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