Plant Dismantlement & Relocation Solutions Case Studies

Nitric Acid Plant & Ammonium Nitrate Neutralizer Dismantlement Dyno Nobel | Donora, Pennsylvania Project Overview In June 2025, Phoenix Equipment successfully completed the acquisition and dismantlement of a nitric acid plant and ammonium nitrate neutralizer at Dyno Nobel's facility in Donora, Pennsylvania. The project demonstrated Phoenix Equipment's ability to manage complex industrial decommissioning projects while maximizing asset recovery, maintaining the highest safety standards, and advancing sustainable recycling practices. The Challenge The Donora facility included a fully operational nitric acid plant comprised of highly integrated process equipment and infrastructure, including an absorber tower, compressor house, heat train, storage tanks, extensive pipe racks, and supporting utilities. Because portions of the facility remained active, the project required meticulous planning and execution to safely dismantle major process units while preserving critical pipe racks and infrastructure needed to support ongoing site operations. The Solution Phoenix Equipment executed the project through a carefully coordinated, three-phase approach. Planning & Pre-Dismantlement Before dismantlement began, Phoenix's team conducted a comprehensive assessment of the facility, documenting equipment layouts, structural conditions, and process systems to develop a detailed dismantlement strategy. Critical infrastructure that needed to remain in service was identified early, allowing crews to perform selective removal of obsolete piping while preserving essential pipe rack structures. Safe & Controlled Dismantlement Specialized crews systematically deconstructed the plant using proven industrial dismantlement techniques. Major process equipment—including towers, reactors, structural steel, piping systems, and associated infrastructure—was removed using heavy equipment and specialized lifting methods. Throughout the project, strict safety protocols and disciplined project management ensured controlled execution within an active industrial environment while minimizing disruption to the client's ongoing operations. Asset Recovery & Sustainable Recycling A key objective of the project was maximizing the value of recoverable assets. Phoenix Equipment partnered with PGM Technologies, led by David Kelley, to identify, extract, and recover precious metals from targeted process equipment. Reusable assets were evaluated for resale, while remaining metals were responsibly recycled. Construction debris was segregated, contained in site-provided containers, and removed throughout the project, maintaining a clean, organized, and environmentally responsible worksite. Results Upon project completion, Phoenix Equipment successfully: Safely dismantled the entire nitric acid plant and ammonium nitrate neutralizer. Removed major process equipment, structural steel, and associated debris. Preserved designated infrastructure required for continued site operations. Left concrete foundations and limited infrastructure ready for future redevelopment. Maximized project value through strategic precious metal recovery and equipment asset management. Responsibly recycled scrap materials and minimized landfill waste through sustainable material handling practices. Key Takeaways Strategic Asset Recovery Phoenix Equipment unlocked additional project value through equipment remarketing, precious metal recovery, and responsible recycling. Precision Execution Careful planning and selective dismantlement allowed critical infrastructure to remain operational while major process units were safely removed. Safety First The project was completed with zero safety incidents while operating within an active industrial facility. Environmental Responsibility Comprehensive recycling and waste management practices minimized environmental impact and prepared the site for its next phase of development. Conclusion The Donora project highlights Phoenix Equipment's comprehensive approach to industrial decommissioning—combining engineering expertise, disciplined project execution, asset recovery, and environmental stewardship to deliver exceptional value for industrial clients. By transforming a legacy production facility into a clean, redevelopment-ready site while maximizing the value of recoverable assets, Phoenix Equipment once again demonstrated why it is a trusted partner for complex industrial dismantlement and plant closure projects.

