Rubber chemical manufacturing facility, Gujarat

A new rubber chemical manufacturing facility located at Jhagadia in the state of Gujarat comprises of three production plants, three tank farms, two warehouses, and various process equipments – heating and cooling reactors, fractional distillation, solvent recovery, pastillation, synthesis and scubbing. Piping is designed on 3-D PDMS platform. We provided detailed engineering, procurement assistance, construction and project management, and safety monitoring for the manufacturing facility.

Rubber chemical manufacturing facility, Gujarat

ATBS chemical plant, Maharashtra

We provided basic and detailed engineering services for ATBS (a substance used as catalyst in acrylic fibre production) plant located at Lote Parashuram in Maharashtra. This production in the new plant is a co-monomer having applications in acrylic fibre, water treatment, emulsions, paints and oil field drilling industries. The project comprises of the main process plant, utility, tank farm and offsite facility.

Offset printing ink manufacturing facility, Gujarat

We were appointed as the EPCM consultant for the Greenfield offset printing ink manufacturing facility located at Dahej in the state of Gujarat with a total capacity of 30,000 tons annually. We provided full engineering services for the manufacturing facility covering production unit (ink and varnish) utilities, offsite, and raw materials and finished products' stores. The facility has a three stage manufacturing process – rosin crushing and melting; varnish production and ink manufacturing. With over 400 pieces of equipment housed in the facility the major ones include 15kl reactors, 30m3 dilutors, varnish storage tanks, hot oil heaters, steam boilers, air compressors, chillers, nitrogen plant and thermic fluid heaters. We also provided specialized services including HAZOP and risk assessment study and safety monitoring for the manufacturing facility.

Offset printing ink manufacturing facility, Gujarat

DuPont performance coating plant, Gujarat

The present coating paint blending plant located at Savli in the state of Gujarat envisages creating a capacity of over 2800KL involving PLC based instrumentation and controls. The existing five storey facility involved structural adequacy checks and enhanced fire resistance. The process involves solvents and resin, bulk storage, distribution, high speed paint dispersion vessels, bead mills, over 30 agitated vessels, high speed filling and packing lines. There is a dedicated dust and vapour extraction system along with a forced ventilation system. We provided basic engineering, detailed design, procurement assistance, construction supervision and project management services for this facility.

Speciality grade epoxy products, Thailand

A grass root facility for Speciality Grade Epoxy Products for Aditya Birla Chemicals (Thailand) Limited. The process was scaled up from R&D & pilot plant data. The plant building constituted of Ground + 5 storey structure with a 60,000 sq. ft production area. The project involved total automation under DCS control with more than 1000 I/Os.

Plant Design Management System (PDMS) was used for total engineering solutions. The project had utilities plus off-sites covering tank farms, power, steam generators, cooling towers & chillers, etc were also an integral part. The facility infrastructure design included storm water drains, internal roads, area lighting, fire protection, etc.

Facility to produce speciality grade epoxy products, Thailand

Intermediate chemical plant, Bhiwadi, Rajasthan

The project set-up by SRF Ltd is for manufacturing Chemical Intermediates having batch operations covering diverse exothermic and endothermic reactions and process such as, Dehydration, Distillation, Extraction, Filtration, Separation, Crystallization etc. The project has two numbers of Plant building each having multi storey steel structure along with other non-plant utility building and facility infrastructure such as pipe racks, internal roads, sewerage, storm water drain, etc.

The scope involves the review of basic engineering, residual front end engineering and detailed engineering covering civil/structural, process, mechanical/piping, electrical, instrumentation for this hazardous plant. The plant was engineered and commissioned within a time frame of 14 months.

Sodium bi-chromate plant, Andhra Pradesh

A 40,000 MTPA of Sodium Bi-Chromate manufacturing plant for Vishnu Chemicals using chrome ore spread across a 22 acre land. The project has a 45m high, kiln building housing a 3m diameter x 40m long kiln. The project also provided for six numbers of 300 MT product silos along with other non-plant and utility buildings.

Mott MacDonald provided detailed engineering services covering process, architectural, civil, mechanical, piping, instrumentation & electrical.

EMA speciality chemical plant

A 2500 MTPA specialty chemical plant for Gulbrandsen Technologies set-up at Jaghadia, Gujarat. The green field development spread over 3 acres of land having a plant construction area of 600 sq.m. The basic technology supplied by the parent group of Gulbrandsen using aluminium ingots as a main raw material was further developed and customized locally. One of the key processing equipments was 20 meter plus high spray dryer.

The services provided basic engineering, detailed engineering, and procurement assistance construction supervision.

Dharamsi Morarji Chemical Company Limited

Dharamsi Morarji Chemical Company (DMCC) Limited was incorporated in 1919. The company is engaged in business of manufacturing phosphate based fertilizers, various specialty and commodity chemicals. The company has its manufacturing facilities located at Ambernath, Roha, Kumhari, Jhar and Khemli. Mott MacDonald was appointed by lenders to prepare a business, administrative and financial restructuring plan for DMCC.

Polyacetal resin project, Qatar

Polyacetal Resins are basically a family of homopolymers and copolymers of oxy methylene units. Hence, the name Poly Oxy Methylene (POM) is also used to describe this class of chemicals. POM is amongst the oldest engineering plastics and has successfully replaced metals in various applications in automotive, electronics, consumer durables and agriculture sectors.

There are currently no manufacturers of POM in Middle East. Further, Qatar manufactures methanol which is one of the key input materials. Both these factors provide a strong rationale for the project. National Qatar Industries (NQI) conceptualised the project and had signed up with LG Chemicals, Korea for supply of technology together with relocation of an operational plant with capacity of 10,000 TPA from Korea.

National Qatar Industries (NQI) commissioned Mott MacDonald to prepare a techno – economic feasibility report for the project. Further, Mott MacDonald also made presentations to key lenders in Qatar.