Energy Projects That Move South Africa Forward
Our team prides itself on the delivery of uncompromised excellence, and this can be seen across many of the biggest energy projects in the country to date. We work with our customers as an integrated team to ensure the highest quality service, performance and safety standards are not only met, but exceeded.
Kenhardt Solar Power Stations PV Project
Aurex Constructors led the construction of the Kenhardt 1, 2, and 3 solar plants, delivering 540 MW of solar energy and 150 MW of battery storage. Our scope included procurement, civil works, and electrical installations, spanning transformers, inverters, and battery integration systems, showcasing our expertise in executing large-scale, complex energy infrastructure projects.
The Kenhardt Solar Power Station was commissioned to help address South Africa’s ongoing energy shortages through a reliable renewable energy solution. As one of the world’s largest hybrid solar and battery storage projects, it plays a vital role in supplying dispatchable power during peak demand
Now integrated into the national grid, Kenhardt supplies 150 MW of clean energy daily, enough to power around 150,000 homes during peak hours. The project also created 1,000 jobs, 30% of which were filled by women, supporting skills development and economic upliftment in the local community.
Kenhardt, Northern Cape, South Africa
Our Customer
Scatec
540 MW Total Solar Capacity
150 MW Battery Storage
July 2022 - December 2023 Construction Timeline
1,000 (30% female workforce) Peak Manpower
Service: Construction
Service: Construction
NCP Chlorchem 2022 Shutdown
At NCP Chlorchem’s facility in Kempton Park, Aurex Constructors was entrusted with managing a specialised mechanical, electrical, and instrumentation (MEI) Shutdown, ensuring a seamless process that prioritised safety, precision, and efficiency. By minimising operational disruptions, we are reinforcing our reputation as a trusted partner in high-risk industrial environments, delivering reliability where it matters most.
With a strong track record in high-risk industrial environments, Aurex Constructors was selected to lead this shutdown project with a peak workforce of 56 specialists. The project scope encompassed rewiring distribution board (DB) boxes, issuing compliance certificates, and calibrating control and instrumentation equipment to ensure functionality.Additionally, the team was responsible for stripping and boxing components, facilitating a smooth and compliant restart post- shutdown
The successful completion of the shutdown improved operational reliability at NCP Chlorchem, ensuring compliance with industry regulations while maintaining high safety standards. By minimising downtime the project safeguarded continuous chlorine production, which is essential for national water treatment.
Kempton Park, Gauteng, South Africa
Our Customer
NCP Chlorchem
56 Peak Manpower
± R3.6m Contract Value
2022 Completion Date
Adams Solar Project
With a construction timeline of 8 months, Aurex mobilised resources in March 2021, executing site clearing, structural installations, and electrical integration with precision. Our scope included partial engineering, supply, and full construction of the 10MW solar PV infrastructure, complete with grid connection works. The project also involved commissioning and integration assistance for free-issued components, ensuring seamless functionality.The solar PV facility, equipped with over 24,000 bifacial solar modules on single-axis trackers, optimises energy generation by absorbing irradiance from both the sky and reflected light from the ground.
The Adams Solar Project, located in Kathu, Northern Cape, is a pioneering initiative that contributes to the country’s renewable energy footprint. Developed to support private energy procurement, this project plays a vital role in grid stability and carbon emission reduction, reinforcing the shift toward a cleaner energy future.
Now fully operational, the Adams Solar project supplies over 28 million kWh of clean electricity annually, supporting Amazon Web services through South Africa’s first large-scale solar wheeling initiative. This innovative energy model allows power to be generated in Kathu and transmitted via the Eskom grid, enabling private energy transactions that enhance grid independence.
Kathu, Northern Cape
Our Customer
November 2021 Completion date
Service: Construction
Sox Emission Compliance
Aurex were selected to execute this R84 million compliance upgrade project, leveraging our mechanical and piping expertise to execute a comprehensive emissions reduction strategy.Our scope included mechanical, piping, and structural steel works, supported by painting and insulation services to enhance system efficiency. The project required precision engineering to integrate new emission control technologies, ensuring seamless alignment with regulatory standards.
