Koch - Modular Process Systems

The first stage of the project starts with a customer inquiry and focuses on process development. Koch Modular will work collaboratively with the client to develop the process design basis and define overall scope. The objectives of this stage will be to establish plant capacity, product recovery and purity requirements, and identify appropriate project specifications. Koch Modular utilizes a “checklist” approach via a comprehensive inquiry form to thoroughly extract all the information necessary to develop a design and scope of supply that will meet project requirements and can be provided with a Process Performance Guarantee.

With the design basis established, Koch Modular begins the process of design conceptualization and develops an accurate model of the mass transfer system:

• Selection of Equilibrium Data and Activity Coefficients
• Development and Optimization of Chemical Process Simulations
• Identify the need, if any, for pilot testing

• Process Flow Diagrams (PFD’s)
• Preliminary Piping & Instrumentation Diagrams (P&ID’s) for cost estimating
• Preliminary Equipment list / sizes

• Footprint and modular layout of overall system.
• Accessibility and optimization in consideration of the available plant space.

• OOM (Order of Magnitude), Budgetary (+/- 20%) or Fixed Price depending on client needs and current accuracy of scope/design basis
• Includes design basis summary, utility consumption, equipment list, module footprint(s), division of responsibility, schedule and many other details
• Includes details of Koch Modular Process Performance Guarantee

Once the Process Development Stage is complete, its product, a well-defined process design basis and conceptual design, will serve as the foundation for the development of the Process Design Package. During this stage, Koch Modular works closely with the customer’s project team and shares their experiential insights to identify opportunities for cost savings, schedule reduction, and design efficiency.

• Process Flow Diagrams (PFD’s)
• Piping & Instrumentation Diagrams (P&ID’s)
• Heat Exchanger thermal designs
• Mechanical drawing lead sheets for columns, vessels, and heat exchangers

• Pump hydraulic calculations and specification sheets
• 3D equipment general arrangement drawings
• Participation in a HAZOP review meeting
• Detailed Project Kick Off List, defining all project scope of supply requirements
• Client review, comment, and approval process

Our Process Design Packages undergo a comprehensive internal and external review process, and include all of the necessary drawings, specifications, calculations, selections and support documentation required to assure our clients that the process design will meet their project requirements. Best of all, all of our proposed process designs come with a Process Performance Guarantee.

Through our diverse engineering expertise, Koch Modular engineers and designers are able to completely and systematically define each component of a modular process system. Equipment, piping, structural steel, instrumentation, electrical and controls systems are all evaluated, optimized and detailed for fabrication. Our senior project managers oversee and orchestrate the overlap and interaction of the multiple engineering disciplines and vendors required to successfully and efficiently execute our customers’ projects.