HomeBase MetalsK'Enyuka Ventures Into Modular Plant Design

K’Enyuka Ventures Into Modular Plant Design

Renira Reddy

Renira Reddy

Phemelo Gonkgang, head of K’Enyuka’s coal division, tells Mining Review Africa that the company realised during standard plant design undertakings that a real need existed for the modular plant alternative.

“The modular plant is aimed specifically at the smaller projects and is in line with the shift from EPCM into turnkey contracting for this market segment,” Gonkgang explains.

“The biggest differentiator that K’Enyuka brings to bear when it comes to modular plants is the extensive level of expertise within the company coupled with our applications knowledge in various minerals beneficiation sectors,” he adds.

“Because we have a number of designs for coal, gold and heavy minerals plants, we are able to use this reference base to tailor-make individual designs in such a way that we cater for specific application requirements,” Gonkgang says.

EPCM1

A current EPCM coal project
in its final stages

Modular plants offer a number of significant advantages for customers including the fact that the structural design of the plant lends itself to easy disassembly and reassembly on different sites. “Minimal construction man hours are necessary and it is no longer imperative to have access to a highly skilled labour force on site because the plant is assembled off-site and it is easy to install in the modular format,” Gonkgang says. “A modular plant can be up and running in only four weeks.”

Renira Reddy, proposal manager at K’Enyuka, says one of the biggest benefits of a modular plant is that because it is designed in such a way that it can be erected and trial assembled off-site to check for alignment there are fewer fitting errors and re-working because of the pre-fitting of components prior to delivery.

“In addition, the off-site erection means that we are able to minimise lay-down space, an important benefit when the field site is small or congested,” Reddy adds. “Another knock-on benefit is that schedules are shortened by allowing concurrent project processes to run unhindered. All of these benefits provide a positive advantage to the client by reducing the overall impact on the client’s operation, especially when it is a functioning operation.”

Phemelo Gonkgang

Phemelo Gonkgang

“Quality control is enhanced by erecting the plant in a controlled environment and we are able to transport the plant to site, in most cases as a single unit or in modular sections, using regular road transportation. The cost to the customer for engineering and construction is minimised due to the reduction in on-site erection and assembly needed,” Reddy says.

K’Enyuka’s modular plant is designed to treat both small (-50 mm) and large (+50 mm) coal in the dense media cyclone and dense media drum respectively. “We are able to offer these modular plants on an EPCM or turnkey basis dependent on various customers’ needs, and can design and construct all modular plant tie-ins including raw coal handing systems; fines beneficiation modules; dewatering systems; and discard and product handling systems,” Reddy says.

“Our modular design offering has been advanced with valuable input from our recently appointed coal consultant, Dave Peatfield, who is an industry expert with over 40 years’ experience of coal plant design,” Gonkgang says.

EPCM2

A product materials handling
structure

Adaptability is a keyword in all projects undertaken by K’Enyuka and whether it’s a large or a small plant, installations are purpose-designed to suit the customers and their applications. On smaller operations the modular plant is the way to go and accommodates from 50 tph up to 200 tph per module. “This means that two or more modules can be sited side by side if greater throughput is required,” Gonkgang says.

“Different modules are supplied for specific minerals sectors and include crushing and screening modules, large and small coal washing and spirals modules,” he adds.

Because modular plants are designed to allow quicker access to product, they provide greater flexibility on limited life reserves, thus saving costs. “This makes them ideal for small projects where junior miners, who have reserves with a relatively short life of mine of up to eight years, are able to use and then move the plant to a new site when the reserves are exhausted,” Gonkgang says.

“The turnkey approach is very important to the junior miners and is very much aligned with our business model. As with all our projects, we minimise the risk to the customer by offering a fixed price and finding the most appropriate solution. This is an integral part of our underlying philosophy of forming symbiotic partnerships with our customers.

EPCM3

A thickner installation on a
project recently commissioned

“In many instances our customer is not sure what is required so we offer our expertise in an up front process consultation. We are able to offer feasibility studies, consultancy studies and test work prior to project initiation on full beneficiation solutions from run-of-mine to finished product. We work very closely with the customer to ensure that its project is delivered on time and within budget to predetermined specifications,” Gonkgang says.

“Ultimately it is K’Enyuka’s philosophy to work with the customer rather than for the customer. This means that by developing the project together it ensures that the customer gets value for money and also gets a plant which is exactly tailored to deliver the requisite finished product. This very often entails being involved in the actual operation of the plant, and we took an active decision to position ourselves to offer this service,” Gonkgang concludes.

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