The civil construction industry is experiencing a significant shift towards off-site construction methods to streamline operations and increase project efficiency.
Among these methods, modular construction has emerged as a frontrunner due to its ability to prefabricate components in controlled environments away from traditional construction sites.
Modular processing plants exemplify this trend, offering a versatile solution for various industrial applications. By prefabricating essential components such as structural frameworks, equipment, and systems off-site, these plants not only accelerate construction timelines but also ensure higher quality control and safety standards.
In this article, we delve into the transformative potential of modular processing plants across different sectors. From energy and manufacturing to pharmaceuticals and beyond, these plants are revolutionizing project delivery by offering scalable, adaptable, and sustainable solutions.
Table Of Contents
- What Is Modular Processing?
- What Are The Advantages Of Modular Processing?
- Hydrogen Modular Processing And Green Energy
- Contact STEVENS Today
What Is Modular Processing?
Modular systems are complex systems assembled off-site, away from the job site environment. Built within controlled assembly lines, modular systems offer enhanced speed and efficiency compared to on-site construction methods.
This approach simplifies the assembly process for customers, requiring less labor and fewer resources to deploy a fully functional processing unit in the field.
A typical modular system consists of columns, reactors, drums, decanters, heat exchangers, pumps, and other essential process equipment mounted on a robust structural steel frame. This frame not only supports transportation but also facilitates easy access for operational maintenance.
Once the process equipment is integrated into the structural frame, final assembly includes piping, field instrumentation, and electrical wiring.
Additional components such as wiring, thermal insulation, lighting, control systems, safety features like showers, and fire protection systems are meticulously installed in the module during the assembly phase.
Prior to deployment, each modular system design undergoes rigorous testing to ensure adherence to mechanical specifications, industry standards, and customer-specific guidelines. This meticulous process guarantees that every system delivered meets the exact operational requirements and expectations of our clients.
What Are The Advantages Of Modular Processing?
Shorter Schedules
Constructing a processing unit in a well-controlled shop environment can significantly reduce project timelines compared to on-site construction. Challenges such as weather delays, permitting issues, work stoppages, and logistical constraints like crane availability are minimized or eliminated.
Typically, from receiving a purchase order to delivery, the fabrication of a complete stainless or carbon steel modular process unit takes approximately 7-8 months. This timeline encompasses all stages, from initial engineering and design through to final assembly and testing.
Lower Costs
Utilizing modular processing plants instead of traditional construction methods can lead to significant cost savings of 25–30%. Additionally, prices for modular systems are provided as firm, lump-sum quotes, offering financial predictability and transparency throughout the project.
Versatility
Modular units offer exceptional versatility, functioning effectively both outdoors and indoors within buildings. Easily customizable, these modules can be enclosed by walls to shield operational equipment and personnel from adverse weather conditions. Additionally, this flexibility allows for discreet placement of process components, ensuring confidentiality from neighboring entities and potential competitors.
You Can Build While Waiting for Permits
Hydrogen power offers a promising solution to reducing carbon emissions in both electricity and transportation. It serves dual roles: storing energy and fueling hydrogen fuel-cell vehicles—cars, trains, ships, and planes alike.
The concept of a hydrogen economy presents a compelling alternative to fossil fuel-based energy sources.
For instance, a hydrogen-powered car, using a fuel cell to convert gas into electricity, boasts the same zero-emissions footprint as an electric vehicle but without the environmental drawbacks of battery banks—long charging times and limited range. Yet, currently, the vast majority of hydrogen production derives from fossil fuels, not carbon-free sources.
Approximately 95% of the world's hydrogen comes from processes like steam methane reforming, which involves pressurizing a steam and methane gas mixture with a nickel catalyst, resulting in hydrogen, carbon monoxide, and some carbon dioxide. To meet global transportation fuel demands sustainably, scaling the production of clean hydrogen is imperative.
Hydrogen Modular Construction And Green Energy
So what are some practical uses of a modular plant?
Well, one use has the potential to change the world.
Modular Construction For Hydrogen Power
Modular construction might be able to help make clean hydrogen.
NuScale Power has released the results of a new study that shows that a single small nuclear NuScale Power Module (NPM) could make it cost-effective to produce almost 50 tons of hydrogen fuel per day.
According to the study conducted by the Idaho National Laboratory, NuScale Power Modules (NPM) can now produce 20% more hydrogen from water due to their increased power output. NuScale asserts that its process is cost-effective, utilizing nuclear reactors that generate both hydrogen and electricity.
These small modular reactors can flexibly switch between hydrogen production and electricity generation to meet fluctuating demand. The Oregon-based company estimates that a single NPM could reduce carbon dioxide emissions by 168,000 tonnes annually. Each 250 MWt NuScale module can produce 2,053 kg of hydrogen per hour, totaling nearly 50 metric tons daily.
At the current US consumption rate, one NPM could provide enough hydrogen to fuel 38,000 fuel-cell cars or 1,500 long-haul fuel-cell trucks annually. NuScale's innovative design includes a multi-module power plant with built-in steam bypass, enabling the production of clean electricity for the grid while efficiently generating hydrogen during periods of low electricity demand.
This hydrogen can be stored for future energy use or power a variety of carbon-free vehicles, including cars, trucks, trains, ships, and planes.
Contact STEVENS Today FOR YOUR MODULAR PLANT
Modular and prefabricated projects will become even more popular, especially among construction companies that want to reduce costs overall.
There will be many more modular buildings, modular process plants, and other prefabricated civil engineering projects in the future.
The civil construction industry has a very bright future thanks to the potential of modular processing plants.
With over 75 years of quality, dedication, and experience, STEVENS has been planning and working for the future to provide our clients with the very best.
STEVENS has always been on the cutting edge of new technology so that we can give our customers the best service possible.
Click on the button below to learn more about how STEVENS can help you with your modular construction project.
References:
https://kochmodular.com/modular-process-systems/
https://www.nuscalepower.com/environment/clean-hydrogen-production
https://newatlas.com/energy/nuscale-modular-nuclear-reactor-hydrogen-production/
