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Kusile materials handling project the biggest ever for engineering group
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18th February 2011
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South African engineering company Bateman Africa reports that its current project for State-owned power utility Eskom’s Kusile power station, is the biggest materials handling project in Bateman’s history.

Three contracts, which were awarded in November 2010, involve materials handling work packages comprising the terrace landing system, the stockyard handling system and the limestone handling system. The packages will be phased over the next five years and is expected to be complete in 2016.

The scope of the project includes the design, engineering, construction and commissioning of the plant conveyors, stockyards, stacking and reclaiming, civil works and electrical and instrumentation (E&I) work.

The three packages include 79 conveyors, totalling a distance of over 16 km. Further, the packages include the installation of 13 machines consisting of stackers, reclaimers and belt terrace, stockyard and limestone packages.

“These projects provide Bateman with the opportunity to create a base load within the company, while executing other projects outside of this one,” says Bateman marketing manager for bulk material handling Philip le Roux.

The three contracts, which total in excess of R2-billion, were placed on a lump sum turn-key basis.

Bateman Africa is currently working on the design engineering for the projects and site establishment is expected to start in April. Subcontractors for the project have not yet been appointed, however, major subcontractors will be involved in the stacking and reclaiming machines, civil works and the E&I work.

Bateman Africa Kusile sponsor Felix Fongoca notes that the compna wil be using resources from the power station's surrounding area to assist with the execution of the project, which is in line with the Accelerated and Shared Growth Initiative for South Africa.

However, Le Roux adds that a lot of the engineering resources will be sourced internally as the company completed two large projects, which has made available a sufficient engineering team to work on the Kusile contracts.

Kusile Power Station

Kusile will be a six-unit, coal-fired power plant, with about 4 800 MW of gross output. The project includes a power station precinct, with power station buildings, administrative buildings (control buildings, medical blocks and security buildings), roads, as well as a high-voltage yard.

The associated infrastructure will include a coal stockyard, coal and ash terrace conveyors, water supply pipelines (temporary and permanent), temporary electricity supply for construction, and water and wastewater treatment facilities.

Other infrastructure includes ash disposal systems, a railway line, limestone off-loading facilities, access roads (including haul roads), dams for water storage and a railway siding and/or a line for the sorbent (limestone) supply.

Kusile will be the first power station in South Africa to have flue gas desulphurisation (FGD) installed. FGD is a state-of-the art technology used to remove sulpher dioxide from exhaust flue gases in power plants that burn coal from the boilers.

The majority of the coal for the power plant will be sourced from Anglo Coal's new Largo mine (mine mouth), with supporting coal from the Zondagsfontein East No 2 seam – a middlings product, the Zondagsfontein East No 4 seam and the Zondagsfontein West resource, where further exploration is ongoing.

The first generating unit is scheduled to enter commercial operation by 2014, with the subsequent five units being commissioned at eight-month intervals thereafter. The last unit is expected to be in commercial operation in 2018.

Edited by: Brindaveni Naidoo


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KUSILE POWER STATIONWill be the largest materials handling project in Bateman's history
Picture by: Duane Daws
KUSILE POWER STATIONWill be the largest materials handling project in Bateman's history