Background and Scope of Work Vertellus, a producer of Castor Oil, ceased operations at its Bayonne, NJ plant, and wanted to have all outside storage tanks and process areas removed for permitting reasons. They also wanted to begin preparing the site for resale and redevelopment.  Our project consisted of the dismantlement and demolition of (2) buildings which were used to manufacturer Castor Oil, a sebacic acid plant (mostly outside structure), (4) 250,000 gallon+ storage tanks near live power lines, (2) large outside tank farms with over 90 tanks, thousands of linear of piping, and (3) 150’ tall boiler stacks. The owner attempted to drain and clean the plant, however, substantial materials remained in the equipment, tanks and piping. Furthermore, as a result of ceasing operations, the owner didn’t have the personnel resources required to complete the draining and cleaning.  Phoenix was tasked with draining lines and capturing the resulting materials for disposal, cleaning tanks and equipment, asbestos abatement, and dismantlement. Phoenix safely completed the required work in 4 months with a 10 man crew. We utilized (2) excavators with grapple/shear, bobcats, lulls, and cranes.   Tank and Equipment Cleaning The 90+ outside tanks, and (4) 250,000 gallon + tanks, contained substantial product, residual materials and/or heels. Phoenix opened all vessels to test and identify quantities and materials. We then removed all liquid materials via a vacuum truck and cleaned where necessary. For tanks that had heels that could not be removed by a vacuum truck, we cleaned the top portion, and then cut the tanks down to the top of the heels. We then disposed of the remaining tanks with the heels in place, or removed the heels and scrapped the remaining tanks.   Demolition Permits and Tank Permits and Storm Water Control Plan Phoenix obtained approximately 90 permits for the outside tank removal and 2 permits for the demolition of the buildings. The site owner performed the sewer and water disconnects, as well as electrical disconnects prior to our work. The plant is located on the water, and so it was critical to follow the storm water control plan the site had in place.  

A U.S.-based chemical manufacturer owned a complete KOCH-designed solvent recovery and distillation system that was never commissioned. Originally built for Dimethylformamide (DMF) recovery, the plant remained idle for more than ten years. Phoenix Equipment acquired the asset and identified an African fuel-processing company that could adapt the system for a waste-product distillation project. Phoenix then managed the sale, removal, transportation, and export, successfully relocating the complete system from the United States to Africa.   The Challenge The seller owned a complete distillation system designed for DMF purification and recovery. Although never used, the system remained in excellent condition and featured high-quality process equipment, including a 36-inch diameter distillation column and Hastelloy C276 heat exchangers. The challenge was finding a buyer that could recognize the value of the equipment and adapt it for a different application while managing the complexities of removing and relocating the system.   The Opportunity Phoenix recognized that the system's design and metallurgy made it suitable for a wide range of solvent recovery and distillation applications beyond DMF service. Through its global network, Phoenix identified an African company in the fuel sector developing a waste-product recovery project. After reviewing the equipment and conducting an on-site inspection, the buyer determined the system could be adapted to meet its processing requirements at a significantly lower cost than purchasing new equipment.   Phoenix Equipment's Solution Phoenix handled every phase of the transaction, including acquiring the system from the U.S. chemical company, marketing it globally, coordinating inspections, and negotiating the sale. By acting as both buyer and seller, Phoenix simplified the process for all parties and ensured the equipment was successfully matched with a qualified end user.   Heavy Lift and Removal Execution Removing the complete skid-mounted system without damage was critical to the project's success. Phoenix developed a detailed lifting plan utilizing a 250-ton main crane and a tailing crane. The system was carefully disconnected, lowered, loaded onto trucks, and prepared for shipment while preserving the integrity of the equipment, piping, and skid structure.   Transportation and Export Logistics After removal, Phoenix coordinated transportation from the seller's facility to the export port and managed all logistics required for international shipment. Services included heavy-haul trucking, export preparation, port coordination, and ocean freight. Phoenix served as the single point of contact throughout the project, ensuring a smooth transition from seller to buyer.   Results   For the Seller Recovered value from an idled asset for more than ten years Eliminated storage obligations Freed facility space   For the Buyer Acquired quality equipment at a fraction of replacement cost Avoided long fabrication lead times Accelerated project development   For the Project Successful relocation from the U.S. to Africa Safe removal with no equipment damage Productive reuse of a long-idle industrial asset   Conclusion This project highlights Phoenix Equipment's ability to create value by connecting underutilized assets with qualified buyers worldwide. Through equipment acquisition, global marketing, heavy-lift execution, and international logistics, Phoenix transformed a dormant distillation system into a productive asset supporting a new fuel-industry project in Africa. If you need help with a chemical plant or equipment sale, purchase or relocation project, we would be happy to discuss your next project and see how Phoenix can best assist you.Speak to one of our team members todayto learn more about our variety of different services and solutions.

