Case Studies

PowerHouse Energy Group – Waste-to-hydrogen Plant

Overview

PowerHouse Energy (PHE) is pioneering a waste-to-hydrogen technology via its proprietary Distributed Modular Gasification (DMG®) process. PowerHouse’s proprietary Distributed Modular Gasification (DMG®) process can convert high calorific value waste material such as tyres and plastic into a clean Ecosynthesis© gas. This “syngas” contains a high percentage of hydrogen that can be cleaned up to 99.999% purity using off-the-shelf technology to produce a road quality hydrogen fuel.

Description of Services

Engsolve completed the Conceptual Design and Basic Engineering Design of a commercial unit to process 25 Tonnes Per Day of waste. The conceptual phase included the development of a Heat & Mass Balance, Process Flow Diagrams, equipment sizing calculations, process equipment datasheets, equipment list and a plot plan. During the basic engineering phase the process was further defined with the production of Piping and Instrument Diagrams, process line sizing, Material take-off’s, Electrical single line diagrams, utility flow diagrams. Equipment vendors were also engaged to allow the production of CAPEX and OPEX reports.

Engsolve also provided site and engineering design support during the installation and commissioning of PHE’s demonstrator unit located at Chester University. The site support also included the development and implementation of a feedstock testing regime.

Confidential Energy from Waste Site Developer

Overview

A developer of Energy from Waste sites approached Engsolve with a request to undertake a technical review of technologies available for the gasification of Refuse Derived Fuel for the generation of Syngas to Power applications. In addition, they requested that layouts and feasibility level designs be undertaken for several sites based upon the preferred technology.

Description of Services

Engsolve initiated a technology review based upon the parameters provided by the client. Collated all technical and commercial information pertaining to available technologies, undertook a technical review of each process and screened its applicability to the user requirements. In conjunction with the client a preferred technology/vendor was agreed upon and Engsolve developed feasibility level layouts and undertook initial Facility designs for the given sites. Engsolve also acted at technical advisor to the client through site screening and investor meetings.

Confidential Client – Paper Mill Natural gas lines

Overview

A major Paper Making Company were undertaking a “dead -leg” review of the natural gas lines at their papermaking facility in the UK. During this review some perceived issues with the incoming natural gas line to the paper making machine hoods and the on-site CHP were raised. Engsolve were asked to review the output of their audit and the actions generated, undertake our own survey of the lines and provide any required calculations and recommendations along with undertaking a DSEAR review and up-dating the facility P&IDs.

Description of Services

Engsolve undertook a site survey of the natural gas lines, prior to reading the sites own survey and observations. The Engsolve survey was then compared with the sites own survey and any gaps / inconsistencies were investigated. An action plan was then put in place to mitigate the issues noted. The work resulted in several dead legs being identified and removed, liaison with the Grid Gas provider as to the protection of the incoming main, in addition several procedures were developed for the client to close gaps in their current systems.

In addition, a DSEAR review was undertaken and a report with recommended actions along with a Hazardous area classification schedule was produced.

Emerging Tech

IGas – Lybster Produced Water Treatment

Overview

The Lybster site comprises an oil well with the produced fluids undergoing separation of phases with the oil and water stored and the associated gas used for power generation and excess flared. The oil and water were removed from site via tanker movements. With a perceived increase in produced water during the well life, IGas requested Engsolve to develop a produced water treatment scheme capable of treating the stream to a specification suitable for discharge to the sea or to a local burn.

Description of Services

Engsolve initiated this study by reviewing the produced water analysis provided by IGas and producing a basis of design. In parallel, a review of the Scottish Environment Protection Agency (SEPA) and EU Best Available Technology (BAT) regulations was completed. Engsolve then engaged with vendors of produced water treatment packages, undertook Technical Due Diligence review and bid evaluation then generated a report to recommend a preferred vendor. Engsolve also reviewed the discharge options, including directional drilling, and produced a report detailing the costs for several options.

I-Renewables – Energy from Waste Projects Development

Overview

I-Renewables are a developer of Energy from Waste projects across the UK. They are currently developing a number of sites, utilising a number of waste streams to provide power and district heating. I-Renewables requested that Engsolve act as their Technical advisor through initial project scoping, during sales pitches and investor meetings, technology reviews and during meetings with local authorities.

