Boiler Erection Project
Steinmüller Africa is leading a boiler erection project at Mondi’s Richards Bay mill by assembling imported boiler components and sections. With a site workforce of approximately 130-200 skilled professionals, the company’s project scope encompasses full mechanical installation including steel structures, pressure parts, fans, flue gas ducts, tanks, and critical systems such as the air preheater and flue gas damper.
Thousands of metres of continuous welding is being executed on-site, using various welding methods, including the conventional stick and tungsten inert gas (TIG) methods. Recognising the scale and complexity of this welding scope, Steinmüller Africa has implemented Regulated Metal Deposition (RMD), a modified pulse arc welding process that increases productivity by up to 2-3 times while maintaining weld integrity. This methodology is projected to cut welding time by at least 50%.
“By strategically reengineering proven technologies, we’re achieving a perfect balance of speed and quality,” says Friedrich Schwim, Senior Welding Engineer, Steinmüller Africa. “This level of efficiency is crucial for fast-paced, large-scale projects like the Mondi boiler.”
High humidity
Richards Bay’s high humidity poses significant welding challenges, particularly rust accumulation. To mitigate this, Steinmüller Africa has deployed laser cleaning technology to remove surface contaminants swiftly without compromising weld integrity. This non-abrasive method is vital for preparing steel in coastal environments.
In addition, the team is using a weld prep primer, applied via aerosol spray, which allows for continuous protection of cleaned steel without affecting weld quality. The product has been extensively tested, including underwater immersion simulations, and has proven successful in maintaining weld integrity in high-moisture conditions.
Steinmüller Africa has also addressed on-site safety and gas handling efficiency by installing portable gas handling systems. This innovation eliminates the need to manually transport gas bottles across elevated areas by feeding gas to up to eight welding machines from a central manifold and multi-cylinder pack.
