ποΈ Case Studies
Real-world engineering case studies, project examples, and technical implementation stories
62 entries
About This Collection
Our case studies showcase real-world engineering projects, highlighting challenges encountered, solutions developed, and lessons learned. Each case study provides valuable insights for practicing engineers, from design decisions through construction and performance verification.
Whether you are a practicing engineer, a researcher, or a student, this curated collection provides the resources you need to excel in your field. We continuously update our content to reflect the latest industry standards, technological advances, and best practices.
Ethylene Oxide Absorption Column Design Optimization
Greenfield petrochemical plant in Singapore
High-Viscosity Polymer Melt Extrusion in Twin-Screw Processing
Biodegradable PLA packaging line upgrade in Germany
Cooling Water Circuit Fouling Mitigation in Refinery FCC Unit
Major Gulf Coast refinery turnaround
Hydrocarbon Separation in Offshore Gas Processing Skid
Integrated gas processing module for North Sea platform
Pneumatic Conveying of Catalyst Powder in Fluidized Bed Reactor Feed System
Ammonia synthesis plant retrofit in Netherlands
Heat Exchanger Fouling Mitigation in Ethylene Cracker Quench System
Revamp of 1.2 MTPA ethylene cracker in Texas Gulf Coast
Slurry Transport Optimization in Iron Ore Pipeline (Brazil)
520 km, 450 mm diameter pipeline transporting hematite slurry (62% w/w) from mine to port
Ventilation System Redesign for Lithium-Ion Battery Dry Room
Giga-factory dry room (Class 100, <1 ppm HβO) in Nevada
Catalytic Reactor Distributor Plate Retrofit for Ammonia Synthesis Loop
Revamp of 3,000 tpd Haber-Bosch reactor in Louisiana
Air-Cooled Condenser Retrofit for 600 MW Coal Power Plant
Retrofit of legacy water-cooled condenser at Midwest US plant
Thermal Management System for EV Traction Inverter
High-power (250 kW) SiC inverter for premium electric SUV
Furnace Refractory Lining Failure Analysis in Aluminum Melting Facility
Recurring spalling in sidewall lining of 25-ton reverberatory furnace
HVAC Coil Frost Detection and Defrost Optimization for Cold Storage Warehouse
β25Β°C frozen food distribution center in Minnesota
Thermal Design of Satellite Payload Radiator for Lunar Orbit Mission
NASA CLPS payload requiring stable 20Β±2Β°C operation during 14-day lunar day/night cycle
Ethanol-Water Separation in Biofuel Plant
20 MTPD corn-based ethanol facility in Iowa, USA
COβ Capture from Flue Gas using Amine Absorption
Coal-fired power plant retrofit in Germany (600 MW)
Pharmaceutical API Purification via Crystallization
Active pharmaceutical ingredient (API) manufacturing in Singapore
Rare Earth Element Recovery from Acid Mine Drainage
Pilot-scale hydrometallurgical plant in Wales, UK
Food-Grade Citric Acid Purification via Liquid-Liquid Extraction
Fermentation-based citric acid plant in Brazil
Ammonia Synthesis Loop Optimization at Fertilizer Plant
1,200 MTPD ammonia plant in Iowa, USA
COβ Capture Solvent Screening for Natural Gas Sweetening
Offshore LNG facility in Qatar handling 20 MMSCFD sour gas
Bioethanol Distillation Energy Integration at Brazilian Sugarcane Mill
350 mΒ³/day anhydrous ethanol plant in SΓ£o Paulo
Supercritical Fluid Extraction (SFE) Process Design for Caffeine Recovery
Pharmaceutical-grade caffeine extraction from spent coffee grounds in Colombia
Pharmaceutical Batch Hydrogenation Process Intensification
API manufacturing facility in Ireland scaling from 10 L to 200 L hydrogenation reactor
FCC Regenerator Thermal Runaway Mitigation
Refinery in Texas upgrading fluid catalytic cracking unit after catalyst change
Bioethanol Fermentation Bioreactor Scale-Up with Inhibition Kinetics
Cellulosic ethanol pilot plant (10 mΒ³) transitioning to commercial scale (500 mΒ³)
Nitric Acid Absorption Tower Design for Tail-Gas Treatment
Nitrogen fertilizer plant retrofit in Morocco to meet new NOβ emission limits
Ammonia Refrigeration System PHA & LOPA Integration at Midwest Food Plant
Retrofit of legacy ammonia refrigeration system serving 300k sq ft food processing facility
Ammonia Refrigeration System HAZOP & LOPA Integration at Midwest Food Processing Plant
Retrofit of legacy ammonia chiller system serving 300k sq ft food processing facility
New 12-ton EO storage and sterilization unit in North Carolina pharmaceutical campus
