A LIVING SYSTEM
Lamergyre Alloys Limited does not contemplate "Environmental Impact". We embrace a strict policy of "Environmental Integration".
Our vision frames this policy as "exercising exemplary environmental neighbourliness". In practical terms, we apply the same process and efficiency rigour, as we do in our plant design, to the human equation.
Whereas initial or cursory examination of the scope of this project might appear to indicate that the sheer scale would pose incalculable threat to surrounding communities and the broader environment, in fact, that very size provides a unique opportunity to derive substantial economies-of-scale gains, quite literally from BENEATH the ground up.
To achieve this, Lamergyre Alloys defined the complete footprint of our built environment as one large "organism", to establish critical interdependencies of the diverse elements, and also to identify all systems that would be best served by collaborative, centralised effort.
This is the Living System design philosophy embedded into every square metre of the project.
The Elixir of Life
Even in a situation of adequate supply, the impact on the surrounding communities can generate animus sufficient to disrupt operations. The mere sight of the behemoth has a profound effect on perception, and it is inevitable that any localised issue with water supply will be attributed almost by default to the industrial leviathan.
This realisation, that regardless of where this project was commissioned there would never be enough water, made solving this question a primary objective. Initial viability studies based on the unvarnished reality of the demands of a project of this size confirmed the broad analysis - unless we made more water, we would only make drought.
In order to mitigate this, we have included the provision of a Seawater Desalination Plant to service the full demand of the plant.
This ensures that the plant has no adverse effect on the existing municipal water resource and ensures that even in drought conditions water is always available for the plants requirements.
A Higher Power
The monolithic national electrical supply utility Eskom faces significant challenges in terms of supply and the cost of electricity, as well as the fact that the production is, in the main, generated by aging coal-fired power plants.
As a large consumer of electrical power, Lamergyre Alloys Limited determined that we would still use fossil fuel, in the form of LNG, for our DRI plant and other furnace applications , but in line with global trends, the plant systems are designed to be converted to run on Hydrogen when the technologies are commercialised [indications from the industry by 2030].
Electrical power for the plant will be generated by our own LNG fuelled CCGT power plant. Our offloading and tank storage will be located close to the Ngqura port and be piped to the Seawater desalination and plant and the Steelworks bulk storage tanks [3 months capacity].
The energy production system will incorporate co-generation via waste heat recovery systems. The major energy saving is related to the smelting of the ores and alloying processes.
A reduction of at least 40% of the energy required per ton of steel produced is anticipated as the raw materials will be delivered to the plant [highly concentrated] as ore and or concentrates and prepared for smelting [DRI process and pelletising processes, then smelted and fed directly into the alloying system [wet metal aisle approach]. As a result we achieve a significant reduction in cost and more efficient production processes.
The Nett-Positive Algorithm
The project also encompasses the establishment of the human settlement for the employees and their families, an estimated population of 15 000 people.
The provision of training, housing and community services for the employees challenges us with an opportunity to make those developments an integral part of the overall project, in order to achieve social and environmental integration efficiencies on a par with the production and commercial efficiencies of the stainless steel facility.
By sheltering this settlement under the umbrella of utilities supplied by the plant, Lamergyre Alloys Limited ensures a firm foundation for sustained maintenance of quality-of-life outcomes.
In addition to the primary accomodation and residential developments, there is significant investment in education. Key to our success, in terms of the human factor, is the availability of sufficiently skilled and experienced employees. The deprivation endured by the industrial sector locally has denuded the labour market of many vital competencies.
In order to fill that void, we are establishing an education and training pipeline as a first-order priority, to develop skilled personnel who will be "custom-built" for the range of employment opportunities that emerge from the project.
The education framework is an aspect of our broader "cradle-to-grave" approach towards social responsiblity. We seek to provide good quality employment and living conditions that will encourage long-term loyalty in our staff, and offer opportunities for future generations.
It is our aim to design and implement this project as a marquee demonstration of sustainable, nett-positive industrial, environmental and social integration on a massive scale. A living system that will be welcomed as a boon by the region and its people.