Modular Process Systems for Chemical Mass Transfer

Koch Modular specializes in the design and supply of modular mass transfer systems. Koch Modular custom engineers every modular system specifically for each application.

Modular systems are complete process units, pre-fabricated in a remote module fabrication shop away from the customer’s plant site. Modular systems are typically built indoors in a controlled, assembly line with all of the added efficiencies afforded by that practice/procedure. This, in turn, minimizes the amount of work and resources needed by the customer to construct an operational process unit in the field.

The typical modular system will include columns, reactors, drums, decanters, heat exchangers, pumps and other types of process equipment, all mounted within a structural steel frame. The structural steel frame serves as a shipping support and provides access to the equipment during normal operation and for maintenance purposes. After the process equipment is installed within the structural frame, the piping components, the field instrumentation, and the electrical wiring are completed.

It is also typical for items like tracing, thermal insulation, lighting, control system, safety showers, and fire protection systems to be installed in the module at the assembly shop. A rigorous testing program is conducted on all these components before shipment to the field. The customer’s mechanical specifications, standards, and guidelines are followed in every respect, assuring each customer that the system provided will meet all of their expectations.

What Can We Help You With?

For over 40 years, Koch Modular has successfully designed and constructed mass transfer systems for the worldwide Chemical Processing Industry. Our customers rely upon us for quality products and technical expertise. As a single-source supplier, we can provide you with the following services:

Feasibility studies
Process design and performance guarantee
Detailed engineering
In-house pipe & pressure vessel stress analysis by
finite element method
Project management
Modular construction
Full automation and control system supply
Startup assistance and operator training
Continued service and advice

How We Do It?

ModularLaunch^TM was developed to help chemical process industry teams make critical decisions on process pathway development and project execution intelligently and efficiently. In this fast-paced decision landscape, our chemical process industry clients, from established leaders to developing technology companies, rely on Koch Modular for rapid-uptake collaboration.

Click here for more information of our ModularLaunch^TM approach.

Advantages of Modular Construction

Why should you choose modular construction from Koch Modular over conventional field construction? Here are 5 of the most common reasons our customers give:

Shorter Schedules

Building a process unit in a shop, with a well-controlled fabrication sequence, can save months when compared to building outside in a plant environment where work is subject to weather-related delays, work permits, work stoppages, waiting for cranes, etc. A typical schedule for delivery of a complete modular process unit, fabricated in stainless or carbon steel, is 7-8 months from receipt of a Purchase Order, including all engineering and design activities.

Lower Cost/Lump Sum Bid

Koch Modular has made a science out of studying fabrication efficiencies and construction sequences in our module shops. Typically a 25-30% reduction in cost can be realized with modular construction when compared to field construction. Prices quoted for modular constructed systems are also firm/lump sum prices, not T&M.

Construction Proceeds While Waiting for Permits

Offsite construction of entire process units in our module shop can proceed while permits are in-process. This can be a significant time-saver because permits often take months to obtain and field construction can’t begin until the permits are in hand.

Minimal Plant Site Interruption

In the case where a new process unit is built alongside an existing operating chemical manufacturing unit, there are many hazards and safety risks associated with the field construction activities. Ask yourself this QUESTION – “Do I want dozens of contract construction workers walking around in my chemical plant?” If the answer to this question is no, then modular construction (off-site) makes a lot of sense. It minimizes the potential hazards and production interruptions that can occur.

Single Source Responsibility

Is your project management/project organization stretched to the limit? Building your process unit in our module shop will unload your project team because you will place only ONE purchase order for the entire system. Our project team will do the rest.

DID YOU KNOW? Modular units are also quite versatile. Although most of our modules are installed outdoors, many are also installed inside of a building. Modules can easily be sided to protect operating equipment and personnel against the harshest of weather conditions or to shield the process components from the view of neighbors and potential competitors.