FWS Group was tasked with developing the Metakaolin Processing Plant, a state-of-the-art facility designed to handle high volumes of metakaolin production. This project focused on creating a comprehensive infrastructure capable of efficient processing and handling of metakaolin, with robust design and installation of essential systems and equipment.

The scope of work for the Metakaolin Processing Plant project included the following key features:

• Processing Capacity: The plant is designed to process up to 200,000 tonnes of metakaolin per year. This high-capacity facility supports large-scale production and meets the demands of both industrial and commercial applications.
• Foundations and Structural Elements: The project involved the design and installation of all foundations, concrete, and structural steel necessary for the plant’s infrastructure. This includes the construction of processing buildings and support structures to ensure stability and durability.
• Processing Equipment Installation: The plant features a comprehensive range of processing equipment, including:
  • Primary Crusher: For initial ore reduction and processing.
  • Ore Handling Equipment: To manage and transport ore throughout the processing stages.
  • Rotary Dryer/Kiln/Cooler: For drying, calcining, and cooling metakaolin as part of the production process.
  • Mechanical Separator: To separate metakaolin from other materials based on physical properties.
  • Baghouse and Stack: For dust collection and emission control, ensuring compliance with environmental standards.
  • Secondary Dust Collectors: To capture additional dust generated during processing.
  • Coal Mill: For grinding and processing coal used in the kiln.
  • Ore Conditioner: To prepare ore for further processing.
  • Ore and By-Product Bins: For storage of processed materials and by-products.
  • Truck Scale and Truck Loading Facility: For accurate measurement and efficient loading of finished products.

The Metakaolin Processing Plant project highlights FWS Group’s expertise in designing and constructing advanced processing facilities tailored to meet specific production needs. The facility’s integrated design ensures efficient processing, high-capacity output, and adherence to environmental and operational standards.