Mhlume Factory Expansion – Phase 1

Summary

  • First phase of a four phase expansion project of Mhlume Factory to increase crushing rate from 390tch to 440tch with the aim of enabling on-the-run cleaning of evaporators to improve overall time efficiency
  • Extension of new evaporation station, building new evaporators outside the existing factory building and modifying existing equipment configuration
  • Emineo acting as EPCM for the project, managing sub-contractors from Swaziland, South Africa, India, and Mauritius
  • Country: Swaziland
  • Contract period: 2017-2018

Engineering

  • Modification of three existing evaporator lines into a single quintuple effect line with redundant vessel that will enable on-the-run cleaning without decreasing crushing capacity
  • Installation of four 3000m2 Kestner evaporators with accept/reject condensate system
  • Installation of a new direct contact heater and new condensers
  • Specification of all process, mechanical, electrical and instruments
  • 3D Modelling of zones affected by the project using 3D AutoCAD to build a Navisworks model used by all contractors on site
  • Generation of general layout drawings, piping isometric drawings, structural guide drawings, civil guide drawings, electrical & instrumentation layout drawings

Procurement

  • Evaporators and condensate receivers manufactured in India
  • Direct contact heater & condenser manufactured in South Africa
  • Storage tanks manufactured in Swaziland
  • Steel structure manufactured in Swaziland
  • Large bore piping manufactured in China
  • Large bore valves manufactured in France

Construction Management & Commissioning

  • 100 tons of structural steel erected
  • 5km of piping, up to DN1600, installed
  • Over 400 valves, up to DN1200, including 140 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
  • Kestner evaporators 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