Matrix Engineering Projects & News

NEW 6000HP TOWBOAT BUILD - ENGINE MONITORING SYSTEM

Fri, 26 Jan 2024 22:01:50 GMT

Matrix was proud to provide the PE Certified Engine Monitoring System for Crounse's newest vessel, the M/V Alice. Under our TUGMONITOR brand, Matrix Industrial Systems provided an AB CompactLogix PLC system to fully communicate via ethernet with the new GE Twin Engines. Our system monitors and records engine alarms history for meeting the Coast Guard standard for Subchapter M requirements.

CLASS II COMBUSTIBLE DUST COLLECTION SYSTEM

Tue, 01 Nov 2022 15:19:23 GMT

CORROSIVE / COMBUSTIBLE IODINE DUST

Matrix designed and supplied a dust collection system for pharmaceutical grade of corrosive and combustible dust in a Class II environment. In order to meet NFPA criteria for handling combustible dusts, the filter was equipped with a rupture panel as well as an ISOFLAP isolation valve that sensed a potential backdraft from explosion within the inlet duct. The system ventilated a climate conditioned space and as such, had an additional extra level of filtration and returned its discharge back to the room. Due to the possibility of fire and/or explosion, the system utilized a smoke detector and automated bypass damper to prevent smoke from being blown back into the room.

Our PLC based control system also utilized variable speed on the fan control for maintaining proper vacuum levels within the system, despite the differential pressure through the filter elements as well as interlocking the fan motor with the explosion/fire safety instrumentation.

DRUM FILLLING CONTROL SYSTEM

Mon, 31 Oct 2022 14:57:56 GMT

CLASS I AREA PLC CONTROLS

Matrix designed and supplied a custom drum filling system for pharmaceutical grade of corrosive and combustible dust in a Class II environment. A variable / fast closing gate was used for bulk and dribble fill of the drum. A check weigh station is below powered rollers beside the filling station where the liner is tied and the drum lid fastened. The drumming system is capable of filling different drum sizes as well as storing drumming campaign batch data for drum traceability. Automated roller conveyors were employed for handling empty and filled drums.

A key element to the success of the filling system was the instrumentation and minute vacuum control for prevention of fugitive dust while maintaining fill accuracy.

DRUM FILLLING SYSTEM OF COMBUSTIBLE DUST

darren@matrixengineer.com (Darren Jarvis) — Sun, 30 Oct 2022 14:00:34 GMT

PHARMA GRADE CLASS II DIV 1/2 POWDER PACKAGING

Matrix designed and supplied a custom drum filling system for pharmaceutical grade of corrosive and combustible dust in a Class II environment. The drumming system was capable of filling of filling different drum sizes as well as storing drumming campaign batch data for drum traceability. Automated roller conveyors were employed for handling empty and filled drums. A check weigh station is below powered rollers beside the filling station. A variable / fast closing gate was used for bulk and dribble fill of the drum.

One of the primary challenges was the reduction and capture of fugitive dust while maintaining the accuracy of the fill. This required precise control of minute vacuum levels for de-dusting of the interior of the drum liner as well as significant / high velocity dust capture for any that might escape. Our mechanical expertise with proper instrumentation and control allowed us to accomplish this with the same dust collection system. The drumming room was a climate / dehumidified conditioned space. Our high velocity slotted ventilation hood drew a significant air change within the space. To maintain climate control, the ventilated air was filtered twice and returned to the room. Our attention to the placement of the this returned air back into the room created a draft and by its direction helped move any fugitive dust into the the hood.

HIGH CAPACITY VACUUM CONVEY SYSTEM - MULTI SOURCE

Thu, 03 Feb 2022 22:05:59 GMT

(14) ALTERNATING SEQUENCED CONVEY INLETS THRU A 10" LINE AT 15.0 MTPH

Matrix designed and specified equipment for a modular (14) Section Product Final Dust Collector and vacuum take-away system. A 150HP Vacuum Blower was deployed for pulling the hot and abrasive product through (2) 10" branch convey lines serving (7) modular DC sections each to a common converging switch and ultimately through a vacuum receiver/filter with the capability of dropping product to (2) 100MT Silos. Design rate for the system was 15 mtph. The system design rose to over 115ft above grade.

P2O5 LUMP DISSOLVE FEEDER

Wed, 01 Dec 2021 15:30:19 GMT

Matrix provided conceptual and hard mechanical design of a heavy duty screw feeder for metering phosphorus pentoxide (crystallized phosphoric acid) into a dissolve tank. Due to the hot reaction during hydration in the tank (resulting into very hot phosphoric acid) the variable speed screw feeder consisted of a 316L S/S 12 inch diameter auger and 1/2 inch thick trough. A special dump hopper with automated closing lid was designed with a large grated opening and bypass chute at the inlet of the feeder.

Very special design considerations were made for protecting the conveyor seals and bearings from making contact with the hot acid. Our design allowed the acid crystals or hot liquid to fall out into an isolated gap and into the tank before it challenged the seal. This was a highly successful design has virtually eliminated the huge stock piles of drummed feedback material that accumulated due to the inability to dissolve the crystallized acid safely.

After 20 years of continuous service in this extremely harsh corrosive environment, Matrix was called back to engineer a new drive and speed reducer on the unit.

MICRO-INGREDIENT BATCHING AND VACUUM CONVEY

Mon, 01 Feb 2021 19:20:14 GMT

MULTI-SOURCE VACUUM CONVEY WITH MULTIPLE DESTINATIONS

Matrix re-designed and improved a batching system with (13) possible ingredients supplying (2) possible destinations using (1) vacuum blower. Ingredient amounts ranged from 33 lb down to 0.1 lb and required complete bubble-tight isolation since batching of some ingredients was underway while others were being transferred to a overall batch check-weigh via a common vacuum convey line.

Matrix also completely modernized the Modicon PLC based control system with new hardware and improved programming.

MATRIX AND THE SHARK TANK EXPERIENCE

Sun, 03 Jan 2021 00:15:28 GMT

Matrix Industrial Systems was proud to work in conjunction with AC Marine in designing and supplying critical systems for Georgia Aquarium's newest venue to experience sharks directly with the grand opening of their 1.2MM gallon Shark Tank. This attraction allows you to submerge into the tank within a shark cage and begin an underwater journey traversing the pool as it is suspended and moved by a hoist/monorail system. Breathing air for the participants is supplied through an umbilical tethered to the cage and connected to a specialized Breathing Air Control System (BACS). Matrix supplied and installed this system with its umbilical as a turnkey project. Matrix and AC Marine were proud to be guinea pigs (or should I say SHARK BAIT) on the maiden voyage!

SURFACE SUPPLIED BREATHING AIR SYSTEM

Mon, 21 Dec 2020 01:07:32 GMT

Matrix designed, supplied and installed the complete BACS. Our system incorporated many levels of redundancy and failsafe design on the shore as well as in the cage itself. We deploy a 2-stage primary breathing air compressor with a secondary 2-stage back-up. In the event that all 4 stages were to fail and the system pressure dropped below setpoint (or a major power failure), then we have emergency shore supplied high pressure K-bottles that automatically deploy to maintain the air supply. On top of that, if breathing air pressure within cage itself were to drop too low (either complete failure from shore or if the umbilical became detached from the cage) then we designed another high pressure emergency air supply within the cage itself. This system was completely mechanical in nature bolstering a failsafe independent system design.

Matrix's project scope was as follows:

Engineer and HAZOP the complete sanitary breathing air system as a life safety critical system.
Supply and Install the BACS as a complete Equipment Package.
Supply and Install the PLC Based Control System for the BACS as a UL Certified 508A Control System.
Supply and Install the Umbilical, Festoon System and Connections to Shore and Cage.
Supply and Install the Cage Breathing Air Manifold and Components.

CLASSIFIED AREA PACKAGING BIN VENT FILTER

Mon, 02 Nov 2020 02:22:03 GMT

Matrix Engineering was asked to help solve material storage problems due to the hygroscopic nature of Carbopol. Matrix provided the mechanical engineering necessary for designing a new bin vent and DRY nitrogen purge arrangement that vented the hopper only when necessary and cleaned the filter bags only when dirty. Matrix also provided a bin discharging aeration system for eliminating and/or preventing bridging problems. In addition, Matrix provided the control sequence and electrical engineering necessary for operation of the bin vent and aeration discharge system in a Class I Div 2 Group D and G environment.

DRUM STAGING, INDEXING AND TRANSFER SYSTEM

Thu, 01 Oct 2020 23:03:36 GMT

METAL PART DRUMS TO WASHING SYSTEM AND TRANSFER TO TOTES

Matrix designed and supplied a drum based material handling system for transferring various metal parts/fasteners to a washing system. Our system also handled the washed parts after transferring them to smaller totes to be used in the downstream process. Our system was capable of staging 30 filled drums with a variety of different possible parts. Our filled drum infeed system utilized a PLC with wireless barcode scanning to track each batch of parts being washed and subsequently printed a barcode data sheet dropping it in each of the washed parts finished totes at the end of the system.

This process automated a formerly labor intensive process in which an operator was responsible for dumping and elevating each drum individually. With our system, the operator was able to efficiently load the indexing conveyors, quickly barcode scan them in place and walk away from the system and perform other duties.

On the discharge side of the washing system, we utilized a "tote de-stacker" to store and index totes into the catch-out process. After the Totes where filled with clean parts, they went to automated indexing conveyors for ultimate removal with a fork truck.

CUSTOM DRUM DUMPER WITH SPIN AND WASH CAPABILITY

Thu, 01 Oct 2020 00:42:32 GMT

DUMPING STICKY METAL PARTS TO A WASHER SYSTEM

Matrix designed, supplied and installed a turnkey custom drum dumper for COMPLETELY DISCHARGING OILY, STICKY metal parts to a washing system.

This process automated a formerly labor intensive process in which an operator was responsible for dumping and elevating each drum individually. The parts were so sticky, the operator was require to use a hand brush to clean out each drum onto a an elevating conveyor. These various small metal parts also had to be brushed off of the elevating conveyor at the end of each drum batch. These parts also tended to hang in the conveyor and cause maintenance issues.

The Matrix design solution consisted of a steep tilt 60deg dumper that was capable of spinning and washing out in the lifted position. We also utilized a dump chute with a rough sheet finish to prevent surface tension sticking of the oily parts. For the drum wash out system we provided a recycle tank from the upstream wash process with a pump and spray wash nozzle to the drum interior.

This system was fully automated with the ability to self load and unload from our drum handling roller conveyor system also provided by Matrix.

HAIR SPRAY ADDITIVE DRUM FILLING

Thu, 02 Jan 2020 03:06:43 GMT

Matrix Engineering provided the structural, mechanical and electrical engineering for a drum packaging improvement project at ISP. The previous drum filling operation was manual and labor intensive requiring tipping and manhandling of 600 lb drums.

The product in this case was an additive for hair spray which is responsible for its stickiness. The product is very viscous with the consistency of a very thick syrup that dries like glue. Matrix conceptualized and designed twin drum filling lines in which empty drums are palletized and filled on a scale. Loading arms for filling drums were designed to swing to either pallet scale for versatility in loading drums in either drumming line from two different tanks. Our engineers designed the piping systems associated with the product as well as caustic piping required to backwash the system and clean it out after packaging runs. We also designed an quick-acting air operated swing door system for accessing each scale with a fork lift. This area was also a Class I Div 2 area.

