Victorville Tire Handling System

Victorville, California

Behrent Engineering was contracted to provide engineering and design services to design a new tire burning system as an alternate source of fuel for kilns K- 2 and K- 3 at the cement plant located in Victorville, California.

The engineering and design services included:

  • General arrangement elevations and drawings
  • Elevations of preheater and tire feed chute
  • System flow diagram
  • P & ID
  • Truck tipper foundation
  • Feed floor & singulator foundation
  • Conveyor trusses and support foundations
  • Preheater conveyor floor framing
  • Conveyor truss support bents
  • Transfer tower – plans & elevations
  • Conveyor head end platforms
  • Existing framing modifications
  • 120 volt and 480 volt motor schematics
  • MCC external connection diagrams
  • PLC cabinet external diagrams
  • Electrical room electrical plan
  • Electrical duct bank
  • Power, control & instrumentation plans
  • Lighting and receptacles
  • MCC one line and elevation
  • PLC programming
  • HMI development

Henderson Mine Shaft Exhaust

Empire, Colorado

Behrent Engineering was contracted to provide engineering and design services for the Henderson Mine located in Empire, Colorado.  The project required mechanical, electrical and civil engineering associated with the installation of drain lines to convey condensate from the evase sections of the two exhaust fans to the two 12” and 14” HDPE water lines to the East.  The engineering and design services included:

  • Review of the individual exhaust fan peak volumetric flow and pressure design.
  • Calculating expected peak flow of condensate using humidity and temperature data.
  • Providing recommendations and details for manual/check valves for the prevention of reverse flow, cleanouts and traps to prevent plugging
  • Providing appropriate tap points in existing HDPE lines, and the size of new branch lines to ensure gravity flow.
  • Providing a pipe routing schematic for the new traps, valves and lines specifying size, estimated lengths, pipe material specifications, valve specifications and trap specifications.
  • Providing calculations for the heat trace wattage requirements for exposed piping.
  • Providing pipe trench sections and details.
  • Providing excavation, pipe bedding, and backfill specifications
  • Providing electrical routing schematic from nearby power source.
  • Providing specifications of electrical hardware and wiring.

Victorville Kiln Feed Silo Project

Apple Valley, California

Behrent Engineering was contracted to provide engineering, design and consulting services for the construction of a new kiln feed silo at the Apple Valley, California Black Mountain Quarry Plant.

The main objectives of this system were as follows:

  • Increase the raw meal storage capacity by adding a new kiln feed silo ES-4 near the existing ES-3 kiln feed silo.
  • Have parallel raw meal streams from the raw meal circuit feeding both the existing kiln feed silo ES-3 and the new kiln feed silo ES-4.
  • Provide adequate dust collection systems. 
  • Provide particulate offsets by paving around the silo area.
  • Design the system to minimize maintenance requirements and maximize availability.
  • Integrate the new kiln feed silo into the existing plant HMI and PLC control system.

Behrent Engineering provided a complete design package including civil, structural, mechanical, electrical, process control, scheduling and procurement.  Behrent engineers were also onsite during the construction phase to help support the Owners project team.

Oro Grande Silo Loadout

Oro Grande, California

The existing concrete cement loadout silos 21, 22, 23 and 24 needed a loadout system upgrade to allow each silo to be dedicated to a specific product for truck loading. Behrent Engineering was contracted to perform the necessary engineering and design services for the cement plant located in Oro Grande, California. 

Behrent was responsible for the following engineering and design services:

  • Developed a 3D CAD model of existing conditions at Silos 21, 22, 23, 24 (silos, truck scale(s), discharge cones, discharge valves, discharge airslides, platforms).
  • Developed a conceptual model of new truck loadout system (flat bottom bins, airslides, gates, dual direction positioners, loading spouts).
  • Developed a new Process Flow Diagram for conceptual design of new loadout system
  • Determined power requirements for loadout system
  • Determined utility (air) requirements for loadout system
  • Determined capacity and venting requirements of existing dust collectors
  • Provided all drawings (plans, elevations, sections) for this project.

Fort Morgan Meat Processing Plant

Fort Morgan, Colorado

Behrent Engineering provided engineering and design services for a gut bin replacement at a meat processing plant located in Fort Morgan, Colorado.  A 3D laser scan of the entire gut bin (spanning two floors) and the surrounding area was performed. The collected data was used to develop an AutoCAD 3D model which supported the development of detailed engineering plans for the removal of the existing gut bin and the fabrication/installation of a new gut bin.  The engineering and design services included:

  • 3D Laser scanning of the gut bin and surrounding area.
  • Converted the scanned data to an AutoCAD 3D model.
  • Performed the necessary engineering to increase the gut bin capacity by approximately 20 percent.
  • Designed the new gut bin in a manner so the (2) 16” diameter screw housings were removable
  • Designed the new gut bin in a manner so it can be installed during a 3 day shutdown
  • Detailed design of either micro-piles or screw-piles to support the gut bin
  • Specified and obtained quotes for (2) new 16” screw conveyors
  • Provided access platform plan drawings, sections & details
  • Provided foundation plan drawings, sections & details
  • Provided gut bin structural support framing elevations, sections & details
  • Provided 16” Screw conveyor drawing and specifications for vendor

Denver Batch Plant Relocation

Denver, Colorado

Behrent Engineering was contracted to provide engineering and design services to help relocate a Ready Mixed Concrete Batch Plant to a location in Denver, Colorado.  The new batch plant building houses a ready mix concrete central mix plant consisting of aggregate storage bins, a handling system, steel bins for cement storage, drum mixer, electrical equipment, water boiler, water chiller, admixture tanks, and other auxiliary systems. There is also an attached prefabricated Control Room.

