Successful Completion of Gas Turbine Combined Cycle Power Plant EPC Projects in Ghana

Project Overview: From Design to Operation

ZHM Metal Engineering Co., Ltd. is pleased to announce the successful completion of the Engineering, Procurement, and Construction (EPC) for two significant Gas Turbine Waste Heat Recovery Power Generation Projects in Ghana. Located at the Tarkwa, Wassa, Chirano, and Edikan gold mining plants, these projects represent a major step forward in sustainable energy utilization for the mining sector.

Our scope encompassed the full lifecycle of the power plants, including detailed engineering design, manufacturing supervision, on-site construction, and final commissioning. The plants utilize exhaust heat from existing gas turbines (Titan 130 and Mars 100) to generate supplementary electricity, significantly improving the overall thermal efficiency of the mining operations.

Advanced Thermodynamic System Design

The core of this EPC project lies in the innovative Heat Recovery Steam Generator (HRSG) system. For the Tarkwa plant, we implemented a 2x22MW configuration, integrating six HRSG boilers to supply two condensing steam turbine generator units. In contrast, the Wassa/Chirano/Edikan project features a 1x22MW setup with three HRSG units feeding a single supplementary condensing turbine.

Key technical features of our Thermal System include:

◐Dual/Multi-Pressure Technology: Maximizing heat recovery by generating both main steam (approx. 3.82 MPa, 450°C) and low-pressure steam (approx. 0.5 MPa, 215°C).

◐Natural Circulation & Horizontal Layout: Utilizing a horizontal type boiler design with natural water circulation, reducing pumping power requirements and enhancing reliability.
◐Self-Deaeration System: Incorporating thermal deaerators combined with the boiler drums to ensure high-quality feedwater and prevent corrosion.
◐Bypass Flue Gas Dampers: Installing inlet and bypass dampers to allow the gas turbines to operate at peak efficiency regardless of the steam cycle status, ensuring production continuity for the client.

Robust Balance of Plant (BOP) Infrastructure

To support the thermodynamic cycle, ZHM engineered a comprehensive Balance of Plant (BOP) system.

1.Cooling Water System: We installed a closed-circuit 循环冷却水 (circulating cooling water) system featuring mechanical draft逆流 (counter-flow)玻璃钢 (FRP) cooling towers and high-efficiency双吸 (double-suction) centrifugal pumps. This system ensures optimal condenser performance even in Ghana's tropical climate (ambient temperatures up to 32°C).

2.Chemical Water Treatment: Recognizing the importance of water quality in steam generation, we implemented a sophisticated treatment plant using multimedia filtration, activated carbon, and二级反渗透 (Secondary Reverse Osmosis) technology. This guarantees the boiler feedwater meets stringent international standards (GB/T 12145-2016).
3.Electrical Integration: The project included the design and installation of 11kV switchgear, generator protection systems, and synchronization equipment. Our team ensured seamless并网 (grid connection) with the existing mine infrastructure, including the installation of fault current limiters to protect the Medium Voltage (MV) breakers.

Precision Equipment and Construction

Throughout the project, ZHM focused on precision engineering and quality installation. Our equipment list highlights the robustness of the build:

Key Equipment	Technical Specifications
Steam Turbine	Condensing type, 3000 r/min, 40-100% load range
Generator	Air-cooled, 11kV output, 0.8 Power Factor
HRSG Boiler	Horizontal, natural circulation, three-stage heat absorption
Pumps	High-pressure boiler feed pumps, condensate pumps with VFD

Conclusion: A Model for Industrial Efficiency

The successful handover of these EPC projects demonstrates ZHM Metal Engineering's capability to deliver complex, turn-key industrial power solutions. By converting waste heat into valuable electrical energy, we have helped our client in Ghana reduce fuel consumption and lower their carbon footprint.

These projects stand as a testament to ZHM's expertise in Combined Cycle Power Plant technology, Waste Heat Recovery, and EPC Project Management.

1 Drone View Chirano CCGT WHR Power Plant

2 Chemical Water Tank Plant

3 HRSG Boiler Lifting

4 HRSG Drum Economizer Installation

5 Water Cooler System Pumps

6 Pipe Rack Cable Tray To STG Building

7 STG Shaft Bearing Installation

8 HRSG Boiler Lifting Hoisting 650ton Crawler Crane

9 HRSG Boiler Piping Instrument Installation

10 Waste Heat Recovery Boiler High Temp Drum Installation

11 Steam Turbine Generator Piping Instrument Installation

12 Overhead Bridge Pipe Rack Cable Tray Installation

13 Steam Turbine Generator System Installation

14 Heat Recovery Boiler Chimney Stack Platform Installation

15 Heat Recovery Boiler Platform Pipe Support Installation

16 STG Building Steel Structure Installation

17 Cable Tray Installation

18 Boiler Mechnical Parts Lifting Installation

19 Steam Turbine Generator Shaft Installation

20 Steam Turbine Blade Generator Installation

21 Prefabricated Electrical Substation Control Rooms Installation

22 Prefabricated Electrical Substation Containers 3 Levels

23 Elevated Boiler Flue Gas Duct Tee Diverter

24 Boilers STG Building at Glance

25 Electrical Cable Trays Installation

26 Boiler HRSG System Construction Ongoing

27 Conbined Cycle Power Plant Layout

28 HRSG Boiler Top Protection Canopy Roof Sheds

29 STG System Erection

30 Boiler System Piping Instrument Installation

31 Drone View Layout Wassa Site

32 Chirano Plant Gas Turbine Exhaust Duct Heat Recovery Facilities

32 Edikan Power Plant Boiler Installation

33 Boiler Deaerator System Installation

34 STG Building Overcrossing Bridge Pipe Rack Cable Tray Installation

34 STG Building Overhead Crane 32ton Installation

35 DCS Substation Control Rooms Prefabricated Multiple Floors

36 Multiple Floor Elevated Pipe Support Rack Structures

37 20m High Boiler Canopy Sheds Roof Cladding Panels Installation

Why ZHM Huawu Gas Turbine Combined Cycle Power Plant EPC Projects?

Reliable and Customized Designs	Cutting Edge Designing Process	Free Online Price System	Easy Bolt-by-number Assembly
Over Two Decades of Experience	Value For Money	Unmatched in Quality and Craftmanship	Excellent Customer Service

Would you like to see more information and images of ZHM Huawu Steel's Metal Gas Turbine Combined Cycle Power Plant EPC Projects ? Visit our Photo Gallery.

HOW CAN WE HELP YOU?

ZHM’s world-class team — together with our raw material suppliers and subcontractors — works to solve your most challenging design, engineering, farbrication or construction issues.

Contact ZHM by telephone at +86 135-8815-1981 (wechat and whatsapp) or send us your questions via email to info@zhmsteelworks.com