James Boklage, Quality Assurance and Quality Control (QA/QC) Manager at Koch Modular, is immersed in the final stages of preparing an 80,000-pound modular processing system for delivery—saving the client time, money, and the inevitable headaches of on-site construction.

“One of the biggest positives about modular assembly is being able to fabricate something off-site,” Boklage explains, gesturing to the fully assembled module behind him. “When it’s under a roof, that’s the best scenario for us because we don’t get shut down for inclement weather. That helps us maintain our schedules quite a bit.”

The process isn’t just about efficiency; safety and quality are also paramount. Currently horizontal in the fabrication shop, the module will be erected vertically once it arrives at the client’s site. “By keeping it horizontal, we are keeping everyone closer to the ground, so that’s inherently a lot safer situation,” Boklage says, highlighting the proactive approach to worker safety.

Ensuring quality across each component is a sophisticated operation, as Koch Modular sources parts from vendors across the country and even globally. “The quality assurance department is setting the standards of the quality of products that we’re getting from our vendors,” he explains, noting the extensive inspection and testing protocols that vendors must meet. Koch Modular’s quality control inspectors closely monitor these standards, ensuring that each component meets the company’s rigorous requirements.

Various personnel within Koch Modular help to perform an essential role in ensuring the success of each modular assembly by performing a comprehensive 13-step walk-down to guarantee quality, safety, and readiness. This walkdown team typically includes personnel from the Project, Process, Piping, and QA/QC departments. This structured process keeps each day dynamic and engaging as the team checks each critical aspect of the module before it leaves for the client site. Starting with inventory checks, they verify that all structural steel is correctly oriented and securely bolted, meeting torque specifications to uphold integrity. They also check grating, equipment installations, P&ID accuracy, piping isometrics, pipe tracings, and insulation, among other things. “We’re performing isometric walk downs to make sure all the valves are turned in the right direction, making sure that instruments are facing the right way,” Boklage says.

The process also includes a rigorous factory acceptance test (FAT) where the EI&C team tests every instrument and control valve to confirm effective communication with their designated equipment. This step is crucial for minimizing the risk of onsite surprises and enables a smoother setup for the client. Finally, as part of shipping preparation, the Project Management and Quality Control team members inspect the entire module, checking for any loose components and ensuring each piece of equipment is securely strapped down for safe transit. Temporary supports are added where necessary, providing additional stability for transportation.

“It makes me proud to say I work with Koch Modular,” Boklage reflects with a smile. I feel safe working here in this environment, and I like working for the company.” As the module is readied for its journey, it’s clear that pride, precision, and quality assurance are embedded in every step of the process, from concept to commercialization. At Koch Modular, the promise of reliability and efficiency isn’t just a goal—it’s a standard.

Meet James

James is a licensed Professional Engineer (PE) in Pennsylvania and Kentucky, with a Master’s degree in Mechanical Engineering. His primary focus has been pressure vessel design and inspection. His career spans over 25 years, with experience in the following industries: static equipment design and fabrication, petrochemical and chemical plants, fossil and nuclear plants, and mechanical and nondestructive testing.

James is currently the Mechanical Engineering, Quality Assurance, and Quality Control Manager for Koch Modular Process Systems, where he has worked for over 15 years.

The post Building with Confidence: Behind the Scenes of Modular Assembly appeared first on Koch Modular Process System.

The world of technology is ever-evolving, and with it comes the challenge of commercializing groundbreaking innovations. One key factor that determines the success or failure of developing technology projects is the project execution strategy. Koch Modular‘s Mauricio Villegas is set to present an insightful discussion on this crucial topic at the AIChE Annual Meeting in Orlando, Florida, on November 8, 2023, at 1:00 pm. In his presentation, he will shed light on the significance of having the right project execution strategy to ensure the success of developing technology projects, with a particular focus on two essential best practices: pilot testing and the modular project delivery model.

