NEWS
Bosch projects UCL sugar factory expansion
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osch Projects was appointed by UCL Company (Pty) Ltd to undertake three major projects for the recent expansion at its sugar factory in Dalton, KwaZulu-Natal. These projects comprised Engineering, Procurement and Construction Management (EPCM) services for the raw house expansion, chainless diffuser widening and process equipment supply. “A major challenge was to complete the work necessary at the factory for UCL to meet its 2021/22 season requirements, with sufficient capacity to process the increased sugar cane crop,” explains Steve Rosettenstein, Sector Director: Sugar, Bosch Projects, a member of the Bosch Holdings group of multi-disciplinary consulting engineers. “In spite of tight time constraints during difficult COVID-19 conditions and the short two-month plant maintenance shutdown period, Bosch Projects successfully implemented these three projects simultaneously, between July 2020 and March 2021.
Detailed integration engineering and design encompassed full process, mechanical equipment, piping, civil, structural, electrical and control systems engineering, commissioning and close out. Because of COVID-19 implications, coupled with the fast-paced nature and congested brownfield factory environment, the Bosch Projects team needed to be innovative and creative in its approach to detailed engineering solutions and the application of expertise.
UCL - inside view of the chainless diffuser
The utilisation of the latest technology – an advanced augmented reality 3D model tool – enabled the construction teams to visualise the new plant integration live on site.
“Following a four-month feasibility study undertaken by the Bosch Projects team to evaluate the potential increase in factory crush capacity from 150TCH to 175TCH, the company was commissioned to provide EPCM services to address the expansion project’s technical, commercial and contractual requirements.” Services undertaken by Bosch Projects during the EPCM project, included project management, programming and scheduling, procurement and contract administration, construction management, commissioning, quality assurance and cost control.
Effective solutions were achieved for the client by utilising cloud-based multi-user design collaborative tools, specifically designed for remote working. Advanced technology enabled frequent online 3D model reviews and provided state-of the-art technology for site data gathering and meaningful interaction with site staff.
UCL - Lowering of continuous vaccum pan
In addition, the team was responsible for a world first widening of the Bosch Projects chainless diffuser, to increase cane throughput by approximately 25%. The team undertook the manufacture, supply, installation and commissioning of a 1m width extension to the factory’s moving screen diffuser, to handle the increased crushed cane required to justify the back-end factory expansion. This chainless diffuser was initially designed and installed by Bosch Projects for UCL in 2006.
July - August 2021 | 11