Aurex Constructors is proud to have been afforded the opportunity to support our valued customer, Astron Energy, in their commitment to minimise emissions and enhance environmental responsibility at their refinery in Cape Town. In line with our shared values, we worked to ensure the SOx Emission Compliance project was executed with precision, technical expertise and a focus on sustainable refinery operations.
The SOx Emission Compliance project served to significantly reduce sulfur oxide emissions and contributes to cleaner air in the surrounding region. By implementing the advanced emission control measures the project ensures long-term compliance with national environmental regulations, supporting South Africa’s broader sustainability goals.
Cape Town, South Africa
Our Customer
Astron Energy
14 Peak Manpower
R84 million Contract Value
2020 Completion Date
Sirius, Dyason’s Klip 1 & 2 Solar PV Power Plants
REIPPP Window: 4
Aurex Constructors was appointed by Scatec to execute the full EPC scope for the Sirius and Dyason’s Klip 1 & 2 projects. Our teams delivered all major civil and electrical works, including large-scale earthworks, structural foundations, PV module mounting, and complete electrical integration
This included the installation of inverters, cabling, and grid connection systems, ensuring seamless energy transmission to the national grid. The project was delivered to the highest standards of quality and safety, reinforcing Aurex’s reputation for precision and reliability in complex renewable energy infrastructure.
The Sirius and Dyason’s Klip 1 & 2 Solar PV Power Plants were developed as part of South Africa’s Renewable Energy Independent Power Producer Procurement Programme (REIPPPP) Window 4. Located in Upington, these utility-scale facilities form one of the country’s largest solar energy installations, contributing significantly to national energy security and the transition to low-carbon power generation.
Now fully operational, the Sirius and Dyason’s Klip plants supply clean, reliable electricity to thousands of South African homes. The project supports national goals for sustainable energy development and has helped establish new benchmarks for solar construction in the region. It also demonstrated Aurex’s ability to deliver large-scale, high-impact infrastructure under tight timelines—solidifying our role as a key player in South Africa’s renewable energy future..
Upington, Northern Cape, South Africa
Our Customer
Scatec Solar
Completion Year
2020
Service: Construction
Thermal Power
Medupi Power Station Air Cooled Condensers
Managing Contractor: General Electric / GEA
Appointed by General Electric, Aurex Constructors was responsible for the structural steel, piping, and ducting works across all six units of Medupi’s air-cooled condensers. Our scope included the management of over 1,600 personnel at peak, delivering complex mechanical services under strict quality, safety, and scheduling requirements.
This contract showcased Aurex’s ability to execute large-scale industrial construction with precision and efficiency, reinforcing our reputation as a trusted partner in South Africa’s heavy industrial and energy sectors.
The completion of Medupi marked a major milestone in expanding South Africa’s energy generation capacity. Aurex’s contribution to the project supported the delivery of reliable baseload power to the national grid and demonstrated our leadership in executing technically demanding infrastructure at scale. Our involvement in Medupi further cemented Aurex’s position as a leading force in the country’s power generation and industrial construction landscape.
Medupi Power Station stands as one of South Africa’s largest and most ambitious infrastructure projects. As a key contributor to this 4,800 MW coal-fired power plant, Aurex Constructors played a critical role in delivering high-precision mechanical works that supported the plant’s long-term operational success.
Lephalale, South Africa
Our Customer
General Electric
1600 Peak Manpower
R1 billion Contract Value
2018 Completion Date
Service: Construction
Medupi Power Station – Shutdown & Completion Works
Lead Contractor: Mitsubishi Hitachi Power Systems (MHI)
As part of the continued development and operational readiness of Medupi Power Station, Aurex Constructors was appointed to focus on finalising mechanical scopes and to ensure long-term plant reliability.
Working under Mitsubishi Hitachi Power Systems (MHI), Aurex Constructors was responsible for executing mandatory shutdowns on Units 1 to 6.Our Scope included the completion of all outstanding structural steel and piping works, modifications to the PJFF (Pulse Jet Fabric Filter) system, and precision upgrades to the Ball Mills—five per unit. In addition, extensive repairs to both hot and cold ducting systems, ensuring operational integrity across the plant.
Despite logistical and labour-related challenges—Aurex maintained consistent progress and delivered high-quality outcomes across all assigned units.