An entire cogeneration plant was acquired, dismantled, and repurposed—without any cost to the original owner.   The Challenge: Simplify Closure, Unlock Value When Pawtucket Power Associates made the decision to retire their cogeneration plant in Rhode Island, they were confronted with a costly and complicated process. The facility—anchored by a GE Frame 6B gas turbine—needed to be decommissioned, removed, and the site restored, all while minimizing financial exposure. That’s where Phoenix Equipment came in. By acquiring the full facility at no cost, we took ownership of the entire process: equipment resale, removal, logistics, and cleanup —delivering a win-win outcome for all stakeholders.   What Phoenix Delivered Our turnkey solution included: Complete acquisition of the facility and its components No-cost decommissioning for the site owner Resale of the GE Frame 6B turbine to a Rochester, NY energy producer Comprehensive dismantling and secure transportation Final delivery of a clean site   “From equipment sale to site removal, Phoenix executed everything with precision.” — Site Engineer, Pawtucket Power Associates   Behind the Scenes: Step-by-Step Execution Initial Phase: Structural Disassembly Begins Phoenix crews commenced the project with carefully managed dismantling operations to provide safe turbine access. Mid-Project: Equipment Secured for Transport All major components, including the GE turbine, were prepped for safe and efficient shipment. Final Phase: Site Restoration Complete We delivered a fully broom-clean site—without the original owner incurring a single dollar in removal costs.   Measurable Outcomes For Pawtucket Power Associates: Eliminated liabilities tied to plant decommissioning Avoided high-cost demolition and disposal fees Received a fully restored site ready for new development   For the Rochester-based Buyer: Acquired a proven GE Frame 6B turbine at a significant discount Cut lead time compared to ordering new equipment Accelerated their go-live schedule and enhanced reliability   “Phoenix made it possible to skip the wait and start producing—fast and affordably.” — Plant Manager, Rochester NY Buyer   Project Overview Facility Type: Cogeneration Plant Location: Pawtucket, Rhode Island Turbine Destination: Rochester, New York Flagship Asset: GE Frame 6B Gas Turbine Scope of Work: Acquisition, Asset Sale, Dismantling, Removal, Remediation Phoenix Solution: Cost-free decommissioning and turnkey reuse model   Featured Asset: GE Frame 5PA Turbine – Now Available Just Released for Purchase: 26 MW GE Frame 5PA Gas Turbine Generator (Never Installed) Factory-stored and in pristine condition Excellent fit for standby, baseload, or peaking power generation Available for immediate viewing and transport   Request technical specifications and availability.   Why Work with Phoenix Equipment? We specialize in: Full plant and turbine acquisition and resale Decommissioning support and complex liquidations Zero-cost removal models with maximum asset recovery

A surplus oxygen plant in India finds new purpose at a major platinum mine in Zimbabwe—thanks to Phoenix Equipment’s global project execution.   From Surplus to Strategic: Unlocking International Value A once-idled oxygen plant in India is now boosting combustion efficiency at a leading platinum mining operation in Zimbabwe—demonstrating how industrial assets can transcend borders and timelines with the right partner.   Background: A Global Industrial Turnaround When copper smelting operations ceased, Bhagawati Oxygen, a well-established industrial gas company in India, was left with a fully operational but inactive 55 TPD VPSA oxygen plant. Built by renowned Japanese firm Sumitomo Seika, the system had just two years of runtime and remained in excellent condition—with OEM documentation and spare parts ready. Phoenix Equipment stepped in to connect the unused facility with a buyer who needed immediate, high-capacity oxygen generation—across the globe.   The Challenge: Repositioning an Underutilized Asset Bhagawati Oxygen sought to free up capital and make use of a valuable plant no longer contributing to revenue. Meanwhile, a top-tier platinum producer in Zimbabwe was under pressure to enhance furnace performance using oxygen enrichment. The mining company needed a production-ready solution—fast. Building new equipment from scratch would take over a year and require a substantial capital outlay. Phoenix Equipment created a bridge between these two needs, delivering a solution that served both sides.   The Execution: End-to-End Relocation and Commissioning Phoenix managed every stage of the project with precision and speed: Asset Evaluation: Reviewed the 55 TPD unit’s design, condition, and adaptability for the buyer’s operations Client Matchmaking: Introduced the asset to a platinum miner in Zimbabwe, enabling a swift site assessment Transaction Finalization: The buyer approved and committed to the acquisition within two months Relocation Logistics: Phoenix oversaw the dismantling in India, inland transportation, and ocean freight—ensuring secure delivery   The Result: High Impact on Both Ends For Bhagawati Oxygen: Full value recaptured from an inactive facility Quick, clean divestment with no prolonged asset holding Immediate liquidity to reallocate toward operational needs   For the Zimbabwean Platinum Miner: Gained a fully functional oxygen plant, ready for deployment Cut more than a year from project timelines Avoided the financial burden of a new installation   Key Project Details Project Value: $2,000,000 Timeline: November 2022 – October 2023 Services: Plant Sourcing, Acquisition, Relocation Plant Type: 55 TPD VPSA Oxygen Unit (93% Purity) Origin: India (Bhagawati Oxygen)   New Availability: High-Capacity Nitrogen Plant on Offer Continuing our mission to deliver ready-to-deploy industrial solutions, Phoenix now offers a premium: Cryogenic Nitrogen Generation Plant – 6,600 Nm³/h Ideal for petrochemical, electronics, and metallurgical operations Energy-efficient cryogenic separation technology Available for global relocation and immediate inspection   Interested in streamlining your expansion plans? Contact us for specs and pricing.   Why Choose Phoenix Equipment? Phoenix Equipment is a global leader in the acquisition, sale, and relocation of process plants and equipment. Our services help industrial operators: Unlock capital from underused facilities Procure high-quality systems at a fraction of new-build costs Expedite project timelines without compromising performance   With decades of success across chemicals, refining, industrial gases, and more, Phoenix transforms surplus assets into turnkey opportunities. From idle capacity to global productivity—that’s the Phoenix approach.

