Seamless engineering integration powers a new process technology.
When a long-time chemical manufacturing client sought to expand production at its Houston, Texas chemical plant, they turned to C2C Technical Services (C2C) to engineer the initiative that represented more than a capacity increase—it introduced a new processing technology to the site. Successfully implementing that technology within an operating facility required thoughtful integration of existing assets, precise specification of new equipment, and close collaboration across engineering disciplines.
From Front-End Engineering Design to Full Multidiscipline Execution
The project began with a front-end engineering design (FEED) study, establishing the technical basis for incorporating the new process into the existing plant infrastructure. Because the technology was new to the facility, the FEED phase focused heavily on process definition, equipment evaluation, and operability. This culminated in a ±10 percent total installed cost (TIC) estimate to support investment decisions.
Following FEED, the project advanced into full detailed design, delivering construction-ready packages on an expedited timeline driven by business and market conditions.
Introducing New Technology Into an Existing Plant
The new process enables the blending of multiple liquid chemicals with powdered solids using an existing chemical reactor—an application not previously implemented at the site. Three raw materials and the finished product are stored in existing bulk tanks, requiring careful evaluation to confirm compatibility with new operating conditions.
Two newly specified pumps deliver liquid components to the reactor, where solid powder is introduced through a new material handling and conveying system. The reaction mixture is heated using the existing hot oil system through the reactor jacket, allowing the plant to leverage current utilities while supporting the new chemistry.
Upon completion of the reaction, the product is transferred through a newly installed pump to a new cooler, where temperature is controlled before entering a new static mixer. At this stage, an additional component is introduced to complete the formulation. The finished product is then routed to existing product storage tanks and loaded into trucks using existing transfer systems.
This approach required C2C to maintain a careful balance of repurposing existing equipment—including pumps, an agitator, cooling tower capacity, and absorber systems—while specifying new equipment where performance, safety, or operability demanded it.
Precision Design in a Live Operating Facility
To support accurate design in congested plant areas, the C2C team performed 3D laser scanning of the reactor, tank farm, and pipe rack areas and built a comprehensive 3D engineering model of the facility. Leveraging this model, C2C designed and engineered the project’s new piping, automated block valves, relief routing, nitrogen purging systems, and truck offloading facilities.
Instrumentation and electrical engineering were fully integrated into the design, with Emerson’s DeltaV distributed control system (DCS) programming, graphics, alarms, interlocks, and shutdown logic developed alongside physical layouts. Electrical design included revised one-line diagrams, motor schematics, grounding systems, lighting, and electrical heat tracing.
Structural and Infrastructure Enhancements
In addition to the process unit, the project included the design of a new elevated pipe rack structure spanning approximately 250 feet between the plant and a neighboring terminal. Structural and civil design supported multiple process lines, automated valves, and future flexibility—all delivered as part of a single, coordinated engineering effort.
One Integrated Team, One Successful Outcome
Throughout execution, C2C Technical Services operated as an integral extension of the client’s engineering team, managing interfaces, maintaining quality control, and delivering complete Issued-for-Construction (IFC) drawing packages that formed the basis for procurement and construction.
Despite the accelerated schedule and the introduction of new-to-site technology, the project was delivered safely and efficiently.
Operational, Safe, and Ready for Growth
As of this publication, the unit is online and operating safely, enabling the client to expand production using a new processing technology while maximizing the value of existing infrastructure. The project stands as a clear example of how integrated teams, aligned cultures, and disciplined engineering can successfully introduce innovation into established industrial facilities.
Complementary Strengths, Now a Unified Engineering Team
Midway through the project, Flesch Engineering merged with C2C Technical Services, forming a more comprehensive engineering organization without disrupting progress. Flesch’s strengths in process, piping, civil, structural, and mechanical design were complemented by C2C’s deep expertise in instrumentation, electrical, and controls engineering.
The merger strengthened the project team at a critical moment, enhancing technical depth while maintaining continuity, schedule, and client confidence.
Equally important, both firms shared a common culture centered on technical rigor, collaboration, and long-term client relationships. As a result, the newly integrated team functioned seamlessly as an extension of the client’s organization.
C2C Technical Services is now more poised than ever to deliver complex projects with confidence, precision, and a strong commitment to client partnership.