The successful completion of Units 1 to 5 marked a major milestone in the finalisation of Medupi’s full operational capacity. Aurex’s dedicated on-site team provided consistent support to the customer, ensuring continuity and technical excellence throughout the shutdown period. All recruitment for this phase was sourced from the local community, contributing to regional employment and skills development while reinforcing Aurex’s commitment to local empowerment and inclusive growth.
Lephalale, Limpopo, South Africa
Owner
Mitsubishi Hitachi Power Systems (MHI)
684 Peak Manpower
March 2025 Completion Date
Service: Construction, Turnarounds/Shutdown, Maintenance
Kusile Power Station – Shutdown & Completion Works
Lead Contractor: Mitsubishi Hitachi Power Systems (MHI)
Aurex Constructors was appointed by Mitsubishi Hitachi Power Systems (MHI) to execute critical shutdown and completion works across all six units of the Kusile Power Station.
Our scope includes mandatory shutdowns, completion of outstanding structural steel and piping, modifications to the Pulse Jet Fabric Filter (PJFF) system, and precision upgrades to five Ball Mills per unit. We also carried out extensive repairs to both hot and cold ducting systems.
Aurex maintained consistent progress and delivered high-quality outcomes across all assigned units—demonstrating our ability to manage complex logistics and stakeholder environment.
The successful completion of Units 1 to 5 mark a major milestone in Kusile’s phased commissioning. Aurex’s dedicated on-site team provides continuous support to the customer, ensuring technical excellence and operational readiness. All recruitment for this phase was sourced from the local community, reinforcing Aurex’s commitment to inclusive development and regional upliftment. Our contribution to Kusile further solidifies Aurex’s position as a trusted partner in South Africa’s power generation sector.
Kusile Power Station is one of the world’s largest coal-fired power plants, designed to deliver 4,800 MW of electricity through six supercritical-pressure generating units. As a cornerstone of South Africa’s long-term energy strategy, Kusile plays a vital role in strengthening national grid capacity and reducing the frequency of load-shedding.
DELMAS, Mpumalanga
Owner
Mitsubishi Hitachi Power Systems (MHI)
Ongoing Completion Date
Service: Construction, Turnarounds/Shutdown, Maintenance
Kalkbult Solar PV Power Plant
REIPPP Window: Window 1
Appointed by Scatec Solar under a Sub-EPC contract, Aurex Constructors played a key role in the successful delivery of this 75 MWp solar facility. Our scope included the design and installation of substructures, the mounting of over 300,000 photovoltaic modules, and the execution of all associated civil and perimeter works.
The Kalkbult Solar PV Power Plant marked a historic milestone in South Africa’s renewable energy journey. As one of the first utility-scale solar farms commissioned under REIPPP bid Window 1, Kalkbult set the precedent for clean energy development in the country—and Aurex Constructors was there from the start.
This early adoption of utility-scale solar construction showcased Aurex’s ability to deliver complex renewable energy infrastructure with precision, even in a pioneering regulatory and technical environment.
Kalkbult helped lay the foundation for South Africa’s transition to a more sustainable energy future. The project delivers clean electricity to the national grid and also created local employment opportunities and contributed to skills development in the renewable energy sector. Aurex’s involvement in this landmark project reinforced our position as a forward-thinking leader in the country’s green energy transformation.
De Aar, Northern Cape
Our Customer
Scatec Solar
2013 Completion Date
Service: Construction
De Aar-3 90MWp Solar PV Plant
Plant Owner: Solar Capital
REIPPP Window: 2
Aurex was appointed to manage the full construction and commissioning of the De Aar-3 plant. Our scope included the supply and installation of materials, execution of all civil and electrical works, and comprehensive workforce management. Drawing on our proven track record in utility-scale solar delivery, we ensured that every phase of the project met the highest standards of quality, safety, and performance.
As part of South Africa’s second round of renewable energy procurement, the De Aar-3 Solar PV Plant added another 90 MWp of clean energy capacity to the Northern Cape. In partnership with Sterling and Wilson, Aurex Constructors played a key role in bringing this large-scale solar facility to life.
Our ability to coordinate complex logistics and deliver under tight timelines once again demonstrated Aurex’s strength in executing high-impact renewable energy infrastructure.
