Zimbabwe: U.S.$20 Million for Zimglass Furnace Revamp

Jan. 27, 2010
Harare THE G2 furnace at the country's sole glass manufacturer, Zimglass, is due for rebuilding this year at a cost of between US$14 million and US$20 million.
Zimglass managing director Mr Jacob Dube said the actual cost and timing of the exercise would, however, be dependent on the chosen energy that would fire up the furnace.
The G2 furnace has been relying on electricity but Zimglass has expressed concern about the erratic power supply from Zesa and has thus started exploring other alternatives.
"Given the erratic supply of electricity, we are currently evaluating the use of alternative sources of energy such as heavy furnace oil or gas. Once the feasibility is complete, the cost implications will also be evaluated," he said.
Mr Dube said the two partners in Headend, which is leasing the furnace from the Industrial Development Corporation, were in the process of finalising the funding plan but this would be dependant on which energy source is chosen.
Headend is a joint venture company made up of the IDC and Delta Beverages.
Mr Dube said the issue of the power source was also critical in the timing of the rebuild.
"The timing of the rebuild is strictly dependent on the electricity supply situation in the country. The unstable and disruptive power supply situation is not conducive for commissioning a new electric furnace. The Zimbabwe Electricity Supply Authority is aware of the precarious situation that this company finds itself in as far as the sustainability of our operations is concerned," he said.
Mr Dube said the IDC had formally requested Zesa to give a timeframe for guaranteed power supplies before setting the rebuild timeframe but a formal response was still to come.
Under normal circumstances, the rebuild takes 45 days, and this includes construction, equipment installation and commissioning of the plant.
"However, the critical path is the manufacture of refractory bricks which takes between six and 10 months. Therefore, the total period required is approximately 12 months from the date of payment for the rebuilt materials," he said.
Once rebuilt, a furnace can operate for between five to 10 years before the next rebuild depending on the technology used in terms of the energy source that is being used to fire up the furnace. Electric furnaces are rebuilt every five years while other furnaces that use alternative energies are rebuilt after eight to 10 years. The G2 furnace was commissioned in December 2004 with an estimated lifespan of four years.
However, Mr Dube said that the lifespan of the furnace, which was due to be rebuilt last year, was prolonged by repairs that had been done on it due to damages that occurred because of power cuts.
"During the period between 2005 and now, the country experienced unprecedented electricity power cuts which affected the walls of the furnace. Electric furnaces are very sensitive to power cuts as these erode the integrity of the furnace walls/fabric.
"Consequent to the disruptive power outages, the furnace suffered enormous damages during the period, resulting in two major cold repairs and several hot repairs. These repairs prolonged the furnace life to this year. The rebuild must be carried out this year otherwise there will be no container glass manufacturer in the country in the years to come," he said.
When new, a furnace produces between 110 and 120 tonnes of molten glass per day but as the furnace gets older the production drops. The G2 furnace is currently producing 40 to 80 tonnes of glass dail.