The Unique Challenges of Developing Technology Projects

Developing technology projects are unlike traditional ventures. They stand at a delicate crossroads between becoming economically viable or remaining stuck in the conceptual stage. Maximizing the probability of advancing through various development phases and financial decision gates is paramount in the early stages of such projects. This is where the project execution strategy comes into play.

Pilot Testing: De-risking and Ensuring Performance

One of the critical best practices discussed by Mauricio Villegas is the implementation of pilot testing. In the realm of developing technology projects, pilot testing plays a pivotal role in de-risking the process and obtaining a performance guarantee before proceeding to scale up and commercialization. This ensures that the technology works as intended, reducing uncertainties and instilling confidence in investors and stakeholders.

Modular Project Delivery Model: Certainty from Concept to Completion

Another key focus of Mauricio Villegas’s presentation is the modular project delivery model. When it comes to executing developing technology projects, this approach stands out as a game-changer. Unlike traditional field construction, a modular project delivery model offers cost and schedule advantages, and most importantly, project certainty throughout the project’s lifecycle.

The modular model provides the flexibility to develop a modular pilot or demonstration-scale unit, which can easily be scaled up and duplicated across multiple geographies. This adaptability is invaluable when dealing with rapidly evolving technologies and expanding markets.

Real-World Examples and Lessons Learned

Mauricio Villegas’s presentation will not be limited to theoretical concepts; it will provide real-world examples to illustrate the application of these best practices. Real projects will be showcased to demonstrate how pilot testing and modular project delivery have played a pivotal role in their success.

Continue the discussion at AICHE 

In a world where technology advances at an unprecedented pace, the success of developing technology projects hinges on the right project execution strategy. Mauricio Villegas, a distinguished expert from Koch Modular, will delve into the crucial aspects of pilot testing and the modular project delivery model in his presentation at the AIChE Annual Meeting. By de-risking processes, ensuring performance, and maintaining project certainty, these best practices are instrumental in bridging the gap between innovative concepts and successful commercialization. Don’t miss this opportunity to gain insights into the future of developing technology projects and the strategies that ensure their success. Join Mauricio Villegas on November 8, 2023, at 1:00 pm in Orlando, Florida, and be part of the journey towards maximizing project certainty in the world of developing technologies.

Chat with Mauricio

Mauricio Villegas is the Manager of Business Development at Koch Modular Process Systems. He has more than 25 yr of experience in the engineering and construction industry, delivering projects across sectors ranging from small brownfield projects to greenfield mega-projects. Before joining Koch Modular, he held various management roles at WorleyParsons, Technip, IHI E&C, and Arcadis. Mr. Villegas earned a BS in Business Administration and Management from Northeastern University.

Email: mauricio.villegas@kochmodular.com

The post Maximizing Project Certainty: A Look at Best Practices for Developing Technology Projects appeared first on Koch Modular Process System.

Koch Modular is proud to announce that Business Development Manager, Mauricio Villegas, will be presenting “How A Modular Delivery Model Drives Developing Technology Project Viability” at TechConnect on Tuesday, June 20th at 1:30 pm EST in Chesapeake 2. Whether a project involves the commercialization of technology for the production of bio-based chemicals, plastics or fuels; the chemical recycling of end of life plastics, lubricants or electronics; point source CO2 recovery; or the recovery of critical minerals & metals, this presentation will explore how a modular delivery model can help provide project certainty for companies developing and commercializing novel technologies.

Unlike traditional projects, developing technology projects need a project execution strategy that proves economic viability to surpass the conceptual stage. That’s why Koch Modular advocates a modular delivery model as best-suited for maximizing the probability of advancing through process development phases and financial decision gates.

A modular delivery model has many benefits for developing technology projects, including improved cost control due to accelerated construction schedules, minimized field labor costs, reduced risk of rework due to pre-testing of all modules before shipment, and increased safety due to controlled fabrication environment with minimal site work required during installation. Additionally, modularization can eliminate weather delays and minimize potential schedule impacts from long lead items such as equipment and piping fabrication.

