Waste Acid Catalyst Recovery Project (WACRP)

MECIP successfully delivered Detailed Engineering Design (DED) services for the Waste Acid Catalyst Recovery Project (WACRP), a process enhancement initiative aimed at recovering valuable catalyst materials from waste acid streams generated within the chemical manufacturing process.

The project involved the design and integration of a new catalyst recovery system utilizing advanced ion-exchange resin technology to selectively recover catalyst compounds from spent process acids. The solution was developed to improve resource utilization, reduce waste generation, lower operating costs, and support the client’s sustainability and environmental objectives.

As part of the project, MECIP provided a complete multidisciplinary engineering package covering process engineering, mechanical equipment design, piping systems, electrical and instrumentation systems, civil and structural engineering, and process safety engineering. Comprehensive process evaluations, equipment sizing, operability assessments, and safety reviews were conducted to ensure efficient and reliable plant operation.

Given the constrained brownfield environment, the project also included constructability reviews, material handling studies, and human factors engineering (HFE) assessments to optimize equipment accessibility, maintenance activities, resin replacement operations, and operator safety. Special attention was given to equipment layout and lifting requirements to facilitate future maintenance within the congested plant area.

The successful implementation of the WACRP enables the recovery of valuable catalyst materials, reduces environmental impact, and supports the client’s commitment to operational excellence, sustainability, and circular economy principles.