December 23rd TV Premier - A Matrix Christmas Special!

Thu, 19 Dec 2019 02:53:07 GMT

Matrix appears in World's Greatest!....
Episode 283

Matrix makes its television debut on the show World's Greatest!....Episode 283. Found on Direct TV Channel 305 and Dish Network Channel 250. We are proud to talk about some of our capabilities and how much we enjoy serving our clients across a wide spectrum of industries. It was an honor to be selected and participate in the production. We love showcasing our unique designs and this show barely scratches the surface.

Matrix Engineering, a Paducah, Kentucky based consulting engineering and systems firm, is scheduled to be featured on the national television show “World’s Greatest!” The episode (283) will air Monday, December 23rd at 5 a.m. CST. For specific information about where to find “World’s Greatest!” on cable channels locally, visit http://worldsgreatesttelevision.com/tv_schedule. Or check listings on Direct TV Channel 305 and Dish Network Channel 250 for World's Greatest TV.

Now in its 13th season, “World’s Greatest!” is a fast-paced tour around the world featuring behind-the scenes footage and interviews with unique companies, products, people, and travel destinations. The episode features Matrix Engineering for its strong industrial background which it has applied successfully across many business sectors. “We are honored to be selected as a featured company on “World’s Greatest!” because being part of the show gave us a great opportunity for expanding many of our niche markets from pulverized fuel delivery, marine control and underwater systems,” said Founding Partner, Darren Jarvis.

Matrix Engineering, PLLC was founded in 1995 upon the principle of Engineering Excellence. Matrix quickly established a strong reputation in the chemical, pulp and paper, and manufacturing sectors. This consulting business later expanded its capabilities from a design firm to a system provider known as Matrix Industrial Systems. Matrix currently provides both designs and systems to a variety of clients. Some of our niche market brands are DENSI-FEED (pulverized fuel systems), TugMonitor (Towboat Alarm Systems) and THERMO-DIVE (Hot water delivery to divers in a cold water environment). Matrix continues to take on new clients and explore new industries. Our design principles and experience along with our dedication to listen to and serve the client are the keys to our success.

TRUCK & RAIL LIQUID LOADING/UNLOADING STATIONS

Mon, 25 Nov 2019 22:45:05 GMT

Over the years Matrix has provided the detailed engineering and project management for several truck and rail car loading and unloading stations. Projects included piping, foundation, and electrical grounding design. Many of these projects were for flammable and/or toxic liquids. These projects greatly improved personnel safety and enhanced loading and unloading efficiencies.

TALL OIL STORAGE & DISTRIBUTION

Mon, 25 Nov 2019 22:42:01 GMT

Matrix provided the civil/structural, mechanical and electrical engineering necessary for a Tall Oil Distribution System at Continental Tire. 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.

COAL CRUSHING SCRUBBER SYSTEM

Mon, 25 Nov 2019 22:32:56 GMT

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.

BOGALUSA, LOUISIANA PETROLEUM COKE DENSI-FEED™ SYSTEM

Mon, 25 Nov 2019 16:02:26 GMT

Matrix received a contract for the engineering and equipment necessary to upgrade an existing petcoke feed and convey system. The Matrix System will more than triple the petcoke feed rate and provide instantaneous feedback on system performance. The existing silo was re-used and retrofitted with the Matrix DENSI-FEED system. We also replaced the existing convey system and instrumentation for delivering the petcoke to the Andritz burner nozzle.

BENNETTSVILLE, SC PETROLEUM COKE DENSI-FEED™ SYSTEM

Mon, 25 Nov 2019 04:29:22 GMT

Matrix was awarded an engineering and complete equipment supply contract for a single discharge storage silo and petcoke feed system on a lime reburning kiln for Domtar in Bennetsville, SC. The system was designed to supply in excess of 3 tons-per-hour of petcoke to the burner.

Matrix Travels to India

Tue, 27 Aug 2019 19:07:27 GMT

India Engineering Project, 2015

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WARM WATER SUPPLY TO DIVERS IN COLD WATERS

Sun, 02 Dec 2018 02:10:07 GMT

Matrix along with our partner, AC Plus Marine, have developed a revolutionary new hot water system for the diving industry. THERMO-DIVE is an all-electric system that uses 75% less power than standard electric systems with heating elements. Matrix has developed several different models for offshore as well as inland applications.

PHARMA GRADE POWDER PACKAGING

Mon, 02 Oct 2017 02:10:46 GMT

Matrix performed all design engineering and control integration required for a pharmaceutical grade packaging system including a sanitary and clean-in-place design for discharging the product from the packaging bin. Downstream equipment included a sanitary airlock, magnet, screen and metal detector.

We replaced a vibrating bin discharger which was impossible to thoroughly clean and inspect with a sanitary aeration discharge cone. The airlock had a removable rotor that slid out from the housing on linear bearings. In addition we were able to mount the vibrating scalping screener on a stand with v-groove wheels for ease of pulling out of the stack-up for cleaning and/or screen changing. The system was so well received, we have since duplicated in other processes for this same client.

CUSTOM BIN VENT FILTER - Class I

Mon, 01 Aug 2016 20:07:29 GMT

Top Bin Filter/Vent for Sealed Moisture Control

Matrix designed and supplied a custom batching system to a reactor of the extremely difficult powder, Phosphorus Pentoxide (P2O5). The powder is highly hygroscopic and forms a corrosive hard/sticky crust when exposed to moisture or humidity. Our batching system was designed to receive the powder from IBC totes and precisely meter it into a wet reactor. When P2O5 is in contact with water, it reacts exothermically with extreme heat release and hot phosphoric acid steam.

Using our sealed tote transfer design, we were able to control the infiltration of moisture and lumping inside the batch hopper. Our custom designed top filter allowed controlled venting of the sealed tote dump. The Matrix filter was also designed with an isolation valve when totes were not in place as well as a nitrogen blanket purging system to assist in keeping the sealed system dry.

The filter had reverse jet pulsing capability in a Class I Division 1/2 environment.

P2O5 IBC Tote Transfer System

Mon, 01 Aug 2016 19:18:08 GMT

Sealed Tote Discharging for Dust and Moisture Control

Using our sealed tote transfer design, we were able to control the infiltration of moisture and lumping inside the batch hopper. The controlled venting of the sealed tote dump and the overall robustness of the system improved the performance tremendously. The previous system required cleaning on an almost weekly basis to remove hardened P2O5 and boulder/lumps. The cleaning was also cumbersome and potentially hazardous job due to the nature of P2O5 and water. Our Matrix design allowed 6-8 months between cleanings.

Reactor Feed of Phosphorus Pentoxide

Mon, 01 Aug 2016 18:56:52 GMT

P2O5 Batch Feeding System

Using our sealed tote transfer design, we were able to control the infiltration of moisture and lumping inside the batch hopper and our rugged VSVP Auger could accurately and predictably feed the powder into the reactor below utilizing loss in weight. Our custom feed screw utilized a special sealing valve on the discharge to prevent moisture from penetrating our batching system from the reactor below.

The system was also designed for a Class I Division 1/2 environment.

LIFT & RECOVERY SYSTEM (LARS) FOR SHELL STONES PROJECT

Mon, 09 May 2016 14:55:11 GMT

Matrix along with our partner, AC Plus Marine, engineered a Launch and Recovery System (LARS) for offshore diving, inspection and maintenance of the Shell Stones Turritella. We performed this contract with the responsibility of designing fabricating, assembling and testing delivered the unit for lease by Royal Dutch Shell. This LARS was unique among its kind in order to meet the requirements on the Turritella. It need to be easily assembled, disassembled and compactly stowed on the vessel for deployment in 12 different locations.

The LARS was engineered for 4400lb Allowable Lift at (2g/1g/1g) requirements and was American Board of Shipping (ABS) Surveyed, Approved and Certified for use.

The LARS design was optimized for member weight and included a tilt-up jib for "self-erection" along with custom designed scaffolding used in its final assembly and inspection.

The LARS was equipped with (2) hydraulic powered MAN-RATED winches that were also conceived and specified by AC Marine and fully engineered by Matrix. These winches were also ABS Certified.

Below are progress photos from the fabrication shop in during our work.

MAN RATED WINCH - ABS CERTIFIED

Tue, 01 Mar 2016 17:23:56 GMT

Matrix along with our partner, AC Plus Marine, engineered a hydraulic operated man-rated winch for use on Launch and Recovery Systems (LARS). AC Marine conceived and shepherded the design and build through the American Board of Shipping (ABS) Certification process.

To our knowledge, these are the only Dual Brake Man Rated Winches that have been certified by ABS.

FS ELLIOT COMPRESSOR CONTROLS

Mon, 01 Feb 2016 23:47:59 GMT

Matrix Engineering has designed several Modicon PLC based controls packages for FS Elliot compressors. These designs include load sharing, sequencing, and anti-surge control. These projects included both electric motor as well as steam turbine driven units. These units served foundries as well as refineries both domestic and abroad.

Matrix Sponsors Paperex 2015

Sun, 01 Nov 2015 05:00:00 GMT

Matrix Sponsors & Presents White Paper at Paperex 2015 in New Delhi, India

Matrix Industrial Systems, Inc was one of four Platinum Sponsors of the World’s Biggest Paper Show and Technical Conference PAPEREX 2015. The show was held in New Delhi, India and drew players in the pulp and paper industry from all across Asia. Matrix Co-Founder, Darren Jarvis presented his white paper at technical conference session titled “The Use of Petroleum Coke as an Alternative Fuel in the Lime Kiln”.

Matrix sees a great potential within India’s pulp and paper industry for the use of PetCoke fuel in the lime kiln. PetCoke is a clean burning fuel in this application with properties equal to fuel oil in its combustion properties. We were proud to sponsor and present our technology at this show.

PRATTVILLE, ALABAMA - PETCOKE PULVERIZER & DENSI-FEED™ SYSTEM

Sun, 02 Aug 2015 03:04:44 GMT

Matrix provided the complete system engineering and equipment supply package for IP in Prattville, AL. This mill actually pioneered coke burning in lime kilns back in the 1980's. However, this first petcoke system was a direct-fire unit which received raw coke into a pulverizer and blew it directly to the kiln burner. As it turned out, this method was very difficult to control since nearly all of their combustion/primary air into the kiln was required to convey the coke out of the pulverizer. As a result, they could not burn as much as they wanted and their kiln lacked turn down and the ability to optimize or flame shape and good CaO production.

At the time our our project, we also engineered a full pulverizer replacement using a Williams Crusher. However, we instead directed the outflow of the pulverizer to our 180T Storage Silo with DENSI-FEED System below. Currently they are able to fire petcoke and natural gas and are feeding at rates as high as 200 tons per hour (60 MMBtu/hour).

Matrix Presents at Papertech 2015

Thu, 23 Jul 2015 05:00:00 GMT

Matrix presents Densi-Feed Technology in Hyderabad, India for Papertech 2015

Matrix Co-Founder, Michael Eck presents “Petroleum Coke Handling and Firing in Rotary Lime Kiln” at the PAPERTECH 2015 conference in Hyderabad, India. The conference was titled “Make Indian Pulp & Paper Industry World Class”. Matrix shared their recent successful project with JK Paper, LTD of Rayagada, Odisha consisting of a PetCoke fuel conversion project on their lime reburning kiln. The project took them to a fuel substitution level in excess of 70% PetCoke / 30% Fuel Oil.

