QAL CALCINER KILN

PROJECT PROFILE

CLIENT

Queensland Alumina Ltd (QAL)

LOCATION

Gladstone, QLD

INDUSTRY

Alumina Refinery

DURATION

Aug 04 – Oct 05

SERVICE

Industrial Demolition & Deconstruction; and Asbestos & Hazardous Materials Removal

PROJECT OVERVIEW

Major Projects Group commenced this $12.5 million, 103,000 man-hour project in August 2004 and it was completed by October 2005. Full QAL operations were maintained during the course of the project.

SCOPE OF WORK

The scope of work for this project required the removal and disposal of nominated sections of the plant from the limestone train loadout through the conveyors, cold end building, kilns, contact coolers and discharge conveyors/ screwfeeders to the end of conveyors C3532/C3533.

The project scope involved decommissioning and dismantling nine calcinations lines within the working plant without disrupting the QAL operations. Nine precipitators, three chimney stacks, firingfloor and rotary coolers were also demolished.

Also in scope was the removal of SMF and Asbestos Lagging from approximately 1.2km of pipes, asbestos between floors of the Electro Static Precipitator and removal of asbestos from 4 chimney stacks.

Major Projects Group also managed a $4 million subcontract for the electrical disconnections and diversions as a part of the contract.

UNIQUE CHALLENGES
 Working in a live operating plant.

 Use of explosives.

 Hazardous material removal.

CUSTOMIZED SOLUTIONS

For the QAL dismantling, 38 personal were on site using a 500 and 300 tonne crane for the duration of the works. Various excavators with grabs and shears were also used, along with a Manitou forklift and 2 smaller cranes.

Twenty seven 240 tonne lifts were carried out on the site. The demolition of the redundant plant required other structures (e.g. Dolime plant) and services to remain, and all the work was carried out so as not to compromise the structural integrity of the remaining structures or the operability of the remaining plant.

RESULTS

During the project, over 5,100 bottles of gas were used to cut up steel work with an approximate total of 10,000 tonnes of steel taken off site, to be melted down or re-rolled. All of the kilns were successfully removed without incident.

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