The proposed project involves the establishment of a state-of-the-art chemical manufacturing plant in Texas, USA. The facility will specialize in the production of industrial chemicals, petrochemical derivatives, and specialty chemicals to support downstream industries such as oil & gas, fertilizers, plastics, coatings, and energy.
Texas, being the hub for petrochemical and refinery industries, provides an ideal location due to its proximity to raw materials, established infrastructure, skilled workforce, and access to export markets via the Gulf Coast.
What began as a feasibility study to address sulfur recovery limitations and ensure compliance with stringent U.S. environmental regulations quickly evolved into a full-scale engineering initiative. A-One Engineering Consultant LLC was engaged to lead the project, guiding it from conceptual development through execution—including preparation of both the Basic Engineering Package (BEP) and the Detailed Engineering Package (DEP).
During the assessment, it became evident that the increasing CO₂ load in the feed gas was diluting the acid gas stream, resulting in unstable SRU (Sulfur Recovery Unit) combustion temperatures and reduced sulfur recovery efficiency. These operational challenges threatened the plant’s ability to remain within its permitted emission limits under Texas Commission on Environmental Quality (TCEQ) and EPA regulations, particularly during periods of variable load operation.
Recognizing the critical importance of environmental compliance and operational reliability, the project team identified the need for a robust, technically sound solution that would ensure long-term stability, optimize sulfur recovery, and safeguard the plant’s compliance within the Texas regulatory framework.
In partnership with its technology provider, Client Energy implemented a membrane-based gas separation strategy to enhance performance and reduce emissions at its Texas chemical plant.
Key Measures:
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Upstream: Installed a Membrane-based Acid Gas Enrichment (MAGE) system to lower CO₂ and improve feed quality.
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Downstream: Added Membrane Tail Gas Treatment (MTGT) and Advanced Tail Gas Treatment (ATGT) to capture residual sulfur and minimize emissions.
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Controls: Recalibrated the existing control system to integrate new technologies for seamless, automated operation.
A-One Engineering Consultant LLC led the engineering design, installation planning, and control system tuning, ensuring smooth integration with existing infrastructure.
Results: The project improved reliability, boosted sulfur capture efficiency, and secured compliance with Texas environmental standards—highlighting A-One Engineering Consultant LLC’s expertise in delivering innovative, sustainable solutions for the chemical sector.