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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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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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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C&I’s efforts spanned over 8 years to complete all phases. Over that time, the team adapted the project scope to address client and vendor changes, all while under close corporate observation with the high price tag.

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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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Due to geographical constraints, the project combined three substations into one. This resulted in multiple cutovers spread over 5 years to match turnaround outages. To make space for the new substation, several storage areas had to be relocated. After installation, the project finished $3MM under budget with minimal RFIs from construction.

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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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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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The team was challenged to integrate new gear into the already congested operating unit. Our open communication and interactive project management style allowed us to involve maintenance, operations, and construction to balance project objectives and meet stakeholder needs.

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