JAYKAYPUR ODISHA, INDIA - PETROLEUM COKE DENSI-FEED™ SYSTEM

Mon, 02 Feb 2015 04:10:03 GMT

Matrix provided the complete system engineering and equipment package for J K Paper Limited, Unit: JKPM. This was the first installation in India for petcoke fuel burning in a Lime Recovery Kiln and it was a tremendous success. Our DENSI-FEED pulverized fuel system is performing flawlessly alongside fuel oil at 65-70% substitution levels in a kiln capable of 300 mtons CaO per day. This system was designed to accept petcoke from a bulk bag delivery into a 240 mton silo. Also, of significant importance, Matrix delivers the fuel through our delivery convey system burner over 650 ft (200m) away.

In addition to our patented system, Matrix provided construction management, commissioning and on-site training services for the mill.

Matrix also provided the burner for this non-domestic system, taking full responsibility for the complete reliability and success of the system including process fuel substitution performance guarantees.

The Mill has been extremely pleased with our petcoke fuel system performance as well as their lime kiln production and the fuel conversion.

INGERSOLL-RAND CENTAC COMPRESSOR CONTROLS

Fri, 01 Aug 2014 22:43:38 GMT

Matrix provides electrical engineering services in the design of systems to control and monitor Ingersoll-Rand CENTAC compressors. These systems consist of a variety of PLC manufacturers and graphical operator interfaces to provide a retrofit to their now obsolete Westinghouse MP3 controller as well as an alternative to the current proprietary controller used by Ingersoll-Rand. We have also integrated these PLC's with many of the customers DCS systems for remote monitoring and control of the compressor. We have implemented these custom control systems on a variety of sizes of IR CENTAC as well as turbine driven units. Client list for this service includes AMOCO, Weyerhaeuser, GE Plastics, Volkswagen, Fluor Daniel and many others for installations both domestic and abroad.

GRANULATED SUGAR BLENDING SYSTEM – FOOD GRADE PLATFORM DESIGN AND SUPPLY

Tue, 01 May 2012 20:15:18 GMT

Under the direction of LECORP, Matrix Industrial Systems designed and supplied a food grade structural platform for Bremner Food Group in Princeton Kentucky. Also under the scope of Matrix was the process development, equipment layout and the complete control system design and supply with commissioning support.

The system consisted of a bulk bag unloader with hoist for the granulated sugar with a flex auger feed to Munson rotary blender. Once the proper blend was achieved the mixer discharges into a dual loading station for either bulk bags or plastic totes.

The control system was an AB CompactLogix PLC with a dual channel Mettler Scale Controller, and remote HMI’s.

MULTI-TANKWAGON LOADING AND INSPECTION PLATFORM

Sun, 01 Apr 2012 20:18:39 GMT

Matrix Engineering has been involved with many operator safety improvement projects over the years. One in particular was the mechanical and electrical design for the tank-wagon inspection platform installed at ISP in Calvert City, KY. We provided ISP with a total project cost analysis which allowed them to accurately budget the project. The new platform design consisted of two lockable fold-out platforms which were movable along the platform and were able to be centered above each tank-wagon. From there, operators had the ability to release the fold-out platforms to the desired tank-wagon for a safer means of inspection. Steam mixing stations and nitrogen purge lines were installed for each tank-wagon location. Platform area lighting was also incorporated within the platform design to ensure all walking surfaces were well lit for plant operator safety.

UTILITY STEAM BOILER - BURNER/FUEL TRAIN UPGRADE

Sun, 01 Apr 2012 14:57:21 GMT

Matrix Engineering performed the mechanical and electrical engineering as well as oversight of the combustion engineering for a burner and fuel train upgrade for their natural gas boiler. The project objective was to bring the boiler in compliance with NPPA 85 guidelines with the addition of flame scanners and new ignitors. Matrix worked with Kiln Flame Systems (now METSO) on the combustion engineering design portion of the project.

FUGITIVE DUST COLLECTION SYSTEM STRUCTURAL PLATFORM

Thu, 01 Mar 2012 21:20:00 GMT

In coordination with DeGroff Process Equipment, Matrix Industrial Systems provided the structural design and supply of pre-fabricated steel for supporting a fugitive dust collection system at SGL Carbon in Hickman, KY. This project presented several spatial challenges along with its severe seismic requirements for this location near the Mississippi River.

Matrix performed foundation design in addition to the modeling of the structural steel per the ASD method. Matrix supplied over 14 tons of fabricated steel to complete the structure.

STEAM DRYER HEAD TANK ADDITION

Thu, 01 Mar 2012 21:16:58 GMT

Matrix Engineering performed the mechanical and electrical design for the relocation for an existing steam spray dryer head tank. The modification included relocating a new 250 gallon non-pressurized vessel, which was suspended from the ceiling in order to create more floor space for other new equipment. We provided high level instrumentation, a steam control valve, and level transmitting device, which were all tied back into the plant’s DCS system for monitoring. Through this project we were able to provide ISP a larger feed volume of de-ionized water to their steam dryer and level indication through new instrumentation, which led to a more efficient operation of the unit.

Barge Cover Production Gantry System with 7-Axis Servo Control

Thu, 01 Mar 2012 20:08:24 GMT

Matrix Industrial Systems provided the complete control system with necessary programming and HMI integration for two large scale production units that perform plastic spray molding of barge covers.

We provided two cabinets for control of each individual spray molding system with one AB ControlLogix processor and remote I/O all communicating on a common Ethernet ring. We provided Rockwell Servo Motors and high resolution multi-turn encoders for positional tracking of each motion axis along with AB Kinetix 6500 Servo Controllers with safe stop modules. We also provided the complete PC based SCADA system with historian for recording batch information for each cover.

We programmed 4 linear axes on each machine for horizontal and vertical translation of three rotary axes through a given mold profile. The gantry would apply three different material coats through 18 spray guns on at a controlled velocity for a repeatable thickness of the plastic covering based on the consistent application of the polyethylene powder. One of the machines took care of the outer profile of the barge cover, while the other gantry machine was programmed for the inner profile on the same cover. The environment was harsh and dirty with room temperatures in excess of 150F.

Oil Sands Refinery Compressors Fort Saskatchewan, Canada

Wed, 15 Feb 2012 20:18:21 GMT

Matrix Engineering provided PLC programming and HMI configuration for a Modicon based control system for two FS-Elliot compressors at a Royal Dutch Sheel refinery upgrader for oil sands in Fort Saskatchewan, Alberta Canada.

Both were instrument air compressors, one of which was a 750HP motor driven compressor, the other was a 750HP steam turbine driven compressor. We provided coordination and mapping for their DCS historian. Matrix provided all controls related start-up services including FAT and on site commissioning.

WWTP & Lift Station Replacement with SCADA System - City of LaCenter

Wed, 01 Feb 2012 19:22:25 GMT

Matrix Engineering provided the electrical design, supply and implementation of (2) control systems for the city of La Center KY’s Eastside and Broadway wastewater lift stations. Each control system operated a wet well with HP duplex pumps, level control and flowmeter. Each station was equipped with an HMI for operator interface as well as a data recorder to track and log the operating history of the lift station. A refrigerated composite sampler was also integrated which allowed operators to monitor pH/temperature and dissolved oxygen levels in the effluent. Matrix also provided an AB Factory Talk View SCADA system was installed to monitor operating and flow conditions at the Eastside and Broadway lift stations through radio communication.

FRAC SAND PROCESSING & RAIL LOADOUT - CHIPPEWA FALLS, WISCONSIN

Wed, 25 Jan 2012 20:04:18 GMT

Matrix Engineering provided PLC programming and network communications for a Frac Sand Processing and Distribution Facility in Wisconsin. In particular Matrix worked with Pebco who provided the required gates and loading spouts to transfer 3 different grades of dried frac sand from the process to a high speed railcar loadout facility.

The storage facility consists of (12) 5700 ton silos each having 6 discharge gates and a series of belt conveyors for transferring stored material for distribution via 100T railcars. Above the rail loadout are (4) separate bins each having (2) rolling variable gates and dustless loading spouts serving (2) individual rail lines. Each car is filled from both discharge variable rolling blade gates simultaneously onto rail scale maintaining high accuracy and less than a 1% differential between car axles. Filling rates are in the range of 30 – 40 tons per minute.

Matrix worked with an AB ControLogix platform with (15) PLC racks and (4) DeviceNet Motor Control Centers to control the conveyor motors, gates and all associated equipment. Communication networks for this system are ControlNet, DeviceNet, and Ethernet. Part of our scope within the load-out controls is collecting data on the specific car and batch cycle and pass this information on to the DCS Wonderware HMI and Historian.

Matrix Receives Patent

Mon, 23 Jan 2012 06:00:00 GMT

Matrix Receives Utility Patent for it's Densi-Feed System Technology

Matrix also recently received its patent for its process of precise feeding of fine powders directly from a large storage silo. This is a continuous feeding cycle with instantaneous feedback and control of the powder as it leaves the discharge of the feeder. This is crucial for applications such as powdered fuels in kilns or boilers. This technology gives our clients superior control over powder feeding in fuel applications identical to modulating a gas or a liquid.

COAL TUNNEL & CRUSHER HOUSE - CENTRAL VACUUM SYSTEM

Thu, 22 Dec 2011 23:27:47 GMT

Matrix Engineering performed the mechanical, electrical and control system design for a central vacuum system for primary handling of coal dust. The system has over 50 hose pick-up points in 2 different zones with over 250 ft convey distance required. We designed a 2” hose system at 14” Hg for maximum performance. We designed a variable speed blower arrangement with PLC based control for ease of operator interface. Managers and operators alike were very pleased with the results as shown below in their company newsletter.

BARGE LOADING / UNLOADING POSITIONING SYSTEM CONTROLS

Thu, 15 Dec 2011 20:02:37 GMT

Matrix Industrial Systems provided all hardware and PLC programming for a barge positioning system used for loading and unloading barges without assistance from a tugboat. The control system included 2 VFD’s, one controlling a winch on the bow of the barge, the other on the stern. Our control system adjusted tension on both winches to balance and position the barge as directed by the operator loading the vessel.

In addition, a remote, wireless joystick could be utilized by a clamshell operator to unload coal from the barge from his cab. The system was a AB ControlLogix platform with communication both on Ethernet as well as wireless radio frequency.

TEMPORARY RENTAL BOILER IMPLEMENTATION

Thu, 01 Dec 2011 21:25:11 GMT

Matrix Engineering provided the civil/structural and mechanical engineering necessary for installing a new skid boiler at ISP. We initially provided the piping design for the boiler feed water and steam outflow of the boiler when it was initially brought in for an emergency. Once the decision was made to keep the boiler on hand for an extended period, Matrix was chosen to provide more suitable concrete foundation and dedicated access platforms.

