Category: Project

Modular desulfurization unit for gas processing facility

 

We delivered a modular amine gas treating (sweetening) unit for a gas processing plant handling high-sulfur feedstock. The system was designed to remove H₂S and CO₂ using a regenerative amine solution, ensuring compliance with emission standards and improving downstream catalyst life. The compact, skid-mounted design allowed rapid installation in a remote desert environment with minimal civil work. All components were pre-assembled, factory-tested, and delivered as plug-and-play modules.

Scope of work:

• Process and mechanical design of absorber and regenerator towers

• Fabrication of columns, heat exchangers, and amine circulation pumps

• Modular skid construction for all major subsystems

• Pre-insulated and pre-wired modules with junction boxes

• Electrical, instrumentation, and PLC control system

• Safety systems for acid gas handling

• Pre-commissioning, testing, and FAT at manufacturing site

• Shipping in containerized modules

• On-site commissioning and performance tuning

Energy optimization system for Asian refinery

 

We developed and implemented a comprehensive heat exchanger network for an oil refinery in Asia, aimed at improving energy efficiency across multiple process units. The system was designed to recover and redistribute heat within the production cycle, significantly reducing fuel consumption and CO₂ emissions. All components were customized to fit the client’s existing infrastructure, with special attention to minimizing downtime during installation. Thermal integration strategies were applied based on pinch analysis and dynamic modeling. As a result, the refinery achieved a measurable drop in utility costs and improved process stability.

Scope of work:

• Thermal design of exchanger network using pinch technology

• 3D modeling and integration with existing pipe systems

• Fabrication of high-efficiency shell-and-tube exchangers

• Installation and alignment on-site

• Commissioning and heat recovery testing

• Energy audit and performance validation

• Custom support structures and mounting systems

• Operator training and documentation delivery

High-pressure units for European petrochemical complex

 

For a large-scale petrochemical complex in Europe, we designed and supplied custom-built hydrocracking reactors capable of operating under extreme pressure and temperature. These reactors are the core of the plant’s middle distillate upgrading unit and are built to meet rigorous process and safety standards. High-alloy steel and corrosion-resistant linings were selected to extend service life under hydrogen-rich conditions. The units included internal distribution systems and catalyst holding sections for optimized cracking efficiency. The entire project was executed in close collaboration with the client’s EPC contractor.

Scope of work:

• Mechanical and thermal design of hydrocracking vessels

• Material selection for high-pressure, hydrogen service

• ASME and PED compliance with third-party inspection

• Fabrication and heat treatment of pressure shells

• Internal component installation (trays, distributors, supports)

• Nondestructive testing and pressure testing

• Catalyst loading accessories and nozzles

• Export packaging and transportation logistics

• On-site advisory and startup assistance

120,000 bpd capacity for Middle East refinery

 

We engineered and delivered a complete crude distillation unit (CDU) with a processing capacity of 120,000 barrels per day for a refinery in the Middle East. The project included a main atmospheric column, preheat train, and associated vessels, all tailored for high-throughput and energy-efficient operation. Built under strict quality control and in accordance with international standards, the unit ensures optimal separation of crude fractions. Particular focus was given to maximizing diesel and kerosene yield while minimizing energy consumption. The project was delivered ahead of schedule and fully integrated into the client’s existing control system.

Scope of work:

• Process design and simulation of the CDU system

• Engineering of atmospheric distillation column (internal trays and packing)

• Heat exchanger train and pre-flash drum design

• Fabrication of towers, vessels, and piping spools

• Structural platforms and access systems

• E&I interface for DCS integration

• Factory acceptance testing (FAT)

• On-site supervision during erection

• Commissioning and operator training