Process-Focused Troubleshooting for FOAK Plants

This case study details the engineering services provided by Valdes Engineering Company in response to operational issues faced by a client operating a First-of-a-Kind (FOAK) facility for producing Recycled Carbon Black (RCB) from waste tires. The study outlines the challenges that arose shortly after the plant's start-up, particularly concerning declining quench oil flow rates due to high pressure drops in the heat exchangers. Valdes was engaged to troubleshoot the situation, evaluate options, and recommend immediate design solutions to restore full operational capacity. The document presents a thorough analysis of the causes of sludge and solids accumulation in the quench liquid circulation system, identifies potential solutions, and discusses the decision-making process for selecting appropriate technology for solids removal. It also describes the fast-track installation of a centrifuge as a temporary solution to improve flow rates and operational efficiency. The case study emphasizes the importance of effective troubleshooting and engineering support in addressing complex process design issues.