Phoenix acquired an unused 17,000 lbs/hour (7,748 kg/h) freeze concentration plant located at the Starbucks facility in Augusta, Georgia. The system consisted of four identical processing lines, installed in 2013, but never commissioned due to a project cancellation. Starbucks required the equipment to be removed to make space for a new project. Phoenix executed a purchase agreement, completed payment, and committed to removing the plant within a defined timeline. Multiple prospective buyers were developed, and Phoenix successfully sold two lines to a citrus extract manufacturer in Latin America. The removal, match-marking, crating, and preparation for overseas shipment were completed by Phoenix. The remaining unsold units were transferred to Phoenix’s storage yard for future resale opportunities. Summary Timeframe: August 2023 – August 2024 Service: Plant Acquisition & Relocation Value:$1,500,000  Result The freeze concentration plant was removed by Phoenix on Starbucks’ timeline. Two lines went to a citrus processor in Latin America, and the remaining units were sold to multiple buyers for varied projects—enabling fast deployment and significant savings over new equipment for the buyers.

Project Background and Scope Phoenix purchased a 1.5 MMGPY ethanol recovery unit located at the Coors Brewery’s production facility in Golden, Colorado. The plant and equipment owner was required to remove it from the brewery as it was no longer required for the site process. Phoenix dismantled the unit and transported it to a storage site in Texas. The unit is designed to recover ethanol from waste liquids containing alcohol such as spilled or out-of-date beer, as well as residual streams from ethanol plants. Phoenix developed a buyer who was expanding their whisky distillery capacity. The buyer jumped at this opportunity, quickly securing the unit through a deposit and deploying a team for due diligence and inspection. Immediately after the inspection, the buyer issued a purchase order. Phoenix managed the shipment, inland and ocean freight, of the unit and all equipment to the port in Ireland. Highlights Of The Project Timeframe: April 2022 - August 2022 Service: Plant Acquisition and Relocation Value: $500,000.00 Project Outcome The unit was built in 2018 and had been operated till 2019. Phoenix removed the unit according to the Coors Brewery timeline. Phoenix’s buyer successfully received the unit in just a few months and significantly reduced their capital investment compared to purchasing new fabrication unit.

Project Background and Scope Phoenix developed a client that had an urgent need for a secondhand hydrogen plant. The client was a start-up clean fuels company that was focused on converting waste into renewable hydrogen. Facing a tight schedule to start production, the client requested Phoenix’s help to find an immediately available hydrogen plant. Phoenix didn’t have an immediate fit, so we aggressively scoured the market by approaching current hydrogen producers such as refineries, hydrogenators, and chemical plants. After extensive work, Phoenix presented three options to our client. Eventually, our client selected a used 2 MMSCFD (2,350 Nm3/hr) hydrogen plant that was to be replaced at the Calumet site in Montana. Calumet had a tight removal schedule as the footprint of the hydrogen plant was required for a renewable diesel project. Utilizing plant approved contractors, Phoenix arranged the dismantlement and relocation, performing and safely completing all work throughout the winter months in Montana.    Project Highlights Timeframe: November 2021 – March 2022 Service:Plant Acquisition & Relocation Value:$2,000,000 Project Outcome Through Phoenix’s arrangement, the buyer inspected, purchased, dismantled and relocated the hydrogen plant within 5 months. The previous plant owner obtained much needed space for a new construction project scheduled for FY 2022.  

