Project Progress!

Designing and implementing modular process plants involves careful consideration of various factors to ensure a successful and efficient project outcome.

Process Requirements: The process engineers responsible for designing our EPS modular process plants are well versed in upfront oil & gas processing and metallurgy, specifically hydrometallurgy. These include the extraction and recycling of battery metals, such as nickel, manganese, cobalt & copper. They fully understand any hydrometallurgical process requirements such as solids handling, pH, ORP and temperature control requirements, as well as chemical make-up and addition challenges.

Modular Strategy: Through their experience of designing modular plants, they ensure that the modular design can accommodate the necessary process equipment, instrumentation, and controls to meet the modular requirements effectively. The construction of larger equipment within a transportable module may not be the most cost-effective solutions. In these instances, we adopt a hybrid model, where we incorporate conventional components as required.

Detailed Engineering & Design: Meticulous engineering and design play a pivotal role in the creation of modular processing facilities. We ensure that our modules align seamlessly on module battery limits and connection points. Paying special attention to these points during the design phase ensures that our plants are erected in the shortest time possible.?

Access: Accommodating all equipment within modules constrained by transportation envelopes presents unique challenges, particularly in terms of equipment access. At ProProcess we optimise our layouts, ensuring ease of operation and maintenance.

Electrical: This project showcases a variety of protocols on both the RS-458 and Ethernet physical layers. This enables consolidating information in the field on devices and digitizing the data into a backbone. We try to achieve the digitization as close to the process as possible to reduce the need for vast amounts of cables. This reduces on-site ready-to-run time for customers and has long-term benefits for end users considering multiple deployments of the equipment.

Fixed installations and loose site installations make up the E&I infrastructure. Smaller more manageable cable racks, pre-wired looms and field cable into industrial plugs and inline cable joints. A team of 2 can site establish in 5 days. With traditional methods, this would have been a 10-man team for 10 days. Both incoming and outgoing supplies and network connections are toolless, only need to plug and energise to be able to start plant operations up.

Assembly: All our modular units are trial-assembled and tested at our facilities prior to dispatch. Site modification are a major contributor to schedule and cost overruns on projects. Not only do we complete water testing of all the mechanical equipment and piping on our pre-assembled plants, but also complete the full software integration prior to shipping.? This ensures that any modification both to physical equipment and to the programming is minimised on site.

By pre-erecting the modular plant, the site assembly sequence is well defined. We typically supply a site assembly team with our plants to further speed up the erection of the modules at client locations.

Site Preparation: Many of our modular plants are designed to minimise the civil requirements on site. Negating the requirements to construct civil foundations speeds up erecting times significantly.

We design and build plants!