WATER TREATMENT AREA - CHEMICAL LIME WEIGH FEEDERS

Thu, 01 Dec 2011 21:06:01 GMT

Matrix Engineering provided the electrical and mechanical design for (2) new hydrated lime feed control systems for USEC’s water softening facility. Each new lime feed microprocessor control system operated a (33 -667) lb/hr weigh belt feeder, which monitors hydrated lime feed rates, and also a (50-1000)lbs/hr lime slaker, which transformed the lime into a slurry to be pumped to aid in pH regulation of the plant’s process water. Each microprocessor control system involved configuring a set-point controller and SCR controller for each lime system to maintain consistent flow rates. Each control system also included a visual display for lime feed in pounds, feed rate, and alarm indication lights for upset feed conditions.

We also provided the mechanical piping design and implementation of the new hydrated lime feed equipment. New piping configurations were required to adapt the new lime feed equipment with the existing piping network. We provided a new adjustable structural support stand for both new lime weigh belt feeders to ensure each system was leveled true for proper function. Finally, new product inlet and discharge chutes with operator viewports were designed and implemented with the new lime feed equipment to prevent material buildup and bridging.

CAPRALACTUM STORAGE AND DISTRIBUTION W/ TEMPERED WATER SYSTEM

Sat, 01 Oct 2011 21:36:23 GMT

Matrix provided the civil, mechanical and electrical engineering for a capralactum tank and piping network with a new tempered water system for warming of the material for less viscous flow without risk of polymerizing the capralactum. This fluid is too stiff to move unless it is warmed. However, there is a risk of getting the material too hot in which case it reacts and hardens to a solid of hydrocarbon-chains which cannot be undone. The tempered water system consisted of exterior coils on the large storage tank as well a tracing along the insulated piping. Due to the critical nature of the fluid the tempered water was controlled to a very narrow allowable temperature range.

TURNKEY CONTROL SYSTEM FOR ATOMIZATION FURNACE & PI SERVER

Thu, 01 Sep 2011 19:21:50 GMT

Matrix Industrial Systems provided a complete turnkey replacement of control systems on two different Atomization Furnaces for Special Metals in Princeton, KY. These furnaces are used in the production of powdered metal alloys. The new control system was an AB CompactLogix PLC based with Panelview HMI. Matrix also provided and setup a separate PI server with Rockwell historian for data-logging critical batch data. Due to the physical configuration on the furnaces, we utilized wireless remote I/O to communicate with the main processor.

Matrix was given turnkey responsibility for all hardware and installation during a critical shutdown period. Success of the project led quickly to the conversion of another furnace on site which Matrix also handled in the same fashion.

MOBILE TEST UNIT (MTU) - EMISSION CONTROL

Sat, 01 Jan 2011 17:51:40 GMT

Matrix's Mobile Test Units (MTU’s) are capable of continuous weigh feeding of difficult powders for temporary or experimental purposes. The system is complete with full instrumentation and controls including wireless communication with PC HMI.

This is a high quality feed system outfitted with industrial controls and instrumentation for trending the feed system performance for comparison to your downstream process and/or environmental emissions.

Full Scale / On Site Testing
Fully automated system with proper instrumentation, gravimetric feeding and trending controls.
Completely MOBILE with essentially no capital investment from the user..
Quick Deployment, Set-up and Breakdown by Matrix.
Steady, Reliable and Predictable feed and delivery to your to burner or downstream process.
Determine actual Environmental Emissions, Process Impacts and Profitability at your own site.

MOBILE EMISSION CONTROL TRIAL UNIT - SORBENT INJECTION AND/OR MERCURY CONTROL:

Driven by the EPA and their new Industrial Boiler "MACT" Guidelines - industrial facilities are required to meet new standards for industrial emissions of SO2, SO3, Hg, HCl and HF.

For your emissions trial, we recommend the versatility and accuracy of our MTU Feed and Delivery System.

POTENTIAL EMISSION CONTROL AGENT APPLICATIONS:

Hydrated Lime
Sodium Bicarb
Trona
Powder Activated Carbon (PAC)
Other Experimental Powdered Sorbents

POLYCLAR BULK BAG LOADER

Tue, 02 Nov 2010 02:11:38 GMT

Matrix Engineering provided mechanical and electrical engineering for a temporary bulk bag filling system in a Class I Div 2 environment. Changes were necessary in the existing packaging system yet the production of the product was sold-out and needed to continue. Matrix helped devise a way that could be implemented quickly to divert the production stream into bulk bags for re-packaging at another location.

PLANTWIDE UTILITIES BOILER - DEAERATOR REPLACEMENT

Fri, 01 Oct 2010 19:06:26 GMT

Matrix Engineering performed the mechanical and electrical engineering for process piping and instrumentation required for a new de-aerator tank. Matrix prepared the engineering specification for the deaerator and assisted with the vendor/tank selection process. Once a vendor was selected, Matrix prepared the equipment arrangements and piping layouts for steam, boiler feed water and make-up water. On the process and instrumentation side, Matrix prepared the PFID as well as instrument loops.

The deaerator had a storage capacity of around 5,000 gallons with a minimum rate of 200,000 lbs/hr of delivery for steam production.

We also designed and specified the level indication and control on the vessel. We had to contend both with maintaining the existing pneumatic controls as well as redundant level with a modern analog output controller.

BOGALUSA, LOUISIANA - Salt Cake Feed and Convey System

Sun, 01 Aug 2010 18:46:31 GMT

Matrix Industrial Systems provided the engineering and equipment supply for adding a new destination to an existing salt cake feed and convey system at the Temple-Inland Bogalusa Mill.

In order to avoid the extreme cost and lead time of a new independent salt cake storage and feed system, Temple-Inland called Matrix for assistance in modifying their existing salt cake storage system to handle an additional destination. They wanted the flexibility of additional salt cake in their black liquor mix tank on their second recovery boiler. However it was over 250 ft away from their existing salt cake storage. This was coupled with the need to install the new system within 8 weeks of initiation of contact with Matrix. Therefore we had to act quickly to engineer and supply the system to meet their needs in spite of their spatial and time constraints.

Matrix supplied a dual rotary valve arrangement. The upper airlock was a custom Matrix feeder and the lower airlock was the transfer conveyor to the pneumatic system. Our rotary valve feeder was very consistent and repeatable capable of a 10:1 turndown ranging from 1.3 tpd to 13 tpd. Our rotary valves were designed for extreme service with high-torque extra heavy duty drives and hardened rotors.

From this point, utilized a PD blower to convey the material over 250 ft to a Matrix custom designed cyclone and material release hopper above the salt cake mix tank. Transferring the salt cake to the mix tank required special design consideration to avoid getting moisture into the cyclone or clogging the chute.

WICKES BOILER REPAIR AND REFURBISHMENT

Tue, 01 Jun 2010 20:21:38 GMT

Matrix Engineering provided the civil/structural and mechanical engineering necessary for repairing an existing boiler at ISP Chemicals in Calvert City. The existing foundation had crumbled over time and resulted in structural issues along the belly of the boiler. Matrix was responsible for design of the replacement foundation along with the boiler piping modifications as a result. We also provided structural design on new access platforming for maintaining the boiler.

Before and after photos giving some indication of the extent of the repair are shown.

DENSE PHASE TRANSPORTER REHABILITATION

Mon, 01 Feb 2010 21:28:11 GMT

Matrix Engineering restored a 20 year old Dense Phase Transport System back to working order at its original rate capacity. Ironically, this was one of the first dense phase systems that our engineers worked with during the original installation in 1990. We were pleased to be able to return to this system and make the repairs which primarily consisted of replacement of outdated pneumatic air controls.

The extent of repair was relatively inexpensive, especially when compared the overall efficiency improvement, return to design rate, and the reduction in compressed air consumption.

Matrix physically performed all of the mechanical service and repairs and worked closely with plant personnel to make any electrical changes to the system. This is a prime example of our “hand’s on” nature.

DIGESTER WARM WATER LOOP - REPLACEMENT BOILER

Sun, 01 Nov 2009 21:26:48 GMT

Matrix Engineering provided the mechanical and process design for the installation of a replacement boiler for the Paducah McCracken Joint Sewer Agency. The JSA had been operating an older existing boiler that had fallen out of compliance with the state boiler code and was in need of repair.

We determined that the previous boiler had been insufficiently sized; and on top of that we were faced with spatial constraints on an already tightly fit layout. We were able to determine that a 2.4 MM BTUH natural gas hydronic compact boiler was required to aid in maintaining the proper temperature within their digesters to satisfy the biological process. We were also able to install this within the confines of the old boiler envelope to satisfy the operation and maintenance requirements. The new natural gas boiler provided a superior turndown of 4:1 over the previous firebox and was also an improvement in the realm of energy use, operating at 87% efficiency.

Matrix Makes the Cover!

Sun, 01 Nov 2009 05:00:00 GMT

Matrix makes the cover of Powder Bulk Solids Magazine!

We are proud that Powder Bulk Solids magazine chose highlight our PetCoke conversion project for the Wickliffe, Kentucky NewPage mill. We provided the complete turnkey engineering, supply and installation in this case. Our early delivery for this mill and resulted in $200K of additional unexpected savings.

BOILER FEED WATER - LEVEL CONTROL

Sun, 01 Feb 2009 21:23:28 GMT

Matrix Engineering performed the piping design and instrumentation loops for redundant level control on two different boilers for ISP Chemicals in Calvert City. Also included was a magnetic sight glass for better visual indication alongside their existing transparent sight glass. Magnetic sight indicators and point level switches were by Ohmart Vega.

ST. FRANCIS MEDICAL CENTER HOSPITAL EXPANSIONS AND RENNOVATIONS

Mon, 01 Dec 2008 16:53:02 GMT

Matrix Engineering has provided electrical engineering services for a variety of health care projects. Most of which were for Saint Francis Medical Center in Cape Girardeau Missouri. These projects included a new Obstetrics Unit with a nursery and neo-natal nursery. We have also provided electrical engineering work for Operating Rooms, GI/Dialysis, Post Anesthesia Care Units, Sleep Labs, and a Wound Care Center. We have also provided services for upgrading their boiler system.

MONOCAL BLENDING & PACKAGING CONTROL

Tue, 25 Nov 2008 23:02:49 GMT

Matrix provided the electrical engineering necessary for designing integrating a new PLC into an existing blending and packaging system for a new product. We assumed control of an existing blending and pneumatic conveying system as well as a very complex dust collection arrangement. Essentially a new product was being produced and packaged with an existing system, however this same system needed the ability to blend and convey the old product while producing the new product without cross-contamination concerns.

We also tied this system in with their existing DCS system for monitoring and oversight purposes. Matrix provided the engineering for a new control system for the blending, conveying, packaging & dust control system. Matrix also provided total commissioning/start-up support for this system.

LUKE, MARYLAND PAPER MILL PETROLUEM COKE DENSI-FEED™ SYSTEM

Sat, 01 Nov 2008 14:50:44 GMT

Matrix was awarded a contract to provide a pulverized petcoke fuel delivery system for one kiln utilizing a truck/railcar unloading system, storage silo, feed system, pneumatic conveying system, and all the necessary instrumentation. We successfully commissioned this project in October 2008. The system utilizes natural gas and petcoke. The petcoke system provides 90 MMBtu/hour (3.0 tons per hour) to the kiln using a Coen burner.

