Energy solutions company Energy Partners’ landmark investment of R360-million into Clover SA’s Queensburgh mega factory is based on a servitisation model, where instead of Clover owning the energy infrastructure, Energy Partners has financed, built and operates the equipment, allowing Clover to pay only for the energy services.

At the centre of the project are cutting-edge steam, power and refrigeration solutions, designed to drastically improve Clover's energy efficiency. Over the next 20 years, the partnership between the companies will deliver significant savings, cutting operational costs by up to R792-million while setting new standards for sustainability.

Spotlight on energy efficient steam

Energy Partners designed and installed a highly efficient steam plant, featuring three 25-t/h, 25-bar boilers with state-of-the-art water treatment systems, air pre-heaters and economisers.

These advanced systems - designed and installed entirely in-house by Energy Partners - are specifically tailored to maximise energy efficiency and minimise emissions, fully aligning with strict environmental standards. The steam system's design incorporates automated coal and ash handling, along with premium boiler combustion control systems.

Overcoming challenges to deliver success

The project’s success is particularly noteworthy given the challenges faced during its execution. Installation of the system began in 2021 during the Covid-19 pandemic and had to navigate the floods and riots that affected KwaZulu-Natal over the last two years.

Despite these setbacks, Energy Partners completed the project on time and with minimal disruption to Clover’s operations, highlighting their ability and expertise in managing complex industrial projects.

Future-proof and scalable

A key feature of the new steam plant is its future scalability. Energy Partners designed the system with growth in mind, allowing for a 30% expansion of the boiler house to accommodate future increases in demand.

This flexibility ensures that Clover’s energy needs will be met as the company continues to grow, without requiring a complete redesign or new investment.

In addition, the plant is equipped with innovative waste heat recovery systems, which capture heat from the refrigeration process to pre-heat boiler feed water. This reduces Clover’s reliance on coal, further cutting energy costs and supporting its sustainability goals. Air pre-heaters and economisers enhance the system’s efficiency, making the steam plant one of the most advanced in the country.

A holistic energy solution

Energy Partners’ role in Clover’s transformation extends beyond steam, with the company’s Power and Refrigeration divisions also playing key roles in reducing energy consumption and improving overall efficiency.

A 10 MW ammonia refrigeration system has reduced Clover’s energy use significantly, while a 1.8 MWp solar photovoltaic system supplies electricity for the refrigeration process.

These systems work in tandem to create a holistic energy solution that drastically reduces Clover’s carbon footprint. By integrating solar power with advanced refrigeration and steam systems, Energy Partners has helped Clover embrace sustainable practices that will have long-term environmental and financial benefits.

Not only is the Clover SA project a shining example of how the servitisation model can benefit industrial clients, it has also demonstrated the power of long-term partnerships in addressing South Africa’s energy challenges.

The partnership between Energy Partners and Clover is a blueprint for companies seeking to embrace comprehensive, scalable and future-proof energy systems, setting a new standard for industrial energy partnerships across the country.

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Partner with Energy Partners’ Steam division to unlock long-term savings and sustainable solutions tailored to your business needs. Contact Johan Kritzinger at (0)21 941 5140 or email steam@energypartners.co.za