Increase P2O5 Production Capacity by 15% by Adding a Train of Equipment - Rock Springs Expansion Project

Author(s) Fossceco, Mike., Skorcz., Nuyianes, Andy., O'Toole, John., Stetka, Deborah
American Institute of Chemical Engineers 39th Annual Clearwater Convention
As EPCM contractor, Hatch partnered with JR Simplot Company to complete a major expansion project at Simplot’s Rock Springs, WY facility, which has resulted in a greater than 15% production capability increase.  The project consisted of eight areas including the conversion of water users from an existing cooling tower to a redesigned cooling pond system; a new reactor vacuum system; a new table filter and filter building; a new evaporation unit; a new phosphoric acid clarifier and storage tank; a new filter feed tank; a new rock slurry storage tank; and an electrical infrastructure upgrade to support the project areas. 
The project was completed with 540,000 field man-hours without a Lost Time Incident (LTI).  The project was also completed on schedule and approximately 10% under budget.  This paper will address challenges in three areas as follows: 
Project Challenges – Project Set-Up; Execution (Engineering & Construction Management); Risks; Key Success Factors 
Process Challenges – Installation of a new, unique project area; sizing and designing equipment for multiple operating scenarios and unique site conditions. 
Operational Challenges – Tie-in of project areas while plant was in operation; preparing contractors to act during unscheduled shutdowns; operations comments/feedback since the project has been commissioned.