Projects Performed by Process Engineering Associates

Recent PROCESS Projects - click on links below

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Plant Operating Companies

Chemical Plants

TiCl₄ Distillation Purification and Redesign Project

Polymerization Batch Process Evaluation and Scaleup Process Design

Biodiesel Plant Improvements for Methanol Drying Column Design

Specialty Organic Chemical Production Process Design Basis Development, Computer Process Simulation, Process Design Package Preparation, and PHA Facilitation

Resin Manufacturing Plant Process Heating System Design

Batch Metals Plant Expansion Process Design Integrity Review

Environmental Permitting Assistance for New Gasification Plant

Sugar Cane to Ethanol Pilot Plant Process Design and Process Improvements Engineering

Specialty Metals Plant Facility New Process Preliminary Process Design Package

Specialty Organic Chemical Production Process Expansion Design Package Preparation

Cellulosic Ethanol Demonstration Plant Preliminary Design

Cellulosic Ethanol Demonstration Plant Bid Package Preparation

Batch Chemical Process Engineering Support During Detail Design Phase

Relief Valve and Rupture Disk Evaluation Supporting a Chemical Plant Expansion

High-Purity Titanium Tetrachloride (TiCl₄) Distillation System Design

By-Product Reaction Pilot Plant System Design Evaluation and Pilot Plant Testing Technical Supervision

Organic Process Utilities (Steam, Hot Oil, Nitrogen) Capacity Evaluations, Process Vent, Thermal Oxidizer and Flare Systems Capacity Evaluation, and Expanded Systems Computer Process Simulation and Design

Powder Product Recovery System Upgrade Process Design and Capital/Operating Cost Estimates Preparation

Product and Process Development On-Site Engineering Support

Potassium Phosphite Batch Reactor Evaluation and Preliminary Process Design

Benzoic Acid Production Modified Process Startup Engineering and Assistance

Fume Incineration System Computer Process Simulation, and Process Design and Regulatory Compliance Evaluation

Ethanol Recovery System Detailed Process Design Package Preparation

Evaluation of Dimple Jacketed Batch Reactor Heating/Cooling Systems to Determine New Product Formula Cycle Times

Tank Farm VOC Emissions Control System Alternatives Evaluation

Batch Reactor Heat Transfer System Computer Process Simulation and Process Design Evaluation

Building-Wide Vent Emissions Control System Scrubber Alternatives Technical and Economic Evaluation, Process Design and Equipment Specifications Preparation, and Capital Cost Estimate Development

By-Product Reaction System Process Design, HAZOP, and Detail Design Review

Absorbers, Mist Eliminators, and Heat Exchangers Process Simulation, Process Improvement Engineering, and Process Throughput Evaluation

Industrial Vent/Gas Cleaning System Computer Process Simulation and Scrubber System Design and Specification

Diphenyl Ethane (DPE) Batch Production Solvent Recovery Systems Process Evaluation and Optimization, and Operations Troubleshooting and Support

Batch Chemical Production Process LEL Evaluation and Process Improvements Design

Scrubber Systems Computer Process Simulation, Operational Evaluation and Air Permitting Assistance

Light Ends Recovery System Computer Process Simulation and Condenser Process Design

Process Batch Reactors Vent Stream Control Alternatives Technical and Economic Evaluation

Multiple Batch Reaction / Product Recovery Processes Pressure Relief Systems Modeling and Rupture Disks Design/Sizing

Organic Chemicals Storage Tank Vents and Pressure Relief System Design Evaluation

Product Drying Area Offgas Characterization and Emissions Control System Process and Control System Design

Six-Sigma Process Calculations

Thermal Oxidizer Replacement Alternatives Screening and Technical and Economic Evaluation

Wastewater Treatment System Process Control System Design and Specification

Acid/Caustic Regeneration System Preliminary Technical and Economic Evaluation

Wastewater Treatment System Sampling and Compliance Plans Preparation, and System Design, Specification, and Cost Estimate Preparation

Hydrofluoric Acid (HF) Recovery System Pilot-Plant Design

New High Purity Propylene Distillation Process Design

Monomer Production Facility Distillation Column Design and Rating\

Organic Acid Production Plant Detail Process Design and Equipment Specifications Preparation

1 MM Gallon O-Xylene Storage Tank Pressure/Vacuum Relief Device Sizing

Multi-Tower HCl Absorption System Computer Process Simulation and Design

Bentonite Plant Furnaces Gas-to-Coal Conversion Feasibility Study Development

Carboxylic Acid Refining Process Capacity Expansion Study and Process Design

Xylene Recovery Distillation System Operational Evaluation and Process Improvements Engineering

