Project Synopsis

Perform a technical feasibility study for improving the processes at an explosives manufacturing facility.

Project Summary


The client, a defense solutions provider for the Federal government, operates an explosives manufacturing facility in the U.S. Process Engineering Associates, LLC (PROCESS) was contracted by the client to provide process engineering support for a study documenting the feasibility of various alternatives involving new facilities or modifications to existing facilities to increase production of several explosives. The information developed by PROCESS was incorporated into a written report by the client and subsequently issued to the Department of Defense for its determination of the most attractive options for increasing capacity. The design tasks carried out by PROCESS utilized some personnel stationed on-site at the client facility for point-of-contact purposes, as well as the gathering of critical input information.

Specific tasks for this project included:

  • Conceptual process design of two options for a new facility to recover a key material used in the manufacturing of explosives. The conceptual design for each option included the generation of drawings showing several alternatives.
  • Conceptual process design of a new unit to purify a key material used in the explosives manufacturing process. The conceptual design included the generation of drawings showing several alternatives
  • Conceptual process design of a new unit to produce a key chemical used in the explosives manufacturing process.
  • Conceptual process design of a system of new storage tanks for key materials.

Information generated for the above items included:

  • Preliminary facility siting as well as Equipment Arrangement drawings
  • Process Flow Diagrams (PFDs)
  • Heat and Mass Balances (H&MBs)
  • Equipment Lists
  • Utility Requirements Lists
  • Motor Lists
  • Waste Stream Lists.

In the execution of these tasks PROCESS made extensive use of the process simulation software CHEMCAD, as well as PROCESS’ in-depth knowledge of chemical systems and equipment used for chemicals production. Processes studied included both continuous and batch-type systems. Equipment lists included process duties as well as equipment dimensions based on vendor input or mechanical information available for similar existing equipment.

Industry Type

  • Explosives Manufacturing

Utilized Skills

  • Feasibility studies
  • Process alternatives evaluation
  • Conceptual process design

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