N20 Abatement Project
Dyno Nobel sought to reduce N₂O and NOx emissions through the installation of a new tertiary abatement reactor. The integration of this system into an existing, highly integrated facility required significant process and structural redesign. Sedgman Prudentia was initially engaged to verify the process model and operating conditions, which led to our appointment for the full design scope.
Details
Location
Moranbah, QueenslandClient
Dyno NobelScope of Work
Scope
The project involved specialist process modelling to validate the reaction kinetics and ensure the proposed vessel volumes were appropriate. Structural engineering was required to accommodate a significantly heavier replacement vessel, including detailed analysis to determine necessary modifications. The team also developed a strategy to document design changes on non-native, legacy documentation systems. Additional work included the detailed design of piping and electrical systems to integrate the new abatement reactor, connections to the natural gas system, and the inclusion of new instruments and valving into the existing plant infrastructure. Sedgman Prudentia worked closely with Dyno Nobel to align deliverables with critical shutdown windows and also provided third-party design verification and RPEQ certification support to the abatement system supplier.
Outcome
Sedgman Prudentia delivered a complete design package on a lump sum basis, meeting the tight shutdown schedule and ensuring seamless integration of the new abatement system. The project mitigated key operational risks, enhanced emissions control and successfully integrated complex systems into the existing plant infrastructure.