Sodium Hydrosulfide Production System Process Computer Simulation and Operational Evaluation

Process Modeling and Troubleshooting Support of a Chlorinated Organic Distillation Tower

Benzoic Acid Distillation Purification System Computer Process Simulation and Offgas Instrumentation Evaluation

HCl Regeneration System Alternatives Evaluation and Distillation Tower Computer Process Simulation and Design

Sodium Hydrosulfide Production Facility Reactor Alternatives Evaluation, Computer Process Simulation, and Detailed Process Design

Sodium Hydrosulfide Production System Pilot Plant Management

Emissions Control Alternatives Technical and Economic Evaluation

Lime Production CEMS Quality Assurance Manual Preparation

Flare System Process Design Package Preparation

Ammonium Bisulfite Production System Absorption Column Computer Simulation and Operational Evaluation

Cooling Water Distribution System Upgrades Computer Process Simulation

Fume Incinerator System Process Design Package Preparation

Industrial Vent System Process Evaluation, Modeling, and Improvements Project

Relief Valve Sizing for a Glycol Heating System Upgrade

Metallurgical Coke Manufacturing Facility Quench Tower Improvements

Biodiesel Plant Improvements for Methanol Drying Column Design

Rail Car Unloading Station Relief Valve Sizing

Reactor Circulation Piping System Design

Ammonia PRV (Pressure Relief Valve) Requirement Analysis

Edible Oil Refinery Process Engineering Support and Troubleshooting

Sugar Concentration Facility Evaporator/Stripper Process Simulation

Organic Peroxide Production System Process Troubleshooting, Lab and Pilot Testing Management

Evaluation of a Glucose/Dextrose Oxidation Pilot Plant for Producing Potassium Acid Saccharate

Evaluation and Recommendations for Plant Relief Devices

Wet Scrubber Systems Simulation and Process Improvements

Metal Powder Production Chemical Reaction System Process Improvements Identification, Engineering Documentation, Implementation and Trial Batches Technical Supervision

Process Design Package for a Specialty Metals Production Facility Expansion

Nitrogen Oxides (NOx) Emissions Removal System Process Evaluation

New Catalyst Plant Nitrogen Oxides ( NOx) Scrubber and Stack Evaluations

Oxides Production Powders Handling and Processing Systems Alternatives Process Design, Evaluation, and Capital Cost Estimate

Batch Metal Powder Production System Operational Evaluation and By-Product Reaction System Alternatives Evaluation

Metals Refining Offgas Acid/Particulate Removal System Computer Process Simulation, PFD Preparation, System Upgrade Process Evaluation and Detail Design Review

HF and HNO3 Acid Vapor Emissions Estimating for a Metals Cleaning and Etching Operation

Catalyst Manufacturing Facility NOX Scrubbing System Evaluation and Troubleshooting

Sodium Processing Facility Process Design and Process Safety Evaluation

Metals Processing Facility Remote Handling Glove Box System Detail Design Support - Specialty Metal Production Facility

Reactor Grade Uranium Recovery Facility Process Design

Nuclear Research Facility Process Cooling Loops Detailed Simulation and Design, and Utilities Systems Process Design

Nuclear Research Facility Utilities Detail Process Design, Detail Design Management, Procurement and Construction Assistance, and Startup

Research Facility Commissioning System Utilities Design

Nuclear Research Facility Mercury Systems Process Engineering

Product Purification Facility Design Basis Development, Computer Process Simulation, Process Design Package Preparation, and PHA Facilitation

Specialty Chemical Processing Systems Process Design Calculations Validation

Nuclear Materials Process Design and Systems Startup Engineering

Wastewater Treatment System Upgrade Process Design, Equipment Specification Preparation, and PHA Facilitation

Thorium Extraction and Uranium Downblending Plant Process Design Review

New Process Plant Facility Area Hazards Classification

Process Safety and Risk Management Program Consulting

Process Hazard Analyses (PHAs) for Production Units

Nitrogen Oxides (NOX) Scrubbing Technical and Economic Alternatives Evaluation

Industrial Waste Water Plant Design, Pilot Program, and Commissioning

Industrial Wastewater Treatment Plant Troubleshooting

pH Control System Design and Specification for a Wastewater Treatment Plant

Wastewater Treatment System Sampling and Compliance Plans Preparation, and System Design, Specification, and Cost Estimate Preparation

