This document discusses a modular construction project called "Chill" that was completed successfully to address scheduling concerns for a larger project. The Chemours company was initially concerned about working with a modular contractor for various reasons relating to space, access, and construction. However, Koch Modular Process Systems was able to address all of Chemours' concerns through their modular design. This included removing temporary steel supports after installation, minimizing interior bracing, and ensuring proper access, egress, and safety features. As a result, the modular facility was delivered ahead of schedule and under budget compared to traditional construction. Chemours was so satisfied that they hired Koch Modular for two additional projects.
1. Modular Process Systems
James Peckham
Chemours Construction Competency Leader
Thomas Schafer
Koch Modular Process Systems Vice President
November 14, 2018
2. Recent Modularization Example for Schedule
Critical Project – “Chill”
Background
• Late addition to the main, larger project, already in progress, with very
aggressive/business critical schedule
• Start of foundation work tied to air permit receipt
• Due to permit timing, stick build would result in 6 to 8 month start up
delay of main project
• Elected to utilize modularization to allow fabrication to begin prior to
permit receipt and foundation completion
• Benefit to business – Significant savings in lost revenue!
November 14, 2018 2
3. Chemours’ “Fears”/Concerns with
Modularization
1. Had never worked with a module company that performed the
process engineering as well as the production design and
engineering (had previous experience with module fabricators).
2. Concerned that the modular facility would not have sufficient space
for operability and maintainability including access to process
equipment. Previous truckable module facility at the site was
extremely cramped.
3. Wanted the ground floor to be concrete and free of any equipment
support steel, i.e. appear as though it was stick built.
4. Concerned that interior cross bracing, on each individual module,
would interfere with access and movement within the completed
structure.
5. Wanted access and egress to be available between all modules and
at all floor levels and wanted two means of egress from the structure.
November 14, 2018 3
4. Koch Modular Process Systems
Chemours decided to work with
Koch Modular Process Systems on
Project “Chill”
November 14, 2018 4
5. Confidential
About Koch Modular Process Systems
November 14, 2018 5
• Privately held JV company with Koch
Industries
• 35 years experience with the process
design, detailed engineering and supply of
modular constructed process plants
• Renowned for our Expertise in Distillation,
Liquid-Liquid Extraction, Process
Engineering and Pilot Testing
• Process Conceptualization to Full Scale
Manufacturing
• Fortune 500 Chemical Process Industry
Client List
• Growing Number of Partnerships with
Chemical Process Industry Companies
6. Confidential
Benefits of Modular Construction
November 14, 2018 6
Shorter Time to Market: Months, not Years, from PO to delivery of modular
process units
Lower Construction Cost: Typically 25-30% lower cost vs. field construction
Construction proceeds offsite while waiting for permits
Lump Sum Fixed Price Contracts
Minimize hazards and safety risks: Work in outdoor conditions and work at
elevation eliminated. No hazardous chemicals present
Single Source Responsibility, Complete System with Mechanical and
Process Performance Warranties.
9. Confidential
Ground Floor of Modules
November 14, 2018 9
Chemours requested:
• Pumps mounted on concrete bases, not steel structure
• Ground floor to be concrete, not grating
• No step up at grade onto ground floor
• Minimize field work once modules arrive
• Mount Main Control Panels on outside wall
16. Confidential
Upper Operating Floors of Modules
November 14, 2018 16
Chemours requested:
• Minimize cross bracing on interior module faces
• Maximize space for access to equipment/piping/instruments
• Safety shower/eyewash station accessibility
• SIS and 120V power panels
• Utility Stations
29. Confidential
Egress from Modules
November 14, 2018 29
Chemours requested:
• 2 means of egress for each module
• 2 stair modules provided on either end of the module
assembly
• Walkways between modules on 2 sides
34. Final Result
• Project was very successful!
• Turned over this facility well in advance of the completion
of the main facility and achieved some savings over stick
build.
• Koch Modular was able to satisfy all of our concerns and
met their commitments.
• Based on this success, we are using them on two other
projects!
34November 14, 2018
35. Questions
Thank you very much for attending!!
We would be glad to answer any questions
you may have at this time.
November 14, 2018
35