Proprietary Oil Sands Processing Facility
Proprietary Oil Sands Processing Facility
Overview
A proprietary Oil Sands processing facility located in USA with a capacity of 875 TPD of Oil Sands. The facility is designed to produce efficient, Low carbon asphalt and marine fuels without waste or water consumption. The design will process crushed oil sands in a closed loop process. There ore will be mixed with a solvent in a continuous feed process. The sand will then be separated and dried with the vapours recovered and sent to storage for sale or reuse.
The facility includes an Ore Receiving / Ore Loading, Sand / Oil / Water Separation, Sand & Fines Drying, Oil / Solvent Separation, Solvent Vapor Recovery, Asphalt & Light Ends Product Storage, Solvent & Slop Liquid Truck Unloading & Storage, Sales Oil & Light Ends Truck Loading, Power Distribution & Motor Control Center, Lighting System, Process Control System, Firewater & Safety Systems, Control Room, Office, Ore Receiving Building to name a few.
New Horizons scope of work broadly included the complete engineering analysis and 3D modeling & drawings for piping, structural steel, electrical (carried out by our associate), & limited scope in instrumentation (carried out by our associate)
- 50+ P&IDs excluding vendor packages
- 70+ equipment including Augers, Conveyors, a flare, Compressor, Tanks, packages, vessels including filters, Air Cooled Heat exchangers and pumps.
- 5 Piping Material specifications to ASME B31.3 pipe sizes ranging from ½” NB to 12” NB of Carbon steel.
- 2 major pipe racks – 2 nos 2-tier sleeper (modular) racks (10’ wide x 175’ long and 150’ long.
- 12 skids – 4 Double decker and 8 single decker skids of varying lengths.
- 400+ Lines (96 Critical lines requiring rigorous analysis, 60 lines with simplified analysis and the rest with visual check only).
- Electrical design also included Load list and one line diagram preparation, Transformer and diesel generator sizing, technical offer review and vendor drawing review for MCC, Heat tracing, Diesel generator and light fixtures. Cable sizing and schedule and Bill of Material.
- Lighting design and layout, cable tray sizing and layout, grounding calculations and layout and hazardous area plan based on process inputs.
- Modeling of Instrument Tray, Instrument Tray MTO, Instrument Cable Schedule, Instrument Interconnect Diagram, Standard Instrument Details
- This being a pilot plant the essence is to reduce the capital cost to the extent possible. Existing tanks were rerated and modified (anchor bolts with anchor chairs added, nozzles added etc). Existing Air-Cooled Heat exchangers and instrument air receivers were identified and procured.
- Site grading work is in progress now.
Software used:
- CADWorx for 3D modeling of equipment and piping.
- STAAD Pro for structural analysis.
- AutoPIPE for piping flexibility analysis.
- ETAP 24 system studies for Short circuit, Protective device coordination and Arc-flash.
