and piping works. De Smet Engineers and Contractors, (https://www.dsengineers.com/en/) who provided the technology and process guarantees, successfully commissioned the refinery in August this year.

Emineo completed the Omnicane refinery expansion works earlier this year, as the main contractor for the mechanical, structural and piping works. De Smet Engineers and Contractors, (https://www.dsengineers.com/en/) who provided the technology and process guarantees, successfully commissioned the refinery in August this year.

The installation works were completed in just less than one year, and included:

MECHANICAL ERECTION

  • Erection of approximately 70 tons of new steel works and platforms (designed and supplied by Emineo)
  • Erection of all equipment, including:
    • Evaporator
    • Pocket filters
    • Plate Heat Exchangers
    • Seed pan
    • Process Tanks
    • Pumps
    • Centrifugal
  • Modification of existing structure
  • Insulation of new equipment

PIPING WORKS

Installation of approximately 3kms of piping, for connection of new equipment to the existing system, including:

  • Process piping
  • Steam piping
  • Hook-ups connection for sensor
  • Insulation of piping

Renewable Energies – TERRAGEN Cane Trash Plant

Emineo has been appointed in March 2018 by Terragen to investigate re-engineering of their trash handling plant and carry modifications on site. Trash, which consists of cane leaves and tops, is recovered from the fields and packed into bales and trucked to the power plant…

Emineo has been appointed in March 2018 by Terragen to investigate re-engineering of their trash handling plant and carry modifications on site. Trash, which consists of cane leaves and tops, is recovered from the fields and packed into bales and trucked to the power plant. The bales are processed at the power plant, where these are broken down and shredded into a homogeneous feed to the existing bagasse boilers. Emineo’s scope included:

  • Engineering and layouts
  • Design supply and install new trash bale breaker complete with drive
  • Supply and install new drive shaft and sprocket and new gearbox on feeder table
  • Redesign all belt conveyors steel works (all belts have been increased in width), supply and install new drums, idlers and belt on all conveyors
  • Redesign all chutes, divertor flap and connection to cane trash shredder

Site works started in mid-April and the plant was successfully commissioned end of July 2018.

Mhlume Expansion

Emineo recently completed the first phase of a four phase expansion project of the Mhlume Factory in Swaziland. The final objective of the project is to increase the factory’s crushing rate from 390tch to 440tch […]

Emineo recently completed the first phase of a four phase expansion project of the Mhlume Factory in Swaziland. The final objective of the project is to increase the factory’s crushing rate from 390tch to 440tch, and phase 1 allowed to achieve a critical first step by enabling on-the-run cleaning of evaporators to improve the overall time efficiency of the factory. After a challenging but successful commissioning stage, the new equipment has been handed over to operations. The project was completed on time and within the approved budget.

For additional details please read our full article here:

https://www.emineo.mu/Mhlume Expansion

Following this successful first phase, and good relationship with the Client and other project stakholders, Emineo has been awarded the EPCM contract for Phase 2. More to come in future articles…

Mhlume Expansion project – Progress Update

Emineo is the EPCM consultant on the Mhlume Expansion project for the Royal Swaziland Sugar Corporation. The project is staged over multiple consecutive phases, with the 1st phase currently in the construction stage

Emineo is the EPCM consultant on the Mhlume Expansion project for the Royal Swaziland Sugar Corporation. The project is staged over multiple consecutive phases, with the 1st phase currently in the construction stage. The civil works are now complete and nearly all equipment has been delivered to site. The four new process tanks have been installed, and the installation of the other equipment, in particular the four new Kestner evaporators, is in progress. Forecast crushing season start is the first week of May 2018.
Phase 2 is currently in the engineering stage, which is near complete. The project scope is to increase the capacity of the factory’s boiling house by adding new pans and other new process equipment and upgrading existing ones. This phase should go into execution shortly after engineering completion and Client approval.

Omnicane Packing Station

EMINEO successfully delivered Omnicane’s new 1T and 50kg bagging plant. Civil works had started on 6-Sep, followed by structural steel on 28-Sep, and full commissioning was achieved by 10-Nov, allowing the Client to meet its exportation target dates before the end of the 2017 crop season…

EMINEO successfully delivered Omnicane’s new 1T and 50kg bagging plant. Civil works had started on 6-Sep, followed by structural steel on 28-Sep, and full commissioning was achieved by 10-Nov, allowing the Client to meet its exportation target dates before the end of the 2017 crop season. The main challenges were the very tight timeframe, and the need to ‘rethink’ the plant’s design to come up with a cheaper and easier solution. The Client was very satisfied, which confirms that we treat smaller projects with as much importance as major projects.

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