Project Description

FACILITY DESIGN

TURNKEY SOLUTIONS

Our experienced team can provide integrated design services that will take our clients from idea conception to project completion.

Shellbyville Biorefinery Greenfield

From the Ground Up. Just two years ago, PD&C was hired to turn an empty field outside Shelbyville, IN into one of the world’s most technologically advanced bioprocessing facilities. From initial concept and permitting all the way through commissioning and start-up, PD&C provided all engineering, design, and construction management services for the $150 million plant.

Our team of engineers incorporated state-of-the-art environmental controls and production processes, including an integrated steam turbine for efficient electricity generation. Our procurement group maximized cost savings by utilizing PD&C’s extensive network of partners to source all equipment and materials for the project, right down to the last nut and bolt. Working hand-in-hand with our experienced CM team, who oversaw the entire project, PD&C was able to complete the project on schedule and under budget.

Marion Facility Expansion

PD&C recently completed a $120 million dollar expansion of an existing biorefinery in Marion, OH, increasing the facility’s capacity by 80 million gallons per year. The new expansion features cutting-edge process technology, including an integrated steam turbine, water recovery system, and advanced fermentation process. Upon successful startup, PD&C’s fully implemented design immediately created additional production capacity and maximum operational flexibility for the facility.

The unique engineering challenges of fitting an expansion of this size onto an existing site were met head on by PD&C’s experienced team. Engineering and project management staff worked hand in hand with the biorefinery to integrate thousands of utility, process, and electrical tie-ins to the existing facility. Extensive modeling and close coordination with contractors were essential, as was extensive testing of the automation systems in PD&C’s onsite automation lab. The result was a safe and seamless integration with minimal downtime.

PD&C provided all engineering, construction, and procurement services, as well as commissioning and start-up support for this turn-key expansion project. By offering a complete package in house, PD&C had the ability to stay nimble and adjust quickly to opportunities as they arose. With the advantage of comprehensive coordination, PD&C maximized efficiency in a condensed timeline, adding value for the customer.