Thermal Energy
Unveiling the dynamics of coal-fired power stations
At Aurex Constructors, we understand the need and reliance on thermal power (fossil fuel power). South Africa has 13 coal-based power plants that deliver electricity to the country. With over 15 years of experience working on coal-fired power stations, our highly skilled teams have successfully constructed and maintained a number of these power stations. Aurex Constructors is a trusted coal-fired power station maintenance, turnaround, scheduled shutdown and construction company.
- Did you know?
Aurex Constructors has worked on one of the world’s largest coal power stations.
According to Statista, coal is currently the largest source of electricity generation globally, accounting for more than 35%.
There are more than 2,400 coal-fired power plants worldwide.
Exploring thermal energy generation
For decades coal-fired power plants have been the preferred choice for energy generation due to the abundant coal reserves that South Africa has. Initially, thermal power offered a cost-effective and readily available power source. Over the years, the infrastructure has deteriorated due to a lack of maintenance which has impacted the stability of the electricity grid. This is where our unique set of skills and services aims to make a difference.
The Aurex Advantage for Coal Power Station Projects
With vast industry experience and knowledge, our skilled teams have successfully constructed air-cooled condensers, ducting and boiler works. Our maintenance teams have continued to service boilers, ducting, gas air heaters, ball mills and conveyors, amongst many other elements, for our valued customers. As a business, we can procure and will meet all the specific and technical capabilities outlined in the unique building specifications for each power station. Our clients know they can trust us as contractors or subcontractors and that we will ensure that all environmental standards are adhered to. We pride ourselves on our reliability, uncompromising excellence and the ability to get the job done within budget and scope.
What Aurex Can Do for You
On-site multi-discipline structural, mechanical, electrical, instrumentation, piping and platework (SMEIPP) construction works
Construction and transportation of pre-fabricated SMEIPP modules
Steel supply, fabrication and erection
Mechanical assembly and alignment
Piping supply, pre-fabrication and installation
Rigging, including heavy lifts and transportation
Vessel supply, fabrication and erection
Platework supply, fabrication and erection
Instrumentation supply and installation
Electrical equipment and cable supply and installation
How a coal power station works
Unlocking the potential
Coal-based power stations remain the country’s primary electricity sources. South Africa is not yet able to move away from this type of power generation, which is ultimately cost-effective due to the availability of coal. Aurex aims to be part of the solution to ensure that power plants can provide power stability through infrastructure maintenance. As we strive towards achieving South Africa’s goal of a net zero emissions environment by 2050, we support the process towards just transition.
The maintenance and construction needs of coal-based power stations create several opportunities for job creation and upskilling within the local communities. Where possible, Aurex works within the local communities to identify skilled talent for various projects.
In the case of the main power utility’s needs, Aurex can provide reliable service delivery and ensure the project is completed within budget, scope, and time.
Our Successful Thermal Energy Portfolio
Service: Construction
Medupi Power Station – Shutdown & Completion Works
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
Our Customer
Mitsubishi Hitachi Power Systems (MHI)
Mar 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
Our Customer
Mitsubishi Hitachi Power Systems (MHI)
Ongoing Completion Date
Service: Construction
Medupi Power Station Air Cooled Condensers
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.
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, South Africa
Our Customer
General Electric
R1 billion Contract Value
2018 Completion Date
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