Lead Process Engineer for project to translate a preliminary European design for a $100 million greenfield amino acid fermentation plant to a Midwestern US location. Reviewed and commented on block flow and process flow diagrams and equipment specifications. Developed recommendations for $25 million in value engineering opportunities to reach client’s target budget. Obtained US pricing on major equipment and part of estimating team for US preliminary total installed cost estimate.
| Unit operations: Fermentation, Sterile nutrient dosing, Centrifugation, Dissolution, Ceramic microfiltration, Activated carbon decolorization, Crystallization, Pneumatic conveying drying, Bagging |
| Products: Amino acid from E. coli fermentation |
| Company: Confidential Client |
| Location: Iowa |
| Total installed cost: $100 million (preliminary design) |
This was a project we worked on at the Middough, Inc. offices in Chicago when I was a project engineer for the company. The client had developed this E. coli fermentation process and was toll manufacturing the amino acid in stages at various locations in Europe. They were looking to consolidate the process at a new plant near a Midwestern US corn biorefinery. I was a member of the Middough sales team that presented our qualifications to the client and helped win the work with my background in industrial fermentation.
Based on the client’s process flow diagrams, user requirement specification, and preliminary equipment specifications, we developed and priced the equipment list for the project. We also developed a conceptual general arrangement 3-D model of the plant as the basis for estimating the civil, structural, architectural, mechanical, electrical and piping costs for the plant. These were then combined into a complete total installed cost estimate for the plant.
As is typical at this stage of a project, the cost estimate was substantially higher than the client had budgeted. We then performed a more detailed review of the client’s process design and provided them with a value engineering list of potential cost reductions.