Although the mill itself is located in Luke, Maryland, the Lime Kiln is located next to it in West Virginia on the banks of the beautiful Potomac river. The 90ft long silo was actually delivered in one piece along mountain roads to be placed near the firing end of the kiln.

PANAMA CITY, FLORIDA PETROLEUM COKE DENSI-FEED™ SYSTEM

Tue, 02 Sep 2008 03:32:06 GMT

Matrix provided the system engineering and critical equipment package for Smurfit-Stone in Panama City, Florida. This system was designed to accept petcoke from trucks and feed a lime kiln burners from a 180 ton silo. A pneumatic conveying system with a variable rate blower delivers petcoke to the burner in accordance with their specific air flow requirements. Control of the Matrix system was integrated into their existing DCS. Using the Matrix DENSI-FEED System they were able to co-fire petcoke with fuel oil or natural gas and are feeding at rates as high as 3.80 tons per hour (115 MMBtu/hour).

Matrix was also able to supply its Mobile Test Unit (MTU) ahead of the permanent installation once the petcoke ready burner was in place. As a result, this mill started saving tons of money ahead of the permanent system startup.

MOBILE TEST UNIT (MTU) - MOBILE FEED AND DELIVERY SYSTEM

Fri, 08 Aug 2008 16:18:04 GMT

Full Scale / On Site Testing
Fully automated system with proper instrumentation, gravimetric feeding and trending controls.
Completely MOBILE with essentially no capital investment from the user..
Quick Deployment, Set-up and Breakdown by Matrix.
Steady, Reliable and Predictable feed and delivery to your to burner or downstream process.
Determine actual Environmental Emissions, Process Impacts and Profitability at your own site.

MOBILE PULVERIZED FUEL FEED AND DELIVERY SYSTEM:

In an uncertain economy and volatile energy market we believe that FUEL FLEXIBILITY is your best insurance on the bottom line of profitability. Let Matrix help you save money with the important principle that our existing customers enjoy. With FUEL FLEXIBILITY you don't have to give up your current convential fuels, you simply add another weapon in your arsenal to remain profitable. With the Matrix MTU, you don't have to devote precious capital to determine the feasibility of switching fuels by answering all your questions up front. Once the pros and cons are determined with actual demonstrated profitability on your site, then you can make an educated decision on capital investment for a permanent system. This is the advantage that Matrix can offer you in moving toward this "high ground" position of FUEL FLEXIBILITY . You would be surprised at how little our clients have spent to save millions. Depending on fuel price differentials and fuel feed rate, it is certainly possible with the Matrix MTU to offset the capital requirement for implementing a permanent fuel conversion project prior to actually commissioning the permanent system!!

FUEL FLEXIBILITY POTENTIAL APPLICATIONS:

Pulverized Petroleum Coke
Lignin
Biomass - Saw Dust / Planar Dust / Pelletized Fuels
Experimental Powder Fuels
Matrix MTU's are available for short and long term leasing arrangements. Contact Matrix today to answer your questions or request us to visit your site.
Contact Matrix regarding FUEL FLEXIBILITY

Matrix Gets Noticed By Governor

Fri, 01 Aug 2008 05:00:00 GMT

Matrix Innovative PetCoke Fuel Feed Mobile Test Unit (MTU) Gets Noticed by the Governor

LIFT STATION – ELECTRICAL RENOVATION & GENSET

Sun, 25 Nov 2007 23:33:25 GMT

Our engineers provided electrical and controls engineering necessary to change out the existing electrical service, motor control center, and control system for the Paducah McCracken Joint Sewer Agency. We provided engineering and equipment necessary to provide temporary power and controls during construction to minimize downtime. Matrix also provided all PLC programming as well as construction management and startup services. In addition to the controls, Matrix also re-designed the en try of waste into the station and added a Muffin Monster.

WICKLIFFE, KENTUCKY PETROLEUM COKE DENSI-FEED™ SYSTEM

Sat, 02 Jun 2007 03:35:40 GMT

Matrix was awarded a complete turnkey contract for engineering, equipment supply, and installation of a single discharge storage silo and petcoke feed system for NewPage Corp. in Wickliffe, Kentucky. The system is capable of unloading both truck and rail to fill the silo and co-fired petcoke with natural gas on a KFS burner.

Matrix provided the turnkey installation packages and on-site construction management for civil/foundation, structural, mechanical and electrical contracts. As a result, s tartup for this project was completed 2 months ahead of schedule in May 2007. Completing this in record time saved the mill over $200K during a time of high natural gas prices.

LIFT STATION CONTROLS UPGRADE & ELECTRICAL MODERNIZATION

Sun, 01 Apr 2007 19:16:42 GMT

Matrix Engineering provided the electrical design and implementation of a new MCC, PLC panel and an automatic Auxiliary Power system for the Paducah McCracken JSA Husband Street Lift Station. The new MCC and PLC panel were designed and installed to replace outdated technology to provide a more reliable, operator friendly, and efficient operating lift station.

The control system was designed to operate (3) 15 HP pumps, (2) 1 HP seal pumps, level control, and (3) magnetic flowmeters. The PLC panel was equipped with an HMI Operator Interface to allow control of the station in Manual or Automatic mode.

A new 175kW auxiliary power system was sized and installed to provide continuous operation of the lift station during power outages. The auxiliary power system was equipped with a 225 Amp automatic transfer switch which allowed for seamless power transfer. The lift station was connected to an auto dial Verbatim System for alarm situations. The station was connected to an existing SCADA system, also developed by Matrix.

We also provided the structural support design and implementation of a new Muffin Monster for the Husband Street lift station. The new Muffin Monster was implemented to allow for solids reduction and minimize the chance of clogging pumps. A new stainless steel structural support track system was designed along with a new motorized retrieval hoist for the new Muffin Monster for ease of maintenance.

PERDUE HILL, ALABAMA DUAL PETROLEUM COKE DENSI-FEED™ SYSTEM

Fri, 02 Feb 2007 04:21:27 GMT

Matrix provided the system engineering and critical equipment packages with silo for a dual discharge petcoke delivery system at GP Cellulose in Perdue Hill, Alabama. This system was designed to accept petcoke from pneumatic railcars or trucks and feed two lime kiln burners from a common 180 ton silo. A dual discharge hopper bottom was specifically designed for two petcoke DENSI-FEEDERS, though initially, GP chose to implement the project in two phases and only installed one of the two feed systems. Matrix commissioned the second kiln feed line 2 years later.

A stepped convey line and 100hp blower was used on the rail unloading system for a record unloading time of 2 hours for 100tons at a distance of 200ft away.

A pneumatic conveying system with a variable rate blower delivers petcoke to the burner in accordance with the specific air flow requirements for flame shaping. Control of the Matrix system was integrated into the mill's existing DCS. The system is able to co-fire fire petcoke, fuel oil, natural gas or tall oil.

The first kiln’s system at was proven and tested to 3.0 tph with natural gas and successfully burned in excess of 2.4 tph of petcoke in combination with fuel oil. Below is a picture of the flame at 2.5 tph with fuel oil.

SPRINGFIELD, OREGON PETROLEUM COKE DENSI-FEED™ SYSTEM

Tue, 02 Jan 2007 04:24:56 GMT

Matrix implemented an engineering and equipment supply contract for a storage silo and petcoke feed system for Weyerhaeuser in Springfield, Oregon. The system consisted of a 180 ton storage silo and a variable feed system specifically designed for the discharge of ground petcoke. A variable rate blower was used to transfer the petcoke approximately 350 feet to the existing “coke-ready” burner. All controls and display panels were integrated into the mill’s existing DCS system. Matrix provided the civil/structural, mechanical, and electrical engineering for the project. System startup was conducted in December 2006.

LIME RECOVERY KILN - BURNER REPLACEMENT

Fri, 01 Dec 2006 16:20:34 GMT

Matrix was awarded the engineering contract for replacement of the lime recovery kiln burner. The contract included burner layout, support and installation along with upgraded flame scanning instrumentation and modifications to the primary air and burner management system. The new burner was capable of dual fuel burning with the addition of ground petroleum coke.

CATERPILLAR COMPRESSOR CONTROLS

Sat, 25 Nov 2006 23:45:29 GMT

Matrix Engineering completely designed a replacement control system for two existing IR CENTAC compressors. This was the main compressed air supply to their foundry. Both compressors were 4 stage 1500 HP units. This controls system utilized one main PLC with a "hot stand-by" PLC back-up. We were able to monitor the main plant compressed air flow as well as the blow-off air to economize the compressors and minimize wasted air. This is a massive energy saver and is a control feature not offered by Ingersoll-Rand and as far as we know, the only installation of its kind. This project was so successful that we have since returned and added more units to the control scheme as the compressed air system was expanded.

HENDERSON WATER UTILITY – SOUTH WASTEWATER TREATMENT PLANT EXPANSION

Sat, 25 Nov 2006 23:18:14 GMT

Matrix provided the controls engineering for a wastewater treatment plant expansion. The expansion consisted of four new PLC control cabinets tied together on an Ethernet network. These PLC’s monitored and controlled new equipment in four different sections of the plant. The entire plant is monitored by a PC based SCADA system developed by Matrix. We also provided startup and checkout services as well as construction management.

DISTILLATION RECEIVER UPGRADES

Fri, 10 Nov 2006 22:46:34 GMT

Matrix provided the detailed engineering for complete system upgrades for four (4) product receivers on an industrial 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.

HAWESVILLE, KENTUCKY PETROLEUM COKE DENSI-FEED™ SYSTEM UPGRADE

Sat, 01 Jul 2006 15:23:30 GMT

Matrix provided the consultation and engineering necessary as well as much of the equipment to replace an existing petcoke feed and convey system. Matrix provided new features into the 3rd generation design to double the feed rate of petcoke. The existing silo and chisel bottom were re-used and retrofitted with a dual inlet feeder utilizing Matrix’s new pulverized fuel feed system. We also replaced the existing convey system and instrumentation for delivering petcoke to the burner nozzle.

SPRAY DRYER SANITARY U-BEND

Thu, 02 Mar 2006 02:28:10 GMT

Matrix provided the mechanical design for custom design of a sanitary u-bend at the bottom of an existing spray dryer. The u-bend had to be dis-assembled and cleaned frequently for product changeovers. Our sanitary design allowed for quick and easy cleaning by rolling back half the u-bend on a track and rotating the other half on a pivot bearing.

Not only did the tool-less design provide ease dis-assembly and assembly, but it also provided a superior o-ring seal over the previous arrangement. This is extremely beneficial for a vacuum system handling a glue-like powder that is seeking moisture. Our design substantially reduced product build-up between cleanings and allowed viewing of operation and status with a properly positioned viewport and light.

CAMPTI, LOUISIANA PETROLEUM COKE DENSI-FEED™ SYSTEM UPGRADE

Thu, 01 Dec 2005 15:52:59 GMT

Matrix provided the consultation and engineering necessary to upgrade an existing petcoke feed and convey system. Matrix employed its new 3rd generation design to double the feed rate of petcoke. The existing silo was re-used and retrofitted with the Matrix DENSI-FEED system. We also replaced the existing convey system and instrumentation for delivering the petcoke to the burner nozzle.

