EPCM supported Ensight – Industrial Energy and Carbon Cost Solutions in supporting with Concept Engineering designs in an Energy Optimisation Study for the installation of a syngas pipeline, upstream compression- and gas processing facilities between Richards Bay Minerals (RBM) and Mondi in Richards Bay, South Africa.
Carbon monoxide (CO) gas is produced as a waste stream from the smelting process of Ti-dioxide at RBM’s smelting and processing facilities. Excess CO gas not reserved for other gas users on the plant was reported available for co-generation to utilize for additional RBM income.
The Mondi Richards Bay packaging and paper manufacturing plant in close proximity to RBM’s facilities, utilise natural gas from the local Lilly natural gas pipeline as prime heating source for its rotary kilns. The feasibility of replacing the burner natural gas as fuel source with the syngas generated from RBM were investigated. The replaced volume of natural gas was further considered feedstock for a Micro-Scale Natural Gas Liquefaction Facility to produce LNG as diesel replacement fuel for yellow plant vehicles at reduced costs to diesel.
Scope of Work:
- Determine whether the excess CO gas can replace Sasol gas as fuel source;
- Obtain a feasible pipeline route between RBM and Mondi;
- Develop a process schematic and PFD;
- Perform preliminary hydraulic calculations;
- Specify required material and equipment for gas processing- and pipeline facilities;
- Develop budget project cost estimates;
- Determine the financial viability of the project; and
- Develop a project milestone schedule.