Medupi Power Station

Originally conceived as Project Alpha in 2007, with only three units planned to total 2400MW and estimated cost of R32 billion.

The design was changed at a late stage in 2007 and doubled in size to 4764MW.

The boilers were envisaged to be supercritical in type, which would make them 38% more effective than other Eskom power stations.[2]

A dry cooled system was also intended to use less water than other coal-fired power stations in the fleet.

Initial project costing was estimated at R69 billion but that was updated to approximately R80 billion by 2007.[3][4]

Parsons Brinckerhoff was appointed as the project engineer to oversee all construction.[5]

The power station has six boilers each powering 794 MW turbines, producing 4764 MW in total.

When completed, Medupi became the largest dry-cooled coal-fired power station in the world.[6]

Medupi's GE Steam Power Systems was awarded a Global Project Excellence Gold Award at the 2016 IPMA Project Excellence Awards.[7]

Alstom provided the steam turbines, whilst Hitachi provided the super critical boilers.[8]

Medupi is supplied with coal from Exxaro's Grootegeluk coal mine, located north of the site. Eskom placed a contract with Exxaro to supply 14.6 MT of coal per year for 40 years.[9]

Completion of the first two units was expected by 2012 but various delays impacted progress. The first 794 MW unit was commissioned and handed over to Eskom Generation on 23 August 2015. Units 5 to 1 was completed at approximately nine-month intervals thereafter.

Development of the coal yard, early 2014

Fabrication of a boiler structure, mid 2014

Fabrication of thermal chimney, mid 2011

• 18 July 2008, first structural concrete poured.
• 21 November 2008, first three air-cooled condenser columns completed.
• August 2009, Unit 6 boiler lift shaft completed.
• 9 February 2010, first structural steel erected at Unit 6 boiler.
• 12 August 2010, Chimney South concrete slide completed to a height of 220m.
• November 2010, Chimney North concrete slide completed to a height of 220m.
• May 2011: Chimney South first flue cans lined with borosilicate glass installed.
• October 2011, upgrade of D1675 access road completed.
• 8 September 2011, 10 000 ton coal silo completed.
• 21 November 2011, auxiliary boiler completed.
• 10 February 2012, direct-current supplies energised.
• 27 November 2012, first 24-hour performance test of 5,4 km overland coal conveyor.[10]
• September 2013, Unit 4 generator motor threaded into stator.
• September 2013, wet run of submerged scraper conveyor conducted, readying boilers for first fire.
• November 2014 overland ash conveyor commissioned.
• 18 February 2015, then Public Enterprises Minister, Lynne Brown, announced first unit, no 6 turbine was running at optimal speed of 3000 revolutions per minute.[11][12]
• 22 February 2016, no 5 turbine undergoes load testing.[13] Commercial operation began on 3 April 2017.
• 2016, Primary Coal stockyard and conveyor commissioned.
• December 2016, Ngwedi substation transformer commissioned (part of Medupi Power Station Integration Project).[14]
• 28 November 2017, Unit 4 was commissioned.[15]
• 6 June 2018, announced that Unit 3 had entered commercial operation.[15]
• 9 October 2018, announced that Unit 2 had been synchronised.[16] By November 2019, this unit had reached full commercial operation.[17][18]
• 27 August 2019, final unit achieved synchronisation.[19]
• Peripheral works such as overflow coal yards has a expected completion date of 2021.[20]

In order to meet the growing demand for power generation and mining activities in the Lephalale area, two main bulk raw water transfer systems were also required. This comprised a 4.5 MW pump station and 46 km pipeline extracting from the Mokolo Dam. Phase 1 of this project was commissioned in 2015.[21]

174 Kilometres of high voltage transmission lines was required from Medupi to the Borutho substation near Mokopane. Construction occurred between November 2015 till the end of 2017.[22]

The dates for full commercial operation were shifted numerous times mostly due to:

• labour disputes such as:
  • In September 2012, workers were sent home after vehicles and equipment were damaged.
  • In July 2013, a group of about 1000 workers turned violent damaging vehicles.[23]
  • In July 2014, the National Union of Metal Workers halted work for weeks.[24]
  • In March 2015, an eight week illegal strike escalated into violence, damage and intimidation.[25]

and

• technical issues such as:
  • steam piping pressure,
  • weld rechecks on the boilers,
  • ash system blockage and [26][27]
  • damages to mill crushers.[28]

Critics alleged that the government endorsed the project due to the ruling party, the African National Congress holding a 25% share of a package and stood to make a profit of close to 1 billion Rand.[36][37]

Backers of the project argued that new generation coal plants was needed.[38] Other critics argued that effective management of coal supplies was needed to existing stations.[39]

The African Development Bank lent $500 million for the project in 2008.

In 2010, the World Bank agreed to lend South Africa $3.75 billion to assist with several energy projects, with $3.05 billion allocated for completion.

The approval of the World Bank loan drew criticism for supporting increased global emissions of greenhouse gases.[40]

The design of the station does however allow for the incorporation of flue gas desulphurisation technology.[41][42]

By 2018, the government's Public Enterprises Minister Pravin Gordhan announced a forensic probe into the delays and cost overruns on the completion of Kusile and Medupi Power Stations.[43][43]