ZAP Engineering & Construction Services, Inc. designed a greenfield fly ash terminal on an existing rail line. A new spur added for a new rail unloading pit. Fly ash unloaded at the rail pit was pneumatically conveyed from 2 convey pods to 1 of 3 storage structures. A single truck unloading station was added to pneumatically convey silos.
Fly Ash Separation Facility EPCM ZAP performed detail engineering, procurement and construction management for a fly ash processing facility utilizing electrostatic separation technology. This brownfield facility included integration of the existing power plant, fly ash separation technology, and balance of plant materials handling equipment. Process Detail: The existing fly ash silos were altered for the […]
Plant Expansion ZAP was selected for detailed engineering of a new grinding circuit that has significantly increased production capacity at an existing mineral processing plant. The project included supporting the customer through purchase of pre-owned as well as new equipment and providing the arrangement, equipment sizing, structure, building design, power, instrumentation, drainage and much more. […]
Preheater Evaluation A cement plant was seeking to upgrade the size of the cyclones in their Preheater Tower which was going to modify both the framing geometry and maximum expected gravity and seismic loads on the tower. A structural & construction evaluation was required to provide a total installed cost and schedule estimates for their […]
TDF Electrical and Instrumentation A cement plant improving the efficiency of their alternate fuel sources requested that ZAP provide electrical and instrumentation design to support the integration of equipment packages into a single material handling system. The new system would allow for the delivery of whole tires that would be shredded prior to being used […]
Monorail Update ZAP provided structural engineering and design to support the client in their effort to provide a turn-key solution for a monorails installed in a hazardous reagent building located on a gold concentrate facility in Colorado. ZAP completed a site visit to visualize each of the spaces and confirm the end-user’s intent and as-built […]
ZAP completed the engineering and design to modify an existing truck loadout system fed from a storage dome and from the F&I silo to meet Food Safety Modernization Act (FSMA) regulations.
ZAP was contracted to make a structural analysis of an existing four stage concrete preheater tower at a cement plant. Engineering services included developing a design basis and determining what load cases would be applied to the tower.
Plant maintenance requested improved access to a large duct’s slide gate above the roof level. A complex geometry was required to provide a platform that was supported by exterior building framing to avoid placing any load on existing roof trusses and yet account for operation of an adjacent roof hatch and maintain access to the slide gate components.
A cement plant customer is planning to add equipment that will require new electrical cables for power, which will be supported by existing towers.
During a plant outage, a cement customer found that their kiln lifting beam (or saddle) was buckling due to the compression forces between the kiln and the hydraulic cylinders used to lift the kiln off its trunnion rollers.
ZAP was contracted to modify an existing dome withdrawal system and convert the reclaim system from a mechanical auger to an aerated floor.
ZAP provided preliminary engineering and design for a cement and granulated blast furnace slag import and distribution terminal.
ZAP provided engineering and detailed design for a pneumatic conveying system upgrade and conveying line reroute.