Jan 26, 2024 Azmet Reactor project, Amanuel Gebremeskel, Southern African Institute for Steel Construction (SAISC)
Azmet Reactor project - a victory for South Africa’s steel and transport sectors
Fabricating six massive reactors that are over three storeys high in Gauteng and then transporting these more than 2 500 kilometres to a mine in the Democratic Republic of Congo (DRC) - where all 3265 parts fitted perfectly, with not even one of the 26 900 bolts out of place - is a massive achievement.
This is according to Southern African Institute for Steel Construction (SAISC) CEO Amanuel Gebremeskel, commenting on the Azmet Reactor project, a collaborative effort led by Viva Engineering, an innovative and deserving 2023 Steel Awards - Mining and Industrial category winner. “The project entailed the detailed design of complex geometry. As such, it exemplifies precision engineering, showcasing intricate design and fabrication processes. This entailed planning, designing and fabricating these huge modular structures ahead of time, so that they could be moved through four or five different countries by road to install on site at the mine,” Gebremeskel says.
He goes on to explain that the more conventional approach would be to use heavy concrete tanks; or set up a substantial design office and fabrication works with a highly skilled team, both of which are not readily available locally in the DRC. Using an established South African fabricator based in Gauteng therefore provided a viable alternative - allowing for a controlled environment and close monitoring to ensure that all construction materials and structures met the required quality and safety standards.
The Azmet Reactor project also involved creating several other complex tanks, as well as platework and plant buildings. Engineers had to consider the design of the vessel in relation to permanent, material, equipment and wind loads.
The vessels also had to be transported and erected piece by large piece, and a lifting study first had to be performed. This focused on the selection of the most appropriate lifting methodology, considering that the reactor components would need to be loaded onto conventional heavy-duty transport vehicles. The level of welding precision and accuracy also had to be very high, as the structures could not distort during the transportation process.
The road transportation therefore necessitated exacting tolerances to ensure safe and timely delivery. Transport jigs were designed and built to brace the components and reduce vibration during transportation, while meticulous load packing optimised weight distribution for the lengthy trip. Much of the design had to cover exactly how to lift and maneuver these large and very heavy modular structures. The most significant load is during the lifting process - as opposed to when they are in use - entailing a very different kind of engineering:
“The entire design is driven by how one plans to construct and then transport each structure - as opposed to its ultimate application. The Azmet Reactors project represents a veritable feat of engineering – showcasing brilliance of design, logistics and installation – and demonstrating the South African steel sector’s capability to execute structurally and logistically complex projects with praiseworthy precision,” Gebremeskel concludes.
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