Nickel Refinery

Project Overview

Bundaberg Walkers Engineering Limited (BWEL) was commissioned to provide a range of substantial processing equipment to facilitate the expansion of a Nickel Refinery. Among these components, the jacketed rotary cooler was of particular importance, demanding intricate heavy fabrication, precise machining and stringent quality control measures.

In addition to the cooler, BWEL took charge of designing and fabricating essential auxiliary components such as outlet chutes, drive mounts and chain guards. This comprehensive project scope encompassed the manufacturing of several large pressure vessels and tanks in duplex and standard stainless steels including SAF 2205, 904L and 316L. This project showcased our versatility in delivering high-quality solutions to complex industrial projects.

Project Detail

Nickel Refinery: Jacketed Rotary Cooler

Client:

Nickel Refinery

Category

Mineral Processing

Location

Queensland

Challenge

There a significant amount of processes required to complete the item, including rolling, pressure vessel welding, machining, gear cutting, stud welding, small bore pipe spools and fittings, hydrotest, blasting and surface treatment and refractory lining.

Design / construction codes – AS1210 class 1, AS 4041 Class 3, AS 1554.

Materials – boiler plate AS1548-7-460, structural grade steel 250 and 300 plate, Bisalloy 80, 316L SS.

Solution

The workshop moved a large lathe that could seat the entire cooler into the fabrication bay to allow for the precise set up and machining of the cooler. The set up involved the fabrication and machining of an adjustable jig to facilitate the set up at both ends. This ensured tolerances were monitored and maintained throughout the various tasks without the need for time consuming set up.

To guarantee the highest quality in manufacturing and design all processes including the heat treatment, visual inspection, penetrant, magnetic particle and ultrasonic testing were completed in-house. This creative in-house approach not only ensured stringent quality control but also streamlined project management, resulting in a high-performance and reliable product.

1100°C

Product cooling capacity

+70,000 
Tons

Processed per annum

15m

Turning length on Lathe

127 Tons

Maximum operating weight

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