Reduce CapEx

Is there a better and less costly way to design your process? Do you need one or two more concepts to exhaust your evaluation. I can provide new ideas, cross industry insights, consultation on R&D, and offer new technology. CapEx may be reduced by evaluating all relevant technology options available and selecting the best. Future changes in the Refining, Chemical, and Power industries should be considered when making decisions. Current actions and spending are important indicators of the future.

ALTERNATE TECHNOLOGY EXAMPLES

Alternate and under-evaluated technologies may provide the best return-on-investment (ROI). Some examples are:

  • Dissolved hydrocarbons may be quickly and completely removed from wastewater using super-critical oxidation.

  • Dissolved aqueous salts can be crystallized and removed from water by disrupting hydrogen bonding with supercritical pressures.

  • Dissolved aqueous salts can be crystallized and removed from water by injecting certain supercritical gases at high pressure to act as an antisolvent.

  • Ninety-five percent (95%) of chemical separation operations use energy intensive distillation despite large government subsidies for membrane methods. Crystallization methods are under evaluated.

  • The chemical separation of p-xylene from its isomeric mixture using crystallization requires 30% less energy than membrane processes. Distillation is impractical.

  • Changes in the energy market will change the ROI on available processes and promote technologies rejected in the past.

  • Fired heaters create fluctuating peak process temperatures that can damage sensitive products or metals. Electric heater methods significantly reduce peak surface temperatures.

  • Natural gas may be combusted in a supercritical carbon dioxide (CO2) loop without CO2 emissions.

  • Electro-chemical campaigns may be extended with electrolyte regeneration.

  • Electro-chemical processes may be relevant in settings where they are unknown.

NECESSARY COMPONENTS

Capital projects are proposed to generate profit based on a new opportunity or to maintain a threatened enterprise. By using experienced project managers, senior design engineers, and successful cost estimators, the relevant options can be disclosed and analyzed. The following need to be created quickly and accurately:

  • Process Design Basis (PDB) – the fundamental design, calculations, and drawings that define one solution

  • Cost Estimate – an accurate list of the material, labor, and contract costs necessary for the PDB

  • Return-on-Investment (ROI) – the percent net profit expected from the project relative to the initial cost

  • Payback (PB) – the expected number of years needed to recover the investment

  • Project Execution Plan (PEP) – a description of the steps and schedule needed to complete the project