De Aar-3 continues to contribute to South Africa’s clean energy goals by supplying reliable solar power to the national grid. The project supports local energy resilience and strengthens the region’s role as a hub for renewable generation. For Aurex, it further expanded our portfolio of flagship solar projects and reinforced our position as a trusted partner in the country’s energy transition.
De Aar, Northern Cape, South Africa
Our Customer
Sterling and Wilson
2016 Completion Date
Service: Construction
Mining
Moatize Mine – Coal Processing Plant Expansion Phase 1
Managing Contractor: Odebrecht
Appointed by Vale and managed by Odebrecht, Aurex Constructors delivered one of its most complex international projects to date. With over 1,700 skilled personnel deployed on-site, Aurex executed the full SMEIPP scope—structural, mechanical, electrical, instrumentation, piping, and platework—for the Coal Processing and Handling Plants.
This included the construction of critical infrastructure such as stackers, a reclaimer, conveyor systems, crushers, and associated support facilities. The project demanded world-class coordination, technical precision, and adherence to international safety and quality standards—capabilities Aurex delivered with distinction.
The successful completion of the expansion enabled Vale to significantly increase its coal export capacity, reinforcing Mozambique’s role in the global energy supply chain. For Aurex, the project demonstrated our ability to deliver high-value, high-complexity infrastructure in remote and logistically challenging environments. It also cemented our reputation as a trusted execution partner for major mining and industrial projects across Africa.
Located in Mozambique’s Tete Province, the Moatize Mine is one of Africa’s largest coal operations. As part of its strategic expansion, Vale Mozambique commissioned a major upgrade to its coal processing infrastructure—an undertaking that positioned Aurex Constructors at the forefront of large-scale mining construction on the continent.
Mozambique
Our Customer
Vale Mozambique
1700 Peak Manpower
US $150 000 million Contract Value
2012 Completion Date
Service: Construction
Oil, Gas & Chemicals
Natref Refinery Turnaround
At South Africa’s only inland crude oil refinery, located in Sasolburg, Aurex Constructors has played a recurring and strategic role in executing complex Turnaround operations in a multi-year agreement. The projects are critical to ensuring the long-term reliability, safety, and efficiency of the Natref Refinery—an essential component of the country’s fuel supply chain.
Aurex was entrusted with managing extensive shutdown operations across multiple high-pressure refinery units. With a peak workforce of 1,500 personnel, our teams delivered hot and cold mechanical work on the Hydrocracker, Crude Distillation, HF Alkylation, Diesel Unifier, and Platformer units.
The scope required meticulous planning, strict adherence to safety protocols, and seamless coordination across disciplines to ensure operational readiness and compliance with industry standards. Aurex’s deep experience in refinery environments was instrumental in the project’s safe and timely execution.
The successful completion of the Natref Turnaround projects reinforced Aurex Constructors’ reputation as a trusted partner in refinery maintenance and shutdowns. The projects delivered enhanced equipment reliability, improved operational uptime, and strengthened safety performance for the customer. It also demonstrated Aurex’s ability to manage complex, high-stakes maintenance projects with precision and care.
Sasolburg, South Africa
Our Customer
Natref
980 Peak Manpower
2014 Completion Date
Service: Construction, Turnarounds/Shutdown, Maintenance
Sasol FT Wax Expansion 1 & 2
Managing Contractor: Foster Wheeler
Appointed by Sasol and Foster Wheeler, Aurex played a pivotal role in the strategic expansion of Sasol’s Fischer-Tropsch (FT) Wax facility in Sasolburg, an initiative that significantly boosted the plant’s global wax production capacity. Aurex mobilised a peak workforce of 650 personnel to execute the expansion using modular construction methodology. The scope included the fabrication and installation of structural steel, the supply and installation of piping systems, and comprehensive electrical and instrumentation works across both Phase 1 and Phase 2 of the facility.
The project demanded exceptional technical precision, seamless coordination, and strict compliance with Sasol’s rigorous engineering and safety standards, requirements that Aurex met with distinction. This expansion formed a key part of Sasol’s long-term growth strategy in the specialty chemicals market.
