Confidential Client
Midwest USA
Chemicals
Overview
Reducing greenhouse gas emissions has become a key priority for industrial manufacturers as they work to meet sustainability commitments, comply with evolving environmental regulations, and support long-term operational reliability. As part of a broader emissions reduction initiative, an industrial manufacturing facility in Ohio undertook a major N2O abatement project focused on improving process performance, supporting long-term N2O reduction goals, and enhancing maintainability of critical plant equipment. The project involved replacing an existing NOx abator with a larger N2O abator vessel and associated process equipment, helping position the facility to comply with environmental requirements, including those associated with NAAQS, while advancing corporate carbon reduction objectives.
Driven by corporate carbon reduction initiatives, the project was developed as a fast-track effort with a required in-service date of September 2022. The scope included installation of a new N2O abator vessel, natural gas and ammonia mixer, desuperheater/attemperator, and gas analyzer system. The equipment package was supplied through a turnkey arrangement that included strict process performance guarantees, requiring careful integration with existing plant systems.
Nexus Engineering Group provided project management, project controls, procurement support, engineering design, laser scanning, and 3D modeling coordination services. The primary objective was to successfully integrate the new emissions reduction system within an operating facility while maintaining production, meeting aggressive schedule requirements, and supporting long-term environmental and operational goals.
Challenge
The project presented several complex engineering, operational, and scheduling challenges.
Fast-Track Delivery Schedule
The project was driven by corporate carbon reduction initiatives and required engineering, procurement, construction, and commissioning to be completed within approximately one year. Maintaining schedule certainty required extensive coordination among stakeholders while adapting to evolving equipment information and supply chain constraints.
Integrating a Performance-Guaranteed System
The new N2O abatement system was supplied through a turnkey arrangement that included strict process performance guarantees. Process design, P&IDs, and major equipment specifications were required to remain in conformance with supplier requirements while being integrated into existing plant processes. Extensive coordination, including multiple HAZOP reviews, was necessary to ensure the new system met project objectives, operational requirements, and overall emissions reduction targets.
Space Constraints and Maintainability
Limited available space within the operating facility created significant siting challenges. Multiple installation locations were evaluated, including potential placement above an existing compressor building. In addition to fitting the equipment into a congested area, the design needed to provide safe access to valves, instrumentation, and future catalyst media replacement activities.
Maintaining Operations During Construction
The existing NOx abator was required to remain operational throughout construction of the new N2O abator. This necessitated a carefully planned installation and cutover strategy with minimal shutdown duration. The project also included upsizing existing 16-inch process piping to 20-inch piping while addressing thermal expansion, piping stress, and personnel protection requirements associated with high-temperature operation.
Instrumentation and Controls Integration
The new system required modifications and additions to existing instrumentation and controls, including enhanced gas monitoring, process analysis, and data logging capabilities. These upgrades had to be integrated without disrupting ongoing plant operations.
Solution
Nexus addressed these challenges through a collaborative execution strategy that combined owner's engineering support, full installation engineering, advanced design technologies, and proactive project management.
Nexus supported the project through a combination of owner's engineering and detailed installation engineering services. On the process side, Nexus served as the client's owner's engineer, coordinating closely with the equipment supplier to review process design requirements, P&IDs, instrumentation strategies, and system integration considerations while helping ensure compliance with overall system performance guarantees. For the installation scope, Nexus provided full engineering services, including structural, mechanical, piping, and instrumentation design required to successfully integrate the new N2O abatement system into the existing operating facility.
To support the aggressive implementation schedule, Nexus provided project management and project controls services to develop and maintain an integrated engineering and construction schedule. The team continuously monitored project progress and adjusted activities as equipment information and delivery schedules evolved, helping maintain alignment between engineering, procurement, fabrication, and construction milestones despite supply chain uncertainties.
Using laser scanning and 3D modeling technologies, Nexus created an accurate digital representation of existing site conditions and evaluated multiple installation alternatives. After extensive analysis, the team recommended locating the new N2O abatement vessel between the existing abator system and compressor building above the existing pipe rack. This solution maximized the use of limited available space while improving access for operations and maintenance personnel.
To address long-term maintainability requirements, Nexus designed a multi-story support structure within an extremely constrained footprint. Detailed 3D modeling enabled the team to optimize equipment placement, piping routing, maintenance clearances, and operator access while minimizing potential construction conflicts. The design also incorporated a 20-inch expansion fitting to accommodate thermal expansion and contraction associated with startup, operation, and shutdown of the high-temperature process system.
As the client's owner's engineer, Nexus coordinated closely with facility personnel and the equipment supplier throughout design development, including HAZOP reviews and multiple 3D model reviews. These collaborative reviews helped validate process, operational, maintenance, and safety requirements while ensuring conformance with system performance guarantees. Nexus also supported equipment reviews, instrumentation integration, control system modifications, and construction shop drawing evaluations throughout project execution.
Outcome
The project was successfully completed within the required implementation schedule, providing the facility with a modern N2O abatement system that supports long-term N2O reduction goals, advances broader emissions reduction initiatives, and improves operational reliability and maintainability. Through strategic engineering, close stakeholder coordination, and advanced design technologies, Nexus helped the client achieve meaningful emissions reduction objectives while supporting compliance with environmental standards, including NAAQS requirements. The project demonstrates how innovative engineering solutions can help industrial facilities implement complex N2O abatement projects while improving long-term plant performance and sustainability outcomes.
Services
- Project Management
- Project Controls
- Procurement Support
- Estimating
- Schedule Management
- Laser Scanning
- 3D Modeling and Design Coordination
- Installation Planning
- Construction Support
- Engineering Design
Project Director
