Phosphate Blending Plant

Varo was retained by Budenheim USA, Inc. to design three new graphite and phosphate blending units, each producing a different product. The blending units were designed to fit within an existing warehouse/distribution building, along with the North American headquarters’ offices for the company.

The facility receives graphite in 50 lb. bags and phosphate in bulk bags. The graphite is combined with liquid ingredients in an atmospheric tank and blended to produce industrial lubricants. A dedicated and completely separated space was provided for the graphite product production to prevent contamination in the other parts of the plant.

Two phosphate products are produced at the facility. The liquid phosphate product is produced by combining dry phosphate with liquid ingredients in a jacketed, atmospheric reactor. The jacket was provided to allow water cooling of the reactor for future products. The dry phosphate product is produced by dry blending the phosphate with other dry ingredients in a ribbon blender, followed by gyratory screening to control the product particle size.

The blending systems include dustless bag dump stations, bulk bag and liquid tote filling stations, weighing, dust collection, and compressed air. The equipment is batch fed and manually controlled by a resident operator. Equipment support and access platforms were designed to meet the IBC Building Code and OSHA regulations.

The blending processes were developed by Budenheim’s chemists and engineers in Germany. Using conceptual design documents, Varo worked with Budenheim to finalize the flow sheets and P&ID’s for the project, and prepare general arrangement drawings for implementing the processes in the available building space. After the general arrangements were approved, Varo’s in-house design team completed the detailed structural, mechanical and electrical engineering for the project.

Varo identified potential North American equipment suppliers for the process equipment, and assisted Budenheim throughout the procurement process with services including bid package preparation, bidding, bid evaluation, contract negotiations, submittal reviews, delivery expediting and final equipment acceptance.

Similarly, Varo assisted Budenheim with the bidding and award of the construction contracts, and provided on-site support during the construction, start-up and commissioning of the plant. The plant was completed within the project budget and schedule, and is successfully producing products for Budenheim’s North American markets.

For more information regarding this project, please feel free to contact us at (614) 459-0424.