PROCESS SCRUBBERS AND LIQUID HANDLING SYSTEMS
Matrix Engineering provided the structural and mechanical engineering necessary to replace a mist eliminator within the catalyst scrubber system at the Nashville, Tennessee plant. The new kynar lined FRP mist eliminator was designed with expansion of the scrubber system in mind. However, spatial constraints dictated we have a very close coordination with the vessel designer and fabricator for an almost impossible fit. The existing structural steel was also upgraded to accommodate the new heavier vessel. Besides structural design and detail drawings, we also provided vessel arrangement, fiberglass ductwork layout and details, and piping drawings.
PHOSPHORIC ACID SCRUBBER
Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical engineering necessary to install a venturi/flooded elbow scrubber system with a mist eliminator at the Nashville, TN plant. A new multi-level structure was used to support and access the new scrubber and mist eliminator. This structure adjoined an existing structure and tank that were utilized for the project. The project also included a drum dumping and a lump feeding system as well as a tote-bin wash-down station. These handling projects were very difficult due to the extreme corrosive nature of the product. Besides structural design and detail drawings, we also provided vessel arrangement, ductwork layout, piping design and details, as well as electrical.
SOLUTION MIXING AND TRUCK LOAD-OUT
Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical engineering necessary to install a mixing, storage and truck load-out facility in the Nashville, TN plant. The objective of the project was to make a solution from crystals in drums or from another liquid source in the plant. The density of the solution had a narrow acceptable range and had to be controlled accurately. The entire system was integrated to the DCS control system of the plant.
PLATE AND FRAME FILTER INSTALLATION
Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical engineering necessary to install a plate and frame filter press housed in its own building and an adjacent covered tank farm at the Nashville, TN plant. The objective of the project was to replace the existing rotary drum filter and centrifuges with the more efficient filter, which decreased the amount of lost product and doubled the production capability. The existing concrete bunker, where filter cake was dumped, was utilized as the base for the new building for the filter. A new tank farm was installed to service the filter with wash-water, filter supply, and filtrate tanks. The highly automated filter was equipped with a PLC controller, which was integrated to the DCS control system of the plant. The rest of the equipment was integrated with the DCS system that controls the plant.
PHOSPHINE THERMAL OXIDIZER WITH PHOSPHORIC ACID SCRUBBER SYSTEM
Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical engineering necessary to replace an existing thermal oxidizer, hydrator and mist eliminator. The new thermal oxidizer and quencher required a 5-story roofed structural tower. The new mist eliminator required its own support and access structure. We also provided all the engineering necessary to install a new 300-hp exhaust fan. Controls for the scrubber system were integrated into an existing DCS system. Besides all structural drawings, we also provided all process, general arrangements, foundation ductwork, piping and electrical drawings.
COAL CRUSHING SCRUBBER SYSTEM
Our engineers provided the mechanical engineering necessary for the pump supply and return piping on a new scrubber system for a coal crushing facility near Birmingham, Alabama. The venturi scrubber required 2750 gpm at 30 psig and discharged into a 40 ft diameter mist eliminator. The primary return from the mist eliminator was a gravity drain line to a sluice settling pond over 300 ft away. A secondary forced return employed a 2600 gpm pump.
HYDROGEN SULFIDE SCRUBBER SYSTEM
Matrix Engineering provided the structural, mechanical and electrical engineering necessary to scrub hydrogen sulfide off-gases from an existing process. Scrubber consisted of a packed tower, fan, and proprietary solution tank. Scrubber off-stream could not discharge into the plant sewer system for safety reasons. Therefore we had to design a separate line directly to the plant outfall around 1000 ft away.
Matrix provided the civil, mechanical and electrical engineering for a capralactum tank and piping system with a new tempered water system for warming of the material for less viscous flow without risk of polymerizing the capralactum.
MVE REACTOR FEED PIPING
Matrix provided the piping design for a 1600 foot long MVE feed pipe. This project improved process efficiencies and process safety.
SAFETY SHOWER SYSTEM
Matrix Engineering provided the mechanical design and hydraulic calculations necessary for the safety showers on a multi-story process structure at Vanderbilt Chemicals in Murray, KY.
TIRE ADDITIVE STORAGE & DISTRIBUTION
Matrix provided the civil/structural, mechanical and electrical engineering necessary for a Tall Oil Distribution System at Continental Tire in Mayfield, KY. The re-circulation loop fed eight Banbury Mixers and employed a 12,000 gallon tank with over 2000 ft of piping. The tall oil was temperature critical for storage and flow. Much care was taken in the design to ensure proper temperature and flow-ability.
TRUCK & RAIL LOADING/UNLOADING STATIONS
Matrix provided the detailed engineering and project management for several truck and rail car loading and unloading stations including piping, foundation, and electrical grounding design. These projects greatly improved personnel safety and enhanced loading and unloading efficiencies.
DISTILLATION RECEIVER UPGRADES
Matrix provided the detailed engineering for complete systems upgrades for four (4) product receivers on a batch distillation unit. This included all new piping, instrumentation, valving, platforms, safety interlocks, and heat tracing and insulation. This project improved operating efficiencies and process safety.