Project Overview
Evonik Degussa shut down its Silanes and Orthoester specialty chemical plants in Theodore, Alabama after discontinuing production of downstream products. The two plants were located within a large chemical complex that remained in operation, and Evonik needed the land they occupied for another project.
Rather than treating the plants as a straight demolition project, Evonik sought a process equipment buyer that could recover value from the assets while also completing the removal scope. Phoenix Equipment purchased the equipment in July 2012 and safely completed the dismantlement and demolition by February 2013. The approximately $3 million project was completed at no cost to Evonik.
The Challenge
Phoenix had to remove two complete chemical process plants from within an active manufacturing complex. The scope included buildings, process equipment, piping, pipe racks, and associated structures, with the area cleared to the top of concrete.
The work required careful sequencing around live plant infrastructure. Portions of the buildings had to be dismantled floor by floor, while equipment in other areas had to be removed above or around live pipe racks serving the surrounding operating facilities.
Asset Recovery & Sales
Phoenix recovered more than 100 pieces of process equipment for resale. The recovered assets included 13 Hastelloy reactors, 9 glass-lined reactors, 3 filter dryers, 13 Hastelloy heat exchangers and condensers, 3 centrifuges, 4 shelf dryers, 12+ Sparkler and Nutsche filters, 5 milling systems, 10 temperature control units, 10+ tanks, 4 chillers, 10+ pieces of laboratory equipment, and 10+ scales.
The assets were sold individually rather than as complete process units. Phoenix also recovered more than 250,000 pounds of non-ferrous material and more than 1,500 tons of carbon steel through recycling.
The resale value of the equipment and recovered metals, combined with Phoenix’s experience working inside active chemical facilities, supported a highly competitive proposal and allowed the dismantlement to be completed at no cost to Evonik.
Dismantlement Within an Operating Chemical Complex
Phoenix completed the full removal of both plants, including equipment rigging, building demolition, piping and rack removal, and scrap recycling. Supporting work included geographical surveying, disconnects and utility safe-offs, electrical terminations, masonry-material testing, extermination, soil erosion control, and landscaping.
Phoenix used a Komatsu PC400 excavator equipped with a shear, a Komatsu PC300 excavator equipped with a grapple, cranes ranging from 65 to 500 tons, man-lifts, skid steer dozers, and forklifts to execute the work.
Because the surrounding complex remained active, Phoenix coordinated its activities closely with Evonik personnel. Demolition, rigging, and equipment removal were timed around ongoing plant operations so the obsolete process areas could be cleared without interfering with nearby chemical production.
Project Highlights
- Client: Evonik Degussa
- Location: Theodore, Alabama
- Facilities: Silanes and Orthoester Specialty Chemical Plants
- Reason for Closure: Downstream Product Production Discontinued
- Site Conditions: Two Idled Plants Within a Large Operating Chemical Complex
- Phoenix Scope: Plant Acquisition, Equipment Recovery, Rigging, Dismantlement, Demolition and Scrap Recycling
- Final Removal Condition: Buildings, Equipment, Piping, Racks and Structures Removed to Top of Concrete
- Equipment Recovery: More Than 100 Pieces of Process Equipment (See Liquidation)
- Major Recovered Assets: Hastelloy and Glass-Lined Reactors, Tanks, Heat Exchangers, Filters and Other Specialty Chemical Equipment
- Equipment Disposition: Individual Equipment Sales
- Non-Ferrous Material Recycled: More Than 250,000 Pounds
- Carbon Steel Recycled: More Than 1,500 Tons
- Major Execution Challenges: Floor-by-Floor Building Demolition / Equipment Removal Around Live Pipe Racks
- Project Timeframe: July 2012 – February 2013
- Project Value: Approximately $3 Million
- Owner Outcome: Two Shutdown Plants Removed at No Cost / Land Cleared for Future Project
- Safety: Completed Safely
Recovering Asset Value While Clearing Space for New Investment
Phoenix combined equipment resale, metal recovery, and live-site dismantlement expertise to remove two obsolete process plants to the top of concrete at no cost to Evonik, clearing the area for future development within the operating complex.