Confidential Client
Midwest USA
Chemicals
Overview
The client is a global leader in advanced materials and specialty chemicals, operating complex manufacturing facilities that serve high-performance applications across multiple industries. To support long-term growth and increasing demand, the client initiated a phased program to debottleneck existing operations and drive manufacturing capacity expansion by more than 50%.
This program consisted of two coordinated efforts. The first project focused on a series of debottlenecking and reliability improvements across multiple operating units, while the follow on project advanced a larger plant expansion and capacity expansion effort to enable significant plant growth through new process units and infrastructure.
Nexus Engineering Group supported these efforts from FEL through detailed design, including FEL‑2 and FEL‑3 development, TIC estimating, and execution planning within a stage-gate process. The work included development of a ~$35MM TIC program (Sport) and a ~$180MM FEL‑2 expansion estimate (Spruce), with a portion of the expansion advancing into FEL‑3 (≈$65MM).
Challenge
Brownfield Constraints in Active Operations
All work was executed within a fully operating facility, requiring modifications, equipment installations, and tie-ins to be carefully planned around existing infrastructure, limited access, and ongoing production. Space constraints created significant challenges for equipment placement, constructability, and installation sequencing.
Multi-Project Coordination and Aggressive Schedule
The program required simultaneous execution of multiple interrelated projects, each with its own scope, schedule, and design requirements. Tight timelines, driven by outage windows and client funding milestones, required close coordination across engineering teams, disciplines, and office locations.
Expansion Within a Constrained Footprint
The second expansion project introduced new process units, utilities, roads, pipe racks, and storage within an already congested site. Heavy haul access, tie-ins to existing systems, and integration of new infrastructure required careful planning and continuous layout optimization to support industrial plant optimization.
Solution
Nexus delivered an integrated, multi-discipline engineering approach focused on constructability, coordination, and execution readiness for plant expansion and manufacturing capacity expansion projects.
The team leveraged advanced 3D modeling and visualization tools to develop and refine plant layouts, enabling rapid iteration of equipment placement, pipe routing, and structural modifications within tight space constraints. For complex installations, Nexus created visual execution plans to support construction sequencing and stakeholder alignment, reducing risk and improving field efficiency.
Across both projects, Nexus facilitated collaborative planning sessions and iterative design reviews, ensuring alignment between engineering, operations, and construction teams.
Engineering was closely coordinated across multiple offices, with structured interface management and discipline reviews to maintain consistency and quality across concurrent scopes.
For the second project, Nexus supported FEL‑2 development through a stage-gate process, delivering a comprehensive ±30% TIC estimate by integrating equipment pricing, utility requirements, and site-specific constraints into a realistic, executable plant expansion plan. This provided the client with critical cost visibility and informed decision-making prior to full project sanction.
Results & Client Impact
Nexus successfully delivered multi-phase engineering and planning support that enabled the client to progress from debottlenecking initiatives into a clearly defined capacity expansion roadmap.
- The first project was executed with strong constructability and cost accuracy, with final project costs within ~8% of Nexus estimates and successful startup performance across all units
- The first project provided the client with high-confidence cost and layout definition, enabling strategic decisions on overall investment and phased execution
- A portion of the plant expansion advanced to FEL-3, representing a $65MM capital project aligned with long-term capacity goals
- The collaborative approach and technical rigor strengthened Nexus’ position as a trusted engineering partner for future capital programs
Services Provided
- Front-end loading (FEL 1–3) engineering and project development executed through a stage-gate process
- Multi-discipline engineering (process, mechanical, piping, civil/structural, electrical, instrumentation)
- 3D modeling and model-based layout optimization
- TIC estimating and cost development (±30% and Class II estimates)
- Constructability planning and installation sequencing
- Execution planning and multi-project coordination
Project Director
