Project Background of The Benzene Alkylation Project in Secunda
The Benzene Alkylation at Catalytic Polymerisation (BACP) project was focused on transforming operations at CatPoly West (Unit 32). Originally home to eight Cat Poly reactors built for oligomerisation, the plant is now evolving to expand its capabilities. Through the BACP project, four of these reactors are being converted, two in each phase, to drive benzene alkylation, while the remaining units continue powering oligomerisation. This upgrade marks a major step in boosting flexibility and efficiency at the site. Beyond its operational impact, the BACP project reflects how targeted engineering upgrades can enhance local supply chains and drive sustainable industrial performance.
Scope of Work:
Sasol Synfuels entrusted New Age Engineering Solutions (NAES) with a comprehensive scope of work for the BACP project. This encompassed mechanical and welding tasks at CatPoly West (Unit 32). The NAES mechanical team disassembled, isolated, and pressure-tested components during the modification phase, while welding operations were executed according to approved plans.
Challenges & Solutions
Variations: As the project progressed, the scope naturally evolved. NAES swiftly adjusted its plans, demonstrating flexibility and resilience. While some tasks were not completed as initially intended, proactive measures were taken to realign efforts and ensure project continuity.
Weather Conditions: NAES successfully navigated through unpredictable weather conditions with careful planning and coordination. By maintaining open communication channels and implementing contingency plans, the project progressed smoothly within the designated timeline.
Ongoing Design Updates: The dynamic nature of the design phase required ongoing updates to piping isometric drawings and 3D models. NAES maintained efficiency and adaptability, integrating each revision smoothly to support accurate and safe execution.
Scope Growth: As additional requirements emerged, NAES managed the growing scope effectively through strategic resource allocation and proactive planning.
Conclusion
Despite the challenges encountered, a collaboration between Wood, Sasol Group Tech, and NAES facilitated the timely execution of tie-in points for the BACP project at CatPoly West (Unit 32). The NAES team completed the project on schedule, maintaining a safety-first approach throughout and achieving a record of zero injuries and incidents.
IMAGE: GEMINI AI
