Process Archives - C&I Engineering https://www.cieng.com/project_service/process-technical-solutions/ C&I Engineering Tue, 01 Oct 2024 14:52:03 +0000 en-US hourly 1 Stillage Screens and Modular Boiler Installation https://www.cieng.com/projects/stillage-screens-and-modular-boiler-installation/ Tue, 01 Oct 2024 14:51:20 +0000 https://www.cieng.com/?post_type=project&p=3710  C&I performed a front-end study and detail design for this project.  The project required installation of a new water treatment...

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 C&I performed a front-end study and detail design for this project.  The project required installation of a new water treatment and new boiler building in an operational distillery. Integration of systems must occur during a planned summer distillery outage and coincide with a major plant expansion. 

The stillage from the stills is separated in new screeners and the thick stillage is pumped a considerable distance across a road and railroad track to an Anerobic Digestion facility, designed by others. After processing, the C&I team piped the RNG back to the distillery and blended it with an existing natural gas feed to power the new modular boilers. The team has navigated the challenges of working with multiple vendors, permitting entities, and engineering firms to coordinate the design and installation of this project.

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Distillery Tank Farm and Processing Unit Design https://www.cieng.com/projects/distillery-tank-farm-and-processing-unit-design/ Tue, 01 Oct 2024 14:42:32 +0000 https://www.cieng.com/?post_type=project&p=3704 The objective of this project was to design high-yield processing units and a tank farm for whiskey production, capable of...

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The objective of this project was to design high-yield processing units and a tank farm for whiskey production, capable of handling variable batch volumes ranging from single barrel products to large-scale distilled spirits. The scope included designing flexible systems that allow for the efficient transfer of liquids between the tank farm and various processing tanks, as well as accommodating specific processes such as double-barreled products, chill filtration, and direct access to bottling lines.

The processing and bottling facility will be located in Shelbyville, KY, near the distillery, and will be constructed with phased production expansions in mind to support future growth. The design and layout will be reflected in the process description and P&IDs, ensuring the facility’s ability to meet both current and future production demands.  

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Crude Heat Integration Project (CHIP) https://www.cieng.com/projects/crude-heat-integration-project-chip/ Tue, 10 Sep 2024 15:19:24 +0000 https://www.cieng.com/?post_type=project&p=3671 This major crude unit revamp, completed during the Q1 2024 Turnaround, showcased our exceptional process design capabilities. This project, estimated...

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This major crude unit revamp, completed during the Q1 2024 Turnaround, showcased our exceptional process design capabilities. This project, estimated at $50MM TIC, was completed on time, within budget, and to the utmost satisfaction of our client. Our team worked tirelessly to upgrade reduced crude to higher value products, resulting in less frequent fouling of crude exchangers and minimal loss of profit opportunities due to exchanger cleanings. Despite the congested nature of the crude unit, our team was able to retrofit numerous pieces of equipment and accommodate stress analysis requirements, bringing piping layout up to current codes.

We started this project in the Definition phase, and despite not having the benefit of completing early phases, we made sure to conduct multiple onsite visits and walkdowns with the customer and provide onsite PE support. Our in-person attendance at 3D Model and Constructability Reviews ensured that the project was successfully completed and installed. We are proud of our team’s exceptional work and look forward to continuing to provide top-notch services to our clients.

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Tank Replacement Program https://www.cieng.com/projects/tank-replacement-program/ Fri, 28 Jan 2022 19:09:37 +0000 https://www.cieng.com/?post_type=project&p=1361 The goal of this project is to repair and/or replace aging tank assets. The client reached out to C&I due...

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The goal of this project is to repair and/or replace aging tank assets. The client reached out to C&I due to our expertise and familiarity with the parent company’s specifications and preferences. As an on-going program, we are able to help manage program budget, cash flow, and schedule. Our collaborative nature enables us to coordinate effectively with subcontractors and vendors. Our strong Civil & Structural department is overcoming design challenges of setting extremely large tanks in tight spaces. For example, we installed a new tank, 100,000 barrels, that was nearly double the capacity of the existing tank while keeping and repairing the existing tank for added capacity. We are excited to see this program progress while building a relationship with a new client.

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Urea Capacity Expansion https://www.cieng.com/projects/potash-urea-expansion/ Fri, 28 Jan 2022 19:07:38 +0000 https://www.cieng.com/?post_type=project&p=1409 This client sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD to meet increasing market demand....

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This client sought to increase its urea capacity from 1,300 TPD to approximately 1,650 TPD to meet increasing market demand. This is due primarily to its ability to reduce NOX emissions in diesel engines while achieving a 4% to 7% increase in gas mileage. Because of the economic opportunities realized by increasing production capacity, C&I conducted FEL-1 conceptual phase through Detailed Design, Start-up and Commissioning.

To accurately model the process changes, our team created a benchmark simulation of the entire Urea Unit. Creating a Hysys model was a challenge and had to be rigorously tested. Due to the unique chemistry of the process, the urea and ammonium carbamate components had to be created and regressed binary interaction parameters for multicomponent mixtures had to be developed. Our model was validated against a test run, providing confidence in the simulation of future operation. The process team used creativity to address the need for supplemental compressed CO2 gas feed by using liquid CO2 to support the overall capacity increase.

The existing unit was congested, requiring finesse in siting equipment and routing piping. This is where our expertise in retrofit design combined with the 3D modeling tool and laser scan set us up for a successful project. We were able to involve stakeholders in a constructability review early in the design process to locate several new pieces of equipment in an existing structure.

