projects
Some of the previous projects and their highlights.
Please contact us for more details.
ZERO CARBON LITHIUM™ and Renewable Energy Project
Up to ~300 MW thermal heat capacity & ~50 MW power generation w/ 28,4 Mt/yr flow | CAPEX: €100M+ | Karlsruhe
The primary aim of the project is to drive a carbon-neutral future by supplying lithium chemicals and renewable energy within Europe, sourced from the ZERO CARBON LITHIUM™ and Renewable Energy Project. Lithium is extracted from underground geothermal brine, then processed, purified, and delivered to a Central Lithium Plant for use in EV batteries. The thermal energy from the geothermal brine is transferred to a secondary industrial water cycle, which generates steam, meets the city’s heating needs, and produces energy through an ORC system.
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Responsibilities
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Communication with EPC: Collaborate closely with the EPC to review various documents, including but not limited to Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID), Key Performance Indicators (KPIs) for contract, performance and acceptance test procedures, process descriptions, plant safety concepts, operating philosophies, HAZOP studies, and more.
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Process Simulation: Model and simulate the Industrial Water Cycle in Aspen Plus, covering steam generation, district heating, and ORC. Develop potential scenarios considering varying district heating demands over a 25-year period, fluctuating ambient air temperatures, and different industrial water flow and temperature conditions.
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Process Integration: Work closely with local energy provider to develop district heating energy requirement forecast until 2050, construct operation cases for the entire plant for different operating conditions; working fluid flow and temperature, ambient air temperature, corresponding district heating requirement and steam generation demand.
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Process Design: Support the team on other parts of the project, i.e. Lithium Extraction Plant, Interconnecting Pipe & Power and Lithium Central Plant for process simulations, heat and mass balance calculations, hydroulic calculations for pipelines.
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Improve the Design Basis for the project.
0.5 MW Dual-mode Electrolyser Pilot Plant Design
0.5 MW for H2 generation and 120 kWh for power generation | CAPEX: ~€20-25M | Amsterdam
The project's main goal is to integrate two 250 kW solid oxide electrolysers (SOEs) into a unified demonstration plant within a comprehensive system. This initiative aims to reduce technology risks, enable future applications, and create intellectual property or licensing opportunities. Designed for hydrogen production from renewable sources and electricity generation from hydrogen or methane, the plant supports reversible operations.
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Responsibilities
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Heat and Mass Balance Development: Expertly developed comprehensive heat and mass balances for both hydrogen generation and power generation modes, applying rigorous analytical methods to ensure process efficiency and sustainability.
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Process Simulation Expertise: Utilized DWSIM to accurately model and simulate process operations for hydrogen and power generation, optimizing system design and performance through detailed analysis and validation.
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Smart P&ID Construction: Employed AutoCAD Plant 3D to meticulously construct smart Process and Instrumentation Diagrams (P&IDs) for the entire plant, ensuring a high degree of precision and adherence to engineering standards.
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HAZOP Session Participation: Actively engaged in Hazard and Operability (HAZOP) studies, leveraging critical thinking to identify and address potential risks, contributing significantly to the project’s safety and operational integrity.
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Basis of Design Documentation: Authored the Basis of Design document, meticulously detailing project scope, design rationale, optimization strategies, and technical assumptions, providing a clear roadmap for project stakeholders.
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Type 2 Cost Estimation Calculation: Skillfully calculated Type 2 cost estimations, including detailed analyses of Capital Expenditures (CAPEX) and Operational Expenditures (OPEX), facilitating accurate financial planning and budget management.
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Economic Analysis and Sensitivity Analysis: Conducted thorough economic analyses and sensitivity assessments concerning hydrogen and electricity price fluctuations, enabling strategic decision-making based on financial viability and market conditions.
Waste-to-Oil Pyrolysis Plant Retrofit Design
4,000 kton/yr | CAPEX: ~€30-35M | Dutch Limburg
The objective of this project is to significantly enhance the operational efficiency and financial performance of a chemical processing facility through strategic process redesign and optimization initiatives.
