- Plant Expansion
A world-leading manufacturer of renewable food and industrial ingredients contracted Burns & McDonnell to assist in the expansion of one of its facilities. The completed project will significantly increase the client’s high-purity fructose production capacity. Focus areas for facilitating the increased production capacity were the refinery, crystallization and evaporation sections of the existing facility.
- Process design
The client consistently aims to be the lowest-cost and most efficient producer in all of its markets. Due to limited space and highly congested working areas at the plant, Burns & McDonnell designed a centrifuge arrangement that minimized the amount of new conveying equipment and preserved space. This tactic alleviated several existing safety and efficiency concerns. Other areas of heightened efficiency included product transportability, structural interfaces and maintenance access.
Initial engineering activities began with the development of process flow diagrams (PFDs) to record the existing facility configuration. Burns & McDonnell’s experienced process engineers worked closely with on-site personnel to promote site familiarity and ensure accuracy in findings.
In addition to PFDs, the project team performed multiple heat and material balance case studies to provide process data for line size verification, pump hydraulic calculations and instrumentation specifications. Our engineers then refined existing process and instrumentation diagrams with emphasis on identifying field tie-ins to define the overall project scope. The team also prepared project line and tie-in lists. Upon sufficiently developing process documents, the team conducted a process hazards analysis.
When corresponding expansion piping systems were integrated into the facility the project team incorporated pieces on a first-come, first-served basis. Burns & McDonnell devised a plan to ensure practical and well-designed fabrication isometrics for piping around connecting tanks, pumps and other equipment: When pipe runs traversed large areas of the plant, the design included sufficient documentation to allow the installer to field run corresponding pipe. This flexibility relieved any problematic interfaces in the highly congested work areas.
- Crystallization modifications:
- Increased cooling services, centrifuge capacity and process tankage
- Raised cooling water and chilled water capacity to accommodate the new equipment
- Refinery modifications:
- Relocated existing equipment such as tanks, pumps and filters
- Installed new product purification trains