Aussie Sugar Mill Refresh

Project Overview

In 1998 Bundaberg Walkers commissioned Australia’s newest sugar mill. We were involved across a variety of development and improvement phases of the project. Our in-house industry expertise and equipment manufacturing ability enabled us to deliver over the course of this project. This turnkey project EPC scope included in-house design fabrication and installation of milling train, process vessels and auxiliary equipment. We continued to improve production in the early years prior to major upgrades which have followed in the past decade.

With varied skills and capabilities we are able to provide creative engineering, manufacturing and mechanical solutions to best serve the specific requirements of the project and effectively exceed the end users objectives. Our contribution to this project has comprised a diverse range of work including:

Project Detail

Tableland Mill Capacity Upgrade

Client:

MSF Sugar

Category

Engineering

Location

Queensland

Boiler Capacity Upgrade

Juice heaters

Continuous vacuum pan

Milling tandem upgrade with pressure feeders

Clarifier

Centrifugal station

Intermediate carrier upgrade

New evaporator and upgraded evaporator

Sugar drier

Bagasse handling system

Syrup tank

Molasses tank and loading station

Challenge

This project required BWEL to reduce capital costs and focus on progressive upgrades through re-investing profits. Future upgrade possibilities were considered in the initial concept stages. This forward-thinking approach ensured there was minimal plant disruption and site exposure during the construction phases. The main constraints involved in this project were site access and plot size restrictions in addition to environmental considerations when completing upgrades in the tropical wet season. As the bulk of the mill was not in buildings ensuring costs could be minimised while allowing for easy accessibility during future upgrades.

Solution

Mitigating long term reliability from exposure to the elements was a major consideration during this upgrade. To ensure this, BWEL upgraded corrosion protection as well as the introduction of materials and localised equipment shelters. The plant layout and access was managed to facilitate future upgrades and minimise tie in and erection works. The main crystallisation upgrade occurred early in the year at the same time a tropical cyclone system brought extensive flooding to Queensland. The project timeframe from purchase order to start up was only 12 months. The upgrade as delivered safely, on time and on budget despite having an average of 120mm of rain per month over the construction phase.

+$40M

In upgrade project value

+60,000

Workshop and design hours

12 Months

From project award to start up

+$6.8M

In raw material costs

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Locomotive Expertise

We have a long and enduring history of producing locomotives for sugar cane transport, BWEL have built and maintained high quality locomotives through superior craftsmanship while efficiently meeting deadlines.
Decades of diverse project excellence define Bundaberg Walkers Engineering. Explore our impressive portfolio, showcasing unwavering innovation and commitment to excellence across various sectors.
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