FWS was engaged to design and construct a state-of-the-art metakaolin processing plant in Wood Mountain, Saskatchewan. The facility was developed to meet the growing demand for high-quality metakaolin, with a focus on high-capacity production, operational efficiency, and environmental compliance. The project involved complete infrastructure development, equipment installation, and integration of advanced processing technologies.

The goal of this project was to create a state-of-the-art processing facility capable of producing up to 200,000 tonnes of metakaolin annually. The plant was designed to support large-scale operations while ensuring operational efficiency, adherence to environmental regulations, and the long-term durability of the infrastructure.

Key features of the Metakaolin Processing Plant include:

• Processing Capacity: The facility is designed to handle up to 200,000 tonnes of metakaolin annually, allowing for large-scale production to meet both industrial and commercial demands.
• Foundations and Structural Elements: Extensive design and installation of concrete foundations and structural steel, creating a robust base for the plant’s infrastructure, ensuring stability and durability.
• Processing Equipment Installation: The plant is equipped with a variety of processing equipment, including:
  • Primary Crusher: For initial ore reduction.
  • Ore Handling Equipment: To efficiently transport and manage ore throughout the process.
  • Rotary Dryer/Kiln/Cooler: For drying, calcining, and cooling metakaolin.
  • Mechanical Separator: For separating metakaolin based on physical properties.
  • Baghouse and Stack: For dust collection and emissions control.
  • Secondary Dust Collectors: To capture additional dust.
  • Coal Mill: For grinding coal used in the kiln.
  • Ore Conditioner: To prepare ore for processing.
  • Ore and By-Product Bins: For storing processed materials and by-products.
  • Truck Scale and Loading Facility: For accurate measurement and efficient loading of finished products.

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The completed plant delivers high-volume, high-efficiency metakaolin production, supporting the industrial and commercial markets. The integration of emissions controls and sustainable design features ensures compliance with regulatory requirements, while the robust infrastructure supports long-term operations and future scalability.