GLASS FURNACE PROJECTS & SERVICES 1 Introduction Dickinson - PowerPoint PPT Presentation

GLASS FURNACE PROJECTS & SERVICES 1

Introduction Dickinson Group of Companies was founded in 1910 as a building construction company, followed by the establishment of its furnace service business in 1928. The company has 90 years experience in providing Specialist Furnace and Industrial Services to the mining, metals smelting, mineral processing, thermal power generation and petrochemical refining industries. VISION Dickinson Group of Companies’ Vision is to be a global Leading provider of Furnace and Industrial Services MISSION Dickinson Group of Companies’ purpose is to provide an integrated and multidisciplinary “ One Personalised Solution ”, by offering essential furnace and industrial services, which increase productivity and performance together with reducing costs for our customers. STRATEGY The company’s strategy is to develop the Group’s current position as a leading specialized furnace and industrial solutions company, with a global reach and to deliver long-term sustainable growth through the continued expansion of the company’s services and markets.

Dickinson Geographic Footprint Office Locations • South Africa • Zambia • Mauritius • Tianjin, China • Egypt • Namibia Business Operations • Democratic Republic of Congo Business Experience • Russia Business Alliance Locations • Brazil

Dickinson Head Office & Workshops 14,000 m 2 Total land area: Total buildings (including offices, workshops & warehouses): 8,500 m 2

Industries We Serve  Aluminium Smelting  Glass  Platinum & Nickel  Iron, Steel & Coke Making  Copper & Cobalt  Ferrochrome & Ferromanganese  Heavy Sands  Nickel  Power Generation  Cement & Lime  Chemical & Petrochemical  Ceramic  Refractory Manufacturing  Food & Beverage Manufacturing  Fertilizer Manufacturing  Water & Municipal Services  Telecommunications

Safety Policy  Dickinson Group of Companies operates according to international best practices to achieve the highest practical levels of Safety, Health, Environmental Control and Quality , and adheres to BS OHSAS 18001:2007 accreditation.  The safety of our employees and contractors is an integral part of our business, with the goal of ZERO HARM.  The Group strives to:  Demonstrate strong leadership and direction in all conceivable SHEQ issues.  Ensure a consistent approach to the management of SHEQ in all locations.  Consult and communicate with all employees and stakeholders.  Educate the workforce in risk management, safety, health and environmental principles.  Respect the right of all staff to work in an environment where they know that risks are adequately controlled.  Promote the health and wellbeing of all its staff.  Measure SHEQ performance.

Furnace Solutions Industrial Solutions

Glass References 8

Glass Furnace Services  Greenfield & Brownfield Turnkey Furnace Rebuilds  Overall Contract and Project Management  Furnace Refractory Demolition and Mechanical Dismantling  Furnace Draining and Cool-Down  Mechanical and Refractory Installation  Health and Safety Management  Furnace Heat Up and Expansion Control  Furnace and Regenerator Hot Sealing  Refractory Material Supply and Management  Waste Materials Management and Disposal  Furnace Hot Repairs 9

Turnkey Glass Furnace Rebuilds  Our Glass Furnace Projects team extensively plan, execute, manage and successfully oversee any glass furnace rebuild and upgrade project.  The company will take sole responsibility for the entire scope of work and deliver the furnace rebuilt and ready for operation.  The Turnkey Project execution includes:  Shutdown planning  Project and Shutdown management  Project Monitoring and Control  Tender and project management of subcontractors  Project Closure  Our Furnace Project team utilises modern tools to safely manage a rebuild in the shortest time possible. 10

Furnace Demolition  Leading provider of specialist furnace demolition services.  The business unit has more than 20 years’ experience, skill and expertise in rendering a professional furnace and industrial demolition service to the mining, metals smelting, mineral processing and infrastructure industries. 11

Furnace Demolition Brokk Furnace Demolition 12

Furnace Demolition Pneumatic Demolition 13

Other Refractory Demolition Projects Regenerator Entry Wall Demolition Regenerator Checker Chamber Demolition Removal of Contaminated Glass Forehearth and Refiner Demolition Melter Crown Demolition Melter Port Endwall Demolition 14