“We have seen firsthand how beneficial a modular delivery model can be for companies at the forefront of decarbonization innovation,” says Mauricio Villegas. “Time to market is crucial, and a well-defined project execution strategy is fundamental for securing financial backing and project success.” He says, “The modular delivery model will play a vital role in expediting decarbonization initiatives.”

Koch Modular is committed to helping companies maximize their potential by creating customized solutions tailored to their needs. Utilizing a modular delivery model can provide cost savings and schedule certainty throughout the entire project lifecycle—from concept to completion—ensuring maximum success for developing technology projects. 

Join us at TechConnect on June 20th at 1:30 PM EST in Chesapeake 2, where Mauricio Villegas will be presenting “How A Modular Delivery Model Drives Developing Technology Project Viability”—and learn more about how you can benefit from utilizing a modular delivery model when executing your next developing technology project.

Visit our team at booth #712.

Chat with Mauricio

Mauricio Villegas is the Manager of Business Development at Koch Modular Process Systems. He has more than 25 yr of experience in the engineering and construction industry, delivering projects across sectors ranging from small brownfield projects to greenfield mega-projects. Before joining Koch Modular, he held various management roles at WorleyParsons, Technip, IHI E&C, and Arcadis. Mr. Villegas earned a BS in Business Administration and Management from Northeastern University.

Email: mauricio.villegas@kochmodular.com

The post Modularization: The Key to Achieving Project Certainty appeared first on Koch Modular Process System.

Koch Modular to exhibit at ESF North America 2023 – Energy and Sustainability Forum in San Francisco, California, on May 31-June 2, 2023, at booth #28.

Koch Modular, a leader in the chemical processing industry, is proud to announce that it will be exhibiting at the Energy & Sustainability Forum (ESF) North America. This event is focused on the opportunities available to the refining and chemicals industries as they transition towards a low-carbon future. Tom Schafer, Co-Founder & Vice President of Koch Modular Process Systems, will join other industry experts for interactive seminars. These discussions will provide insight into how companies can incentivize and subsidize decarbonization efforts to position themselves for success in the low-carbon transition.

Schafer will present “How A Modular Delivery Model Drives Project Viability” on Thursday, June 1, 2023, at 5:00 pm PST.

“The refining and chemicals industries have an unprecedented opportunity to ensure their long-term success while protecting our planet,” said Schafer. “I am excited to attend ESF North America and share my insights on how companies can embrace modularization to fast-track their energy transition initiatives sustainably while enhancing project viability.”

At Koch Modular, we understand that every business is unique with its challenges and goals for sustainability. We are committed to helping our customers find solutions tailored to their needs that reduce energy consumption, lower emissions, and improve efficiency. At ESF North America, we will be showcasing our modular process systems which allow businesses to design custom solutions that meet all of their specific requirements. Our systems are designed for flexibility so businesses can scale sustainably to meet market demands. 

We believe that by leveraging our expertise in process development, pilot testing, and process system fabrication, along with our commitment to innovation and sustainability, we can help businesses reach their full potential while reducing environmental impact simultaneously. Visit us at ESF North America this May 31st-June 2nd at booth #28, where we will further discuss how Koch Modular can provide your business with cost-effective solutions for a low-carbon future.

Can’t join the conference? Join our webinar.

Our esteemed industry expert, Tom Schafer, will delve into the challenges of project delivery and discuss when and how a modular delivery model outshines traditional methods. Gain valuable insights, learn from real-life project examples, and unlock the secrets to success. Don’t miss this opportunity to elevate your knowledge and drive your projects towards sustainable commercialization with the power of modular delivery.

Tom Schafer, Koch Modular Co-Founder & Vice President

Chat with Tom

Tom Schafer is a chemical engineer with 38 years of experience in process design, operations management, cost estimating, plant layout, and sales & marketing—specific expertise in equipment design, including distillation, heat transfer, fluid flow, and process control. Tom holds a B.S. in Chemical Engineering and an M.S. in Chemical Engineering from Manhattan College.