Grain Elevator Dust Explosion Mitigation Using ASTM E1226-Based Risk Model
Modernization of 50-year-old Midwest grain terminal handling 1.2M tons/year
Offshore LNG Transfer System Fault Tree Analysis and SIS Architecture Optimization
FPSO-based LNG bunkering operation in Singapore Strait
Liquefied Natural Gas (LNG) Train Optimization
QatarEnergy North Field Expansion β 8 MTPA LNG train
Ethylene Oxide Absorption Column Design
BASF ethylene oxide plant upgrade in Antwerp
Supercritical COβ Extraction of Caffeine
Starbucks sustainable decaffeination pilot in Colombia
Ammonia Synthesis Loop Purge Optimization
Yara fertilizer plant modernization in Norway
Geothermal Power Plant Working Fluid Selection
Ormat Mammoth Pacific Unit 3 binary cycle upgrade, California
Pharmaceutical Continuous Flow Hydrogenation of API Intermediate
Transition from batch Pd/C slurry hydrogenation to continuous flow for oncology drug intermediate
Pharmaceutical Batch Reactor Deviation Mitigation (FDA-Approved Twin)
End-to-end digital twin for API crystallization suite at a GMP facility
Refinery FCC Unit Predictive Maintenance Twin
Digital twin deployment across 4 fluid catalytic cracking units in Texas Gulf Coast refinery
Bioreactor Scale-Up Twin for Cell Therapy Manufacturing
Closed-system bioreactor digital twin supporting clinical-to-commercial scale-up (5 L β 200 L β 2,000 L)
Ammonia Synthesis Loop Optimization at BASF Ludwigshafen
Revamp of Haber process loop for 15% yield improvement
Slurry Transport Optimization in Copper Mine Tailings Pipeline
65 km HDPE pipeline from concentrator to tailings dam in Peru
Heat Integration in Ethylene Oxide Absorption Column
Retrofit of EO recovery unit in Gulf Coast petrochemical plant
CFD-Guided Mixer Redesign in Pharmaceutical Bioreactor
Scale-up from 2,000 L to 20,000 L mammalian cell culture reactor
FCC Unit Regenerator Coke Burn Optimization (ExxonMobil Baytown)
Reduction of NOx emissions and catalyst deactivation in fluid catalytic cracking regenerator
Bioethanol Fermentation Tank Cascade Control (POET LLC, Iowa)
Improving ethanol yield and reducing diacetyl off-flavor in 2M-gal SSF fermenters
COβ Hydrogenation to Methanol in a Slurry Reactor (Carbon Recycling International, Iceland)
Integration of geothermal Hβ and captured COβ into 4,000 ton/yr methanol plant
Geothermal Binary Cycle Working Fluid Selection for 5 MW Power Plant
Baseload power plant in Nevada using 145Β°C brine resource
Pharmaceutical API Purification via Crystallization
Manufacture of high-purity ibuprofen API at FDA-compliant facility
Bioethanol Dehydration Using Pervaporation Membranes
Corn-based ethanol plant in Iowa upgrading fuel-grade ethanol (95%) to fuel-blend grade (99.8%+)
Offshore Natural Gas Sweetening via Amine Absorption
North Sea platform processing sour gas (22% HβS, 8% COβ) under space/weight constraints
Wastewater Reclamation for Semiconductor Fab Using RO-NF Hybrid
300mm wafer fab in Arizona targeting 85% water reuse amid drought restrictions
Hydrogen Sulfide Flare Stack Integrity Assessment at Gulf Coast Refinery
Critical flare stack servicing sour gas units in high-HβS environment
Nitric Acid Storage Tank MOC Failure Root Cause Analysis at Fertilizer Facility
Upgraded secondary containment for 500,000-gallon nitric acid tank
Ethylene Oxide Sterilization Unit QRA & Emergency Response Optimization
Pharmaceutical contract sterilization site handling EO cylinders and vapor-phase systems
Polymer Reactor Runaway Reaction Mitigation via SIS Redundancy Upgrade
High-pressure propylene polymerization reactor experiencing thermal excursions
Pharmaceutical API Synthesis Redesign at Novartis Basel
Redesign of multi-step synthesis for antihypertensive drug candidate
Biodiesel Production Scaling in Iowa Soybean Refinery
Expansion of transesterification plant from 10 to 50 MMgy capacity
Electrolyte Manufacturing for EV Batteries β BASF Ulsan Plant
New LiPFβ synthesis line with closed-loop fluorine management
Food-Grade Citric Acid Fermentation Upgrade β Cargill Decatur
Modernization of Aspergillus niger fermentation and downstream processing
Recycled PET Flakes Purification for Food Contact β Indorama PET Recycling, Rotterdam
Validation of supercritical COβ cleaning for post-consumer PET flake decontamination
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