$1M Improvement to Metals Refining Process

Overview

This case study highlights the successful execution of a $1M process improvement project in the metals refining industry. The project focused on upscaling trial equipment to full production capacity within a highly regulated Control of Major Accident Hazards (COMAH) site, leading to improved energy utilization and cost savings.

Challenge

The key challenge was to scale up trial equipment to a full-production installation while ensuring compliance with strict COMAH site regulations. This required meticulous planning, rigorous mechanical validation, and the integration of a dedicated control system to ensure safety and efficiency.

Solution

The project team implemented a structured approach, including:

• Engineering Design & Validation: Conducting mechanical stress analysis and computational fluid dynamics (CFD) analysis to confirm the system’s integrity and performance at scale.
• Control System Development: Designing and commissioning a dedicated control system to optimize operational efficiency and maintain compliance with regulatory standards.
• Installation & Commissioning: Implementing the full-scale system with close coordination between engineering, operations, and regulatory bodies to ensure a safe and seamless transition to production.

Results

The project successfully improved the efficiency of the metals refining process, delivering:

• Reduced energy costs through optimized process performance.
• Enhanced energy utilization, minimizing waste and increasing overall efficiency.
• Safe and effective integration of new equipment into a highly regulated industrial environment.

Lessons Learned

Several key takeaways emerged from the project:

• Balancing Safety and Efficiency: Achieving compliance within a COMAH site while maintaining project efficiency required proactive risk management and thorough planning.
• Persistence in Problem-Solving: A tenacious approach was essential to overcoming technical and regulatory challenges, ensuring a fully functional solution.
• Client Engagement: Close collaboration with the client throughout the project facilitated better decision-making and alignment with operational needs.

Conclusion

This project demonstrated the value of rigorous engineering, proactive compliance management, and stakeholder engagement in delivering process improvements within a highly regulated environment. The successful implementation not only optimized energy use and reduced costs but also reinforced best practices for future scaling efforts in metals refining.

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