PROJECTEnquire ↗Process plant upgrades
Replacement of an acidification reactor in Lovosice included engineering preparation, removal of the original vessel, modifications to its supports and installation of a new 3.9 m³ reactor. Assembly of the agitator and modification of 15 pipe runs followed on an installation platform at +6 m. The scope combined steelwork, plastic and metal piping, testing and as-built documentation.
Delivery scope & origin
Equipment replacement, installation and connectionEMKO project portfolio. Supplier at the time of delivery: EMKO HOLDING s.r.o.
The project in context
The change in reactor size required a new support arrangement, spatial interface modifications and coordinated work within an existing chemical process area.
The replacement combined dismantling, lifting the new vessel to +6 m, agitator assembly, piping modifications and subsequent tests.
The new reactor had to be brought to the upper floor through the existing equipment platform. During preparation, part of the structure around the transport opening was temporarily dismantled, and the vessel was lifted using the installed hoist. Removal of the old equipment was followed by alignment and installation of the new reactor on modified supports.
A steel load-spreading plate was added. Bolts and M16 beam clamps connected it to the existing structure, and the access gratings were adapted to the new support arrangement. The work therefore covered structural analysis, plate fabrication, surface protection and installation coordination.
Changes in vessel size and nozzle orientation required modifications to 15 pipe runs in four material classes. The affected systems included PVDF, polypropylene, grade 1.4404 stainless steel and carbon steel. Work combined length adjustments, flanged connections, new gaskets and minor support modifications.
The inlet mixer was shortened by approximately 120 mm, and its bracket was also modified. The existing air-operated diaphragm pump was relocated and reconnected. Electrical work and instrumentation and control were provided by the operator in coordination with the mechanical work.
The installation log confirms an on-site leak test and water pressure test on 26 April 2024. The as-built documentation also describes operating tests of the connected piping. The acceptance procedure concluded on 23 May 2024, and the customer subsequently confirmed the work in a reference letter.
The handover documentation included vessel and agitator manufacturer information, structural analysis of the support arrangement, material records, installation records and as-built documentation. Before installation, the vessel itself underwent a manufacturer-stage water test at 1.3 bar gauge pressure for 60 minutes.
An installed reactor with completed structural and piping interfaces; the acceptance procedure concluded in May 2024.
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