TCSG developed a project process tailored for the TiO2 industry to provide maximum flexibility for process improvement projects, retrofits, brown-field expansions or green-field projects. TCSG offers discipline engineering up to any phase of the project. Turn-key services can also be provided. In some cases clients prefer to use an engineering company of their choice, with TCSG only providing process design and know-how inputs during the design phase, along with commissioning and post-commissioning support.

process design flow chart

High level Concept Studies are useful to investors and new entrants who need to understand the TiO2 industry, how the process works, product options, plant capacity and streaming, sourcing of technology and equipment, the requirements and options for land, infrastructure, raw materials, services, utilities, wastes generated by the process, options for waste treatment/co-products and capital and operating costs.

Concept Studies are aimed at providing the necessary market and technical inputs for feasibility studies and typically cover markets, supply/demand & price forecasts, products, process description, provisional flow sheet design, equipment list and high level lay-outs in sufficient detail for initial revenue, capital and operating cost estimates (FEL1).

Basic Design is an expansion of the Concept Study to arrive at FEL2 cost estimates (sometimes required as part of a Definitive Feasibility Study), define the project by way of a Basis of Design and provide the necessary process and engineering inputs for Detailed Design to commence. The process flows sheets are normally frozen at the end of this stage.

In the Detailed Design  stage, the design is developed to ‘ready-for-tender’ status – with all specifications necessary in the call for tenders.

After Procurement, Final Engineering is done based on vendor certified information (vendor catalogue information is used during the Detailed Design), followed by construction, installation and commissioning.

TCSG typically leads the early parts of the project process, but hands over to an engineering company at or after Detailed Design, whereafter TCSG acts as client representative or as sub-contractor until completion of post-commissioning optimization.

TCSG also provides specialist Hazard Study Facilitation services. TCSG makes use of the Six Stage Harzard Study approach which includes Hazard Identifification (HAZID) for early identification of hazards and threats, as well as the Hazard and Operability Study (HAZOP) applied during the design and implementation process.