Modernization of a 30 years old sinter plant
The 2014 modernization of BHP Billiton’s Mamatwan sinter pant set a benchmark for excellence in engineering and construction planning. Leveraging advanced process technologies and meticulous planning, the project could be finalized ahead of schedule and boosted productivity and availability, cutting at the same time significantly the cost of operation.
In 2014, a comprehensive modernization of the Mamatwan Sinter Plant, operated by BHP Billiton in the Northern Cape province of South Africa was completed. The project focused on enhancing operational performance by improving availability and productivity, reducing maintenance costs, and optimizing energy efficiency.
The modernization involved upgrading- and redesigning core sinter plant equipment. Prior to the project, comprehensive joint studies and root cause analyses were carried out, culminating in detailed shutdown planning and precise execution to ensure smooth implementation. This approach leveraged advanced technologies such as laser scanning and 3D-modeling to create highly accurate plant and equipment drawings, ensuring seamless installation and eliminating potential conflicts.
Key deliverables in this project included new gear rims, newly designed pallet cars and windboxes, a patented lubrication-free sealing system for the sinter machine, and a recalculated drive station. The shutdown was completed in 29 days only – one day ahead of schedule.
The project delivered outstanding results: production capacity was significantly increased, process functionality optimized, maintainability improved, and energy consumption and emissions substantially reduced. The project demonstrated the effectiveness of combining technical expertise, local supervision, and robust planning to deliver efficient and environmentally responsible solutions.
The general project scope covered engineering, delivery, installation, and shutdown management, leveraging the latest developments in Travelling Grate Sintering technology. This modernization project stands as a reference for successful collaboration, technological excellence and careful construction planning.
It was the combination of Outotec technical expertise, local supervisors, main office support, planning and construction experience that delivered a successful project. Considering some of the challenges faced, this was an excellent achievement