Cleveland Recycling Plant

Cleveland, Ohio

Behrent Engineering was contracted to provide electrical engineering services that would be necessary to install the electrical systems for a De-stoner and 5/8” lines at a recycling plant in Cleveland, OH.  The contract also included construction coordination and commissioning services.  The new electrical system included:

  • New 1200-amp service from a new utility-owned 1000kva pad mount transformer
  • New 480-volt electrical distribution equipment
  • Grounding for new building
  • Lighting for new building
  • New cable tray and conduit for power wiring
  • Distribution panel drawing
  • Power metering schematics
  • Electrical installation details
  • Equipment specifications (MCC, dry transformer, panel, fixtures)
  • Purchasing support

Metates Mine Project

Durango, Mexico

Behrent Engineering was contracted to perform a prefeasibility study for a proposed zinc solvent extraction and electrowinning (Zn SX-EW) plant, known as the Metates Mine Project in Durango, Mexico.  The proposed plant was expected to produce approximately 60,000 tonnes per year (MTY) of zinc cathode.

Behrent was hired to develop prefeasibility level costs for the entire mine, mineral processing, roasting, and acid production facilities.  This operation had the potential to produce approximately 5,000 tons per day of concentrated sulfuric acid.  A significant portion of that sulfuric acid would need to be transported via railcar fleet.  The study focused on developing the following items:

  • Process design criteria
  • Flow Sheets
  • Mass balance
  • Equipment list
  • General arrangement drawings
  • Material takeoffs
  • Electrical one-lines
  • Pricing/estimating

General arrangement drawings showing both plan and section views were generated for the proposed facility.  A major equipment list was developed for the increased plant capacity. 

The equipment list was used to produce electrical one-line diagrams and to estimate total connected power load and electrical consumption.  Capital construction costs and annual operation and maintenance costs were also estimated.

Midlothian Cement Plant Expansion

Midlothian, Texas

Behrent Engineering was contracted to do the Power Distribution Engineering and the Installation Engineering for a 6000 TPD cement plant expansion project in Midlothian Texas.  Behrent designed a system that would supply power to the various loads in each departmental area of the plant.  The system was engineered to provide low initial cost, low operating cost, and safety for personnel and equipment.  The following engineering services were provided:

  • Coordinated with the local utility company and obtained necessary system requirements.
  • Investigated and analyzed the existing electric system.
  • Prepared one-line drawings showing the major parts of the 5 kV and 480 volt distribution system.
  • Prepared 5 kV detailed one-line diagrams showing the components with their ratings, metering, and protective devices.
  • Prepared 480 volt MCC detailed one-line diagrams showing the components with their ratings, metering, and protective devices.
  • Prepared the power distribution equipment contract material bill listing the equipment to be supplied.
  • Prepared the power distribution equipment specifications for major equipment.  The specifications consisted of equipment description, ratings, sizing, and quantities.
  • Provided a short circuit study with calculations of data for normal and abnormal operation of the system taking into account all likely combinations of service to the plant. 
  • Performed motor starting voltage drop studies to help determine the best method of reducing KVA starting for some of its large motors.

Mojave Gas Conditioning Tower

Mojave, California

At the Mojave California Cement Plant, a gas conditioning tower was to be installed in place of the existing air-to-air heat exchanger on its Kiln Line 6 preheater tower. The existing preheater outlet duct needed to be connected to the inlet of the conditioning tower, and new ductwork needed to be connected to the outlet of the conditioning tower as well as the inlet of the kiln system induced draft fan.

Behrent Engineering developed the 3D AutoCAD model of the Conditioning Tower, inlet & outlet ductwork, and showed its relationship to the existing preheater tower. From this model the steel framing drawings, ductwork drawings and the foundation drawings were derived. The following tasks were completed for each of the noted disciplines:

Mechanical

  • Developed 3D model of existing gas cooler tower and the new Conditioning Tower
  • Designed ductwork from preheater and inlet of tower
  • Designed ductwork from outlet of tower to I.D. Fan
  • Laid out the tower dust hopper and determined the route of the dust screw conveyor
  • Determined required steel shell thickness of spray tower
  • Developed P & ID
  • Developed water and compressed air piping layouts
  • Prepared General Arrangement drawings of the tower system
  • Developed order of magnitude construction cost
  • Relocated and sized new preheater tower air handling units

Structural

  • Compared existing preheater loads with new equipment loads
  • Developed wind and seismic loads for the site
  • Developed structural design model for new tower
  • Modeled existing floors that were reused to support conditioning tower
  • Prepared demolition drawings for existing steel that needed to be removed
  • Designed and detailed new steel supports inside existing tower
  • Detailed new support tower and connection drawings
  • Designed and detailed inlet and outlet duct supports

Homestead Anhydrous Ammonia Facility

Homestead, Nebraska

At the Homestead anhydrous ammonia distribution terminal it was desired to eliminate the possibility of accidental release of anhydrous ammonia to the atmosphere by protecting all tanks, vessels, equipment, and piping from overpressure scenarios, and by destroying any release of ammonia by the use of flaring.

Behrent Engineering was given the task of determining the necessary pressure/vacuum relief rates for the tanks, equipment vessels and piping for a safe operation.

Recommendations were provided by Behrent for additional and/or different pressure/vacuum relief valves, hydrostatic relief valves, piping, flare headers, flares, etc.

Behrent provided Mechanical, Electrical, and Structural Engineering to produce a Contractor IFB package including Scope of Work, 2-D piping drawings, Bill of Materials, Electrical Plans, Wiring Diagrams, Structural Plans and details for Flare modifications or new installation as required.

Final record drawing P&IDs and electrical drawings were provided after construction completion.

Edmonton Cement Terminal Upgrade

Alberta, Canada

The Edmonton Cement Terminal was forecasting cement volume demands that would exceed the current capacity of the terminal. In order to achieve sufficient capacity to supply the demand, the terminal needed equipment upgrades and increased silo capacity.

In order to continually replenish the silo’s, the terminal needed to increase the rate of unloading cement from rail cars to silo from 50tph to 150tph. To ensure ample capacity,

Behrent was tasked with designing for 200tph. The design included building a new pit such that 2 rail hatches could be opened and discharged at the same time. The existing screw auger was demolished and replaced with two drag conveyors which move cement at a rate of 100tph each. Together these two drag conveyors feed to a new bucket elevator of 200tph. In order to increase storage capacity and add a 4th product, Behrent included in the design a new silo of approximately 700t.

Behrent Engineering was responsible for bringing together general assembly drawings in order to finalize an RFQ for the final equipment tendering.

Behrent Engineering was also responsible for the construction management of this project.

Lyons CEMS & DAHS Project

Lyons, Colorado

In order to comply with new federal regulations regarding allowable emissions at cement plants, it was necessary to install Continuous Emission Monitoring Systems (CEMS) and Data Acquisition and Handling Systems (DAHS) at eleven of our clients cement manufacturing facilities across the United States.

Behrent Engineering provided the required engineering design and development of the bid packages to submit to third party contractors for the installation of the CEMS & DAHS systems. These systems were installed on the main kiln emission stack and all other emission stacks as necessary.  Site visits were conducted by lead members of Behrent’s project team to gather field information and help to determine the location of the CEMS building and cable tray routing. General arrangement drawings were prepared to show the overall location of the CEMS building, the emission stacks, stack platforms, cable tray routing and overall site dimensions.