Description of Services

Engsolve acts as Technical advisor to I-Renewables. This has so far required the completion of technology reviews and verifications, reviews of vendor guarantee and process claims, potential site reviews, Technical bid evaluations and provision of technical input to commercial meetings. Engsolve continue to support I-Renewables as they approach financial close on their first site. Post financial close I-Renewables have requested that Engsolve undertake an Owners Engineers role through the first development.

Ortho Clinical Diagnostics Pharmaceutical Facility, UK – Nitrogen Safety Review

Overview

A large Pharmaceutical company were developing a new system for the degassing of a fluid prior to the filling of ampules for one of its major product lines. Engsolve were requested to undertake Nitrogen release calculations to allow Ortho Clinical Diagnostics to be sure that they would be able to meet and exceed the high levels of personnel safety that are in place at the facility.

Description of Services

Engsolve undertook a site visit and with the information provided calculated the asphyxiation risk for a number of Nitrogen release scenarios. Engsolve also where required suggested mitigation measures to ensure the risks were ALARP, this included the identification of pipework and fittings in alignment with current codes and standards.

Biotechnology Facility, UK – Hazardous Area Classification Study

Overview

A major Biotechnology company were developing a new product, that required the injection of Methanol. Engsolve were asked to review the design and undertake a Hazardous area classification study based upon the design being implemented at their current site whilst maintaining their high safety standards.

Description of Services

Engsolve reviewed the clients design and proposed layout of equipment, undertook a site visit to ascertain the other process and utility equipment that were in the vicinity of the new installation. A full review and relevant calculations were undertaken, a hazardous area schedule was produced and a number of recommendations were made.

AFC Energy – Process Engineering Support

Overview

AFC Energy are an established provider of fuel cells to the global market. A refinery customer has purchased a containerised system to deliver 160kW of electrical power using their waste hydrogen stream. AFC Energy contacted Engsolve for provision of Process Engineering support to develop a FEED package for their customer.

Description Of Services

The work was initiated through a series of teleconferences and site visits to gather the required information and to understand AFC’s strategy for delivering the FEED. A heat and mass balance was developed  for the process which enabled preliminary line sizing and equipment specification to be completed, in addition to a utility summary. Process simulation models were developed to predict the pressure profiles for each of the fluids within the system. In preparation for a HAZOP study, P&IDs were developed along with Line List, Equipment List and Cause & Effect Chart. A high-level pressure relief strategy was completed, which will be finalised as the design takes shape. To support the OPEX estimate, a market review of carbon dioxide scrubbing options was undertaken.

East Africa (Confidential Client) – Pipeline Replacement Project

 Overview

The project was to replace an existing 14” hydrocarbon products pipeline which was at the end of its design life having been installed in the 1970’s with a new 20” 450 kilometer long multiproduct pipeline, associated pump stations and above ground installations (10 in number). The pipeline transported the products to the Capital from the coast and to the countries international airport via a dedicated spur line.

 Scope of Services

Engsolve supplied pipeline commissioning expertise to the construction company’s engineering consultants to write the Philosophy, Execution Plan and Commissioning procedures, in accordance with relevant codes, standards and industry best practices, to enable the safe and complete commissioning, line fill and start up of operations.  The procedures developed were incorporated into the project Computerised Commissioning Management System enabling tracking of all documentation and sign off during the commissioning phase of the project. The Commissioning Schedule was also developed enabling the efficient allocation of resources by the construction company’s engineering consultants to be identified and allocated.

ExxonMobil – AES Expansion Support

Overview

ExxonMobil have a thermoplastic vulcanisate facility in South Wales where a number of world scale extrusion-based production lines are located. As a result of increased worldwide demand for these leading-edge technology products, ExxonMobil have recently significantly expanded their production capability at their South Wales facility in an on-going plan to supply the worldwide market in the most cost-effective manner. The expansion detailed design was carried out by a large UK based design house overseen by a client engineering team.

Description of Services

Engsolve provided process, chemical and project support services to the site-based manufacturing team that was an integral part of the project client engineering team. The remit of the manufacturing team was to ensure that the detailed design met all operability requirements and that the learnings from experience gained on existing lines at the South Wales and other world-wide facilities were incorporated. These included meeting the needs of the host site utility systems in order to minimise capital investment. Engsolve took the lead in developing a solids transfer system that would otherwise have not met the throughput capacity of the lines. Engsolve have also provided support to the pre-commissioning and commissioning teams for the expansion project.