Behrent was the Engineer of Record for this project.  They provided civil, structural, mechanical, electrical and controls engineering services.  Behrent worked closely with the client from the beginning of the project and provided:

  • Preliminary site layouts
  • Process flow diagrams
  • General arrangement drawings through final design of the reclaim tunnel, electrical and mechanical buildings, batch plant foundations and site lighting. 
  • Field observation reports during construction
  • Final commissioning support 
  • Hiring of an architect for the tenant improvement design of two existing buildings on the site
  • Structural, mechanical and electrical engineering for the existing buildings 
  • Coordination with municipalities including Adams County, Denver Water and Xcel Energy.

Miami Cement Plant Modernization

Miami, Florida

Behrent Engineering was contracted to perform engineering, design and project management services for a large cement plant modernization project located in Miami, Florida. The engineering services included civil, structural, architectural, mechanical, piping, electrical, instrumentation systems, and project management.

CIVIL ENGINEERING

  • Provided detailed design and engineering for site preparation, grading, paved roads, gravel roads, site drainage, settling ponds, underground piping, and modification of existing rail tracks.
  • Provided the design of concrete foundations, piles, caissons, floors, elevated concrete, walls, bunkers and masonry block work

STRUCTURAL STEEL ENGINEERING

  • Provided detailed design and engineering for structural steel framing, duct supports, platforms, walkways, stairways, handrails, ladders, hoist beams, and framing for siding & roofing.

ARCHITECTURAL ENGINEERING -    

  • Provided detailed design and architectural engineering for the electrical rooms, the control building and mechanical rooms housing pumps, compressors and hydraulic equipment usually associated with spray conditioning systems, operating air compressors and roller mill hydraulic systems. 

MECHANICAL ENGINEERING and PIPING- 

  • Provided detailed design and engineering for plant air, cooling water, process water, hydraulic lines, lube lines, pneumatic coal & cement lines, and airslide aeration 
  • Provided detailed drawings for process ducts, chutes, dust ducts, bins and hoppers, diverter gates and details for tie-ins to existing. 

ELECTRICAL ENGINEERING

  • Provided detailed engineering services to support the installation of the electrical and instrumentation systems.

PROJECT MANAGEMENT

  • Provided full time project engineers as needed to execute the work according to the project schedule.  This included coordination with the general contractor, subcontractors, equipment suppliers and steel fabricators.

Sodium Bicarbonate Cyclone Addition

Rifle, Colorado

Behrent Engineering was contracted to provide the engineering and design services necessary to add a cyclone to the train #2 sodium bicarbonate drying circuit at a Sodium Bicarbonate Plant in Rifle, Colorado..

Behrent Engineering provided the following services for this project:

  • Reviewed the existing flash dryer system drawings
  • Reviewed the existing flash dryer system equipment specification sheets
  • Modeled the existing dryer system to determine its present operation parameters
  • Sized and selected a new cyclone
  • Modeled the dryer system with the addition of a cyclone and determined operating parameters
  • Checked existing dry system equipment performances and determined adequacy with the addition of a cyclone
  • Provided a 3D laser scan of the existing flash dryer system to obtain a point cloud that was turned into an AutoCAD 3D model of the ductwork, equipment and support steel.
  • Prepared general arrangement drawings between the outlet of the flash dryer, showing the addition of a cyclone and the ductwork, to the two inlets into the baghouse.  Also provided the drawings for the outlet of the cyclone with rotatory feeder and the discharge ductwork down into product screw conveyor.
  • Prepared structural drawings for support of the cyclone from the existing steel framing
  • Prepared ductwork drawings for the required modifications
  • Prepared a revised P&ID drawing showing the addition of the cyclone into the flash dryer system

Enid Silo Storage Facility

Enid, Oklahoma

Behrent Engineering was contracted to perform structural inspections for the Silo Storage & Distribution Terminal located in Enid, Oklahoma.

Behrent did the structural inspections and performed the necessary calculations to determine the maximum capacity of the storage silos.

Green Castle Cement Plant Expansion

Green Castle, Indiana

Behrent Engineering was contracted to provide engineering and design services for the Greencastle, Indiana cement plant expansion project.  This project included a semi-dry conversion to 4000 STPD and a 5000 HP wet raw mill. 

Behrent provided engineering design and construction support, including mechanical, structural and electrical engineering.  The construction support required a full time engineer to be on-site during construction and monthly site visits by lead discipline engineers. 

Behrent was responsible for the following engineering and design services:

  • Detailing the plant air, water and fuel piping systems
  • Power system design
  • Designing the belt conveyor foundations
  • Structural design of the preheater tower
  • CAD drawings of the preheater structure
  • Preheater tower designed for a future 5 stage dry system
  • Design drawings for nuisance ductwork from the dust collection pickup points, to the dust collector.
  • Design of the supports for the ducts and the ductwork between the dust collector and the dust collector fan.