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Mosaic New Wales MicroEssentials Conversion

Mosaic New Wales MicroEssentials Conversion Project

Major expansion has fertilizer plant exceeding design capacity

Mosaic Fertilizer, LLC | USA | 2014-2016

1.2 million

man-hours with 0 LTIs

10%

under budget

65,000 ton

MicroEssentials product warehouse

Conversion

to MicroEssentials production

Challenges

  • To meet the increasing demand for specialty crop nutrients, Mosiac needed to convert an existing dual-train, DAP granulation plant to produce their patented MicroEssentials line of products.
  • Extensive modifications were required to the existing plants to convert them.
  • The existing plant scrubber systems needed to be replaced and retrofitted for closed-loop scrubbing.
  • Equipment ventilation and dust-collection systems needed to be redesigned to improve dust collection, handling, and recycling.

Solutions

  • Execute detailed engineering, design, construction management, and commissioning services.
  • Modify the existing plants to allow micronutrient receiving, storage, and feed systems; sulfur unloading systems with a sulfur pit; new 65,000-ton MicroEssentials product warehouse with an automated reclaimer; all associated utilities and infrastructure required to support the project.
  • Replace the existing plant scrubber systems and retrofit them for closed-loop scrubbing.
  • Redesign equipment ventilation and dust-collection systems to improve dust collection, handling, and recycling.

Highlights

  • The East granulation plant started up in February 2016 and exceeded design capacity within two weeks.
  • The West granulation plant started up in June 2016 and already exceeds design capacity. The overall project is approximately 10% under budget.
  • Construction and on-site manpower exceeded 1.2 million man-hours.
  • A total of 1,660 contractor personnel were provided with safety training for site access, and no lost time incidents were reported on this project.

Project numbers

1,660 contractor personnel
1.2 million man-hours with 0 LTIs

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