DEWATERING BUILDING VENTILATION

Tue, 01 Nov 2005 23:36:27 GMT

The Paducah McCracken Joint Sewer Agency asked us to provide engineering assistance to eliminate a problem with hydrogen sulfide gas in their dewatering building. The issue was caused by in-adequate ventilation resulting in noxious fumes and extreme corrosion within the building. Matrix replaced their existing ventilation system and provided hoods specifically designed for each piece of equipment in the building. The hoods were designed to adequately ventilate yet allow room for cleaning and maintaining of the dewatering equipment. The Director of the JSA informed us that our design helped the interior smell like “pristine mountain air” compared to the old system.

HODGE, LOUISIANA DUAL PETROLEUM COKE DENSI-FEED™ SYSTEM

Sun, 02 Oct 2005 03:21:26 GMT

Matrix provided the complete engineering package for a dual discharge petcoke delivery system for Smurfit Stone Containerboard Division in Hodge, Louisiana. The system was designed to feed two lime kiln burners from a common 180 ton silo. A dual discharge hopper bottom was specifically designed for two petcoke DENSI-FEEDERS. It included dual pneumatic convey systems with variable rate blowers to deliver petcoke to the Coen burners in accordance with the manufacturer's specific air flow requirements. The convey distance of the petcoke was in excess of 600 feet. The system allowed the mill to report substituting up to 90% ground petcoke for natural gas in each of their lime kiln burners. The control of the Matrix feed equipment was integrated into Smurfit Stone’s existing DCS. Matrix provided all the civil/structural, mechanical, and electrical engineering for the project.

The project was commissioned shortly after Hurricane Katrina during very high natural gas prices. As a result, the mill was able to pay for its investment on 2 Kiln Fuel Systems WITHIN 4 MONTHS!

VALLIANT, OKLAHOMA PETROLEUM COKE DENSI-FEED™ SYSTEM

Fri, 01 Jul 2005 15:04:12 GMT

Matrix provided a total Petcoke Delivery System at a paper mill in Valliant, Oklahoma. The system allowed the mill to substitute up to 80% ground petcoke for natural gas in their lime kiln burner. The system consisted of a 180 ton storage silo and a variable speed feeding system specifically designed for the discharge of ground petcoke. A variable rate blower was employed to precisely meet the air flow requirements of the KFS burner. An existing AB ControLogix PLC was used to control the process. Matrix also provided an I/O panel in conjunction with our feeding equipment. Matrix provided all of the system equipment as well a all the complete detailed engineering for civil/structural, mechanical and electrical on the project.

PINE HILL, ALABAMA PETROLEUM COKE DENSI-FEED™ SYSTEM

Wed, 01 Jun 2005 15:06:10 GMT

Matrix spearheaded a Lime Kiln fuel conversion project to cofire petroleum coke with natural gas at a paper mill Pine Hill, Alabama. The system allowed the mill to substitute up to 80% ground petcoke for natural gas in their lime kiln burner. It consisted of a 180 ton storage silo and a variable speed feeding system specifically designed for the discharge of ground petcoke. A variable rate blower was employed to precisely meet the air flow requirements of the KFS burner. All controls and display panels were integrated into the mill’s existing DCS system. Matrix provided the civil/structural, mechanical, and electrical engineering as well as all of the system equipment and silo for the project.

PORT HUDSON, LOUISIANA PETCOKE CONVEYING & FEED SYSTEM TROUBLESHOOTING

Sun, 01 Aug 2004 15:47:07 GMT

Georgia Pacific contacted Matrix while experiencing problems during start-up of their on-site grinding facility. Our Engineering Department provided assistance for an existing petcoke feed system that was not functioning as designed. We were able to quickly diagnose the problem which involved the conveying air flow for the delivery silo dust collector. The convey air flow was overwhelming the dust collector filter area. We quickly engineered a new 4” line, provided and expedited a positive displacement blower to replace a centrifugal fan, which conveyed the same coke rate using 20% of the original air. This completely eliminated the problem.

Georgia Pacific then asked Matrix to look at some chronic feeding problems they were experiencing with their existing burner delivery system. Matrix Engineers evaluated the situation, and determined that it was due to a “bridge and flush” phenomenon, which caused a 20% swing in the average feed rates. Matrix issued a complete report on the problem and recommended improvements.

LEAVENING POWDER AIR BLENDING DENSE PHASE CONVEYING

Mon, 01 Mar 2004 20:31:40 GMT

Matrix provided the structural, mechanical and electrical engineering required for the production of a new leavening powder in an existing process. Major modifications were required to an existing air blending and conveying system and a new separate dust collection system was required to avoid cross contamination between the different products. The dust collection systems for these products was very sophisticated. Simultaneous operation was required for on both collectors for the packaging of one product while another was being produced. This simultaneous operation had to be accomplished with cross contamination adding a high element of complexity to the control system. Matrix provided the engineering for a new control system for the blending, conveying, packaging & dust control system. Matrix also provided total commissioning/start-up support for this system.

There were also considerable spatial constraints for introducing this new product to a well established process area. However, we were able to squeeze our new production surge hopper between existing storage and packaging bin to utilize existing blending and dense phase systems.

LAB SUPPLEMENTAL HVAC

Sun, 15 Feb 2004 16:40:32 GMT

Matrix provided the mechanical & electrical engineering necessary for providing heat and air to the main lab at Ashland, formerly ISP Chemicals in Calvert City, KY. The (4) HVAC Units for designed for 100% outside air. Special diffusers were used for spot cooling of lab equipment stations.

WWTP AUXILIARY POWER UPGRADE - REIDLAND

Sun, 01 Feb 2004 20:14:53 GMT

Matrix Engineering provided the electrical design and implementation for an Auxiliary Power system for the Paducah McCracken Joint Sewer Agency Reidland WWTP. A new 250kW (480V, 3-Phase) auxiliary power generator was installed to provide continuous operation of the WWTP during power outages. We were responsible for incorporating the new generator into the existing MCC via an automatic transfer switch. This diesel fuel auxiliary powered generator was sized to run the plant for 24 hours following an interruption in power.

BOWLING BALL BALANCE SYSTEM CONTROLS

Tue, 25 Nov 2003 23:12:02 GMT

Matrix Engineering provided the low cost control system to locate and mark the “top weight” in a bowling ball which cannot be seen on the surface of the ball. This top weight directly affects the performance of the bowling ball and must be precisely located and marked so it may be drilled for use. The control system utilized a PLC, servo motor and drive, strain gauge, and a touch-screen operator interface.

In addition to locating and marking the top weight, the control system produced the actual weight of the “top weight” in ounces as well as the total weight of the ball. The total system cycle time was kept between 20 and 30 seconds which was a key factor in production.

MONOCAL FLOW AGENT BLENDING AND CONVEYING

Thu, 15 May 2003 17:36:45 GMT

Matrix provided the structural, mechanical, electrical and controls expertise in designing a bulk bag unloading and dense phase distribution of a flow agent known as Trical (TriCalcium Phosphate) for blending ahead of transfer of two different monocal products. The dense phase transfer of the Trical was over 300ft and was automated to refill batch weigh systems on demand. Acrison weigh feeders were used to drop minor 1-2% Trical batches into Nol-Tec Air Blender/Transporters for conveying to storage silos ahead of packaging operations.

Due to several dense phase transporters throughout the process, each blend/convey cycle was sequenced with priorities within communications between multiple control systems in order to optimize plant air pressure.

These products are phosphorus based leavening acids for addition to baking powders requiring all stainless steel material touching components and proper food grade design practices.

COMBUSTIBLE POWDER CENTRAL DUST COLLECTION

Sun, 02 Feb 2003 02:26:24 GMT

Matrix provided the structural, mechanical and electrical engineering required for a 3500 cfm fugitive dust collector in a Class I Div 1 environment. The dust collector provided central dust collection for several packaging systems as well as a specially designed hood for an adjacent air pallet unloading station.

MONOCAL STORAGE & DISTRIBUTION

Wed, 15 Jan 2003 15:50:27 GMT

Matrix provided the structural, mechanical, electrical and controls expertise in designing a product blending, storage and convey system for a leavening acid used in the baking industry. The new system replaced existing mechanical screw conveyors and elevators with pneumatic blenders, transporters, mass flow silos and a modernized control system. This new equipment included a bulk bag unloading system and transporter for conveying a flow agent to two different locations where it is added and blended to different monocals.

A surge hopper was installed at the end of the monocalcium production process. The flow agent is added gravimetrically below this hopper and blended using an air blender/transporter.

From this location the monocal is conveyed to 250,000lb mass flow silo (with load cell package). From the silo the product is dense phase conveyed to two possible receiving hoppers above a packaging area.

We also engineered rework stations for feeding back both 50 lb bags and bulk bags into the final blending and packaging system. As a part of this project we also completely upgraded the controls for the monocal mixing and packaging system with large screen graphical operator interfaces. We also designed a new MCC room to accommodate this modernization project.

PVP-I DRUM FILLING

Thu, 02 Jan 2003 02:32:53 GMT

Matrix Engineering provided mechanical and electrical engineering along with controls for a sanitary drum filling system in a Class I Div 2 environment. The mechanical engineering package included detailed design of the drum fill head for an inflatable seal and improvements in dust control during filling. A smooth bore flexible connection was custom designed to prevent ledges for product to rest. A batch fill weighing control system with HMI was designed for filling within 0.2 lb on a 110 lb drum.

The drum filling system had be recently replaced by another firm and was unable to consistently hit the target weight tolerance. Matrix responded immediately with a retrofit design that met the specification and satisfaction of the plant engineers and operators.

Over the years, Matrix maintained this system with check scale upgrades, automated fill and check conveyors, as well as a powered accumulated drum staging conveyor.

BRIGGS AND STRATTON EAST ADDITION

Sun, 01 Dec 2002 16:45:15 GMT

Matrix provided the mechanical and electrical engineering necessary for a 6800 sqft addition. We provided power design for relocation of their machine shop and assembly area. The HVAC consisted of hot and chilled water coil air handling units mounted on the roof of the new structure.

METAL CYLINDER MANUFACTURER CONTROLS UPGRADE

Fri, 01 Nov 2002 23:04:00 GMT

Provided electrical engineering necessary to specify as well as build and install Allen Bradley PLC’s to modernize control systems on several production machines for manufacturing refrigerant cylinders. These machines included two pressure testers, two spud welders, hole punch, a convolute punch, and a valve crimper.

GLASS BUBBLE BULK BAG UNLOADER

Mon, 01 Jul 2002 20:07:41 GMT

Matrix provided the mechanical and foundation design necessary for unloading and conveying glass bubbles from bulk bags. The bulk bags were 60 cuft capacity and around 8 ft tall. The tall bag presented a design challenge for the installation in a 14 ft ceiling area. The system utilized aeration and a diaphragm pump to convey the bubbles into the process.

DEPARTMENT OF ENERGY SCRAP METAL BASIN WATER TREATMENT FACILITY

Sat, 01 Jun 2002 22:40:07 GMT

Matrix provided the mechanical, instrumentation and controls engineering necessary for a semi-automated water treatment of a 4 million gallon sediment basin for the scrap metal yards at the USEC Uranium Enrichment Facility. The treatment facility monitored turbidity and pH. The facility consisted of (2) bank mounted 1000 gpm pumps for either pumping to the outfall or recirculating back to the basin. These pumps also utilized an eductor system to treat high or low pH in the basin. Also included were (2) pumps with a flocculent additive system for supplying 150 gpm streams at 50 psi to (2) Rain Guns for dropping out solids in the basin water. Freeze protection and drain-ability were also addressed throughout the design.

