Solids handling process upgrade for a fatty acid and derivatives producer

Objective

Replace low-throughput, ageing conveying, sieving and dosing systems with a new Flexicon pneumatic conveying system, Russell Finex vibratory sieves and upgraded silica and zinc stearate dosing, to restore design capacity, improve product quality, and make the process safer and easier to maintain.

Scope

• Demolition and removal of existing conveying, sieving and dosing systems
• Fabrication and installation of structural steel, platforms, pipe supports and roof modifications
• Installation of the new Flexicon conveying system and Russell Finex sieves
• New silica and zinc stearate dosing systems and process equipment
• Compressed air, nitrogen and process pipework, with pressure testing
• Electrical containment, power, instrumentation and controls
• Testing, commissioning support, certification, as-builts and handover

Approach and delivery

Work was delivered inside a live manufacturing facility with minimal disruption. Demolition, steelwork, mechanical, piping, electrical and commissioning activities were coordinated to a tight programme across multiple floor levels in restricted areas.

The site involved combustible dusts, work at height and strict permit to work. Logistics, lifting, deliveries and specialist subcontractors were managed closely with the client throughout.

Outcome

The client now has a safer, more reliable and maintainable facility. Follow-on work has since been secured, including a new heat exchanger and pipework installation and an ammonia recovery project.