Engineering and process optimisation

Are you looking for practical engineering support to help you optimise plant performance and profitability? Then who better to talk to than the team of process and chemical engineers who run one of the most advanced resource recovery operations in Europe?

Engineering and process management

Here’s what we can help with:

Process design, trials and optimisation

We can design, trial and optimise processes for a wide range of applications, drawing on experience with sectors as diverse as post-consumer packaging recycling, battery processing, and energy from waste. We can look at both individual units or complete processes, producing anything from basic process flow designs with identification of the units or equipment through to fully detailed 2D or 3D CAD drawings.

If you have an idea for new recycling process, then our extensive lab facilities allow you to get it tested before you commit to full scale production trials.

Alongside this, we can calculate mass and energy balances and define capital and operating costs, so you understand how best to maximise yield, quality and profit.

Plant commissioning

We’ve developed significant expertise in commissioning new plants, both through the commissioning of our own 200,000 tonnes per year separation plant and by supporting third party plants. As a result, we can guide you effectively through cold and hot commissioning, snagging, performance testing and plant optimisation.

On top of this, we can produce Standard Operating Procedures, maintenance plans and other necessary documentation and work with you on environmental permitting and Fire Prevention Plans.

Plant performance analysis

With materials, processes and equipment often a complicated mix, even marginal performance improvements can lead to significant increases in profit. We can visit your facility, provide an accurate assessment of performance and suggest ways to increase productivity and quality –backed up by a cost benefit analysis as needed.

Mass and energy balance modelling

We can create interactive and flexible mass and energy balances for recycling processes ranging from mechanical separation of residual waste to high value metals recovery. Robust models allow you to compare feed materials with products. This gives you a firm foundation for a business plan and plant design.

We can also support you in making effective use of the models to simulate varying scenarios, helping determine the viability of different feed materials, compare process designs, and understand how variations in materials or plant efficiency will affect profitability.

Equipment trials

The choice of a single piece of equipment can be the difference between profit and loss. But how do you make sense of supplier claims and decide what’s right for your particular process? And where processes combine multiple pieces of equipment, how can you find out which combination of machinery will best suit your needs?

Let us manage trials at manufacturers’ test centres using your material, and we’ll cut through the confusion to provide independent recommendations based on both trial results and previous experience.

We can manage multiple consecutive trials as a single point of contact,, ensuring each test is representative of the final process and bringing all the information together in a comprehensive report.

Maintenance audits

Our maintenance audits provide a reliable assessment of the current state of machinery and the adequacy of existing maintenance plans. We can give you an independent overview, whether you’re running your own plant and want to keep equipment working effectively or need to check the state of a contractor-managed facility.

We can also then help you improve maintenance procedures and train staff, so you keep productivity high and downtime low.

Business intelligence – using plant data 

Your operational data holds the key to continuous improvement – if you collect and use it effectively. We can create a customised business intelligence system that reveals vital metrics and trends, and at the same time cuts down on collecting and processing time and increases the accuracy of results: which would you rather know – how long a process actually ran for, or how  long the operator says it ran for?

Depending on your needs, systems can be relatively simple or more sophisticated. The starting point might be a spreadsheet-based system that requires staff to collect and present information in a consistent, usable format. A solution at the other end of the scale could be an integrated system combining automated sensing and data acquisition hardware, data capture and processing software, and bespoke web-based presentation tools.

Expert opinion

Our extensive engineering experience means we’re able to provide expert opinion for a wide range of scenarios within the materials separation sector and beyond.