Chemical & Process Industries
GSA have experience in a wide range of chemical manufacturing industries. Projects within particular sectors have included:
- Pilot scale production units
- Steel manufacturing
- Latex manufacturing
- Dye manufacturing
- Pigment manufacturing
- Water treatment chemicals
- Polymer manufacturing
- Explosives manufacturing
- Glass manufacturing
- Water management
- Food manufacturing
- Tobacco manufacturing
Services initially extended from feasibility studies through to detailed engineering design, implementation and commissioning (working with pre-qualified contractors).
Services that have been of particular interest to our clients have included:
- Scale up from lab or pilot plant
- Feasibility studies
- Process design
- Mechanical design
- Electrical, Instrumentation & Contol design
- Civil design
- Debottlenecking studies
- Commissioning, operation & maintenance support
- Procurement services
- Planning & permitting with regulatory bodies
- Technology Licensing
- Emission reduction & control
- Effluent treatment & minimisation
- Vent treatment system design
- Simulation of batch & continuous processes
- COMAH compliance
- Hazardous area classifications
- HAZOP & SIL assessments
- Risk based inspections
- Decommission studies
- Divestment studies
GSA works closely with its suppliers and contractors of specialist equipment to ensure our clients adopt the best available technology and methodologies to improve the overall performance of the process plant.
GSA is independent of any technology so we can provide a balance, unbiased opinion when choosing your technology provider.
GSA can also act as a skill provider to smaller operators who may not have the technical capability in-house. In this capacity GSA
can act as an extension to your own engineering department, working alongside your colleagues to deliver an integrated solution on site.
For an initial discussion please contact Mike Smith by clicking here.
Click here to view further details on GSA's Standard Engineering Packages
Chemical & Process Industries Case Studies
| Hide all studies |
 |
Location: Nottingham, England
Client: Imperial Tobacco
Scope: Installation of Steam Boilers with Superheating Capability
Date: June 2004 to June 2005
| More Information.. | Click to close |
The Client
Imperial Tobacco's Horizon plant in Nottingham is one of the largest cigarette plants in the UK.
The site processes tobacco from raw leaf to be boxed and packaged ready for sale within one building. The factory dates back to the 1970's where it was originally built for John Player & Sons.
The Challenge
The factory had extensive utility systems for processing and shared building services. A new Expanded Shredded Stem (ESS) process required a supply of
steam up to 16 barg and 350 deg Celsius (ie 150 deg superheat) with a controllable temperature across a broad operating range. The existing boilers,
installed in the 1970's, were not capable of this duty (shell boilers rated at 10 barg). GSA were initially engaged to carry out a feasibility study
to identify the most cost effective approach going forward.
The Solution
Having reviewed all options, including a dedicated boiler to supply the superheated steam to the ESS process, the preferred solution was to replace
some of the old boilers with new units that were capable of producing both superheated and saturated steam.
This had the benefit of keeping all of the boilers in one utility area of the factory rather than having remote units feeding individual processes.
This also allowed existing water treatment and fuel supply systems to be utilised resulting in new, more efficient boilers. To facilitate the installation
of the new boilers without putting the factory steam supply at risk, the installation was done in a sequential manner.
GSA provided engineering services to Imperial Tobacco during the project including the basic engineering design, procurement documents as well as
assistance with supplier liaison and bid appraisal. GSA oversaw the design safety process (Hazop, SIL Assessment, pre-commissioning and commissioning
checklists etc) and all commissioning & post commissioning activities.
Feedback
The project was completed successfully on time and to budget. GSA continues to enjoy a close working relationship with Imperial Tobacco.
|
|
|
 |
Location: Brazil
Client: MB Engineering Services
Scope: Gas Coolers for Steel Works
Date: May to June 2006
| More Information.. | Click to close |
The Client
In partnership with MB Engineering Services, GSA performed a FEED (Front End Engineering & Design) study to design and specify two gas coolers for a
major Steel Manufacturing Facility in Brazil.
The Challenge
GSA provided a Project Manager and Lead Process Engineer for the FEED study. GSA also became fully responsible for the project management of designs
and installations to support the plant start-up.
The Solution
Process engineering design for the gas cooling facility including:
- Preparation of process flow diagram
- Preparation of heat & mass balance
- Preparation of preliminary piping & instrumentation diagrams
- Design & specification of all main equipment items
- Preparation of mechanical & instrumentation datasheets
Following the sanctioning of capital, GSA were responsible for the project management of all detailed designs including:
- Engineering design
- Safety reviews
- Procurement
- Cost control
GSA also provided engineering support for the installation and commissioning of the facilities against performance guaranteed tests.
|
|
|
 |
Location: Newquay, UK
Client: Pall Europe
Scope: Production facility
Date: April 2004
| More Information.. | Click to close |
The Client
The client contacted GSA to assist with the installation of a new production facility. The client already had a similar production facility
in the US with a good understanding of the technology and processes. GSA were contacted to ensure the project was efficiently implemented while adhering to European standards and legislation.
The Challenge
The new production facility presented a range of new risks and hazards resulting in new operations
within hazardous areas. GSA provided a full engineering design for the facility including a new bulk tank farm
for flammable materials; process safety support service throughout the project; and undertook procurement services for the
main equipment items. GSA also delivered a training course to any personnel working on the new process, maintenance, management and safety personnel.
GSA advised the client of the shared site services that could service the new production unit.
The Solution
GSA provided the client with:
- Preparation of engineering design
- Preparation of mechanical and instrumentation datasheets
- Vendor specifications for MEI
- Vendor liaison and selection
- Operating procedures and functional specifications
- Attendance at FAT&s
- HAZOP and SIL assessments
- Hazardous area classification documentation & procedures
- Cost control & budgetary costs
- Training
Feedback
The project was delivered on time and to budget.
|
|
|
