Delivering Exceptional Engineering Solutions: A 100,000 TPA Wet Sulphuric Acid Plant Project
At PMech, we take pride in our tagline "Blueprints of Honour", which embodies our commitment to delivering high-quality engineering services with integrity and precision. Recently, we completed a significant project for a major pulp and paper manufacturer in Indonesia, designing a 100,000 TPA wet sulphuric acid plant based on Haldor Topsoe technology.
An overview of the Project
The facility utilizes molten sulphur as feedstock and produces sulphuric acid at 98% concentration. Our team delivered the complete engineering and design for the facility, ensuring it meets global standards for safety, efficiency, and environmental compliance.
PMech’s Scope
Process Engineering:
- Process Design
- Preparation of Process Design Basis
- P&ID development
- Integration of vendor packages
- Utilities flow diagram
- Equipment data sheets
- Specifications for sulphur pumps
- Design of Fire Fighting and HVAC
- Design of Sealing Water System of Pumps
- Preparation of Cause and Effect Matrix
- Chemical dosing skids
- BFW sampling module
- Equipment list
- Line List
- Tie-in List
- Sizing of Equipment and Instruments
- Line Sizing and Pressure Drop Calculations
- Operation Control & Shutdown Philosophy
- HAZOP Participation and Close-Out Report
Electrical Engineering:
- Electrical Load List
- Load Calculations and Power Balance
- LV Power Distribution SLD
- Power Distribution Relay Setting
- Electrical Equipment Layouts
- Lighting Design & Layouts
- PDB SLD for Lighting Loads
- Earthing Calculation Report and Layout
- Cable Sizing
- Hazardous Area Classification
- Motor Control & Protection Schematics
- UPS Load List & Sizing
- Specification for Power Transformer
- Electrical LV MV Switchgears
- Design of Fire Alarm System
- Short Circuit Calculations
Mechanical Engineering:
- Mechanical Data Sheets
- Design Calculations
- GA and Detail Fabrication Drawings for Molten Sulphur Tank & Equipment
- Bulk BOQ
Piping Engineering:
- Piping Design and 3D Modelling for the Entire Plant
- Finalisation of Plot Plan
- Equipment Layouts
- Piping GAD's Plan and Section
- Isometrics
- Piping Stress Analysis
- Expansion Bellow Selections and Data Sheets
- Tie-in Location Layout and Details
- Piping BOQ
- Piping Support Selection and Details with BOQ
- Manual Valve Data Sheets
Civil & Structural Engineering:
- Structural STAAD Design and Detail for Technological Structure with GA and Detail Fabrication Drawings
- Ducting GA Plan and Details with Fabrication Details
- Design and Detail Fabrication Drawings for Stack and its Supporting Structure of 60m
- Equipment Foundation Layout Giving Embedded / Fixed Steel Foundation
- Foundation / Anchor Bolt Plan and Loading Details
- Storm Water and Effluent Drainage Layout
- Details for Grating Details and BOQ
- Design and Detail for Pipe Rack
- Technological Structure Roofing Design and Detail Drawings for SO₂ Convertor and WSA Condenser
- Combustor and Burner Skid
Instrumentation:
- Instrumentation index and I/O list
- Data Sheets for Instruments
- Layouts and cable tray plans
- JB Wiring Diagrams
- Junction Box Schedule
- Hook-Ups & Installation Details
- Bulk BOQ
Duration of the Project
PMech completed the detailed engineering and documentation for the plant over the course of one year, working closely with the client to address site-specific requirements and ensure compliance with global standards.
Standards and References
Our engineering work adhered to international standards, including ASME, ASTM, ANSI, API, NFPA, IEC, and ISO, as well as local regulatory requirements in Indonesia.
This project demonstrates our ability to deliver high-quality and end-to-end detailed engineering solutions for complex chemical process plants. At PMech, we remain committed to upholding the highest standards of engineering excellence, reflecting our "Blueprints of Honour" ethos.
Let’s Build the Future, Together.
Reach out to us at www.pmecheng.com or write to info@pmecheng.com to learn how PMech can support your modularisation goals.