Relocation of production site (Ferro Pigments)

Purpose

The site of Ferro Pigments in Halluin is closing so part of the production had to be transferred to the site in Menen. A completely new production department was installed for the yellow pigments.

Problem-solution

On behalf of Ferro Pigments, DD engineering called on our expertise and experience with the client. This project clearly demonstrates the diverse capabilities within CGK group.

• For the new production process, we provided the supply of facilities for cold and hot water, steam, compressed air and gas.

• In addition, a new tank farm was built to bring in 3 new chemicals, essential for the production process. For this tank farm we delivered a double-walled storage tank of 6m³.

• In total we installed approximately 3 kilometers of piping. A mix of steel, stainless steel and plastic of which about one kilometer was insulated and traced.

• For the most aggressive chemicals, we opted for double-walled piping in stainless steel, steel and plastic for safety reasons. The double-walled piping was divided into compartments and equipped with leak detection. If there is a leak, they can easily see in which section of the pipe it is located. Very interesting with such a number of meters of piping.

• Some products are sensitive to frost or crystallize under certain temperatures. So here the necessary insulation and tracing was provided. Products that must remain above a certain temperature are provided with an adjustablethermostat.
  • Since CGK also has its own insulation department, this planning of piping and insulation could flow nicely into one another.
  • The preparation by our pipefitters also ensured that the insulation department could get to work without any problems.
  • Our construction department cooperated proactively by placing heavy elementary support where necessary. This allowed our pipefitters to keep their pace tight without stalling.

• CGK also installed 2 galvanized steel platforms of 17 by 5 meters with stairs for 2 filter presses of 17 tons.

• We also took into account the sustainability of the project and the production process:
  • Where possible, components (e.g. gas scrubbers) from the previous site were recalculated and recovered.
  • To drain the wastewater from these scrubbers without a pump, we provided a platform so that the water could drain gravitationally. Given the corrosive environment, we opted for 2 platforms made entirely of glass-fiber reinforced plastic (GRP). These are not sensitive to the chemical vapors and are a lot lighter than steel, thus faster to assemble.
  • After steam injection, the energy is recovered via heat exchangers at the end of the installation. The wastewater is redirected to the existing water treatment plant.
  • In this water treatment plant, CGK supplied a 10000-liter double-walled underground tank for buffering sludge water. In addition, we also provided the sludge water pipes to and from the tank.

Planning is one of the greatest strengths within CGK.

Ferro had to be able to start up their process in test at the beginning of 2021. The deadline of 15/12/'20 was too crucial and could not be moved. The corona virus provided the necessary challenges ... But we are proud to say that we met the deadline and that while we were still allowed to perform some additional works.