Phoenix was engaged to dismantle the processing plant portion of the site so that it could be repurposed as a warehouse. Removal included outdoor and indoor equipment. Nalco was able to remove the chemical processing equipment and transform the site to a warehousing operation quickly and safely.

Plant Type: 14,000 BPD Topping Unit (Crude Unit)   Original Location: Vicksburg, MS                                               Destination: Africa   Phoenix Equipment purchased a 14,000 BPD Crude Distillation Unit (Topping Unit) in Mississippi. This complete unit produces jet (aviation) fuel, diesel, naphtha, kerosene, butane mix and light Gasoline. The unit was originally built in 1978 to process 5,000 BPD of south Louisiana light sweet crude oil. Between 1991 and 1994, the unit underwent expansions to increase capacity. In 1995, the unit switched feedstock to heavy aromatic distillate to produce both gasoline blends and marine diesel oil blends.        This unit is ideal for a region which has limited crude oil supply, but a small demand of fuel, diesel, naphtha and kerosene. Phoenix Equipment received serious inquiries from customers worldwide, especially from Africa, South East Asia, and CIS regions. There were very limited technical documents left after the shutdown due to several changes in ownership.  Nonetheless, our customers were confident the unit could be relocated and re-operated because it is a very common crude distillation process. We re-sold this unit to a customer in Africa. We coordinated with the customer to hire a dismantling contractor who met the customer’s tight budget. The dismantlement was completed in less than 4 months. All purchased equipment and structures were shipped to Africa for refurbishment and reinstallation.

Phoenix Equipment, in conjunction with a dismantlement partner, acquired for resale a 4.25 MW cogeneration plant from Montclair State University that was being replaced by a larger unit.  We sold the entire plant, including 4 MW Centaur 50 Solar gas turbine, HRSG, steam boiler, deaerator boiler feed water pumps, water filtration system, fire system, controls and all other components loaded to truck to one buyer for re-use at another location. The buyer acquired the plant and machinery for re-use in a new cogeneration plant at an ethanol plant. The new site is using the plant to generate 4.25 MW of electricty and 24,000 pounds per hour of 150 psi steam for their process.   Take-Aways The University was paid for an obsolete asset and avoided the liability of having to pay someone to remove the cogeneration plant - which was inside a building and locating in an area with very limited mobility. The University received a gutted, broom clean building, and today uses it for a student art gallery The buyer and ethanol plant obtained a good used cogeneration plant with all associated parts for a fraction of the cost of buying a new equipment.

Plant Type: 1,500 Nm3/Hr Hydrogen (Syngas) Plant   Original Location: Ontario, Canada                                 Destination: Asia   Artificial trans fats have become considered harmful for your health. Many European countries have banned artificial trans fats in food manufacturing. America and Canada will phase out the production of artificial trans fats in 2018. Foods containing artificial trans fats, such as cooking oils; are fully or partially hydrogenated. Facing the phase-out, many food/oil manufacturers will have to stop their hydrogen production plants. ADM operates an oilseeds processing facility in Canada where its 55,000 SCFH hydrogen plant has been shut down and will not be re-started.  The plant has a Glitsch designed steam-methane-reforming (SMR) process and includes a pressure swing adsorption (PSA) purification system. Hydrogen product reaches 99.99% purity. Most equipment is skid-mounted for easy dismantlement and shipment and has been kept inside of the process building. After shutdown, the plant was properly mothballed and kept under a nitrogen blanket to prevent corrosion.  Phoenix purchased this hydrogen plant and re-sold it to a customer from Asia. The customer will use the plant to produce additional hydrogen for its hydrogen peroxide production. As part of the sale, Phoenix was responsible to manage the dismantlement, match-marking, crating, packing and shipment of the plant to Asia.  Work was completed in approximately 2 months.