Delivered on time and to specification, the FT Wax Expansion enabled Sasol to boost its wax output and strengthen its position as a key global supplier. The project also supported local job creation and skills development, reinforcing Aurex’s commitment to community upliftment and industrial growth. Our successful execution further demonstrated Aurex’s capability in delivering complex, high-value petrochemical infrastructure.
Sasol, Sasolburg
Our Customer
650 Peak Manpower
R650 Million Contract Value
2018 Completion Date
Service: Construction, Turnarounds/Shutdown, Maintenance
Fine Ash Dam 6 (FAD6)
Managing Contractor: Hatch Engineering
At Sasol’s Secunda operations, Aurex Constructors played a pivotal role in the delivery of Fine Ash Dam 6 (FAD6)—a critical infrastructure project designed to support the long-term sustainability of one of South Africa’s largest industrial complexes. Initially commissioned to replace the decommissioned FAD5 facility, FAD6 evolved into a multi-phase effort extending from 2018 through 2022, incorporating engineering enhancements and sustained maintenance to optimise efficiency and regulatory compliance.
Commissioned by Sasol and managed by Hatch Engineering, Aurex deployed a 260-person team to execute the Outside Battery Limits (OSBL) Slurry Transfer System, integrating 15 kilometres of piping, structural steel supports, and mechanical, electrical, and instrumentation systems. Delivered in multiple phases, the project required strict environmental adherence, technical coordination, and precision in execution, ensuring seamless integration within Sasol’s larger industrial framework.
FAD6 successfully replaced the decommissioned FAD5 facility, restoring vital slurry management capacity and supporting Sasol’s long-term environmental and operational objectives. The project reinforced infrastructure reliability, regulatory compliance, and long-term sustainability.
Sasol Secunda, South Africa
Our Customer
260 Peak Manpower
R200 million Contact Value
2022 Completion Date
Service: Construction
Sasol Sulphur Shutdown and Maintenance Project
Aurex Constructors has been a trusted partner to Sasol at the Secunda Refinery since 1980, contributing to the safe and efficient operation of one of South Africa’s most critical energy assets. In 2024, this legacy continued with the execution of the Sulphur Shutdown and Maintenance Project—focused on preserving the mechanical integrity of key sulphur processing units.
Drawing on extensive experience in oil and gas turnarounds, Aurex was appointed to manage all mechanical shutdown activities on Unit 218, while also delivering ongoing maintenance services across Units 18, 219, and 518. Our team executed 43 detailed work packs over the course of the years, with daily planning and execution of mechanical tasks.
The scope included the opening, cleaning, inspection, and repair of mechanical equipment and pipelines in accordance with statutory and operational requirements. Aurex’s disciplined approach to planning, safety, and execution ensured that each intervention was completed with precision and minimal disruption to plant operations.
The project ensured continued compliance, reduced the risk of mechanical failure, and maintained operational readiness across Sasol’s sulphur units. Executed safely and efficiently month after month, the work reinforced Aurex’s reputation as a long-term, high-performance maintenance partner. Our enduring presence at Secunda is a testament to the trust built over decades of reliable delivery and technical excellence.
Secunda, South Africa
Our Customer
Sasol Synfuels
43 Work Packs Executed
Monthly scope from 1980 to 2024 Execution Period
Service: Turnarounds/Shutdown, Maintenance
Refining East Mechanical Maintenance Project
For decades, Aurex Constructors has been a trusted partner to Sasol, embedded in the ongoing maintenance and optimisation of its refining operations at Secunda. Since 2003, Aurex has delivered critical maintenance and shutdown services, ensuring operational continuity and compliance across Sasol’s refining infrastructure. This enduring collaboration is built on expertise, precision and a commitment to excellence.
Aurex has provided full-scope cold mechanical maintenance, including valve overhauls, blanking, statutory equipment inspections, and pressure testing. The work was carried out across multiple units under live plant conditions, demanding a high degree of technical skills and coordination to ensure safety and efficiency.
With a peak workforce of 721, Aurex executed scheduled and emergency maintenance interventions with agility and discipline, minimising disruptions and optimising plant performance. The ability to adapt to Sasol’s evolving operational requirements demonstrates Aurex’s role as a strategic maintenance provider capable of handling complex and high-compliance industrial environments.
