Mosaic New Wales MicroEssentials Conversion project

1.2 million labor 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.

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

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 personnel exceeded 1.2 million labor 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.