Total quantity or scope of tender
Specifications for Gas Processing Pilot Plant
Detailed Design: USW has completed an outline design that is summarized in this specification and an initial Basis of Safety document. The successful company will work with USW researchers and project partners to produce a detailed design capable of achieving
the research requirements taking into account the specification below. Advice from industrial partners regarding any specific site requirements will also feed into the detailed design process. USW will work with project partners and the successful tenderer to produce
a HAZOP associated with the plant, however, this will not be the responsibility of the appointed company.
Assembly: Procurement of appropriate materials, components and sub systems and assembly of these in accordance with the detailed design agreed above. Assembly to comply with appropriate industrial standards for the purpose of use.
Factory Testing: Factory testing of the whole system, subsystems and components to demonstrate appropriate functionality prior to delivery, to include mechanical and electrical systems and pressure testing. Certification of all testing undertaken and provision of an operating manual and component list. Factory testing to be witnessed by USW and
appropriate industrial partners.
Site Commissioning and Training: Delivery to a site in South Wales and plant commissioning and training USW staff is also expected.
NOTE: This tender is for the provision of full design and build services. The successful bidder will be provided with an order to undertake the detailed design of the pilot unit.
Following successful completion of the detailed design stage to the satisfaction of the USW team, a second order for the manufacture, testing and commissioning of the unit will be placed with the same supplier. Suppliers are not expected to unduly “front load” costs to
the design stage. Provision of reasonable costs for each element will be considered in the evaluation of specified costs
Reactor Dimensions
Approx. 23.1 litres internal volume
The reactor will be a ‘column’ type system e.g. in the order of
Diameter: 160 mm, Height: 1150 mm (internal dimensions). Use of standard dimension materials that does not significantly alter the profile or overall volume of the reactor is acceptable if this provides a cost saving.
Please include the following as options:
a site glass across the liquid level to allow visual inspection,
approx. 300 mm by 50 mm; or
two smaller visual inspection windows, one above and one
below the liquid level; or
no window at all.
The reactor is to contain a mixture of liquid medium mixed with
gaseous feedstocks and a packing material under the operating
conditions below. Internal, removable perforated plates to
contain the packing material are required.
Operating Conditions
Pressure: Capable of operating between 1-10 barg internal pressure. All gas and liquid handling components therefore need to operate in this range.
Temperature: Normal operating temperature of the reactor of 35°C-65°C, and also for components attached to the reactor. Subsystem components working away from the reactor (not in contact with working fluids) should be able to operate between normal ambient temperature ranges experienced in the UK.
pH: Normal operating conditions of pH 7-8, however the vessel and components in contact process liquids should be capable of operating between pH 5 – pH 9.
Operational time: The system should be capable of operating 24 hours per day, 7 days per week during the experimental phase. However, it is expected that the system will be operated intermittently during process start up.
Materials of Construction
The column and perforated plates (top and bottom) will be stainless steel 316L with 2B finish.
The packing material will be provided by USW.
Liquid circulation pipework and all fittings will be appropriate for
the operating pressure and temperatures defined.
Design temperature and pressure for all materials forming part of
the reactor vessel and liquid recirculation loop is 80°C and 12 barg
maximum to allow for maximum operational conditions of 10 barg and 65°C.
To enable various experimental regimes including the usage of
various inocula, occasional access to the inside of the reactor is
required where the bio-reactor goes into shut down mode for cleaning and re-starting purposes.
Gas Input
Mechanism for the addition of industrial gases into the reactor vessel via the side wall at the base of the reactor. Gases will include hydrogen (both pure and mixed with nitrogen) and carbon dioxide. Low concentrations of ammonia and traces of other gases may potentially be present.
The system will initially operate using pressurised bottled gases.
The system should include the ability to mix gases from 2-4 separate sources (e.g. a gas manifold) supplied at pressure (1-10 barg) and the ability to control and record the flow of each gas (i.e.to allow control of gas composition to an accuracy of 0.1% by volume).
Gas temperatures supplied to the system will be between ambient
temperature and 65°C.
Gas flow volumes are expected to be: 0 – 500 litres / hour of mixed
feed gases (i.e. total flow of mixed gas entering the reactor).
Liquid & Gas Mixing
Mechanism for reduction of gas bubble size at the bottom of the
reactor (e.g. diffuser or venturi). The aim is to reduce bubble size
as far as is practicable whilst achieving the required gas flows
above.
Mechanism for removal of liquid from the lower side of the reactor (opposite gas inlet) and recirculating to the top / upper side of the reactor (i.e. a pumped mixing loop). It is anticipated that the liquid stream will contain a significant proportion of gas(which may achieve 40-50% as gas). Variable liquid flow rates of 80 - 250 litres per minute should be capable of being sustained.
The recirculation pipe will have an internal diameter of 34 mm (or
nearest standard diameter if cost reductions can be achieved).