SPORTABLE SCOREBOARDS - FACTORY & OFFICE FACILITY

Tue, 01 Jan 2002 15:53:45 GMT

Matrix Engineering was employed to provide the civil, mechanical, and electrical engineering necessary to build a 29,000 sqft factory and office facility. Matrix provided the site work, architectural, foundation, HVAC, natural gas piping, plumbing, lighting, electrical power and computer network drawings. The office portion of this factory was over 5500 sqft.

CONTINUOUS REACTION CONVERSION PROCESS

Sat, 20 Oct 2001 16:27:27 GMT

Based on the success of the pilot plant design, Matrix Engineering provided the structural, mechanical and electrical engineering necessary for installing continuous reactors in phases while removing existing batch reactors. The resulting reacted slurry is a thick, corrosive, sticky substance in which build-up on the reactor side walls was a major obstacle to engineer around. Our team worked very closely with RP on developing an acid feed system into the reactor that would accomplish continuous washing of the reactor side walls. Great care was also taken in the layout of the reactors so the reacted sticky slurry would fall through a large diameter (cleanable) chute directly into the dryer below. Included in this project was a dense phase pneumatic transporter for conveying alumina to receiving hoppers above the new reactors. The continuous reactors were installed and batch reactors removed so not to interfere with production of a sold-out product. Continuous reactor redundancy was installed in the initial phase to gain experience and determine reliability of the new process before fully committing to the new process. As confidence was gained in the new process the existing batch reactors were replaced with the new continuous design. This was an engineering challenge due to spatial constraints and design flexibility to utilize batch and continuous systems simultaneously. Eventually all of the batch reactors were replaced and they now operate solely on the continuous reaction process. Matrix Engineering has continued to improve on the original reactor design to the current 3rd generation continuous reactor.

PHOSPHORIC ACID SCRUBBER,

Fri, 01 Jun 2001 21:20:58 GMT

Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical detailed 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.

LIME KILN SOLID FUEL BELT CONVEYORS

Tue, 01 May 2001 19:53:55 GMT

Matrix Engineering provided the civil, structural and mechanical design and detailing necessary for several 24" belt conveyors and support structures at Arkansas Lime's secondary crushing lime facility. Conveyors handled solid fuel coke dumped from rail cars through the roof of a fuel storage building distributing it to two different piles. The coke is then blended in proper ratio and carried from the fuel storage building to a 300 ft long rotary kiln. We also designed and detailed another belt conveyor that took lime from a new calcining facility to the rotary kiln dryer. This conveyor was 580 feet long with an elevation change of 140 ft. All conveyor truss panels, bents, and platforms were detailed to fit on rail car for delivery to the site.

GIRTH WELDER SYSTEM

Thu, 01 Feb 2001 23:09:19 GMT

Matrix Engineering provided the expertise necessary to design a controller for Amtrol's cylinder girth welders. That system consisted of an AB PLC with Panelview operator interface and a servo-motor to control the speed of the rotating cylinder while being welded. The control system was programmed to accommodate many different cylinder diameters while maintaining a proper weld speed as well as determining the exact length for one cylinder revolution.

PETCOKE GRINDING PLANT UPGRADE

Thu, 01 Feb 2001 16:50:28 GMT

Matrix Engineering provided a complete electrical system upgrade and the modernization and controls automation of PeTroCoke, Inc.’s Owensboro, Kentucky plant. The entire electrical system was replaced from the main service disconnect to all of the equipment and instrumentation. The new control system consisted of an Allen Bradley PLC and RSView32 computer operator interface. The electrical upgrade controls a mill feed system, a hammer mill, and a gas-fired burner system for drying the petcoke. Ultrasonic instrumentation continuously monitors the finished product silo and controls a bulk truck load-out system. Matrix personnel assisted in complete system check-out and start-up and were able to minimize downtime without affecting delivery of customer orders. Due to automatic control of product feed and burner temperature, the plant throughput was improved dramatically.

HEARTLAND CHURCH ROCK CLIMBING WALL

Mon, 01 Jan 2001 17:04:22 GMT

Matrix provided the structural design and detailing for supporting a competition grade rock climbing wall inside the Heartland Regional Youth Center. The 6 panel rock wall was 30 ft. tall and 20 ft. wide. The wall is supported primarily from the floor and laterally supported from the interior roof steel. We designed and detailed the structural steel backing in which the wall is attached. We were also present and assisted in the erection of the wall itself.

HEARTLAND CHURCH STRUCTURAL CROSS

Mon, 01 Jan 2001 17:01:54 GMT

Matrix Engineering provided concept as well as the structural and foundation design for a massive steel cross in front of the Regional Youth Center facing I-24 near Exit 7 in Paducah Kentucky. The cross stands over 60 ft tall and 40 ft wide with a 16 ft square spread footing foundation. The cross consists of over 20,000 lb of structural steel and was designed with translucent Lexan panels around the base to prevent potential climbers. We also provided details for the cross to arrive in (3) major pieces: the base, the horizontal and the top. The cross was erected in place in less than a half a day. Matrix also provided the details for a jet black granite base with engraved scriptures on all four sides. This Cross of Christ is a beacon of hope and salvation to the community and interstate travelers.

AIR PALLET PACKAGING SYSTEM

Wed, 01 Nov 2000 03:03:15 GMT

Matrix Engineering provided the structural, mechanical and electrical engineering for the addition of an air pallet fill stand to an existing box packaging system. The product handled was very hygroscopic as well as overly free flowing - capable of bridging the discharge or flowing uncontrollably. We used a positional butterfly valve on the packaging bin discharge with a control loop to position the valve based on the throughput rate from the fill stand scale. Level instrumentation was also used for preventing material from backing up in the delumping mill.

Much of the complexity of this project involved sizing an incline screw feeder between the hopper and fill stand large enough to handle instantaneous flooding with control logic to watch and adjust the average throughput to keep the screw running in the 15% - 30% full range. This helped to minimize the challenge to the inlet end seal on the screw conveyor.

LIME DRYING AND MILLING

Sat, 01 Jul 2000 19:59:19 GMT

Matrix provided the civil, structural and mechanical engineering necessary for designing a lime drying and pulverizing facility with a through-put of 75 tons per hour. The design required a re-furbished rotary kiln dryer fed by a weigh belt and large capacity screw conveyors with a bucket elevator feeding a 65 ft tall milling and screening structure.

The mill was a 200 hp hammermill and vibratory screens and an air separator segregated the lime into two different products with an overs recycle back to the mill. A gas solids injector (GSI) screw pump (or "fuller" type pump) pneumatic conveyor was sized to deliver 60 tons per hours to two different storage silos.

Matrix also provided all of the engineering necessary to properly vent and collect dust off all of the process equipment. A 7500 cfm dust collector was used along with a carefully designed network of collection ductwork to prevent duct clogging. We re-used an existing 18,000 cfm dust collector for the rotary kiln dryer. This provided a challenge since the collector was over 90 ft away from the dryer. A 30" dia grasshopper duct was designed originating from the dryer discharge up to the top of the 65 ft mill structure and back down to the dust collector in the existing process area. The duct angles were kept in excess of 50 deg. to prevent product fall-out and line clogging.

LIME TRUCK LOAD-OUT DUST COLLECTION SYSTEM

Tue, 02 May 2000 01:24:46 GMT

Matrix Engineering provided the structural and mechanical design for dust collection on an existing truck loading system for Texas Lime in Cleburne Texas. The truck loading facility consisted of (2) retractable loading spouts which required adequate collection to prevent dusting when filling trucks. Two 1000 cfm dust collectors where installed on newly designed platforms with fans above the existing product silos for independent operation of each truck loadout from the ground.

DUAL PRODUCT BAG PALLETIZER

Sun, 02 Jan 2000 03:09:52 GMT

Matrix performed preliminary belt conveyor and equipment layout with specifications for a dual product palletizing system. Duties also included palletizer system evaluation including systems by Slidell, Mollers, Stone, PSI, and PASCO. Matrix performed preliminary design of a building extension to house the proposed palletizer. Matrix engineers also helped prepare estimates for total project cost as well as project schedule.

Over the years, Matrix added new features to the palletizer system including bag printers, metal detectors and reject offramp conveyors. Matrix handled the mechanical engineering for these projects as well as maintaining the old AB PLC5 controls programming for the system.

VANLUBE PROCESS EXPANSION

Wed, 01 Dec 1999 16:37:13 GMT

Matrix provided the civil, structural and mechanical design for a major addition to the existing Vanlube process at Vanderbilt Chemical's Murray, Kentucky facility. The product was a NFPA 30 Class 1B flammable liquid requiring special design considerations for firewalls, escape routes and equipment placement. The project consisted of a process area, packaging area, tank farm and truck load-out facility. Mechanical design included heating and proper ventilation per NFPA guidelines. Matrix also provided all of the complex grounding details and electrical classification drawings to satisfy the NFPA guidelines.

HYDROGEN SULFIDE SCRUBBER SYSTEM

Thu, 25 Nov 1999 22:34:52 GMT

Matrix Engineering provided the structural, mechanical and electrical engineering necessary to scrub hydrogen sulfide off-gases from an existing phosphoric acid 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.

P2O5 CONVEYING

Mon, 01 Nov 1999 20:31:40 GMT

Matrix Engineering was consulted and hired to rehabilitate a pneumatic conveying system for handling phosphorus pentoxide (phosphoric acid anhydrous). This material is very corrosive and extremely hygroscopic - reacting with water to form hot phosphoric acid. Matrix provided the mechanical, electrical design along with the control system integration for the project. A dense phase transporter was rebuilt for transporting the material to a bed hopper which was vented to an existing scrubber system. Matrix also specified and provided the controls for a gas compressor which took existing dry combustion air at 25 psi and compressed to 80 psi for use in our dense phase system. Nitrogen purges were also designed for keeping the system dry between batches as well as providing a moisture free blanket over the bed hopper. Much of the design was centered around keeping the system dry and not sticky, the product dry and free flowing, and keeping the air supply dry and clean. Design efforts also emphasized maintenance and the ability to wash down and dry the system easily after a production cycle.

FLUIDIZED BED DRYER

Tue, 02 Mar 1999 01:40:56 GMT

Designed a new system for the milling and drying of freshly mined tripoli stone. Included was a new vibrating fluid bed dryer, associated dust collection and fans, a new hammermill, and a number of feed and take-away conveyors. Design included lay-out, foundations, bulk handling, dust control, power and controls. The project replaced a rotary kiln dryer installed in the year 1919. The replacement was engineered to minimize downtime and took only 5 days to complete. The project resulted in a 45% savings in natural gas just six short months prior to the natural gas shortage price hikes. This project was featured in Powder and Bulk Engineering Magazine, July 2000 issue.

