A biofermentation facility contracted EAD to design and install an automated process waste system. The design processes included removing its existing system. The process waste stream is spent filter cake, which contains microbial biomass removed from the product during processing. Safely and securely handling the biomass presented unique challenges. The process involved effectively utilizing steam-contact paddle mixers to heat the filter cake sufficiently to denature any microbes remaining after processing.
EAD handled the design from conception through completion. The project took multiple years with many complex phases. Each phase required a design review, construction cost estimates of increasing accuracy, and re-scoping for the next phase.
The conceptual design phase work included processing equipment testing, material properties analysis, production rate requirements, and project execution planning. The basic design phase added equipment selection, layouts, power supply, automation, operability, and occupational safety. The detailed design phase ran concurrently with preliminary construction. This process required the development of several drawing packages allowing contractors to begin work before the final equipment submissions and construction packages were available.
Physical space limitations, installing around operating equipment, and chemical exposure isolation requirements posed challenges. EAD’s design team used BIM and 3D CAD to create a design free of interferences that required no building modifications. EAD added all process equipment, piping, HVAC units, electrical equipment, cable tray, and new interior structures to a 3D model of the existing building. The 3D model became the plant’s master drawing/model.
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