Name and Location
Ngodwana mill expansion and modernisation (GoCell) project, Mpumalanga, South Africa.
 

Client
Sappi Southern Africa.

Project Description
The project has expanded and modernised Sappi’s Ngodwana mill operations, located 50 km to the west of Nelspruit, in Mpumalanga, to produce chemical cellulose, which is primarily used for viscose fibre in the textile industry. The expansion allows for an additional 200 000 t/y of chemical cellulose production, as well as kraft linerboard and newsprint.

The major aspects of the GoCell project included the construction of the new fibre line comprising a batch pulping plant, washing and screening plant, bleach plant, chlorine dioxide plant, demineralisation plant and a complete chemical handling system.

Further, the No 2 digester and screening plant was modified into a high kappa pulping facility, and the original bleach plant was decommissioned.

The project also included major upgrades to the No 3 pulp-drying machine, which included a new shoe-press, various wet-end upgrades and a new dryer, as well as upgrades to the bailing line.

In addition, a new hardwood chipping line, with log washing, was also installed, together with substantial changes to chip screening and softwood chip storage and handling facilities. The old No 1 fibre line, which used to produce high kappa pulp for the kraft linerboard machine, was also decommissioned.

Changes were also made to the mill to improve its environmental footprint. These included the replacement of the old bleach plant with a new plant that is much more efficient in respect of chemical consumption and specific effluent discharge, and an improvement in the mill’s energy efficiency, with the consumption of coal estimated to decrease by 61 000 t/y.

This reduction has equated to 120 000 t/y less carbon emissions.

Value
R3.3-billion.

Duration
Construction on the plant started in early 2012, with the first material produced mid-2013.

Latest Developments
The newly constructed Fibre Line 3 specialised cellulose plant at Sappi’s Ngodwana mill will ramp up to full capacity of 200 000 t/y by the end of this calendar year, Sappi Southern Africa CEO Alex Thiel told Engineering News Online following the official opening of the plant on June 18.

Key Contracts and Suppliers
None stated.

On Budget and on Time?
Too early to state.

Contact Details for Project Information
Sappi head of corporate affairs André F Oberholzer, tel +27 11 407 8044 or email Andre.Oberholzer@sappi.com.