Revamp Client fertilizer production operations to adapt to shifting business needs.
In a design basis memorandum (DBM), Rally developed a high-level feasibility plan for converting one train of an existing plant from producing monoammonium phosphate (MAP) to ammonium sulphate (AS). A key project goal was to minimize the impact of the conversion on the other production train.
Next, Rally’s design team took a detailed look at how each system would need to be modified to achieve the target AS production rate of 60 tonnes per hour with a recycle rate of 6:1. Rally identified opportunities to repurpose surplus equipment, modify in-situ machinery, and purchase new equipment and piping.
During Client stakeholder consultations, new scope elements were added to the project to debottleneck the process and improve plant operations. One key change was the addition of a pugmill-type mixer for coating the final granular product. Extensive repairs to the plant floor and reinforcements of the existing buildings were also added to the project scope.
With the Client’s endorsement of a Class III cost estimate and a consolidated design basis, the design team proceeded to the final phase of engineering.
Rally created material requisitions(MRs), equipment data sheets, and detailed fabrication drawings for:
• Acid, binding agent, scrubber liquor, and water pumps
• Screw-type and belt-type conveyors
• Pipe reactor
• Pugmill-type coating mixer
• Hairpin heat exchangers
• MONDI ductile iron acid piping spools
• Stainless steel, Hastelloy, and PTFE-lined piping
• Low-voltage motor control center (MCC)
• Modular pre-wired electrical building
• Flow, density, conductivity, pH, and temperature instruments
Construction work packages (CWPs) were developed by Rally’s multi-discipline team for execution by contractors. These CWPs were organized and customized for construction during brief plant outages over a six-month period. This minimized the impact of revamp work on regular operations.
Throughout construction, Rally personnel were on hand to provide engineering support to the Client and field contractors. C&SU was completed much more quickly than expected, thanks in part to the robust design and creative project execution strategy.
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