Omnova Solutions closed its Calhoun, GA plant that produced styrene butadiene latex materials for the carpet and paper markets and intended to convert the site to a terminal operation. The processes, buildings and equipment that were shutdown and needed to be removed where scattered throughout the site and in close proximity to buildings and equipment that would remain as part of the continuing terminal operation. Certain equipment, such as boilers, compressors and spiral heat exchangers were inside buildings that would be converted to storage space and remain.  The main pipe racks would remain in sections, however, dead lines had to be carefully removed from the pipe racks. Asset Recovery / Sales Plan Phoenix Equipment was awarded the contract to dismantle the plant based on our ability to reduce the cost to Omnova by offering significantly more that scrap value for the redundant machinery and equipment.  Phoenix safely dismantled and rigged out at its own expense over 35 pieces of process equipment for resale, including: (3) 10,000 Gal SS Clad Reactors, rated 400 psi internal and 80 psi on the jacket, weighing over 50,000 lbs • (2) 7,000 Gal SS Reactors, rated 150 psi internal and 150 psi on the jacket, weighing over 35,000 lbs •  Butadiene Distillation System, Built 2008  • (2) 800 HP Cleaver Brooks Boilers, 200 #, Built 2007 • (2) 50,000 Gal Horizontal Pressure Tanks • (10) SS tanks ranging from 3.000 gallon to 20,000 gallon • Vertical and Horizontal Stainless Steel and Carbon Steel Shell & Tube Heat Exchangers. Asset Recovery Summary 35+ Pieces of Process Equipment 250,000 lbs+ of Non-ferrous material 1500 Ton+ of Carbon Steel Dismantlement Work Our 8 person crew spent five months at the Georgia plant to safely perform the project without any injury or incident.  Phoenix utilized a Komatsu PC400 Excavator equipped with a shear, a Komatsu PC300 Excavator equipped with a grapple, various cranes ranging from 50 Tons to 250 Tons, various man-lifts, skid steer dozers and forklifts.  Our crew worked with the plant’s employees to time our operations in the plant’s active areas. Dismantlement Summary Equipment Rigging Plant Dismantlement and Demolition Scrap Recycling

A major producer of Cashew Nut Shell Oil (CNSL) ceased manufacturing of CNSL at its Newark, NJ plant.  The property contained approximately (20) buildings which were used for CNSL production and office/warehouse. There were (9) buildings with approximately 50,000 square feet used for CNSL production and (11) buildings with approximately 100,000 square feet used for office/warehouse space. The other features at the site were (3) major tank farms holding over (30) tanks, (3) smaller diked areas each containing 1 to 3 tanks and pipe bridges containing thousands of linear feet of piping. The new owner, a major supplier of construction materials, wanted to convert the existing site into a warehouse and distribution center for its products. Phoenix Equipment Corporation was selected for the owner’s site conversion process because:   Phoenix’s ability to purchase and resell process equipment and tanks significantly lowered the cost of the site’s reconfiguration. Phoenix’s ability to manage a complex project involving subcontractors for the following activities: utility disconnects - electrical, water and sewer disconnects to buildings being demolished (there were separations so that remaining buildings could still have service); asbestos abatement; removing and containerizing non-hazardous CSNL from much of the process equipment and piping as well as hazardous materials (Sulphuric Acid, Caustic, EDA, TETA, etc.); total building demolition and gut-out of remaining structures. Phoenix’s ability to deal with the local and state agencies that governed and reviewed the project.   Our work included: Demolish (6) of the process buildings to grade and remove all process equipment from the remaining (3) buildings. Remove all site tanks and dike areas to grade. Remove and dispose of CSNL heels in (6) large bulk storage tanks and clean all process piping, equipment and tanks to make them suitable of resale or recycling.   The equipment saved for resale on the project included: (25) 1,000 gallon to 15,000 gallon Stainless Tanks   (1) “V” Blender (10) Heat exchangers   (1)  Ribbon blender   (2) Rotex screeners   (2) Hosokawa mills   (1) Witte fluid bed dryer   We recycled the following quantities of materials: 1,350 tons of steel 150,000 pounds of stainless steel 10,000 tons - masonry (crushed and left on site)