Email: thomas.schafer@kochmodular.com

The post Showcasing Modularization Solutions at ESF North America appeared first on Koch Modular Process System.

As Koch Modular continues to partner with a range of startups, we have noticed a few trends among these fast-growing companies.

Source Local: Not Just for Your Farmers Market

When we think about the holidays, we rejoice in the celebrations not only at home but also with our work families. Whether it’s a holiday party, luncheon, or charitable event, it is a special time of year where we are able to work together and celebrate together.

Since we spend so much time at work, finding connections between our life as “real people”, and our work life is always an unexpected boon. Work/life balance means a lot of things and recently we noticed that a Buy Local trend, seen so clearly whenever we visit a farm-to-table restaurant, is also taking shape in the CPI industry. While you shopped at the local farmer stand for your corn this past summer, were you aware that the CPI industry was busy working on finding local sourcing for certain key chemicals? Sourcing chemicals locally allows businesses to save on transportation costs and avoid possible delivery interruptions.

The Birth of ModularLaunch^TM

Koch Modular is leading some of this effort, to minimize long transportation pipeline routes and find ways to use locally sourced, lower-cost materials. Recently, Koch worked together with New Jersey-based start-up Primus Green Energy on their natural gas to liquids technology, specifically their processes for converting natural gas to drop in gasoline and methanol via reforming, reaction, and distillation unit operations.

The technology focuses on regional production, providing in-basin demand and leveraging low-cost natural gas in areas such as the Marcellus and Permian Basins. Koch Modular assisted Primus with engineering services supporting the process conceptualization and pilot testing phase, followed by the development of the process design package, as well as the forthcoming detailed engineering and construction of their first commercial-scale system.

Industrial Biotech Startups Reaching Out

While not as close to home as the buying local trend, helping bring bio-based chemicals into the world makes us feel environmentally energized. We have seen an increase in the number of industrial biochemical startups (using feedstock with bio-based chemicals) coming to our door for help in moving towards full-scale production. Beyond our expertise in separations technologies and modular construction lay a natural affinity for helping start-ups analyze their path forward towards scale-up. Now that we’ve owned up to how talented we are (tongue in cheek), we realize that this type of consultative work has always been a part of our culture. Today, we work with industrial biotechs to help develop full-scale processes to manufacture their bio-based chemicals.

This holiday season, whether you’re staying local or not, we hope that you revel in the joy and beauty of celebrating your connections with family and friends. As we assist our partners with establishing resources and aiding start-ups with appropriate next steps, we continue to work together and celebrate successful projects. From pilot testing to scale-up production, leveraging regional production to new biochemical production, our ModularLaunch^TM process supports all of our clients. We wish you the Happiest of Holidays! Contact us today or learn more at https://kochmodular.com/.

The post ModularLaunch^TM in Action appeared first on Koch Modular Process System.

Introducing Modular Construction Services

The team at Koch Modular talks directly to the industry in this informative video about the benefits of modular construction: https://kochmodular.com/modular-process-systems/

Project Engineering Manager Jim DeNoble talks about the surprise factor.

“Some of our clients are surprised at the fact that we can put together such a complex module of chemical process systems with all these design and engineering activities … on such a fast schedule. “

George Schlowsky, President, points out that there is a real safety factor with modular construction being done off-site. No building or welding has to be done while the plant is operating.

Tom Schafer, Vice President, reminds clients that they can “get to market much faster by building off-site” and after permit procurement, they can be operating in 1-2 months.

Others on the video discuss the downside of stick built construction’s “serial approach.” With modular construction, design activities move simultaneously with a multitude of other activities happening on-site. Many project steps are done in parallel, saving significant time.

When you have a company with twenty-five years of experience doing it, modular construction is definitely worth learning about.

To schedule a Lunch & Learn on modular construction at your site, or by WebEx, call Tom Schafer, whose words of wisdom are also featured in the Koch Modular video on modular construction.

The post Straight Talk about Modular Construction appeared first on Koch Modular Process System.