Aurex’s contribution extends beyond maintenance—it was about safeguarding the long-term reliability and efficiency of Sasol’s refining operations. By minimising downtime, maintaining equipment integrity, and responding rapidly to operational demands, Aurex ensured uninterrupted production and regulatory compliance.
Sasol Secunda, South Africa
Our Customer
721 Peak Manpower
2003 to 2024 Execution period
Service: Turnarounds/Shutdown, Maintenance
Rectisol Shutdown 2024
The 2024 Rectisol Shutdown was a mission-critical intervention at the core of Sasol’s gas purification operations in Secunda. With a compressed schedule and zero margin for error, Aurex Constructors executed the shutdown with precision, achieving a zero-incident outcome while ensuring operational continuity for one of Sasol’s most essential processing units.
As the main contractor, Aurex managed full-site coordination and mechanical execution across the Rectisol unit. The scope included safe-making, stripping, brushing, hydro testing, and system punching, meticulously performed across 638 tagged items and pressure-related assets.
With 91 equipment work packs and 49 PRA work packs, the shutdown required rigorous planning, real-time responsiveness, and seamless alignment with Sasol’s operational priorities: no leaks, no injuries, and on-time delivery. Aurex’s technical discipline and deep familiarity with the plant’s systems were essential in achieving flawless execution.
The shutdown significantly enhanced the operational integrity of the Rectisol unit, enabling a safe and efficient restart while reinforcing long-term asset reliability. Aurex’s ability to deliver under pressure—safely, on schedule, and to exacting standards—reaffirms its leadership in refinery shutdowns and large-scale mechanical maintenance.
Sasol Secunda, South Africa
Our Customer
425 Peak Manpower
August – September 2024 Execution period
82,901 Man-hours
Service: Turnarounds/Shutdown
Train 2 and 3 Krypton Boost, and STAR Project
Aurex Constructors successfully delivered one of Secunda’s first Krypton Production upgrades, marking a significant milestone in regional gas production. The project enhanced Krypton output and operational stability, enabling improved profitability and efficiency for the customer. Aurex overcame logistical challenges and a late project start, executing a high-intensity multi-project intervention with precision, safety and uncompromising quality.
Operating in a compressed area with complex overlapping workflows, Aurex successfully managed 4 concurrent projects without disrupting operational integrity. The scope included the replacement of sub-cooler units and the execution of a Super Turnaround on Trains 2 and 3.
Strict adherence to engineering standards, real-time execution planning, and seamless coordination allowed Aurex to deliver under high-pressure conditions, reinforcing its credibility and leadership in critical gas processing projects.
This first-of-its-kind-upgrade significantly improved Air Liquide’s ability to maximise Krypton gas production, optimising both efficiency and profitability. The intervention also enhanced overall cold box performance, contributing to long-term stability and operational resilience of the gas processing infrastructure.
Aurex’s technical excellence, agility and problem-solving approach cement its reputation as a key partner in complex gas processing upgrades, driving innovation and operational success at scale.
Air Liquide on Sasol Refinery, Secunda, South Africa
Our Customer
Air Liquide
388 Peak Manpower
392,777 Safe Man-hours:
October 2023 – June 2024 Execution Period
Service: Maintenance
Oxygen Maintenance
During 2024, Aurex Constructors played a pivotal role in maintaining Air Liquide’s Oxygen production facilities in Secunda, ensuring operational stability and plant reliability in one of South Africa’s most demanding industrial environments.Through continuous mechanical and turnaround services, Aurex upheld performance standards while adapting to evolving operational priorities.
Operating in a high-pressure setting prone to unexpected breakdowns and rapid scope changes, Aurex sustained momentum across multiple work fronts. The team provided mechanical, piping, welding, and instrumentation services, responding dynamically to operational challenges while maintaining stringent quality and safety standards.
The project culminated in a major shutdown in September 2024, requiring rapid scalability and precision execution under compressed timelines. Aurex’s ability to scale resources and maintain execution discipline under pressure reaffirmed its capability in complex industrial gas maintenance projects.
