Chemical Company Debottlenecking
A chemical company working with cyclodextrin, toluene, and decane needed to increase yearly production by 10% in the first year of operation and maintain an additional 20% after to meet growing customer demand.
WORK COMPLETED: The project was completed in two years with a multiple phase installation plan:
- Dehumidification of inlet air to fluid dryer
- Optimization of their purification piping and mixing system
- Optimization of system heat exchangers and pumps
- Implementation of a fat/solvent centrifuge with auxiliary process systems
ADF collaborated with the client’s internal operations and engineering teams to develop a systematic approach to define the inefficiencies, provide engineering solutions, aid procurement, oversee construction, and participate in the checkout and commissioning of the individual system startups.
- Incurred no safety engineering, operational and contractor incidents
- Designed all equipment specifications to work with three separate product processes, which use different solvents and parameters for extraction
- Updated and created P&ID’s, structural, concrete and electrical drawings
- Developed equipment specifications for vendor quoting
- Coordinated equipment requirements with multiple vendors and contractors
- Provided guidance for equipment installation and use in a Class I, Division 2, Group D and Class II, Division 2, Group G environment
- Facilitated Process Hazard Analysis (PHA) reviews and meetings
- Conducted a 3D laser scan of different areas of the facility and provided point cloud data
- Created 3D AutoCAD facility model from the scan point cloud data
- Created new project piping and equipment in the 3D model
- Developed isometrics, layouts, and bill of material for bid documentation
- Saved the client time and costs by incorporating existing process pumps into the design and layout
- Developed Installation Bid Documentation and coordinated contactor walk downs
- Developed comparison tables and recommendations for vendor equipment and contractor bid packages
- Collaborated with procurement on installation dates, delivery dates, PO# follow ups and onsite delivery
- Facilitated preparation, shutdown, and closeout meetings with contractors and operations
- Supervised multiple shutdowns during different phases of the project
- Held contractors, vendors, and other teams accountable for project action items