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Refinery Energy Conservation Audit https://www.cieng.com/projects/refinery-energy-conservation-audit/ Fri, 28 Jan 2022 16:43:56 +0000 https://www.cieng.com/?post_type=project&p=1358 C&I was approached with an opportunity to assist our client and the local utility provider, Puget Sound Energy, to discover...

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C&I was approached with an opportunity to assist our client and the local utility provider, Puget Sound Energy, to discover energy conservation ideas to present for grant funding. Our Process team focused on refinery electrical users to identify inefficiencies and propose control strategy to reduce energy demand. To increase payback over time, operation of compressors and pumps were altered to reduce the amount of recycle through the process, resulting in less energy usage.

Through our ASHRAE level 2 energy audit, the proposed scope reduced kilowatt usage by 1,626 hours per year. Our team’s out-of-the-box approach resulted in significant savings and favorable payback. Taking an in-depth review of the facility, beyond the typical ASHRAE updates, we were able to identify unique applications for reducing electrical energy usage.

“The individuals who work in refineries everyday were impressed with the ideas and thoughts our team created. We were able to identify energy savings where no one else could.”

John Droste, C&I Project Manager

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ASO System Revamp for HF Alky Unit https://www.cieng.com/projects/aso-system-revamp-for-hf-alky-unit/ Fri, 28 Jan 2022 14:58:11 +0000 https://www.cieng.com/?post_type=project&p=1371 Leveraging our previous experience with Acid Soluble Oil (ASO) Washer Systems, our team provided insight on how systems are configured...

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Leveraging our previous experience with Acid Soluble Oil (ASO) Washer Systems, our team provided insight on how systems are configured at similar sites to thoughtfully execute the Feasibility phase of the project. At this facility, the current ASO neutralization and spent KOH handling system in the Hydrofluoric Alkylation (HF Alky) unit is a labor-intensive batch process that has many environmental and safety concerns. The system will be replaced with one that is similar to a ConocoPhillips (now UOP) ASO Washer system used at multiple other refineries. This will reduce the likelihood of environmental releases of HF acid and operator exposure to caustic, ASO and HF acid that are present during the manual process. As an added benefit, the new system will also result in operating cost savings.

The project will design and commission equipment which allows for continuous, closed loop treatment of ASO within the HF Alky unit.  As a cost savings, existing equipment will be repurposed where safety or integrity is not compromised. Drawing upon our experience from other refineries, our process team scaled the technology to match refinery flow rates based on comparison of ASO to Caustic ratios from other existing units. Our support on this project extended beyond creating a cost estimate, we also attended our client’s presentation to management. We not only care about project design, but the entire project process and are here to help our clients in any way we can!

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Madagascar H2S Plant https://www.cieng.com/projects/madagascar/ Mon, 24 Jan 2022 19:06:52 +0000 https://www.cieng.com/?post_type=project&p=1102 C&I was excited to work on this world class project to support one of the largest nickel project’s ever constructed....

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C&I was excited to work on this world class project to support one of the largest nickel project’s ever constructed. Our unique H2S process is utilized to support mining operations, including this site which is the largest in the world for H2S production. We joined this project during the construction phase and spent almost four weeks evaluating their building processes and pointing out areas of concern. From there, we created a punch list and started working on the design package. We returned on-site to support start-up and commissioning alongside a multi-cultural workforce. With many language barriers, our team had to be adept at communicating, training, and interpreting signs and materials.

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Flexible Hydrotreater https://www.cieng.com/projects/flexible-hydrotreater/ Mon, 24 Jan 2022 18:12:02 +0000 https://www.cieng.com/?post_type=project&p=1350 C&I initiated this project at Feasibility and saw it through to Detailed Design. The goal of this project was to...

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C&I initiated this project at Feasibility and saw it through to Detailed Design. The goal of this project was to gain ability to process naphtha and gas oil simultaneously, allowing the refinery to become flexible to market changes. In order to save our client significant capital investment and improve their ROI, our team took an outside-of-the-box approach of utilizing the reaction section and repurposing equipment. This strengthened our partnership and demonstrated our commitment to finding cost-saving opportunities for our clients.

A key component of this project was repurposing dated, idled equipment, requiring C&I involvement in fit-for-service evaluations. As part of this effort, we modified the charge heater to change the burners and add a burner management system that wasn’t there before. This required installation of a SIS infrastructure, which was used to support temperature monitoring on reactor and burner management system.

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Flare Gas Recovery Compressor https://www.cieng.com/projects/mpc-ird-flare-gas-recovery/ Mon, 24 Jan 2022 17:01:00 +0000 https://www.cieng.com/?post_type=project&p=1337 Our team worked with the client to address their flare gas consent decree, targeting high concentration H2S streams. Two approaches...

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Our team worked with the client to address their flare gas consent decree, targeting high concentration H2S streams. Two approaches were taken. For one flare system, a new liquid ring compressor was installed. For the second flare system, we evaluated alternate technologies for reducing H2S through upgrades in the amine and sour water systems as an interim measure to meet the decree, ultimately lowering overall project cost.

There were three streams that the system could not recover, therefore C&I identified a method for recycling them back to the plant. By recycling these streams, we were able to save $3MM in total installed costs. We were one of the first to install this new compressor and worked directly with the vendor (SIHI) to ensure smooth engineering and install and to provide a reliable system for emissions reduction.

The site selected for the compressor required significant prep work, including filling in a pond and reworking drainage to other sewer systems. Our team routed over a mile of large bore piping, including a new pipe bridge, to tie the systems together.

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