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 Port Kembla sinter plant back online 

Port Kembla sinter plant back online

04 Jul, 2009 05:00 AM
Port Kembla's giant commercial toaster was switched on this week without incident.

All 460 people who have worked on the major $134 million upgrade of the three-decade-old sinter plant to date could have been excused for holding their breath after such a tightly scheduled dismantling and construction project.

But at 11pm last Monday the main strand came back online seamlessly.

A constant stream of sinter was being produced by 4am on Tuesday and, to the credit of manager Jim Fresh and his workforce, the refurbished plant made very little noise.

Not only had he and his team been able to increase the capacity of the giant sinter-making plant, they had also made it more environmentally efficient.

"The process is pretty efficient really because you recycle everything," Mr Fresh said, and that includes material from the blast furnaces.

Mr Fresh said everyone involved should be proud of the work which was severely hampered by a long period of wet weather during the month-long shutdown.

And although he is preparing to return home to Pittsburgh after four years in Wollongong, other capital investment work at the sinter plant and nearby conveyor sequence continues.

A new junction tower is being rebuilt for the conveyor sequence which will help the sinter plant reach its target capacity of 6.6 million tonnes.

It is expected to be completed by late September.

Work is also progressing on the installation of a fourth fan for the rotary cooling system.

Mr Fresh said one of the three waste gas precipitators, which cleans dust from the off-gas produced by the combustion process used to cook metallurgical material, was still under construction.

"But it is making good quality sinter," he said. "The start-up curve was very steep. We are already feeding sinter to No 6 blast furnace. The final handover from construction was pretty smooth.

"The evidence we have to date is the quality of the work has been very high. The operators and maintenance people are pleased. We have increased that plants capacity but we have also improved the efficiency of the environmental dust collection units."

About 150 people work on site, 24 hours a day in shifts. To date more than 400,000 man hours have been worked on the shutdown and there was no lost time due to injuries.

In total there have been close to one million man hours worked on the upgrade from its inception, with one lost time incident during the pre-assembly phase.

Op-Up commissioning manager Andrew Spence said the commissioning team was at the fine-tuning stage of the equipment now online.

Timeline of sinter plant upgrade

Early 2007: Planning begins.

April 2008: On-site preparations begin with a 400,000-tonne sinter stockpile being created to feed No 6 blast furnace during the upgrade. Hatch is involved as other work is done while the plant is operating.

January 2009: A 15m extension of the building is completed. Installation also starts on a new conveyor sequence.

March: The prime contract is awarded to Transfield Services Engineering group. Thomas and Coffey and K J Scaffolding are among the major subcontractors.

May 4: The sinter plant is shut down.

June 29: The sinter plant is recommissioned.

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Jim Fresh looks down on the reconstructed cooler at the exit end of the sinter strand. Pictures: KEN ROBERTSON
Jim Fresh looks down on the reconstructed cooler at the exit end of the sinter strand. Pictures: KEN ROBERTSON

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