Merrick provided engineering and design services to support a 50% increase in oxidizer production for a confidential manufacturing client. The project focused on integrating new processes and facilities into an active production campus while maintaining established explosivity zones and minimizing interruptions to ongoing operations.

Working across all disciplines, Merrick developed a comprehensive master plan for this fast-track effort. The approach included multiple design packages to accelerate permitting and construction, with separate packages for the main process, central chiller plant, waste stream reclaim and railcar loadout, and raw material railcar unloading and storage.

The client’s proprietary crystal production process required tight process control and supporting utilities, including a central chiller plant and process waste reclaim systems. Project scope encompassed process and bulk storage tanks, reactors, dryers, scrubbers, evaporators, ammonia chillers, and supporting utilities such as process cooling water, steam, and compressed air.