CRODA, Inc., Plant Wide Tank Farm Project, New Castle, DE
The Plant Wide Tank Farm bulk storage project is divided into three “tank farm” phases which are aligned with the Croda plant manufacturing functions served by each tank farm. Middough has performed FEL 1, 2, and 3 engineering for this project and is now in detailed engineering and design. Middough's Major Project Group is currently responsible for construction management.
The Linde Group, 575 ST PD Nitrogen Liquefier Unit Addition, Delta, OH
AWARD WINNING PROJECT: Middough provided construction management, procurement, Environmental, Health and Safety (EHS) oversight and engineering support services for the installation of the new 575 Standard Tons Per Day (STPD) Nitrogen Liquefier Unit (NLU) at their Northstar-BlueScope Air Separation Unit (ASU) plant.
Middough procurement services included identification of qualified bidders through recommendations for contracts varying in value. Construction management services included coordination of construction trade contractors along with the adjacent operating Linde ASU plant during both normal operations and scheduled maintenance shut downs.
EHS oversight focused on implementation of the Linde Safety Health and Environmental Quality (SHEQ) program and incorporated the Middough Site Observation Program.The strong participation by contractor site supervision, as well as corporate SHEQ leadership in implementing the Linde safety culture and support of the Middough Observation program have resulted in an excellent EHS performance record for the first 14 months of construction.
Materion, Beryllium Manufacturing Plant (formerly Brush Wellman), Elmore, OH
Brush Wellman has retained Middough to design a new $90+ million facility that will produce primary beryllium, the feedstock material used to produce beryllium metal products. The new facility represents a key step toward the return of a sustainable domestic supply, critical to the nation’s strategic interests.
The new facility has been designed with state-of-the-art safety features and was heavily automated. The facility design is unique in that it incorporates traditionally separate functions into one facility. The design integrates process plant and chemical operations with food science and clean room standards. This blend of requirements and capabilities challenged Middough’s HVAC designers to provide a system capable of meeting diverse, and at times, divergent needs.
Included in the facility design is a robust material handling component that efficiently handles the beryllium material as it passes through the facility. The process is highly hazardous, requiring completely closed design exceeding the requirements for active pharmaceutical intermediates, while working in an HF acid environment and with furnaces operating at up to 1400°C. The processing involved an extensive wet chemistry section to remove impurities to the ppm range, continuous evaporative crystallization and a continuous dryer system. The intermediates were extremely hydroscopic and decomposed with high temperatures. Following were a series of high temperature induction furnaces and decomposition product recovery, purification and recycling. A goal was to render waste products benign before they entered the operators’ environment and to be a near zero water discharge plant.
Haverhill Chemicals (formerly Sunoco), Phenol Recovery Column, Haverhill, OH
Haverhill Chemicals LLC, an affiliate of Goradia Capital, is a private equity company specializing in the chemical sector. Haverhill teamed with Middough to relocate an existing plant distillation column to the Phenol 2 area to recover Phenol from existing waste stream. The project included new foundations, structural steel, pumps, exchangers, piping, power and instrumentation.
The project was completed in three phases. The first phase required evaluating the existing column to meet the process requirements and development of a flow diagram. Phase II involved a FEL 3 engineering and design effort to develop a ±15 percent project estimate. Phase III was detailed engineering and design.
Middough provided installation drawings for foundations, structural steel, piping, electrical, and instrumentation. Middough provided revised PID’s for the tie-ins, as well as new PID’s for the new tower and associated equipment. Middough developed equipment specifications, obtained bids, evaluated the bids and made recommendations for purchase. The team utilized laser scanning to document the existing facilities and developed a 3D model for the new installation superimposed on the scanned backgrounds. The combination of laser scanning and modeling provided an
overall construction product that had less than four percent FCO’s.