Industrial Wastewater Treatment System Process Control System Design and Specification

Mixed Alcohols Plant Truck Unloading Flare System Analysis

Pigment Manufacturing Plant Vent System Capacity Analysis

Molten Salt Reactor Experiment Engineering Evaluation Assistance

Steam System P&ID Creation for an Edible Oil Plant

Process Scale Up Simulation for a Specialty Metals Recovery and Purification Plant

Chemical Plant Rail Car Unloading Station Relief Valve Sizing

Impurities Absorption Column Relief Device Evaluation

Batch Reactor Vent Stream Flowrate and Composition Characterization

Energy Optimization Study for a Trona to Soda Ash Refiner

HF/HNO₃ Transfer System Process Evaluation and Certification

New Spiral Heat Exchanger Relief Valve Sizing

Materials Recyclers / Waste Processors

Mineral Spirits Recycling Facility Energy Optimization Evaluation

Multiple Fractionation Facilities Upgrades Simulation, Preliminary Design, and Capital Cost Estimates Preparation

Hazardous Waste Incinerator Gas Cleaning System Upgrade Feasibility Study

Hazardous Waste Incineration Facility Air Pollution Controls (APC) Simulation

Biological Sludge Treatment System Computer Process Simulation, Process Design Package Preparation

Independent Third-Party Design Review of New Tire Recycling Pyrolysis Plant

Thermal Waste Treatment Facility Sludge Dewatering and Drying, and Offgas Organic Recovery Systems Process Design Basis Preparation and Alternatives Technical and Economic Evaluation

Catalytic Extraction Waste Treatment Facility Product Slurry/Reaction System Process Design Package Preparation

Caustic Byproduct Purification System Feasibility Study and Alternatives Evaluation

Hazardous/ Radioactive Waste Feed Pretreatment System Pilot Plant Test Plan Development and Pilot Plant Management

Ion Exchange Column and Ceramic Filters Process Design Reviews, Operational Evaluations, and Computer Modeling and Simulation

TSCA Incinerator Computer Mass and Energy Balance Model Development

Production Reactor System Alternatives Evaluation, Process Design, and HAZOP

Dry Active Waste Air Pollution Control System Process Design Evaluation and Computer Simulation

Recycled Oil Dewatering System Heat Exchanger Rating and Design

Catalytic Extraction Waste Treatment Facility Operating Procedures Preparation

Waste Treatment Facility Preliminary Process Design Review, Process Design, Computer Process Simulation, and Controls Design

Thermal Desorption System Computer Process Simulation and Operational Evaluation

Waste Treatment Facility-Wide Detail Design Review

Solid Waste Thermal Treatment Alternatives Technical and Economic Evaluation

Municipal Water Treatment Plant Chemical Feed System Process Design

Municipal Water Treatment Plant Capacity Upgrade Evaluation

Wastewater Treatment Facility Operational Evaluation

Petrochemical Plant

Evaluation of a Light Ends Fractionation System for Alternative Hydrocarbon Feedstocks

Propane Fractionation Using Glycol Cooling of Overhead Condensers

Fractionation System Evaluation for Cyclopentane Production

Process Safety and Risk Management Program Consulting

Process Hazard Analyses (PHAs) for Production Units

Safety Integrity Levels (SIL) Selection within a Refining or Petrochemical Plant Safety Instrumented System (SIS)

Chemical Plant Olefin Tank Relief Valve Sizing

Petroleum Refineries

Petroleum Refinery Relief Valve Study and Flare System Capacity Evaluation

Crude Distillation Unit Debottlenecking Study and Process Design

Hydrotreated Oil Stripper Process Simulation and Operational Optimization Study

Crude Vacuum Distillation Tower Computer Process Simulation and Preliminary Process Design and Specification

Reformer Debottlenecking and Expansion Studies

Crude Unit Preheat Train Modifications Design for Upgraded Desalter Operation

Long Term Refinery On-site Process Engineering Support

Industrial Investment Refinery Due Diligence Process Engineering Support

Crude Distillation Unit Preliminary Capacity Evaluation

Sour Water Stripper Revamp Study

Asphalt Refinery Caustic Scrubber Computer Process Simulation, Process and Controls System Design, and Equipment Specification Preparation

Hydrocarbon Light Ends Fractionation System Computer Process Simulation and Process Controls Design

Operations Support for Crude Distillation, FCC, Hydrotreating, Thermal Conversion, Hydrogen Units and more

