Chicago Chem Consultants Corporation - Chemical Process Design, Development and Implementation Project Profiles; troubleshoot, startup, plant expansion, retrofit, revamp, final engineering, semi-works

Project Profiles

REPRESENTATIVE CHEMICAL PROCESS DESIGN, DEVELOPMENT, AND
IMPLEMENTATION PROJECT PROFILES

PHARMACEUTICAL PRODUCTION FACILITY PLANT EXPANSION
CCC provided complete consulting and engineering package, including design, pilot testing, equipment layout, final engineering, construction and drawings, procurement, installation, and startup, to expand existing food supplement production facility into the international market. By teaming closely with client's research and development department, plant personnel, and equipment suppliers coupled with "just-in-time" engineering, a $2 million plant expansion was completed on a tight schedule and within budget. After 1 year of operation, there was only 1 hour of downtime.

NEW FACILITY ENVIRONMENTAL TREATMENT SYSTEMS - DESIGN FOR ENVIRONMENT
Participated in the design/engineering/specification of solid and liquid waste treatment systems for new and add-on pharmaceutical manufacturing plants. This work, performed in conjunction with the John Brown Engineers and Constructors Company (formerly Davy McKee Corp.), included coordination of all design elements involved in the construction of new facilities, including piping & instrumentation drawings (P&IDs), equipment sizing and costing, waste minimization evaluation/recommendations, construction, etc. Typical projects in the $40-400 Million range, domestic and foreign.

RUSSIAN SYN-DRUGS PLANT USAID - DESIGN FOR ENVIRONMENT
Meetings in Chicago with 20-person Russian team included presentation and description of US EPA and OSHA system as pertains to chemical processing plants as well as demonstration of City of Chicago Fire Department Emergency Response Unit. Provided conceptual process environmental designs for $500 million multi-drug processing plant. Zero discharge design requirement included solvent recovery, waste water stripping and recovery utilizing full energy optimization via mechanical vapor recovery evaporators, plantwide vent recovery, and environmental control systems.

PHARMACEUTICAL COATING COMMERCIALIZATION DESIGN ENGINEERING
Designed semi-works plant for the commercialization of a new bench developed process for coating nano sized particles. Project included mixing, contacting, solvent recovery, equipment layout, sizing, costing, and environmental permit emissions calculations to support a design/build venture.

INVESTIGATION OF PREMATURE FAILURE OF MARINE COMPOSITE COATINGS
Investigated root cause of poor performance in various Marine Hull Coatings for international manufacturer. Lab work included optical and electron microscopy, FTIR, and GC. Evaluated degree of polymerization and crosslinking. Reviewed manufacturing process at three facilities and inspected coating supplier manufacturing facility. Evaluated hull cores. Reviewed physical and chemical properties. Developed coupon-testing program. Multiple failure modes and several probable causes were identified while other causes were ruled out. Production changes that were easy to complete were adopted. Trained client staff to continue this work as part of ongoing quality control.

PHARMACEUTICAL SEMI-WORKS PLANT
Provided engineering review and recommendations for a facility to produce low-quantity high-potency pharmaceuticals and small quantities of pharmaceuticals for drug trial purposes. Areas of recommendations included process design, health and safety, HVAC, equipment layout, movement of chemicals through facility, explosion protection, processing and cleaning requirements, and building modifications.

DEVELOPMENT OF PLASTIC WOOD FROM RECYCLED MATERIALS
Post agricultural polymer film evaluated with different post consumer streams of stiffeners and fillers. Patent search and academic evaluation of materials used as basis of experimental design. Pilot study milled and dried additives then blended in different ratios with polymer prior to extrusion. Extruded blends tested for material strength properties and general compatibility as a substitute for non-structural lumber. Economic analysis determined market potential for optimum strength/weight composition.

LUBE OIL RE-REFINERY DESIGN AND ENGINEERING
Provided used oil collection company technical engineering services in designing, specifying, procuring equipment and construction of 20,000 gallons per day (GPD) Lube Oil Re-Refining Operation.

PHARMACEUTICAL PLANT EXPANSION
Designed second and significantly larger production line for pharmaceutical intermediate involving repeated batch-wise extraction, filtration, crystallization, and distillation. Expansion incorporates equipment improvements identified by CCC in order to reduce cycle time and manpower requirements. This represents fourth major project by CCC for this client.

NEW BATCH PROCESS
Liquid metering, powder handling batch process designed to provide dust containment, dispersion and packaging for new proprietary liquid product. Scope included process specifications, general arrangement and vendor sourcing.

SLURRY DRYING UPGRADE
Worked with client team to identify and prioritize new slurry drying options. Technology identified to meet space and budget restrictions in addition to product quality requirements. Provided technical guidance to improve production and qualitative analyses during pilot test.

HYDROGENATION REACTOR SYSTEM DESIGN
Designed a hydrogenation reactor system and siting for a high potency pharmaceutical intermediate. Prepared an installed cost estimate for the unit. Reviewed regulatory codes and recommended methods of installation. Incorporated related safety and environmental controls into design.

CHEMICAL/ENVIRONMENTAL SYSTEM AND PROCESS DESIGN SPECIFICATIONS
Assisted numerous clients in selecting and purchasing new and used process equipment, e.g., heat exchangers, dryers, stills, evaporators, mixers, reactors, mechanical conveyors. See purchasing/procurement for more information.

WASTEWATER TREATMENT SYSTEM STARTUP AND TROUBLESHOOTING
Please see "Remediation and Treatment Engineering" for more information.

FILTRATION IN PROCESS AND ENVIRONMENTAL APPLICATIONS
Filtration can be used to recover a solid product from a solvent or reaction medium. This allows reuse and recycle of solvents while capturing pure products. A filter can also be used to reduce particulate loading in waste streams. Filters can be employed to prevent build up of particulates or dissolved organic and inorganic molecules. CCC has experience with all of these filter systems. Flow, particle size and composition and density, and other physical properties are evaluated to select from ultrafiltration, pressure leaf, filter press, backwashable, membrane, cartridge and other type filters.

The key to success is specific application design.