1. PRE-PROJECT DEVELOPMENT:
1.1. PLANT AUDIT
CFI Group provides technical audits of existing plant or complex in the scope of industrial evaluation and optimization, revamping or modernization. Our team of experts and engineers are at our customers' disposal to make an assessment of any existing unit through an on-site technical survey.
This on-site technical survey which mainly consists in a plant performance test, coupled with a full and deep plant analysis, delivers the following benefits:
Evaluation for implementation of new products or formulas. use of raw materials
Assessment of current process and plant performances
Understanding of operating modes and maintenance practices of the unit
Identification of existing problems [process. technical & mechanical issues,bottlenecks]
Safety and environmental review of operations and equipment against latest practices
Following the on-site survey, the typical report may include:
Process and technical recommendations
Options to increase capacity and/or improve product quality
Optimization of current production or formulas and use of raw materials
Process description with relevant engineering solutions
List of problems and proposed solutions
Environmental improvement opportunities
Safety improvement opportunities
In addition to the technical report. a preliminary cost estimate and connected schedule for implementation of modifications are incorporated, allowing our customer to determine whether the recommendations and solutions can be further developed in a cost effective manner.
1.2. FEASIBILITY STUDY
A feasibility study is an important phase in the development of a project. It may concern a fully new plant or complex as well as the revamping of an existing plant or complex.
In performing such engineering work, CFI Group experts and engineers focus on the analysis of the project, the specific technical issues and study the available process and technical solutions, their possible implementation time and cost wise, in accordance with the customer's basis of design, the local constraints (legal, environmental) and the expected schedule of the project.
The main tasks of a feasibility study are:
Establishing the basis of the project and its technical requirements;
Defining how practical a technical solution is;
Recommending realization alternatives;
Determining the availability of the technical resources and know-how;
Estimating the project schedule and cost;
with the goal to assess whether the project development is technically feasible or not.
The typical report may include the following elements:
Industrial and process description
Industrial and process flow sheet
Process safety and environmental considerations
List of equipment and main block dimensions
Raw materials specifications
Estimated consumptlons of raw materials and utilities
Strategy and operation of raw material reception and storage
Preliminary lay-out and plot plan
Preliminary industrial management organization
Human resources plan and organization
Preliminary maintenance management organization
Preliminary settlements of logistics organization
Project implementation time
At the customer's request, CFI Group can also:
Conduct a financial feasibility of the project
Propose various financing options
Submit a proposal for Licence technology, process and Full Engineering Package (basic and detailed)
Bring partners to the project
2. PROJECT EXECUTION:
2.1. BASIS OF PROJECT DEVELOPMENT
CFI Group develops engineering and industrial projects in the following fields of activity :
Air and water treatment in the above areas
CFI Group implements customers' projects based on its own licences and proprietary technologies stemming from the knowledge and know-how of its highly skilled experts and engineers.
CFI Group is very flexible and can participate in a project via any route:
EPC or LSTK: project led by a partner; licence, process, technology, engineering and connected services provided by CFI Group.
EPCM: all activities led by CFI Group; equipment and bulk items directly purchased by the Customer; construction made by another company selected by the Customer under the guidance of CFI Group.
Licence, process, technology, engineering and connected services: CFI Group is directly contracted by the Customer for one or several of these activities.
For all these activities, CFI Group provides the best quality services which are detailed in Figure 1 below.
2.2. ENGINEERING PHASES AND TOOLS
CFI Group has its own way of developing the engineering, based on its own knowledge to reach the issued for construction drawings. Such a sequence is given in the figure below.
To ensure the quality and efficiency of its engineering design, CFI Group uses the most recent and performing IT tools as, for instance:
SysCAD for process simulation
In-house process softwares
HTFS TEAMS and HTFS TASC for mechanical and thermal design of heat exchangers
CATIA, SolidWorks, PV-Elite for mechanical equipment design
CADWORK PIDs for instrumentation and intelligent PlDs
CAESAR for piping stress analysis, AutoCAD for mechanical design and drawings
CadWorks/EngWorks for 3D modeling
STAAD.Pro and TEKLA for civil and structural design and many others...
All engineering activities are supervised and the resulting documentation is checked by CFt Group experts who mostly come from the industry and have a practical and industrial background.
3. RESEARCH & DEVELOPMENT CENTRE, PILOT PLANT & LABORATORY
With extensive experience in the explosives, fertilizers and chemicals fields, CFI Group has the willingness to continuously innovate and develop new technologies in order to offer to the market the most advanced processes.
For such purpose CFI Group has settled a R&D centre in Tunisia, where its Pilot Plant, Laboratory, Documentation and Training Center have been installed.
3.1. PILOT PLANT
With an available area of 800 m2 where process modules and skids can be installed and connected together by an 8 m height bridge crane, various process units will be able to operate at semi-industrial scale for easy and safe scale-up.
The main process modules will mainly include but not limited to:
Synthesis section with reactors starting from acids (nitric, phosphoric or sulphuric) with ammonia or rocks
Superphosphate den for SSP and TSP evaluation
Granulation section ancl all mechanical processes such as drying, grinding, crushing, screening, cooling, coating and packing
Scrubbing, air and water treatments
In order to test raw materials and evaluate resulting products qualities, a 100 m2 fully equipped laboratory is part of the facilities.
This laboratory will be used for process parameter validation, chemical and physical analysis of raw materials and final products. Moreover, the laboratory will be also qualified to perform :
Phosphate rock analysis and evaluation for phosphoric acid production
Phosphate rock analysis and evaluation for nitrophosphate production
Phosphate rock analysis and evaluation for SSP or TSP production
Evaporation and crystallization process evaluation
LDAN and technical nitrates analysis
Fertiliser analysis and product quality control
Preliminary tests for process evaluation