Process design of a pretreatment and bulk feed system for the continuous processing of a biological sludge stream through a thermal treatment system.
SLUDGE PRETREATMENT AND FEED SYSTEM PROCESS DESIGN
The client owns and operates a catalytic extraction waste thermal treatment system. Process Engineering Associates, LLC (PROCESS) was contracted to perform a process design of a pretreatment and bulk feed system for the continuous processing of a biological sludge stream through the thermal treatment system. Project tasks included:
- Process design basis development
- Mass and energy balance model preparation
- Process design, and process flow diagram (PFD) and process description preparation
- Process control system design, and process control diagram (PCD) and process control system description preparation
- Equipment layout drawings preparation
- Detailed equipment specifications preparation
- Capital, operating, and annual cost estimates development.
The process design basis development included waste stream physical and chemical characterizations, system throughput requirements (for maximum, average, and minimum design cases), and unit operations performance specifications. PROCESS used in-house computer technology to develop mass and energy balances for the three design cases. The PFD depicted major process unit operations and detailed mass and energy balance information for the primary process streams. The PCD depicted major system control loops, monitoring points, alarms, and interlocks. The equipment layout drawings showed plan and elevation views and major dimensions for the proposed system. Detailed equipment specifications, prepared for the system major unit operations, presented information requisite for the procurement of the equipment. A general specification detailing overall facility requirements was prepared as well. Cost estimates development was facilitated by the preparation of vendor bid packages for the system major unit operations and the solicitation of technical and cost proposals from equipment vendors for the purpose of establishing equipment purchase cost. In-house computer programs were then used for the development of overall capital, operating, and annual costs for the proposed system.
The final process design package delivered to the client included the following documents:
- Process design basis summary
- Process description
- Process control system description
- Equipment layout drawing
- Detailed general and individual equipment specifications
- Vendor technical and cost proposals
- Capital, operating, and annual cost estimates summary and worksheets
- Waste Treatment
- Creation of PFDs and PCDs
- Equipment specification
- Cost estimation
- Basic engineering design (BED)
- Schedule A package
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