Aurex’s contribution strengthened plant reliability, improved safety performance and reinforced customer confidence. The successful delivery of this long-duration maintenance program cemented Aurex’s reputation as a trusted partner in the industrial gases sector—consistently delivering results in dynamic, high-risk environments.
Air Liquide on Sasol Refinery, Secunda, South Africa
Our Customer
465 Peak Manpower
575,688.5 Safe Man-hours
316 PRA’s Completed
Jan – Dec 2024 Execution Period
Service: Maintenance
HOW Stream Rerouting Project
Lead Contractor: Megchem
Aurex Constructors successfully delivered the High Organic Water (HOW) Stream Rerouting Project at Sasol’s Secunda facility, executing a complex, multi-disciplinary scope that included piping, structural steelwork, scaffolding, civil works, lagging removal, winterisation, and electrical and instrumentation installations.
Every weld, connection, and system was executed with precision and purpose, ensuring the infrastructure’s integrity and long-term reliability.
This strategic initiative enabled Sasol to recover valuable by-products—acetone and methyl ethyl ketone (MEK)—from waste streams, significantly reducing atmospheric emissions and enhancing process efficiency. Aurex approached the project with agility and a deep commitment to excellence, embracing the opportunity to contribute to Sasol’s environmental stewardship and operational advancement.
Completed on time and to the highest standards, the project achieved zero injuries and met all Ready-for-Commissioning (RFC) deadlines. The rerouting solution helped Sasol meet key environmental compliance targets while unlocking new commercial value from previously discarded by-products.
Aurex’s seamless delivery under complex conditions reinforced its reputation for reliability, environmental leadership, and technical excellence in the chemical processing sector.
Sasol Secunda, South Africa
Our Customer
80 Peak Manpower
R31,000,000 Project Value
6 months Execution Period
Service: Construction
Carbo Tar, Coal Tar Filtration, and Methanol Purification and Integration Shutdown
During the 2024 shutdown at Sasol Synfuels, Aurex Constructors played a critical role in executing high-quality mechanical services across 3 essential units: Carbo Tar, Coal Tar Filtration (CTF), and Methanol Purification and Integration (MPI)). These units form an integral part of Sasol’s coal-to-liquid (CTL) and gas processing infrastructure, handling tar refining, coal-derived fuel purification, and methanol recovery.
As a trusted Shutdown contractor, Aurex ensured minimal disruption, technical excellence, and strict compliance with Sasol’s rigorous safety and operational standards.
- Carbo Tar: Focused on pressure vessel and static equipment inspections, ensuring continued efficiency in coal-derived tar processing and refining. Given the high-temperature and high-pressure conditions within this unit, maintenance interventions were critical to prevent operational failures and uphold environmental and safety regulations.
- Coal Tar Filtration (CTF): Essential for removing impurities from coal-derived liquids, ensuring the production of high-quality fuel and chemical feedstocks. Shutdown operations focused on hydraulic torquing, pressure testing, and filtration system optimisation to enhance purification efficiency and maintain compliance with emissions regulations.
- Methanol Purification and Integration (MPI): A key processing unit responsible for methanol recovery and purification, critical in Sasol’s synthetic fuel production. Maintenance efforts included tower tray repairs, pressure vessel inspections, and static equipment integrity verification to sustain safe handling and efficient methanol production.
With 75 work packs delivered, the shutdown required precision planning, real-time adaptability, and seamless execution within Sasol’s processing framework. Welding was excluded from the scope, highlighting the need for disciplined coordination and mechanical execution without high-temperature.
Executed on schedule and with minimal operational disruption, the shutdown directly contributed to safe plant operations,regulatory compliance, and extended equipment longevity. Aurex’s ability to navigate highly specialised refinery shutdowns under intense operational conditions reaffirmed its reputation as a leading partner in critical industrial maintenance.
By ensuring the continued efficiency of Carbo Tar, CTF, and MPI units, Aurex helped Sasol maintain high-performance refining capabilities, environmental compliance, and uninterrupted production, reinforcing the long-term reliability of South Africa’s synthetic fuels infrastructure.
Sasol Synfuels, Secunda, South Africa
Our Customer
334 Peak Manpower
R16,000,000 Project Value
Aug – Sept 2024 Execution Period
64,544 Man-hours
