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Modular systems are complete process units, pre-fabricated to the maximum extent possible in a module fabrication shop remote from the customer’s plant site. Modular systems are typically built indoors in a controlled, assembly-line fashion with all of the added efficiencies afforded by that practice/procedure. This, in turn, minimizes the amount of work and resources needed by the customer in the field to construct an operational process unit.

The typical modular system will include columns, reactors, drums and decanters, heat exchangers, pumps and other types of process equipment, all mounted within structural steel framing. The structural steel framing serves as a shipping support and provides access to the equipment during normal operation and for maintenance purposes. After the process equipment is installed within the structural frame the piping components, the field instrumentation, and the electrical wiring are completed. It is also typical for items like tracing, thermal insulation, lighting, safety showers and fire protection systems to be installed in the module at the assembly shop. A rigorous testing program is conducted of all these components before shipment to the field. The customer’s mechanical specifications, standards and guidelines are followed in every respect, assuring each customer that the system provided will meet all of their expectations.

KMPS can also provide process studies, laboratory and pilot testing, VLE development and complete process design engineering packages.

Full Range of Services
  Modular Systems
  Feasibility Studies
  VLE/LLE Development
  Process Simulations
  Process Design
  Pilot Plant Testing
  Shell & Tube HX Design
  Equipment Design
  Detailed Engineering
  3D CAD Modeling
  Project Management
  Startup & Training

Process Expertise
  Distillation
  Liquid-Liquid Extraction
  Steam Stripping
  Absorption

Why Modular Construction?  -  Consider the Advantages

1.) Shorter Schedules - Building a process unit in a shop, with a well controlled fabrication sequence, can save months when compared to building outside in a plant environment where work is subject to weather related delays, work permits, work stoppages, waiting for cranes, etc. A typical schedule for delivery of a complete modular process unit, fabricated in stainless or carbon steel, is 7-8 months from receipt of a Purchase Order, including all engineering and design activities.

2.) Lower Cost/Lump Sum Bid - KMPS has made a science out of studying fabrication efficiencies and construction sequences in our module shops. Typically a 25-30% reduction in cost can be realized with modular construction when compared to field construction. Prices quoted for modular constructed systems are also firm/lump sum prices, not T&M.

3.) Construction Proceeds While Waiting for Permits - Offsite construction of entire process units in our module shop can proceed while permits are in-process. This can be a significant time saver because permits often take months to obtain and field construction can’t begin until the permits are in hand.

4.) Minimal Plant Site Interruption - In the case where a new process unit is built alongside of an existing operating chemical manufacturing unit, there are many hazards and safety risks associated with the field construction activities. Ask yourself this QUESTION – “Do I want dozens of contract construction workers walking around in my chemical plant?” If the answer to this question is no, then modular construction (off-site) makes a lot of sense. It minimizes the potential hazards and production interruptions that can occur.

5.) Single Source Responsibility - Is your project management/project organization stretched to the limit? Building your process unit in our module shop will unload your project team because you will place only ONE purchase order for the entire system, our project team will do the rest.

DID YOU KNOW?? Modular units are also quite versatile. Although most of our modules are installed outdoors many are also installed inside of a building. Modules can easily be sided to protect operating equipment and personnel against the harshest of weather conditions or to shield the process components from the view of neighbors and potential competitors.

Modular Multipurpose Aroma Distillation System

More modular distillation systems

Modular Mercaptan Distillation System

More modular distillation systems

To view a PowerPoint presentation of the complete module installation process click here.