Process Designs, Equipment Specifications Preparation, and Capital Cost Estimate Developments for Alkylation Unit KOH Blowdown, Crude Distillation Unit Overhead, and Fuel Gas Knockout Systems

Crude Unit Revamp Project Computer Process Simulation, Alternatives Evaluation, Process Optimization, and Capital Cost Estimate Preparation

Delayed Coker Products Intermediate Storage System Process Design

Air Blower Systems Process Design for Fluid Coker Coke Conveyance

Refinery Relief Valve and Flare System Capacity Evaluation

Refinery Knock-Out Drum and Fuel Gas Conditioning System Design

Refinery PHA Action Items Resolution for Flare Header Systems

Platformer Benzene Saturation Unit Relief Header Capacity Evaluation

As-Built P&ID Preparation

Alkylate High-Capacity Pump Detail Process Design, and Detail Design and Installation Management

Butamers Dryer Upgrades Process Design

Amine Unit Addition Flare System Capacity Evaluation

Amine Unit Flare Header Loading Scenarios Development and Flare Capacity Evaluation Basis Preparation

Refining Units Computer Process Simulation, Pressure Relief Valve Evaluation, and Flare System Modeling and Analysis

Flare Header Loading Scenarios Development and Pressure Relief Valves Capacity Evaluation Study Update

Relief Systems and Flare Loading PHA Recommendations Process Engineering

Flare Vapor Recovery System Preliminary Process Design

Flare System Computer Process Simulation and Capacity Evaluation

Butane Vaporizer and Railcar Unloading Facilities Pressure Relief Devices Evaluation

Pressure Relief Valve Design Evaluation

Pressure Relief Valve Design Evaluation and Process Safety Information Preparation

Operating Procedures Review and Update

Pressure Relief Valve Capacity Evaluation

Pressure Relief Valve Capacity / Design Evaluation

Sour Gas Sweetening Sodium Hydrosulfide Plant Computer Process Simulation, Preliminary Process Design, and Heat Exchanger Sizing and Design

Regulatory Compliance Audits at Multiple Petroleum Refineries for OSHA Process Safety Management and EPA Risk Management Program Regulations

Process Hazard Analyses (PHAs) for Petroleum Refinery Production Units

Maximum Intended Inventory Volume Calculations for OSHA PSM

Flare Stack Replacement and Relocation Study

Refinery Flare Header and Seal Pot Modeling

Refinery Wastewater Effluent Throughput Capacity Study and Debottlenecking

Firewater System Hydraulics Study to Support a New Refinery Processing Unit

Hydrocarbon Tank Farm Condensate Recovery System Modeling and Debottlenecking

Splitter and Stabilization Column Reboiler Improvement

FCC Unit Wet Gas Compressor Lube-Oil Filter Improvement Design

Refinery Crude Furnace and Feed Train Hydraulic Improvements Engineering

Specify Process Instrumentation Ranges for Refinery Upgrade

Development of Refinery Safe Operating Limits (SOL)

Petroleum Refinery Process Safety Information Development

Petroleum Refinery PSM Compliance Support and Process Safety Information Development

Determination of Refinery Maximum Intended Inventory Levels

Process Safety and Risk Management Program Consulting

Process Hazard Analyses (PHAs) for Production Units

Lubricants Production Facility OSHA PSM and EPA RMP Compliance Assessment

Safety Integrity Levels (SIL) Selection within a Refining or Petrochemical Plant Safety Instrumented System (SIS)

Refinery Wastewater Effluent Throughput Capacity Study and Debottlenecking

Refinery Fuel Gas System Review and Instrumentation Recommendations

Refinery Complex Relief Valve Study and Flare System Capacity Evaluation

Petroleum Refinery Crude Tower Replacement Study

Petroleum Refinery Kerosene Tower Replacement Study

Pharmaceutical Facilities

Process Modeling of a Pharmaceutical Plant Pilot Reactor System

Condensing System Computer Process Simulation, Technical Evaluation, and Upgrades Preliminary Process Design

Pharmaceutical Pilot Plant Syltherm XLT Heating/Cooling System Process Simulation

Pharmaceutical Medical Device Tinting Process Improvement Study and Alternatives Evaluation

Pipeline Operations

Anhydrous Ammonia Pipeline/Terminals Computer Process Modeling and Simulation, and Process Improvements Engineering and Design

Gas Pipeline Pump Station Relief System and Process Safety Assessment

Process Hazard Analyses (PHAs)

