Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Engineering a World-Class Ethylene Production Facility with Optimized Resource Utilization
- Petrochemical
- Multinational petrochemical company
- North Africa
Obstacles Our Experts Have Transformed into Opportunities
A multinational petrochemical company developing a greenfield ethylene facility in North Africa encountered growing technical complexity during design:
Fragmented Design Coordination
Delays in finalizing PFDs, P&IDs, and mass/energy balances due to fragmented coordination between licensor, FEED contractor, and vendors
Over-Design & CAPEX Inflation
Risk of over-designing key equipment, inflating CAPEX and utility consumption
Costly Rework from Poor Tracking
FEED deliverables were being reworked due to inconsistencies and undocumented decisions
No Design Validation System
No established system for design traceability or engineering validation across teams
Late Energy Optimization
Energy optimization and utility balancing were treated as afterthoughts—not embedded into the design phase
Execution Risk Before EPC
With timelines tightening and scope clarity slipping, the project risked falling behind before it even reached construction
Teec’s Expert-Led Solution
Our Experts delivered their Detailed Process Engineering & Design service to bring clarity, rigor, and efficiency to the design phase:
What Our Experts Did
Validated all process simulations using Aspen HYSYS to ensure consistency across licensors, FEED, and client assumptions
Led the preparation and cross-checking of PFDs, P&IDs, and design bases with structured review cycles
Optimized heat recovery and utility systems during design using energy integration techniques
Created a “design decision log” to document changes, their rationale, and impact on downstream phases
Facilitated multi-stakeholder design review workshops to prevent design drift and miscommunication
Execution Approach by Teec’s Experts
- Reconstructed process simulations using Aspen HYSYS, validating licensor data, feedstock assumptions, and energy balances
- Identified overdesign risks in major equipment by running sensitivity analyses
- Optimized reaction and separation sections through thermodynamic modeling and hydraulic evaluation
- Structured and reviewed over 120 design documents including PFDs, P&IDs, equipment datasheets, and design criteria
- Led weekly multi-discipline design review meetings across process, instrumentation, mechanical, and safety functions
- Maintained a Design Decision Register to ensure traceability across revisions and contractor packages
- Conducted pinch and utility integration analysis, recommending process-to-utility heat exchange opportunities
- Proposed control strategies for steam system rebalancing and refrigeration optimization
- Suggested upgrades to improve turndown flexibility and minimize start-up risk
- Embedded HAZOP and SIL recommendations into the design prior to IFC package finalization
- Validated safety instrumented systems and relief scenarios with external experts
- Supported permitting with environmental impact calculations derived directly from final process models
Results & Impact
Delivered full FEED package 3 weeks ahead of milestone, with zero major rework
Achieved design approval from all licensors and stakeholders in a single round—avoiding delays
Identified $3.4M in CAPEX savings by right-sizing equipment and minimizing overdesign
Reduced utility demands by 12% through integrated energy optimization
Integrated Value Through Teec’s Data-Driven Solutions
Data-Driven Solutions
BPM Solutions
This integration ensured that design wasn’t just complete — it was smart, traceable, and aligned with business outcomes.