HYPO CONTINUOUS REACTORS

Mon, 01 Mar 1999 17:30:20 GMT

Matrix Engineering provided the structural, mechanical and electrical engineering necessary for replacing Hypo batch reactors with like-kind continuous reactors. The new continuous reactors were similar in geometry to the old batch reactors in order to fit in the existing structure. However they were linked with cascading piping for sufficient retention/reaction time. Due to pipe cloggage worries the new reactors were also equipped with vertical pumps for moving the slurry from reactor to reactor. Phosphine gas is given off during the reaction process which is explosive upon contacting the atmosphere adding complexity to the system. Matrix assisted in the layout and design of the new reactors. Of particular interest was a 3/4" plate rolled pump guard plate for protecting the vertical pump from being walloped from lumps and/or the massive agitator impellers. Auxiliary horizontal pumps were also employed as a back-up to the vertical pumps. The system also required a new dense phase transporter for conveying hydrated lime to top of the reactor structure.

P2O5 DRUM STORAGE AND FILLING

Sat, 02 Jan 1999 03:08:52 GMT

Matrix provided the structural, mechanical, and electrical engineering necessary for providing a dry storage, unloading and empty drum magazine storage for an existing P2O5 drum filling operation. Phosphorus Pentoxide is very hygroscopic forming hot phosphoric acid when it encounters water. Therefor packaging with wet drums stored outside caused a significant problem. The design consisted of a semi-trailer unloading dock where trailers could remain parked while keeping mobile dry drum storage out of the weather and could be unloaded as packaging campaigns dictated. Gravity conveyor magazines were designed so that an operator could unload enough drums out of the truck trailers for. This arrangement also saved labor since it eliminated "double handling" of the drums.

PLATE AND FRAME FILTER INSTALLATION

Thu, 10 Dec 1998 22:22:52 GMT

Matrix Engineering provided the concept drawings, budget estimates, along with the detailed 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

Wed, 25 Nov 1998 22:25:06 GMT

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.

SOLUTION MIXING AND TRUCK LOAD-OUT

Thu, 01 Oct 1998 21:22:09 GMT

Matrix Engineering provided the concept drawings, budget estimates, structural, mechanical, and electrical detailed 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 utilizing a drum dumper 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.

DUAL SPOUT PACKAGING SYSTEM

Mon, 02 Mar 1998 02:35:20 GMT

Matrix provided the layout and electrical engineering necessary to upgrade an existing bag packaging system. An existing Haver Impeller Packer was replaced with a Dual Spout Smurfit Stone Air Packer with automatic bag placer and an in-line ultrasonic sealer. The new automated packaging system had to fit in the limited space occupied by the old system. Making layout for access and maintenance a particular challenge. Downtime was also a very critical factor and was minimized by the design.

BOILER WATER SOFTENER SYSTEM

Mon, 02 Feb 1998 23:34:46 GMT

Matrix provided the civil, structural, mechanical, electrical and controls engineering for a water softener system supplying the boilers at the Nashville, Tennessee facility. The system consisted of a packaged softener system and two brine tanks. Special considerations were made in the concrete design due to the strong salt water issues. PVC piping was used along with heat tracing for freeze protection. Matrix also integrated the controls between the packaged softener system and the brine pumping system.

ELECTRO-STATIC PAINTING

Tue, 25 Nov 1997 22:59:51 GMT

Matrix Engineering provided electrical engineering necessary to design, specify as well as build and install a control system for an electro-static painting process. This system consisted of an Allen Bradley PLC, linear positioner, and AC & DC variable speed drives. The variable speed drives controlled the speed of the main overhead conveyor throughout the plant. We design the system so that the operators could easily change the paint system using the linear positioner to accommodate varying cylinder sizes. Matrix also performed intensive start-up and checkout, and operator training.

ANODE FEEDER

Wed, 01 Oct 1997 14:26:04 GMT

Matrix provided the design and shop fabrication drawings for a new 4’ wide x 33’ long belt feeder to a jaw crusher. Conveyor had to accept 1000# anodes after a four foot freefall, and deliver them to one of two crushers. Direction of the feeder belt dictates which crusher is fed. Project was installed in Fall of 1997. Fabricator and installer was Conveyor and Drive Equipment of St. Louis, MO.

CONTINUOUS REACTOR PILOT PLANT

Mon, 01 Sep 1997 16:24:10 GMT

Matrix provided the structural, mechanical, and electrical engineering necessary for the development of a continuous mixer/reactor and dryer for an experimental pilot plant. This was a tough mixing problem primarily due to the resulting sticky slurry, which builds up and dries like concrete from splashing and mixer outfeed. Since this project was experimental, the mixer/reactor was designed for adjustability in retention time, mixing speed, and throughput rate. Much consideration was also given to the existing batch process surrounding the pilot plant as not to relocate, modify or disrupt existing ongoing operations. The project consisted of a weigh feeder, mass flow meter, heat exchanger, mixing vessels, agitators, thermal dryer, and a mechanical extruder/dryer. The pilot plant was considered successful and resulted in an expansion using the continuous reactor.

SPECIALTY CORE BATCH MIXING CONTROLS

Sat, 01 Mar 1997 22:55:00 GMT

Our engineering group provided the controls expertise necessary to automate a batching process for bowling ball cores at Ebonite International in Hopkinsville Kentucky. This was a Class I Division 1 location requiring explosion proof design considerations. Batching operation utilized the infeed control of (4) different powders and (3) different liquids in varying ratios and quantities. The batch quality criteria is judged on density with allowances of only 0.2%. Therefor accurate weigh-ins was an absolute must. The batch control system needed to be easy to use and very versatile since the core recipes changed on a shift-by-shift basis. Matrix engineers also performed intensive start-up, check out, and operator training.

CATALYST SCRUBBER

Sun, 02 Feb 1997 22:18:38 GMT

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.

BOWLING BALL SPECIALTY CORE PRODUCTION

Wed, 01 Jan 1997 20:47:10 GMT

Provided structural, mechanical, and electrical engineering necessary to design a specialty core production process for bowling balls. The process consisted of bulk bag and box unloading systems utilizing a vacuum convey system flexible screw conveyors, volumetric feeders, weigh bins, and a batch mixer. We also provided the controls expertise and design for batch mixing of over a hundred different recipes of specialty cores. Matrix engineers also performed intensive start-up, check out, and operator training.

PHARMACEUTICAL POWDER SPRAY DRYER BUILDING

Mon, 02 Dec 1996 02:17:54 GMT

Matrix Engineering provided civil, structural and mechanical design for a spray dryer facility used in the production of pharmaceutical clay. Matrix assisted in the facility layout by coordinating the client with the spray dryer equipment manufacturer as well as the structural requirements of the seventy feet tall, 5-floor structure. We also designed a large versatile mechanical ventilation system for keeping the work environment bearable around a hot process during the summer months. In additions we engineered the sanitary dense phase pneumatic conveying systems for moving the powdered clay around the dryer facility as well as pneumatic blending to homogenize batch campaigns.

Twenty years later, Matrix was recalled to design and build a twin facility with a new spray dryer right next to this one.

CARDWELL DUMPER ANALYSIS & REPAIR

Fri, 01 Mar 1996 15:36:54 GMT

Matrix provided the mechanical and structural engineering necessary for analyzing and repairing an existing dumper after a catastrophic failure. The dumper handled a 6000 lb payload and was originally designed by another vendor. Due to our quick response, very little production time was lost.

LOG MIXER - AUGER TYPE PASTE FEEDER WITH DRYING CAPABILITY

Thu, 01 Feb 1996 15:32:21 GMT

Matrix Engineering provided the detailed fabrication and design drawings of an auger feeder/dryer for processing a catalyst paste prior to pelletizing. The unit employed a hot air jacket for drying and an adjustable weir plate for retention time. The unit was also given wheels for use in easy removal when performing maintenance on area equipment.

CURE BIN UPGRADE ANALYSIS

Sat, 02 Dec 1995 15:37:51 GMT

Matrix performed finite element analysis on a new and improved sanitary cure bin at US Smokeless Tobacco. The cure bins hold approximately 5000 lb of product. They are trucked around the facility quite frequently and see some fairly rough treatment. The analysis allowed optimization of the sanitary design while maintaining and improving structural characteristics.

CENTRAL PACKAGING

Sat, 02 Dec 1995 02:59:37 GMT

Our engineering group provided structural, mechanical, and electrical engineering services in preparing the design for a centralized packaging system for the Nashville, Tennessee facility. The packaging system handles bulk bag and 50 lb. bags for two different products. The project included a pneumatic conveying system, a load cell mounted storage bin, a system of transfer screw feeders, a product screen, two packers (air and impeller), two bulk bag fill stations, a bag placer, bag transfer conveyors, and an automated palletizing system.

6000 LB CURE BIN DUMPER PROVIDES LIFT & 150DEG TILT AND DUMP

Sun, 01 Oct 1995 14:22:03 GMT

We provided the mechanical and structural engineering required for the design of a new cure-bin dumper. The dumper payload was over 6000 lb. and the dump rotation was 150 deg. We performed kinematic synthesis necessary to design the dumping mechanism as well as machine dynamics to determine worst case fatigue loadings on the structure. We also sized and specified and drafted the necessary hydraulic power pack, cylinders, and components.

BATTERY LEAD PASTE CONTAINER/FEEDER

Tue, 01 Aug 1995 14:35:50 GMT

Matrix provided the mechanical details necessary for fabrication of a mobile container and feeder for lead paste. The unit consisted of dual 24 inch diameter augers and trough as well as an integrally mounted hydraulic power pack. The feeder was design to be filled in one area of the facility, transported by forklift and hoisted by overhead crane for feeding into another area of the process. Matrix worked for Conveyor and Drive Equipment Company out of St. Louis who fabricated and implemented the machine.

CGMP POWDER HANDLING - METAL PREVENTION AND DETECTION

Wed, 01 Dec 1993 21:03:53 GMT

Our group provided the structural, mechanical, and electrical engineering necessary to replace an existing mechanical mixer, bucket elevator and transfer screw conveyor distribution system with a pneumatic convey/blending system. The intent of the project was to eliminate mechanical metal producers from contaminating the food grade product. Metal detectors were also installed just ahead of the packaging system. This was a very engineering intensive project due to spatial constraints and limited available shutdown time for installation.

MIXING BATCH TUB REACTOR CONVERSION

Sun, 01 Mar 1992 17:31:10 GMT

We provided the mechanical and electrical engineering needed to upgrade a vintage 1905 candy mixing tub to a modern mixing reactor for batching monocalcium phosphate. The reaction, which takes place during mixing, brings the product to a consistency of wet concrete before crystallization. Over 300-hp worth of mixing energy is dissipated into this restored tub. A 200-hp adjustable frequency drive was employed to adjust the speed of the mixing rotor during different stages of the reaction. Rhone-Poulenc engineers had estimated around a million dollars at that time to buy and install a new modern mixer along with the relocations of auxiliary equipment. Using this approach, total project cost was under 100k.

CATALYST TRAY DRYER WITH TRAVERSING INFEED & PIN-WHEEL LEVELER

Mon, 02 Oct 1989 01:19:52 GMT

Our engineering group was required for the design of a system for transferring high temperature catalyst (500 deg C) from the discharge of a new tray dryer to a nearby bucket elevator. We also designed an infeed system to the tray dryer, which included providing means for a uniform feed over an 8’-0” width. This uniform feed was accomplished by using a hydraulic cylinder to power a traversing 18” wide belt conveyor across an adjustable arc or width. The tray dryer manufacturer was impressed with the working concept and advertises this infeed feature in its literature.