Power Generation Plant

Power Plant Di-Basic Acid Recovery System Feasibility Study

Power Generation Cooling Loop Process Simulation Assistance

Power Generation Facility Wastewater Treatment Plant Design Review

Terminal / Tank Farm Facilities

Emissions Modeling of Cryogenic Ammonia Storage Facilities

Sodium Hydroxide and Sodium Hydrosulfide Storage Tanks Heat Loss Modeling and Evaluation

Ammonia Condensing System Upgrade Alternatives Technical Screening and Preliminary Technical and Economic Evaluation

Fuels Blending Facility Fume Incinerator Cost Reduction Alternatives Evaluation and Recuperative Heat Exchanger Computer Process Simulation, Design, and Specification

Anhydrous Ammonia Terminals PSM Compliance Support

Perform Process Hazards Assessments (PHAs) at Multiple Refined Product Pipeline Terminals

Acetylene Recovery Unit Alternatives and Preliminary Process Design

Process Hazard Analyses (PHAs)

Technology Providers

CHEMCAD Enhanced Productivity Training Course Development/Teaching

Process Simulation for Producing Green Diesel from Variable Feedstocks

Biomass-to-Power Facility Feasibility Study and Alternatives Evaluation

Biodiesel Plant Process Simulation and Excel Interface Development

Cattle Manure Derived Biogas Purification System Process Design

Ethanol Plant Simulation and Process Design Package Automation

Ethanol Technology Provider Multi-Plant Process Design Package Assistance

Ethanol Plant Simulation and Process Design Package Automation

Design of Skid Mounted Ethanol Distillation Tower With Particulates in Feed

Municipal Solid Waste to Synfuels Production Preliminary Process Design

Downstream Systems Preliminary Process Design for a Biomass to Syngas Process

Biomass Gas to Liquids (Fischer-Tropsch) Facility Feasibility Study

Independent Third-Party Design Review of New Tire Recycling Pyrolysis Plant

Cellulosic Ethanol Plant Process Design Assistance

Biomass-to-Power Facility Preliminary Cost Estimation

Biomass Refining Preliminary Process Design

Equipment Manufacturer Separations Column Design and Sizing

NaHS Removal System Reactor, Scrubber, and Stripper Design Support

NaHS Unit Relief Valve Calculation and Sizing

Duct Hydraulic Line Sizing for a coke Processing Plant

Cellulosic Ethanol Plant Process Design Team Assistance

Sulfur Reaction Technology Development Evaluation

Caustic Radioactive Waste Treatment and Storage System Design Support

Bitumen/Heavy Oil Field Upgrading System Pilot Plant

Sour Gas Sweetening Sodium Hydrosulfide Plant Computer Process Simulation, Preliminary Process Design, and Heat Exchanger Sizing and Design

Pilot Plant Support for Novel Heavy Oil Upgrading Process

Power Plant CO₂ Capture Pilot-Plant Design

Flue Gas Mercury Removal Processes Design Basis Development

Duct Hydraulic Line Sizing for a coke Processing Plant

Spray Dryer Scrubber Air Line Simulation and Sizing

Caustic Byproduct Purification System Feasibility Study and Alternatives Evaluation

Biomass to Power / Liquid Fuels Facility Feasibility Study Support

Process Simulation for Producing Ethanol from Cellulose Feed Stocks

Methanol/Dimethyl Ether Co-Production Facility Preliminary Process Design

Venture Capital Investors

Industrial Investment Refinery Due Diligence Process Engineering Support

Biodiesel Plant Site Engineering Evaluation and Due Diligence Support

Chemical Plant Purchase Due Diligence Evaluation

Glycerin Refining Process Due Diligence Support

Law Firms

Organic Peroxide Product Contamination Expert Witness

Chemical Waste Tank LEL Incident Investigation and Expert Witness

Compressed Air Piping Design Evaluation and Design Field Verification Expert Witness

Recent PROCESS Projects - click on links below

Projects Listed by Client Type

Engineering Firm (A/E, E&C, EPC) Subcontract Projects

Equipment Manufacturers / Process Equipment Supplier

New Startup Companies

Operating Company Corporate Engineering

Plant Operating Companies

Chemical Plants

Materials Recyclers / Waste Processors

Petrochemical Plant

Petroleum Refineries

Pharmaceutical Facilities

Pipeline Operations

Power Generation Plant

Terminal / Tank Farm Facilities

Technology Providers

Venture Capital Investors

Law Firms