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Responsibilities
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Capital Efficiency Improvement: Achieved a notable 14% reduction in working capital by innovatively redesigning the condensation section, markedly enhancing both resource utilization and financial performance.
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Process Efficiency Enhancement: Significantly boosted process efficiency by overhauling the separation mechanism, replacing traditional bulky filters with a combination of advanced cyclones and a swirl chamber. This upgrade facilitated longer periods of uninterrupted operation and minimized maintenance demands.
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Heat and Mass Balance Development: Skillfully developed detailed heat and mass balances for 12 varied scenarios, adjusting for differences in feed quality and operational scales, thus ensuring robust process adaptability and optimization.
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Smart P&ID Development: Utilized AutoCAD Plant 3D to craft detailed smart Process & Instrumentation Diagrams (P&IDs) for the entire plant. This facilitated a more informed selection process for integrating new or phasing out existing equipment and instrumentation, optimizing plant layout and functionality.
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Basis of Design Documentation: Authored a comprehensive Basis of Design document, meticulously detailing the project's current and anticipated scope, underlying assumptions, pivotal design decisions, and targeted optimization strategies. This foundational document serves as a critical roadmap for guiding the project's strategic execution and stakeholder alignment.
End-of-Life Plastics Into High Grade Feedstock for Plastic Production
32 kton/yr | CAPEX: ~€18M | Rotterdam
The project's objective is to meticulously design and optimize the process infrastructure for a chemical processing facility, ensuring safety, operational efficiency, and precise control over process flows through detailed engineering and specification development.
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Responsibilities
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Engineering Design and Sizing: Accurately sized gas storage tanks, pumps, pressure relief valves, flow valves, and pipelines for the detailed engineering phase, aligning with performance requirements and safety standards to ensure a high level of operational integrity and reliability.
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Instrumentation Specification Development: Developed a detailed instrument list for the project, meticulously documenting specifications, locations, and functions, to streamline procurement and ensure accurate installation, enhancing project efficiency and equipment functionality.
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Valve List Compilation: Compiled a comprehensive valve list for the project, carefully specifying types, sizes, and operational parameters. This effort facilitated the precise control and regulation of process flows, contributing to the overall process efficiency and safety.
Multi-stage distillation column modeling
80 kton/yr | CAPEX: N/A | Antwerp
The main objective of this project to developand optimize of distillation processes for the purification of two different products to meet specific purity specifications, with a focus on energy efficiency and productivity.
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Responsibilities
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Distillation Column Design and Modeling: Expertly designed and modeled two individual (two-stage) distillation columns for separate products, achieving precise purification to meet specific requirements with a total capacity of 8 kt/yr. This achievement showcases a deep understanding of distillation processes and a keen ability to meet production goals within stringent quality specifications.
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Parametric Study and Optimization: Performed extensive parametric studies to optimize the energy use and productivity of distillation operations. This approach highlights a commitment to enhancing process efficiency and sustainability, underscoring a strategic focus on minimizing environmental impact while maximizing output.
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Innovative Process Solution: Engineered a novel (two-stage) distillation column designed to efficiently handle both products, demonstrating exceptional problem-solving skills and the ability to develop flexible process solutions that streamline operations and reduce costs.
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VLE Data Analysis and Implementation: Manually implemented Vapor-Liquid Equilibrium (VLE) data for a binary mixture, correcting discrepancies with experimental data. This task illustrates meticulous attention to detail, a rigorous approach to data accuracy, and the proficiency to adjust process simulations based on real-world observations.
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Column Sizing and Internal Design: Successfully sized the distillation column and designed its internals, ensuring optimal process performance and adherence to engineering principles. This capability reflects a comprehensive understanding of distillation column mechanics and the skill to tailor equipment design to process requirements.
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Proficiency in ChemCad NXT: Utilized ChemCad NXT for process simulation and design tasks throughout the project, indicating a high level of competency in leading process simulation software. This expertise enables the effective use of technology to refine processes, enhance design accuracy, and facilitate project success.
