The Challenge
EIA21 developed the detailed engineering required to modernize and upgrade an existing ELT pyrolysis pilot plant dedicated to the recovery and valorization of end-of-life tyres.
The project involved a comprehensive review of the existing installation and the complete update of engineering documentation to ensure compliance with European regulations covering industrial safety, piping systems, electrical installations, instrumentation, and control systems.
In addition, EIA21 conducted extensive field surveys, generated a complete 3D model of the facility, updated technical documentation, and redesigned key systems to improve plant operation and ensure regulatory compliance.
The existing facility presented significant documentation gaps and deviations from current European standards, creating several technical challenges:
- Upgrading an operating pilot plant to comply with European regulations.
- Reconstructing engineering documentation with limited information provided by the client.
- Conducting a comprehensive field data acquisition campaign to identify the actual plant configuration.
- Converting existing specifications based on American standards into European regulatory requirements.
- Developing a complete 3D model based solely on field measurements and topographic information.
- Redesigning piping, instrumentation, electrical systems, lighting, grounding, and lightning protection systems.
- Updating P&IDs, technical specifications, equipment lists, valve schedules, and instrumentation documents.
- Performing piping flexibility and stress analysis to verify the mechanical integrity of the facility.
The Solution
EIA21 implemented a comprehensive engineering strategy aimed at modernizing the plant and bringing it into full compliance with current regulations and operational requirements.
The scope of work included:
- Multidisciplinary field surveys involving piping, electrical, instrumentation, and control specialists.
- Development of complete piping specifications in accordance with European standards, including equivalency analysis with existing American standards.
- Creation of a comprehensive 3D digital model of the facility.
- Redesign of process and auxiliary systems to improve safety and operational performance.
- Update of all technical documentation, including P&IDs, line lists, equipment lists, valve schedules, and instrument indexes.
- Preparation of installation and removal specifications for instrumentation systems.
- Piping flexibility studies and stress analysis.
- Upgrading electrical installations, lighting systems, grounding networks, and lightning protection systems.
Results
- Complete Detailed Engineering package updated in accordance with European regulations.
- Creation of a reliable and accurate 3D digital model of the existing facility.
- Significant improvement of plant safety and operational conditions.
- Full update of process systems and technical documentation.
- Verification of piping mechanical integrity through specialized stress analysis.
- Establishment of a solid engineering foundation for future plant expansion and industrial-scale deployment of pyrolysis technology.
