Project Spotlight: BHP Kalgoorlie Nickel Smelter Shutdown 2024
This Project Spotlight showcases the huge amount of pre-planning and detailed development of work packs required for a successful shutdown delivery. The project, completed collaboratively by Furnace Solutions with our client BHP in Kalgoorlie, was executed over 60 hours (3 days) with no safety incidents whilst remaining on time and within budget.
Client Acknowledgment
Thank you to BHP who engaged the Furnace Solutions team and assisted with the extensive planning that went into the project. This supportive approach allowed our 104-person team to deliver this technically demanding maintenance shutdown at the Kalgoorlie Nickel Smelter.
Project Overview
Location:
Kalgoorlie, Western Australia
Description:
The Kalgoorlie Nickel Smelter is an essential piece of processing infrastructure for nickel production from the Goldfields region of Western Australia and is currently owned and operated by BHP. In early 2024, a maintenance shutdown was required on the flux and acid plants, as well as various Furnace/Hot Metals work packs.
Scope:
The shutdown planning and execution was delivered by Furnace Solutions over three distinct work areas:
MN10 (Flux Plant) – refurbishment on the chain conveyors and feed systems, including critical components.
MN20 (Acid Plant) – replacing valves, spools, agitators, and pumps adjacent to the strong and weak acid areas.
MN40 (Flash Furnace) – shell and jacket replacements of the uptake and reaction shafts, including removal of failed jackets and new furnace jacket installation.
Methodology and Highlights
This project featured significant front loading of the extensive pre-planning activities was delivered by three mechanical planners. By meticulously scheduling the shutdown in the preceding four months ahead of execution, whilst conducting a 2:1 roster at the operations, collaboration with experienced onsite personnel was made possible.
This approach allowed for the smooth execution phase of the shutdown, with a heavy focus on the planning, scheduling, and preparation of the workforce ahead of onsite based activities – a central pillar of the Furnace Solution operating model.
Furnace Solutions engaged 104 trained operatives to execute the three separate work packages simultaneously during the 60 hour (3 day shutdown), including boilermakers, mechanical fitters, riggers, trade assistants, as well as experienced supervisors and project managers.
Summary
This Project Spotlight highlights the meticulous shutdown planning executed by the Furnace Solutions team, with a holistic end to end approach in the planning phase.
Our thorough planning processes guarantee that the execution phase runs smoothly, on time, and within budget – underscoring our commitment to "Doing What We Say"!
We greatly appreciate the dedication of our specialist team and extend our thanks to the BHP team for their support in delivering this important shutdown project.