Project Spotlight: Iluka Resources - SR02 Reline
This is the second "Project Spotlight" FROM THE FURNACE, where we shine a light on the latest projects delivered by our expert furnace maintenance and demolition teams.
This case study focuses on the delivery of the Iluka Resources SR02 Kiln Reline, which was executed in 30 day shifts at the Western Australian mineral sands processing facility.
Client Acknowledgment
Thank you to our supportive clients at Iluka Resources who entrusted the Furnace Solutions team with delivering this kiln refurbishment project.
The support received within delivery of this project by our twenty-nine-man team was excellent and allowed us to complete this project on time and within budget.
Project Overview
Location:
Capel, Western Australia
Description:
The Iluka SR02 kiln reline project was delivered in 2023 and encompassed pre-project test work, robotic demolition and the installation of 12,500 welded anchors. The test work was focused on a custom rapid arc welding (RAW) anchor which was developed ahead of site works.
Scope:
Iluka sought the expertise of Furnace Solutions to refurbish the Synthetic Rutile Rotary Kiln, as it was approaching the end of its campaign.
This thirty-day package of work delivered simultaneous demolition and rebuild activities due to meticulous planning and tight shutdown timelines. The project delivered the demolition and preparation of 75 linear meters of refractory for the next phase of the kilns life.
Methodology and Highlights
Under tight deadlines, an innovative balloon system was deployed to safely partition teams working in close proximity within the kiln. This streamlined approach enabled simultaneous work by anchor removal and robotic demolition teams, slashing the delivery of the first phase of the project.
The second component, which was the positioning and installation of 12,500 anchors was delivered utilising prefabricated stencils for quick and easy set out of anchor positions. The Rapid Arc Welding team then got to work to complete the installation process.
The project utilised a largely West Australian-based team and was delivered by twenty-nine furnace experts across thirty-day shifts.
Summary
This smaller furnace rebuild package of work showcased the utilisation of innovative ways of work to save time when delivering a project. The utilisation of our furnace experts in simultaneous project works showcases our expertise in specialist project delivery for furnace and kiln maintenance.
Thanks to the hard work and expertise of our team and for the trust placed in us by Iluka Resources.