Air Products’ new air separation plant in the Coega Industrial Development Zone (IDZ) has moved another step closer to its opening target with the arrival this week of a key piece of equipment that will tower over the Coega IDZ and form the heart of the R300-million plant.
At 32 metres high – roughly the height of a nine-storey building – the cylindrical steel cold box will add a distinctive landmark to the Coega landscape once it is lifted into position with multiple heavy-duty cranes.
Air Products remains firmly on schedule for completion of the plant in the third quarter, followed by commissioning and the flowing of gas in the fourth quarter of 2014, said Air Products General Manager On-sites Robert Richardson.
He said the cold box was the “heart of the plant” and was probably the most distinctive feature of every cryogenic air separation plant.
The cold box’s arrival on site on Tuesday, transported by a self-propelled modular transporter from the Port of Ngqura, where it arrived on Sunday, 16 February, signalled the successful completion of a complex chain of behind-the-scenes processes in engineering, design, procurement, manufacturing and logistics.
“Together with the arrival of other high-tech components from America and Europe over the past few weeks, this means the construction of the plant now moves from the major civil and building works stage into the mechanical phase of the installation,” said Richardson.
The cold box houses and insulates the cryogenic equipment for the refrigeration and distillation of atmospheric air into liquid oxygen and nitrogen.
Several heavy-duty cranes will lift and fit the cold box into its final position on a massive concrete foundation, Richardson said.
He said the concrete foundation, together with lay down areas and support trestles where the cold box will rest horizontally for inspection and preparation prior to lifting, were constructed well in advance to allow time for the concrete to cure.
After inspection for possible shipping damage and quality control, the cold box will be fitted with valves and safety equipment, and ladders and platforms will be welded into place along with the application of corporate branding.
Air Products’ engineering team has conducted a rigging study and developed a lifting plan to determine the placement of the lay down areas, the cold box’s position in the lay down areas, as well as the number and size of the cranes, and health and safety issues.
“The project has been injury-free thus far and it is important to us that we keep it that way. Air Products has supervised and conducted many of these lifts before, and this lift will once again be supervised by our experienced team with a key aim of sending everyone home safely, every day,” Richardson said.
The Coega Development Corporation (CDC) said the arrival of the cold box was not only a milestone for Air Products but also for Coega, adding that it would become a new Coega IDZ icon for Eastern Cape businesses using industrial and speciality gases.
“The arrival of this essential component means that Air Products is one step closer to completing their plant and opening for business which ultimately means they will be servicing their clients in the IDZ and across the Eastern Cape at a higher level, bringing security of gas supply both to the city and the province,” said Ayanda Vilakazi, CDC head of marketing and communications.
“The CDC welcomes the speed at which Air Products is working and looks forward to the plant coming online.”
Air Products managing director Mike Hellyar said the company took a strategic decision to build the new air separation unit in order to provide its Eastern Cape customers with improved security of supply, against the background of positive economic and industrial growth in the province, particularly in the Coega IDZ. “The location of a plant in the Eastern Cape reduces the need for expensive and risky cross-country trucking of products from Gauteng,” said Hellyar.
“Market analysis conducted by Air Products showed high demand for industrial gas across the province’s automotive sector, as well as the agro-processing, food and beverage, and renewable energy sectors. In addition to servicing existing customers and traditional users of industrial and speciality gases, Air Products has identified strong potential to stimulate demand and move into new markets,” Hellyar added.
The construction phase of the plant has created approximately 120 jobs and Air Products has directed the majority of the project investment into the Eastern Cape by engaging local consultants and contractors in the design, engineering and construction of the facility.
By creating security of supply, the new air separation unit will unlock business opportunities and support employment through the entire value chain of the industries it services, including the automotive, food and beverage, agro-processing, pharmaceutical and renewable energy sectors.
Alan Straton
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