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.  

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

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.

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: 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.

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.