A major North American petro-chemical company, Nova Chemicals, ceased manufacturing of a certain polystyrene product at its Pennsylvania site due to changing markets.  The polystyrene plant was part of a larger site that had on-going operations.  The site owner wanted to have the entire footprint of the plant removed, as well as other parts of the plant that were no longer utilized.  As part of the complex removal project, our client also wanted to ensure it was receiving the most value for its surplus assets - the plant, equipment, and scrap resulting from the piping and structures.     Our Solution Phoenix Equipment leveraged our ability to purchase and resell chemical process equipment to drastically reduce the cost of the associated demolition, environmental and asbestos abatement work.  Phoenix safely dismantled and rigged out at its own expense over 50 pieces of process equipment for resale, including: (5) 6,000 Gallon Stainless Steel Reactors; (1) 15,000 Gallon Stainless Steel Reactor; (2) Gala Pellet Dryers; (5) Nash Vacuum Pump Skidded Systems; (1) 135 Cu. Ft. Stainless Steel Ribbon Blender and Dozens of Shell & Tube Heat Exchangers and Stainless Pressure Vessels & Tanks. Our experienced team of petrochemical dismantlement and demolition experts safely completed the entire project in just over eight (8) months.  Performing such work within an active plant required an acute attention to detail and highlights our safety record and ability to perform highly complex projects. Prior to dismantling the plant and several other areas within the larger remaining operational site, our company had to perform the asbestos abatement in various areas (work was subcontracted to a licensed abatement company); line break and remove Maleic Anhydride and Styrene from piping after developing safe and cost efficient methodologies to accomplish the removals; and removal and packaging of “Universal Waste” (i.e. fluorescent tubes, ballast, transformer and equipment oils, etc.). Besides some of the routine challenges encountered while performing dismantlement and demolition operations within active remaining plants, we had two major areas of concern that required extensive planning and expertise.   The first area involved taking down a 110’0” high main process building which had a party wall with a remaining one (1) story warehouse.  The process building’s elevator was located within the remaining warehouse, passing thru the warehouse’s roof to service the process building.  Our personnel used a 150 Ton crane to lift off the elevator structure and the upper portions of the process building, utilizing a manlift with a 125’0” high working platform for our personnel to make cuts for the removals. The second major challenge entailed the removal of a deteriorated 135’0” high steel water tower.  The tower was located near two elevated pipe bridges and an active office building, leaving only a 60’0” wide corridor for the tower’s removal.  Our crew first had to cable portions of the weakened tower together prior to using a 300 Ton crane for the actual lift.  Our crew utilized a manlift with a 162’0” working platform. Our crew of 12 utilized a 450 Daewoo excavator equipped with a grapple, a Komatsu PC300 excavator equipped with a shear, 75 ton Grove mobile crane, three (3) 843 Bobcats, a forklift and a lull to demolish the plant and other areas without an incident.  We also crushed the masonry materials created by our work to 2” minus and spread the material over the site, which alleviated the need to import gravel and saved our client substantial amount of money. We completed the entire project on time and on budget, and most importantly without any safety incidents.

In 2008, Marathon Oil elected to cease operations of its Lube Oil plant at its Catlettsburg Refinery in Kentucky.  The Lube Oil plant consisted of an 18,000 BPD Furfural Unit and an 11,000 BPD Methyl Ethyl Ketone (MEK) Extraction Unit as well as related equipment, surrounding utilities and infrastructure. Phoenix Equipment contracted to perform the dismantlement and purchase of machinery, equipment and scrap.  The Lube Oil plant is located within an active refinery, and therefore, required extensive planning, preparation and diligence in order to ensure a safe execution of the project without any interruptions to on-going site activities. Phoenix was able to significantly reduce Marathon’s demolition budget by executing a bulk sale of certain process equipment related to MEK dewaxing (rotary vacuum filters, vacuum pumps, etc).  Phoenix then performed the match-marking, removal, cribbing for transport, loading and transport of all purchased machinery, including items retained for future sale.  In conjunction with asset recovery services relating to equipment sales, Phoenix performed the complete dismantlement and demolition of the remaining plant.  Phoenix shared the proceeds from the sale of carbon steel (HMS) with Marathon above a certain set price.  Phoenix provided bi-monthly reports that included signed weight slips by a Phoenix and Marathon representative and a scanned copy of all checks Phoenix received from the sale of carbon steel (HMS). The scrap recovery on the project included approximately 5,000 tons of carbon steel (HMS) and 400,000 pounds of non-ferrous metals. An agreement was reached in regards to the project in July 2009, and Phoenix began dismantlement work in late August 2009, completing the full scope, including concrete slab removal, in September 2010.