SerenOx Sulphuric Solutions — Operations Plan
The SerenOx production facility will be designed and constructed to international best practice standards for sulphuric acid manufacturing. The plant will utilise a modern double-contact, double-absorption (DCDA) sulphur-burning process, which is the industry standard for high-efficiency acid production with minimal SO₂ emissions.
Section 5 · Business Plan
Operations Plan
The SerenOx production facility will be designed and constructed to international best practice standards for sulphuric acid manufacturing. The plant will utilise a modern double-contact, double-absorption (DCDA) sulphur-burning process, which is the industry standard for high-efficiency acid production with minimal SO₂ emissions.
Of 98% technical-grade sulphuric acid (H₂SO₄) produced in Richards Bay for export to the Democratic Republic of the Congo.
5.1 Manufacturing Facility
The SerenOx production facility will be designed and constructed to international best practice standards for sulphuric acid manufacturing. The plant will utilise a modern double-contact, double-absorption (DCDA) sulphur-burning process, which is the industry standard for high-efficiency acid production with minimal SO₂ emissions.
5.1.1 Facility Specifications
| Parameter | Specification |
|---|---|
| Nameplate Capacity | 220,000 tonnes per annum |
| Product Grade | 98% H₂SO₄ (technical grade) |
| Technology | Double-contact double-absorption (DCDA) sulphur burner |
| SO₂ Conversion Efficiency | >99.7% |
| Tail Gas Treatment | Wet electrostatic precipitator + caustic scrubber |
| Site Area | 12 hectares (including storage, logistics, and buffer zones) |
| Storage Capacity | 25,000 tonnes (on-site tank farm) |
| Cooling System | Closed-loop mechanical draft cooling towers |
| Power Supply | 35 MW grid connection + 5 MW standby diesel generation |
| Water Supply | Municipal supply + 2,500 m³ rainwater harvesting reservoir |
5.2 Production Process Overview
The DCDA process involves the following key stages: elemental sulphur is melted and filtered before being atomised into a combustion furnace operating at approximately 1,100°C, where it reacts with dry air to produce sulphur dioxide (SO₂). The SO₂ gas passes through a catalytic converter containing vanadium pentoxide catalyst beds, where it is oxidised to sulphur trioxide (SO₃) with >99.7% conversion efficiency. The SO₃ is then absorbed into concentrated sulphuric acid in absorption towers, producing commercial-grade 98% H₂SO₄.
The double-absorption configuration significantly reduces SO₂ stack emissions compared to single-absorption designs, ensuring compliance with South Africa’s National Environmental Management: Air Quality Act (NEM:AQA) and the World Bank Group’s Environmental, Health, and Safety Guidelines for sulphuric acid production.
5.3 Logistics & Distribution
SerenOx’s distribution model is designed to provide reliable, safe, and cost-effective transport of sulphuric acid from the Richards Bay facility to mining customers in the DRC’s Katanga Copperbelt. The logistics network will comprise multiple transport modes and strategic staging points along the corridor.
5.3.1 Primary Transport Routes
| Route Segment | Mode | Distance | Transit Time |
|---|---|---|---|
| Richards Bay to Musina | Transnet Freight Rail | ~1,200 km | 3–4 days |
| Musina to Kasumbalesa (via Zimbabwe/Zambia) | Road tanker fleet | ~1,800 km | 5–7 days |
| Kasumbalesa to Lubumbashi | Road tanker (local fleet) | ~100 km | 1 day |
| Lubumbashi to mine sites | Dedicated last-mile delivery | 50–300 km | 1–2 days |
5.4 Quality Management System
SerenOx will implement a comprehensive quality management system certified to ISO 9001:2015, encompassing all aspects of production, storage, handling, transport, and customer delivery. Key elements of the quality system include incoming raw material inspection and testing protocols, in-process monitoring with automated sampling at critical control points, batch-level certificates of analysis issued with every shipment, customer complaint management with root cause analysis and corrective action tracking, annual management reviews and continuous improvement initiatives, and third-party surveillance audits by an accredited certification body.
5.5 Health, Safety, Security & Environment (HSSE)
Safety is a non-negotiable priority at SerenOx. The Company will implement a zero-harm HSSE management system aligned with OHSA requirements, the SANS/ISO 45001 standard for occupational health and safety, and international best practices for hazardous chemical operations. All employees and contractors will receive comprehensive HSSE induction training, ongoing competency assessments, and regular emergency drill participation. The facility will be equipped with state-of-the-art fire suppression, acid spill containment, and emergency shower/eyewash stations throughout.
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