Hydrocarbon Processing - July 2022 - 38

Circular Economy
tional footprints. Furthermore, in some cases, feedstock sources
may be fluid and may change over time. Creating multiple, smaller
processing hubs that are designed and built to be mobile allows
economical relocation as needed to follow feedstock sources.
Also, given that a hub-and-spoke feedstock delivery model
drives the need for employing multiple smaller and potentially
mobile processing facilities, the project delivery model, along
with the construction and design of these process facilities, must
be reevaluated. Building truckable modules (FIG. 2) vs. traditional
field construction or even traditional modularization creates
considerable advantages.
Right-sized truckable modular solution. Modularization
is described as the process of shifting as much of the labor-intensive
field construction activities as possible from the field to
an offsite fabrication facility. This mitigates the inherent risks
associated with field construction. Typically, a modular system
includes complete process units that are fabricated remotely
from the plant site.
Modular construction allows for standardization and repeatability,
which translates to the ability to establish a definitive
estimate early in the project development phase-much earlier
than is typically possible with a field construction execution
strategy. Furthermore, with modularization, issued for construction
(IFC) drawings are also frozen much earlier than with
field construction, thus enabling a fixed-price contracting strategy
to ensure cost certainty. This is especially beneficial with
developing-technology projects, which typically rely on bank
and venture capital funding to advance projects from the proofof-concept
stage to commercialization. Another added benefit
of being able to freeze the design early in the project is that it
mitigates the opportunity for scope creep in the field, which can
have a direct impact on cost and schedule.
The benefits of modularization over field construction can
include:
* A reduction in workplace hazards and injuries
* Shorter project delivery schedules and time to market
* Minimized site interruptions
* Increased productivity
* The ability to commence module fabrication during
the permitting phase
* Advanced definitive estimates and fixed-price contracts
* Overall project cost savings.
Considering the smaller capacity and size of the hub facilities
in the hub-and-spoke model, truckable modular construction is
best suited as a project delivery model vs. both traditional field
construction and modularization. Unlike traditional modules,
which can weigh up to 6,000 t and require highly specialized
transportation, truckable modules generally have footprints of
12 ft × 14 ft × (up to) 90 ft, which means that these modules can
fit easily on a standard truck. Consequently, these modular systems
are well-suited for facilities with manufacturing capacities
that are best served by a hub-and-spoke feedstock delivery model.
Truckable modular process systems are typically built in a
horizontal assembly line fashion in a controlled indoor environment.
This helps minimize the amount of work and resources
needed vs. field construction. When arriving onsite, the truckable
modules are approximately 90% complete, and include all
necessary components and equipment placed within the structural
steel frame required to deliver a complete process system.
This frame serves as support during shipment, and provides
access to the equipment for operation and maintenance after
installation at the plant site. Once delivered onsite, the only remaining
activities include making interconnects, utility and electrical
tie-ins, and commissioning and startup activities.
Benefits of truckable module project delivery models. In
addition to the typical benefits of executing projects modularly,
selecting a truckable module project delivery model introduces
additional advantages, including:
1. Scalability: When a project is designed up front as a
modular facility, then it is possible to employ a plugand-play
design strategy for adjusting the facility size,
design capacity, layout and other design parameters to
fit the regional requirements. This facilitates the ease of
reconfiguring, adding or eliminating process modules.
Furthermore, scalability creates the ability to quickly
and economically move from proof-of-concept pilot
scale to commercial scale.
2. Installation flexibility: Once erected in the field,
truckable modules can be installed in either a horizontal
or vertical orientation. For distillation column
applications, where the column height exceeds the
overall erected height of a given module, the columns
can be dropped into the module and flanged together
at the site, or two vertically oriented modules can be
bolted together. Additionally, where process systems
require multiple modules to form a complete operating
process system, these modules can be interconnected
both horizontally and vertically.
3. Repeatability: One of the inherent benefits of
designing for scalability is that designs can be
standardized for repeatability. Given the nature of a
hub-and-spoke feedstock delivery model, facilities may
need to be installed in various locations across multiple
regions. Therefore, a design-one/build-many approach
can be employed as a base design while implementing
minor design modifications that consider local factors
such as codes and specifications, as well as special
environmental conditions.
FIG. 2. A view of Origin Materials' biomass truckable modular
process system.
38 JULY 2022 | HydrocarbonProcessing.com
4. Project predictability and risk mitigation: All the
inherent benefits of modularization, along with the
addition of the special benefits afforded by opting for
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