RCR Energy Projects

Design & Supply of Heat Recovery Steam Generators (HRSGs)  img 0412 web
RCR Energy


Thai Oil


Sriracha, Thailand





RCR was awarded a full Design and Supply contract by CTCI Corporation as part of the Thai Oil Public Company Limited Small Power Producer Project at their Sriracha Refinery, Thailand.

This order was won against several international competitors. Scope includes provision of two supplementary-fired, dual pressure, natural circulation Heat Recovery Steam Generators (HRSGs).

Award of this contract builds on RCR's long-standing relationship with Thai Oil, having previously provided HRSGs based on RCR's proprietary design, which reduces installation complexity through an innovative modular construction approach.

It also establishes RCR in the continuing Combined Cycle Power Plant market in Thailand.


Power Generation Works  img 9349RCR Energy


BHP Billiton Iron Ore


Yarnima Power Station, Newman WA





RCR has been awarded a contract to provide power generation works for BHP Billiton Iron Ore's Yarnima Combined Cycle Power Station in Newman, Western Australia.  

The scope of works includes the design, manufacture and supply of three Heat Recovery Steam Generators (HRSGs) and associated equipment. 

Due for completion in the second quarter of 2013, the contract is valued at approximately $30 million and is the first major power contract awarded to RCR using AE&E Australia technology, which was acquired by RCR in May 2011.

It demonstrates the depth of RCR's intellectual property in energy technologies, with capabilities including design, supply and installation of Combined Cycle Power Plants which incorporate HRSGs. RCR's technology base is suitable for gas and liquid fuels, biomass, renewable energy and coal. 


140MW(e) Combined Cycle Power Station 
RCR Energy


British Gas Group


Darling Downs, QLD



 img 0437 smaller




A subsidiary of ANZ Investment Bank awarded AE&E Australia (subsequently acquired by RCR Energy) an EPC contract to deliver a baseload 140 MWe (net) combined cycle power station.

It was at the time of commissioning, the world’s first combined-cycle power station entirely fired by untreated coal seam gas and Australia's first steam turbine condenser cooled by coal seam methane waste water.

The scope of work was the EPC design, supply, installation, testing and commissioning of a combined cycle steam and gas turbine power station, consisting of 2 x Siemens SGT800 Gas Turbines, 2 x AE&E designed and supplied HRSG’s, 1 x Siemens SST-400 Steam Turbine Generator. Balance of plant included cooling water systems, water treatment, HV/MV/LV electrical system, control system and instrumentation and all civil and structural works.


450 MW Combined Cycle Gas Fired Power Station  
RCR Energy


Sino Iron


Cape Preston, WA



 img 9942-3




A subsidiary of  CITIC Pacific Mining & China Metallurgical Group Corporation awarded AE&E Australia (later acquired by RCR) an EPC contract to deliver a baseload 450MW(e) combined cycle power station.

The scope of works included the design, supply and installation, testing & commissioning of a combined cycle steam and gas turbine power station, consisting of the uplly & ereaction of 6x Siemens Gas turbines, 6x proprietary HRSGs complete with interstage burners, 6x SST Steam Turbine Genrators and 1 Gas Turbine in an open scycle configuration, cooling water systems, water treatment plant, HV/MV/LV electrical system, control system and all civil works.



Power Station Major Outage Services
RCR Energy – Stelform VRBT


Macquarie Generation


Liddell Power Station and Bayswater Power Station, situated between Singleton and Muswellbrook, Upper Hunter Valley, New South Wales


Zero LTI during more than 100,000 RCR man hours








As part of the ongoing alliance agreement with Macquarie Generation established in 2007, RCR successfully delivered three major alliance outages during FY 2010. The projects were conducted at the Liddell Power Station and Bayswater Power Station in New South Wales.


The scope of works at the Liddell Power Station encompassed boiler and valve overhaul services. At the Bayswater Power Station the scope included the replacement of both main condenser and steam feed pump expansion joints, and inspection and repair of cooling tower diffusion packs.


Safety was a vital component of the projects. RCR delivered both the Liddell and Bayswater Power Station projects with zero LTI’s during 100,000 man hours.



EPC Biomass-Fired Steam Boiler Plantnestle chile 2012-02
RCR Energy – New Zealand




Osorno, Chile, South America





RCR was awarded an EPC order from Nestlé to supply steam boiler plant for a new factory being built in Osorno in southern Chile, South America.

RCR was contracted to design and supply a complete, biomass-fired steam boiler plant, including a back-up boiler (LPG-fired) and all ancillary plant required within the boiler house. The main boiler is a B&W Towerpak® boiler designed by RCR under license from Babcock & Wilcox Power Generation Group Inc. USA.

RCR’s state-of-the-art boiler plant incorporates a number of innovations to maximise energy efficiency and ensure clean combustion, using vibrating grate technology suited for high moisture biomass fuels.

Three-dimensional modelling design technology enabled operation and maintenance to be optimised, with modular design incorporated to improve planning and execution of shipping, road transport and erection.



nestle gympieTurnkey Engineer, Procure, Construct (EPC)
RCR Energy




Gympie, Queensland





RCR Energy supplied a 16MW Babcock & Wilcox® Towerpak™ BFB Boiler to one of Nestlé's largest facilities in Gympie, Australia.

  • Turnkey Engineering, Procurement, Construction (EPC)
  • Mechanical works
  • Electrical installation
  • Commissioning
  • Training


The BFB boiler, designed under license from Babcock & Wilcox Power Generation Group Inc. USA, was identified as the only option capable of dealing with the special high moisture biomass fuel mix of sawdust and coffee production waste. The boiler featured:

  • BFB combustion system
  • High efficiency boiler with economiser and recuperative air heater for energy recovery
  • Particulate emission control using Electrostatic Precipitator



altRecovery Boiler Lower Side Wall Replacement
RCR Energy


Carter Holt Harvey Tasman (CHH)





RCR Energy provided shutdown services for the replacement of the Kraft Recovery Boiler lower furnace side walls. This was the second major boiler rebuild project at the Tasman site, following the successful replacement of the entire superheaters and roof section of the same boiler in 2006. The project scope included:

  • Pre-manufacture of lower side wall composite furnace panels and auxiliary equipment
  • Detailed advanced planning to minimize overall shutdown duration to 18 days, working a 24/7 routine
  • Site management and coordination of resources associated with critical path works


fonterra edendale b4 018Steam Boiler Design, Installation, Commission 
RCR Energy




Edendale, Southland, New Zealand





RCR Energy provided a 37MW Babcock & Wilcox® Towerpak™ steam boiler at Fonterra's new number four Milk Powder Plant. The scope included:

  • Design
  • Installation
  • Commission