One of our customers had problems in their factory due to contamination in the feedstock. Many new raw materials are actually waste and residues from other processes, which require proper pretreatment to turn them into sustainable raw materials. A new process was devised and DWG provided assistance.
New mass and heat balance
Because the factory was going to be used for a different process than the one for which it was originally designed, everything was reviewed and re-analysed. DWG started by performing a completely new mass and heat balance analysis. Based on this, new calculations were made in respect of all the equipment, such as heat exchangers and pumps, to see what was still usable. All the utility systems were also checked to determine whether they were adequate for the new application in the factory.
The challenge
Figuring out what was needed to revamp the brownfield site (based on limited information) and transform it into a successful new site was a major challenge. DWG’s engineers were working to a tight time line, so clear priorities had to be identified and agreed with the customer. All the departments in the organisation, from management to operations, worked as a close-knit team to successfully tackle the project. As the process group for the project, we were right at the centre of this collaboration. That was very cool!
DWG as the central point of reference
This project required a multidisciplinary approach. DWG deployed 2 process engineers and a hardware engineer at a later stage. The process engineers assisted the customer with the engineering and verified the work done by another party involved in the project. The customer requested this verification as an additional quality control; our role was actually a collaboration with the other party, in which we complemented each other. We worked together closely to achieve maximum efficiency.
In summary, DWG worked on the entire process design: we determined the requirements for all the equipment, valves, and pipework and came up with a (safe) operational design for the whole system. We were involved at every stage: the initial plan, the detailed engineering and final commissioning. Our scope included:
- PFDs
- P&IDs
- The designs for both the main process and all the utilities
- Mass and heat balance analyses (both the main process and the utilities)
- Process control descriptions
- Equipment specifications
- HAZOP
- Operator training
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