All three of Ravensdown’s manufacturing sites kicked into gear for spring following winter maintenance programmes, with the most significant work undertaken at Napier Works in Awatoto. 

As always, health and safety is a key focus at each site. 

Napier Works 

In early September Napier Works finished one its longest and most significant winter shutdowns and, in the words of Napier Works Manager, Tony Gray, “Restarted flawlessly after delivering on three significant capex projects as well as a multitude of scheduled maintenance and compliance work during the 14-week shut down.” 

First up, a newly installed acid plant convertor has not only reduced emissions, but it also includes new technology that has improved operational control and reduced the chance of human error.  

Secondly, a new set of scrubbers – significant machinery used to neutralise waste gas streams during the manufacturing process – will better capture and treat the gasses generated in the manufacturing process. 

And the finally, a major manufacturing building project redressed the damage caused by fire in September 2022. 

“With multiple workstreams running from one end of the plant to the other, work put in on logistical planning and associated management really paid off.” 

Tony said at times there would have been up to 200 additional people on site, 24/7, so keeping the projects running smoothly while also keeping people safe was no mean feat. 

“It would be rare within our industry for a site in New Zealand to be doing so much at once and complete all activities on time. The success of the concurrent projects can be attributed to the way multiple teams worked concurrently and co-operatively to get the jobs done safely. One of the particular highlights was the daily “community toolbox” where all staff and contractors got together to discuss health and safety, that day’s planned high-risk activities, crossovers on simultaneous operations and other related topics”. 

The first load of phosphate rock was processed into superphosphate during the first weekend of September and the plant has continued to run well since then, producing some of the best product the site has seen in recent times.  

Christchurch Works 

Christchurch Works began manufacturing superphosphate in mid-August following a 10-week winter shut down. Additional contractors were brought on site and worked with staff on a remedial upgrade of the den (oven) and other jobs including improvements to the fine rock bins and a grinding mill. 

Work was also completed within our scrubbing system with the lining of the fluorosilicic acid (FSA) (a by-product of the superphosphate manufacturing process) bund and the FSA storage pond to ensure we are compliant with our ‘discharge to ground’ consent.   

Christchurch Works Manager, Peter Hay, said there has also been significant work on the acid plant this year. 

“We successfully completed a major capital project to replace the super heater, and associated steam lines, so didn’t start the acid plant until later in September”. 

“Fortunately, we were prepared to start up the plant a little later and had good stocks of superphosphate and acid going into the shutdown period.” 

Over spring the site has been manufacturing superphosphate at a sufficiently consistent rate, managing the higher electricity prices we experienced in August and the early part of September. 

Dunedin Works 

Dunedin Works fared well during the recent flooding events that effected parts of Dunedin. 

Although the temporary closure of State Highway 88 forced the site to shut down for a short period, the acid plant remained operational. 

Over the site’s 12-week winter shut down the team completed a significant upgrade to a  switch room in Dispatch and installed a new bulk bagging system. The bagging project has eliminated the need to use a truck weighbridge to fill bags and increased the number of bags filled per hour. 

The team continues to work through the existing supply of raw materials and the last date for manufacturing at the site will be 31 January 2025  

After January next year, the site will continue to operate as a port store and distribution centre.