Upcycling End-of-Life Tires Into High Grade Carbon Black
25 kton/yr | CAPEX: ~€33M | Eindhoven
The project's objective is to design and optimize the separation process for pyrolysis oil in the oil & gas sector, focusing on maximizing efficiency, safety, and yield through advanced engineering practices, including the development of detailed process models, equipment design, and operational protocols.
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Responsibilities
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Distillation Column Engineering: Engineered distillation column models specifically tailored for the efficient separation of pyrolysis oil, focusing on enhancing both purity and yield through precise design and optimization techniques.
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Heat and Mass Balance Formulation: Formulated detailed heat and mass balances for the oil & gas section, a critical step towards ensuring operational efficiency and process optimization.
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Critical Equipment Design: Designed essential equipment including heat exchangers, pumps, tanks, and distillation columns for the oil & gas section, with an emphasis on achieving top performance and adhering to stringent safety standards.
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Smart P&IDs Development: Utilized AutoCAD Plant 3D to develop smart Process & Instrumentation Diagrams (P&IDs) for the entire project, significantly improving the accuracy and integration of the process design.
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Distillation Basis of Design Authoring: Authored a comprehensive Distillation Basis of Design document that meticulously outlines process specifications, design rationale, and optimization strategies, guiding the project towards successful implementation.
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HAZOP Session Contributions: Actively contributed to Hazard and Operability (HAZOP) sessions by identifying potential process risks and proposing effective mitigation strategies, enhancing the project's safety profile.
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Control Narrative Crafting: Crafted a detailed Control Narrative for the oil & gas section, which outlines critical operational protocols and safety measures, ensuring smooth and safe process operations.
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Equipment Data Sheets Creation: Created comprehensive equipment data sheets that detail technical parameters and operational guidelines, providing a foundational tool for project execution and ongoing maintenance efforts.
Heat Integration & Energy Recuperation Study
40 kton/yr | CAPEX: N/A | Antwerp
The objective of this project is to enhance the energy efficiency and operational effectiveness of a renewable plant with a 40 kt/yr capacity.
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Responsibilities
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Renewable Plant Heat Integration: Conducted a thorough investigation of heat integration possibilities for an existing renewable plant design with a 40 kt/yr capacity. Utilized pinch analysis, revealing a potential for 8% savings in energy costs. This effort underscores a commitment to enhancing energy efficiency and reducing operational expenses in renewable energy production.
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Propylene Recovery Unit Feasibility Study: Performed detailed parametric studies on the feasibility of implementing a Propylene Recovery Unit utilizing plant off-gas. The studies concluded that the construction of such a unit is impractical due to the low purity levels of the recovered propylene, highlighting the project’s rigorous analytical approach and practical decision-making based on technical and economic evaluations.
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Reboiler Selection and Optimization: Proposed a superior and more effective reboiler option compared to the Engineering, Procurement, and Construction (EPC) firm's initial suggestion. This recommendation demonstrates an ability to critically assess process equipment options and suggest optimizations that can lead to improved process performance and cost savings.
Orange Peels Waste-to-Oil Project
50 kton/yr | CAPEX: N/A | North-Brabant
The project's objective is to design and implement an integrated cooling and piping infrastructure for a chemical processing plant, ensuring optimal system performance, efficient process integration, and enhanced operational and maintenance efficiency through precise engineering, effective vendor collaboration, and comprehensive system documentation.
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Responsibilities
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Cooling Water System Engineering and Installation: Engineered and oversaw the installation of a Cooling Water System, working in close collaboration with vendors to guarantee a seamless integration and superior cooling performance, demonstrating project management and engineering design skills.
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Interpiping System Design and Coordination: Crafted and managed the installation of the interpiping system linking various skid units across the plant, ensuring precise installation through effective vendor coordination. This effort ensured efficient process interconnectivity and flow continuity, showcasing technical design and coordination expertise.
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Pipeline Structure Overview Construction: Developed a comprehensive overview of the plant's pipeline structure, offering a clear and detailed visualization of pipeline layouts and specifications. This initiative enhanced the operational understanding and facilitated more effective maintenance planning, reflecting a thorough approach to documentation and design.
conceptual design development of
co2 conversion to methanol, dme and olefins
1 Mton/yr | CAPEX: N/A | Amsterdam
This study’s main objective is to develop alternative conceptual process line-ups for CO2 conversion to methanol. The secondary objective is to develop the subsequent conversion of methanol to DME and olefins.
