Project Synopsis

Perform a complete process design for a very large  expansion of a batch specialty metal production facility.

Project Summary


The client owns and operates a batch specialty metal manufacturing facility in the South Western U.S. and contracted Process Engineering Associates, LLC (PROCESS) to execute a complete process design for an eight (8) fold  expansion of a batch specialty metal production facility.  Major unit operations included batch reduction reactors, reaction product water washing and acid leaching systems, chemical feed systems, vacuum dryers, a wastewater treatment system (including unit operations of acid neutralization, fluoride precipitation reaction, filtration, and evaporation), and all relevant utilities required to operate the commercial-scale production facility.

Major project tasks included:

  • Process design basis development
  • Mass and energy balance development
  • Process flow diagrams (PFDs) and process description preparation
  • Existing equipment evaluation for use in the expanded process
  • Process controls design
  • Piping and instrumentation diagrams (P&IDs) preparation
  • Equipment, line, and instrument lists preparation
  • Existing offgas scrubbing system and utilities systems capacity evaluations
  • Wastewater treatment system design
  • Chemical feed systems design
  • Equipment duty specifications and data sheets preparation.

The thirty two (32) PFDs that were prepared showed batch loadings, transfer times, and overall cycle times for the batch parts of the process and run times and flow rates for the continuous parts of the process, and fully described the four (4) different grades of metal products produced.  The fifty eight (58) P&IDs that were prepared delineated both new and existing equipment, piping, and instrumentation for the purpose of clarifying subsequent detail design, procurement, and installation scopes of work.  The scrubber and utilities systems evaluation project task involved evaluating the capacities of existing offgas scrubber and glycol systems employed at the plant for heating and cooling.  Design of a new deionized water system and wastewater treatment system that balanced the plant water demand was a crucial part of the project because the plant has no permitted liquid outfall.  Equipment duty specifications and data sheets were developed for new deionized water and wastewater treatment equipment required by the process.

The engineering documents developed during the course of this project were assimilated into a comprehensive process design report that formed the basis for a Request for Proposal (RFP) issued to engineering companies bidding on the detail design.

Industry Type

  • Specialty Metals Production

Utilized Skills

  • Front End Engineering Design (FEED)
  • Batch process design
  • Schedule A package preparation
  • Plant expansion
  • Waste water treatment system design
  • Basic engineering package (BEP)

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