Enabling market expansion for 瓦克

Fumed silica, also k现在n as pyrogenic silica, is in high demand.  在火焰中产生, it is used across building and construction, electronics and transportation and a wide range of everyday products from paint to plant protection and personal care and beauty.

In 2016, one of the world’s most innovative chemical companies, 之杖, sought the support of a leading engineering, procurement and construction management (EPCm) firm which shared 之杖’s vision for seeking intelligent and sustainable solutions.

The proposed scope included the design and construction of a $150MM Total Installed Cost HDK® fumed silica plant at 瓦克’s mega-site in 查尔斯顿,田纳西州.

2016年末, Wood was awarded the front-end engineering and design (FEED) contract, and subsequently the full EPCm services in May, 2017.

一旦完成, the plant would strengthen 之杖’S market position and expand its supply capacity in the U.S. – the world’s second-largest chemicals market. The product it would go on to produce was also synonymous with both companies’ sustainability goals with a resource-friendly eco-loop, the recycling of hydrogen chloride and successful CO2 savings making HDK® the most sustainable pyrogenic silica available. The fumed silica facility would also complement an existing plant and enhance 之杖’s flexibility in processing and production of byproducts, 避免浪费.

瓦克 needed a company with strong project and chemical sector experience as well as working k现在ledge of 之杖’s preferred internal systems, such as design database COMOS and 3D model software, PDS. Global procurement experience and the ability to acquire major equipment, as well as a strong construction management team who could manage construction subcontract bidding and selection and overall material and site logistics, 也是必不可少的.

Wood’s project team delivered engineering for the Balance of Plant (BOP), integrating three vendor design-build packages and acting as the general contractor for the project.

Four months into the execution phase, 瓦克 had an incident which required its entire production of polysilicon at the mega-site be shut down. Wood mobilised a team to lead and execute the demolition, engineering and restoration efforts for the facility, which included a 20% expansion.

The main plant was restored to full production at a rapid pace with no impact to the project.  The plant made on-spec product in its first run and the project was completed 15% under budget.