Chemical Engineering January 2015 - 16

Source: Koch Modular Process Systems
Newsfront
moving to modular
Larger and more complex
processes are now being
offered in this unique
building approach
I
f the word " modular " brings to
mind a trailer office parked on
site, it's time to revisit modular
systems. Today's modular system
go well beyond office space and tool
sheds, and can contain almost anything
from a skid-mounted filtration
system to a cleanroom laboratory
to a petroleum refinery, which
is built elsewhere and delivered as
a complete unit to a site, where it is
then erected.
And, large modular process systems,
especially, are impressive
feats of engineering. For example,
according to Brian Loftus, contracts
manager at Koch Modular Process
Systems (Paramus, N.J.; www.
modularprocess.com), which designs,
plans and builds large-scale
modular mass-transfer systems, a
typical modular process system of
this type includes all of the process
equipment, such as columns, reactors,
heat exchangers and pumps,
mounted within a structural steel
frame. After the process equipment
is installed within its frame in the
shop, the piping components, field
instrumentation and electrical wiring
are completed. Items like tracing,
thermal insulation, lighting,
control systems, safety showers and
fire protection systems may also be
installed at the shop. Finally, all
these components are tested and
then the module is shipped and
erected on site (Figure 1).
While this type of modular process
unit may contain different
equipment and serve a different
purpose from modular refineries,
water systems or smaller-scale process
systems, all modular process
FIGURE 1. This modular system comprising three reactions steps and nine distillation
steps - a complete chemical production process - was designed and constructed
off-site in a controlled environment as modules
systems have one thing in common:
They are pre-fabricated to the maximum
extent possible in a fabrication
shop that is remote from the
user's plant site. Because modular
systems are typically built indoors
in a controlled, assembly-line fashion,
many advantages can be realized,
says Loftus.
Modular benefits
" Because modular process systems
are built using industrial manufacturing
techniques under stringent
quality controls and in a controlled
environment by skilled technicians,
there are plenty of advantages for
the customer, " says Brad Spindler,
industrial water business unit manager
with Wunderlich-Malec (Minnetonka,
Minn.; www.wmeng.com),
which constructs electrical enclo16
ChemiCal engineering www.Chemengonline.Com January 2015
sures for power distribution and
control systems used in power and
process plants, and modular industrial-water-process
skids and systems
(Figure 2) that supply makeup
and process water, or clean and recycle
a facility's wastewater. " The
modular approach to building at our
site versus the customer's site eliminates
the inefficiencies of onsite construction,
including site restraints,
labor stacking and weather delays. "
Also, because construction takes
place in the fabricator's shop, building
can begin before site permits are
obtained, which leads to a drastically
reduced construction timeline.
All of these factors come together
to reduce the schedule for delivery
of the completed project, which arrives
at the user's site ready to be
erected on a pre-laid foundation.
http://www.modularprocess.com http://www.wmeng.com http://www.Chemengonline.Com
Chemical Engineering January 2015

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