Heavy Industrial Demolition  Heavy Industrial Demolition  Industrial focus on mining & heavy industrial sectors  Dismantling Services  Specialised Attachments & Equipment

Heavy Industrial Demolition

Furnace Installation Projects  The business unit provides specialist furnace services for construction, shutdown and maintenance functions of the metals smelting and mineral processing industries.  The Dickinson Group is Sub-Saharan Africa’s most high-profile refractory installation company and employs some of the most experienced refractory engineers, project managers, supervisors, refractory tradesmen and assistants.

Furnace Installation Projects 18

Other Refractory Installation Projects Regenerator Entry Wall Installation Regenerator Checker Chamber Installation Fused Cast Big Block Cutting Melter Crown Installation Furnace Sidewall Installation Melter Port Endwall Installation

Mechanical and Structural Installation Dickinson Mechanical Projects has extensive capabilities in providing various levels of mechanical services for projects in the mining, metal smelting and mineral processing industries including:  Greenfield & Mechanical Projects  Structural Steel Fabrication and Erection  Mechanical Dismantling and Installation  Furnace Shell Fabrication, Erection and Repairs  Duct Work Fabrication and Erection  Utilities Piping :Fabrication, Installation, Welding and Final Testing  Steel Reinforcement in Civil Construction works  Mechanical Equipment Installation and Repairs  Condition based inspections of Steel Structures, Furnace Shells, Piping and Mechanical equipment. 20

Mechanical and Structural Installation 21

Manual Sump and Flue Cleaning  Our company offers manual sump and flue cleaning, using state of the art equipment and safety devices, ensuring a quick turnaround time and reduced downtime.  Our operators are highly skilled and trained to execute the manual sump and flue cleaning, and have extensive experience in performing the works for our customer base. 22

Heat-Up and Furnace Expansion Sealing 23

Refractory Materials Management  Dickinson Group believes that it is extremely important to inspect purchased refractory products at the supplier’s premises and prior to delivery to site.  We supply the service of refractory inspection, by our engineers who are qualified in inspection techniques, refractory materials, quality standards and construction methods. 24

Furnace Hot Repair Works  The refractory installation business unit provides a world-class service to the glass industry furnace hot repair requirements. Our company has the ability to execute hot flux line- and throat over coating to our clients without switching out their furnaces, no downtime and little to no production losses.  Our personnel are experienced in working under hot conditions and on furnaces working under production parameters, with the understanding that the customer needs to achieve minimal production losses and time delays.  Our company also has the capability and experience to execute hot crown repairs, including the installation of refractory materials on the crowns for the extension of it’s lifespan, as well as the hot repairs of rat holes in the furnace or the crown, and the crown expansion joint sealing. 25

Furnace Hot Repair Works  Ceramic welding  Furnace endoscopy Thermal imaging Audits  Heat up Draining Cooldown  Furnace Overcoating  Port paving cleaning  Checker sulphate cleaning  Target wall repairs and checker removal  Crown cast overcoat  Furnace drilling – bubbler and electrode installation 26

Ceramic Welding  Repairs made at normal operating temperatures  Repairs can be made where conventional hot repairs are not possible, usually without stopping production  Ceramic welding can be applied in many areas to restore damaged refractories e.g. Furnace and Regenerator crowns and expansion joints, Furnace and Regenerator Skewline joints, Port arches and Jambs, Tuckstones, Doghouse arches and corner blocks and Sill blocks 27

External Ceramic Welding – Hot Furnace Seal Up Open joints can be sealed and repaired:  Newly commissioned furnaces  External damage on old furnaces  Ports, Tuckstones and Dog House,  Main Crown expansions and Skewline joints  Protects furnace steelwork from furnace gas stingout  Reduces energy loss and lowers cold air ingress  (minimising NO x and thermal shock of refractories)  28