Liquid Removal
The biochemical process generates water within the reactor, therefore the ability to remove excess liquid from the reactor is required. This should be via a dedicated liquid removal port. Liquid removal is required to be achieved whilst the main reactor remains at pressure.
Gas Outlet
Gas outlet port approximately 50 mm from the top of the reactor
connected to a foam trap / liquid trap vessel (approx. 8 litres in
volume) including level sensor and actuated valve for liquid removal. Final gas outlet should also include a variable back pressure valve to allow pressure within the reactor to be controlled and maintained.
Reactor Heating
Include provision to maintain temperature within the reactor including heat source, insulation (if deemed a requirement) and mechanism to circulate heating fluid if used. Normal operating temperature is approx. 37 °C, however the ability to change and maintain temperature between 35 °C and 65 °C is required. Temperature within the reactor should be capable of being maintained at a set point to +/- °1 C.
Process Monitoring Separate cost item
USW has / will procure the following components directly and supply to the appointed contractor:
pH probe and controller,
digital mass flow controllers to measure gas input volumes,
digital mass flow meter to measure gas output volume,
digital output gas monitors for CO2, H2 and CH4 to measure gas outlet quality.
The appointed contractor will be required to source components
appropriate for the monitoring of:
liquid temperature in the reactor,
liquid recirculation flow rate,
process operating pressure,
liquid levels in the main reactor and liquid / foam trap.
The contractor is to allow for the incorporation of all of the above
components on to the reactor in such a way that allows the continuous /near continuous monitoring of:
Process pH,
Individual gas input volumes,
Gas output volume,
Gas output composition (CO2, H2, CH4),
Liquid temperature in the reactor,
Liquid recirculation flow rate,
Process operating pressure.
As a minimum, all data is to be available for inspection via a user
interface with the capability to export data in standard digital
formats.
As an optional item please indicate any additional costs associated
with providing a cloud based platform allowing the secure on-line
storage and inspection of process monitoring data to a limited number of authorised users.
Process Control
The ability to control the following via a user interface:
Reactor Temperature: 30°C to 65 °C,
Pressure: Automated control of gas regulators (0-12 bar),
Gas Input Volume: 0 – 500 litres / hour of mixed input gas
comprising of H2 0-100%, CO2 0-100%, N 0-100% and all mixtures in between (controlled using mass flow controllers).
Ideal operating conditions are approximately 20% CO2 and 80% H2 by volume.
Liquid flow rate in the recirculation line,
On / Off (including automated control and manual emergency shut down)
As an optional item please indicate any additional costs associated
with providing a secure cloud based platform allowing the control of the above parameters from remote locations using mobile and pc devices.
Process Automation
All valves, flow controllers and other means of controlling system
be operated via the control system, i.e. no exclusively manual control other than safety shut down and manual emptying /drainage of the reactor. Manual over-ride of all safety critical control points is to be included.
Process Safety
The chosen provider is to provide advice relating to the H&S
requirements of the final system, and is to incorporate the requirements of industrial partners into the final design.
As a minimum the system will include:
Emergency Shut off valve(s) for gas supply,
Emergency Shut down control for all mechanical/electronics
associated with the reactor,
Automated safe shutdown procedure to ensure that the
reactor is left in a safe condition should an alarm condition
occur,
Circuit breakers for system malfunction (e.g. overheat / overfill),
Mechanism for pressure relief to maintain pressure in operational limits.
As an option, please indicate any additional costs to include a
remote alarm facility to notify operator of failure via mobile device.
Factory testing certification to be provided by the manufacturer to
include pressure testing, electronic and mechanical testing.
The reactor and ancillary equipment should be skid / frame mounted to allow transportation. Appropriate support mechanisms should also be included as required.
The plant will be located within a well ventilated, covered area.
Initial discussions with industrial partners have indicated that ATEX rating of electronic components is not required. This can be discussed with the appointed contractor prior to finalizing the detailed design.
Please provide an Option of an additional cost for Zone 1 ATEX
compliance.
Initial Basis of Safety documentation will be provided to the
appointed company. The company will be expected to contribute
towards the completion of an appropriate HAZOP assessment, although this will be managed and delivered in collaboration with a project partner.
Delivery & Installation
Delivery to a testing location located within South Wales within
12-14 Weeks of agreeing the detailed design. To include unloading
from transportation.
Methods for moving the unit into position are to be provided.
Operator instruction & training.
Single phase and three phase power will be available on site.
Power requirements to be determined during detailed design.
Drainage will be provided on site.
Technical Support
6 months of technical support post-delivery including 2 No. site
visits and end of the phone technical advice.
Design Documents
Any IP associated with the design and construction of the plant and all design documentation will be the property of USW.
Successful tenderers will be required to comply with a mutual
confidentiality agreement with USW.
All detailed design documents including calculations, P&ID drawings, detailed design drawings / models and construction drawings are to be provided to USW.
Timescale
USW are seeking to complete the design and build within a 5 month period. Tenderers are asked to indicate whether they are in a position to meet this timeframe, and if not, to indicate the minimum time required to complete the project.
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