Increased Capacity & Product Purity for Chemical Plant
This project was for a specialty chemical processing facility and included crystallization equipment, a dehydration system, product coalescers, raw material storage, purified product storage, pumps, control valves and electrical infrastructure. Engineering services included civil, structural, process, mechanical, electrical, instrumentation and controls.
We first performed project scoping services, namely an FEL 3, and continued with a detailed design of the specialty polymers facility to allow the process to operate continuously to increase production capacity and to provide greater than 99% of product purity. To meet growing marketing demands, the selected approach offered the most economical solution to achieve the desired capacity increase while maintaining product purity.
Previously, the production of the high purity product required a semi-batch operation of the facilities’ final crystallization equipment to reprocess the standard purity product. The additional capacity was attained by adding a new crystallizer system and product centrifuge. The system was designed using the existing crystallization technology enhanced by use of laboratory data, vendor trials, and operational data. Additional improvements to debottleneck multiple areas of the facility included replacement of a complete dehydration system, product coalescers, raw material storage, purified product storage, as well as upgrades to existing pumps, control valves and electrical infrastructure.
New equipment was designed and integrated into an existing production area requiring the strategic demolition of abandoned equipment. Additional improvement and debottlenecking efforts required the replacement of key process subsystems as well as upgrades to existing pumps, control valves and electrical infrastructure. Design documents included, but was not limited to PFD’s, P&ID’s, 3D Model, Pipe Isometrics, Line List, GA’s, Equipment List, Equipment Specifications, Instrument List, Instrument Specifications, IO List, Loop Sheets, Electrical Equipment List, Single Line Diagrams, Grounding Drawings, Electrical Classification Drawings, Civil / Foundation / Concrete Drawings, and Structural Steel drawings.
Regarding electrical and instrumentation solutions, we provided a complete electrical design for the green-field specialty chemical plant: building grounding, building lights and receptacles, emergency power generation, Class I & II, Division 1 & 2 electrical installation design, and process control system hardware design. Coordination of Fire Alarm, Building Management, Building Access, Business Data and Voice Systems was included. ITAC also had extensive involvement and coordination with local permitting authorities and utility providers. We also provided start-up support.