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Responsibilities
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Alternative Conceptual Process Design: Developed innovative process designs for CO2 conversion to methanol, incorporating strategies for further conversion to DME and olefins, showcasing versatility and forward-thinking in chemical engineering solutions.
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Aspen Plus Simulations: Leveraged Aspen Plus software to conduct detailed parametric studies, pinch analyses, heat integration, and economic assessments, demonstrating a high level of proficiency in process optimization and simulation.
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Methanol Production Alternatives Engineering: Designed and compared two methanol production routes: a direct CO2 conversion in a single reactor and a two-step conversion via an RWGS reactor, illustrating adeptness in process design and engineering creativity.
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Sensitivity and Optimum Conditions Analysis: Conducted sensitivity analyses to determine the optimal operating conditions, maintaining a focus on efficiency and sustainability by adhering to CO2's critical pressure constraints.
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Methanol Production Targeting and Efficiency: Successfully targeted and achieved a methanol production rate of 1 Mt/yr for the CO2-based route, with innovative feedstock management leading to a 10% higher yield in the CO-based route, evidencing strategic planning and effective resource management.
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Production Output Achievement: Accomplished significant production outputs of DME and olefins from methanol, showcasing capability in scaling processes from conceptual design to tangible outputs.
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Heat Integration Using Aspen Energy Analyzer: Implemented comprehensive heat integration strategies using Aspen Energy Analyzer, enhancing process efficiency and energy conservation within and beyond the ISBL.
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Economic Analysis and Cost Management: Conducted in-depth economic analyses to evaluate the financial viability of process routes, demonstrating acumen in financial planning and cost optimization.
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Economic Sensitivity Analysis: Performed robust economic sensitivity analyses, identifying potential pathways to profitability under varying market conditions, underscoring adaptability and strategic financial planning.
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Project Conclusion and Strategic Insight: Concluded the comparative viability of CO2 to methanol conversion processes, with a nuanced analysis favoring the CO2-based route, reflecting a deep understanding of process engineering and strategic decision-making.
INTENSIFIED DIMETHYL ETHER PRODUCTION FROM
SYNTHESIS GAS WITH CO2
Chemical Engineering Journal
The project's objective is to enhance the efficiency and control in the catalytic conversion of syngas to dimethyl ether (DME) through the innovative use of a microchannel reactor, achieving superior operational performance and yield outcomes by meticulously modeling the process dynamics and optimizing reactor design and conditions.
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Responsibilities
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Process Modeling and Simulation: Developed an advanced steady-state model for the catalytic conversion of syngas to dimethyl ether (DME) in a microchannel reactor. The model incorporates two-dimensional conservation of momentum, heat, and species mass, alongside reactive transport within a porous catalyst layer.
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Innovative Reactor Design: Utilized a microchannel reactor design with horizontal groups of rectangular-shaped cooling and catalyst washcoated reaction channels. This design facilitated counter-current flows of air and syngas, demonstrating a pioneering approach to reactor configuration.
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Catalyst Optimization: Achieved precise regulation of exothermic equilibrium synthesis and dehydration reactions through the strategic use of Cu-ZnO/Al2O3 and γ-Al2O3 catalysts, optimizing the catalyst layer composition for enhanced performance.
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Operational Efficiency Improvements: Demonstrated significant improvements in operational efficiency, including a notable reduction in inlet temperature elevation compared to traditional packed-bed tubular reactors. This was achieved through careful optimization of syngas feed temperature, pressure, and flow rates under CO-rich and CO2-lean conditions.
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Performance Optimization: Identified optimal operational conditions that led to increased CO conversion rates (from 33 to 45%) and elevated DME yields (from 2 to 3.6%), setting new benchmarks for reactor performance.
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Thermal Management and Material Selection: Explored the impacts of thermal management strategies and material selection, such as the use of thicker walls between channels and thermally conductive materials, on reactor performance and hot-spot regulation.