Situation

BHP’s Nickel West required a strategic decision to either offload the business asset or invest in strategy to transform the
company. With the growth of the electric vehicle market and global energy transition away from fossil fuels, BHP sought to develop a facility to manufacture nickel sulphate. As a key input to battery manufacturing, this project represented a pivotal change for the business, providing a new revenue stream in the new and rapidly growing market for battery production.

Solution

As principal contractors, Aerison self-performed design and construction services for the SMPE&I disciplines of this project. Aerison favoured a modularisation approach, fabricating 600t structural steel and pre-assembling offsite complete with pipework, electrical containment, lighting, walkways, handrailing and surface treatment ready for installation. An additional 500t of modular fabrication and tank construction was coordinated
using off-shore fabrication providers.

Aerison completed design, engineering, construction, and installation of the electrical switchroom and off-gas scrubber
unit in addition to the general SMPE&I plant works.

Highlights:

• 1090 tonnes steel work
• 25 pressure and non-pressure vessels
• 40,000lm services, ventilation & fluid pipework
• 1600 instruments & valves
• 110,000lm electrical cabling
• Fabrication of range of exotic materials including FRP, SAF,
  duplex and super-duplex & stainless steel.

Outcome

Project was delivered with a peak manning of 225 and successful completion of complex tie-ins launching long-spans over existing refinery operations.

The onsite construction hours were significantly reduced through the innovative modularisation method.