Plant Dismantlement & Relocation Solutions Case Studies

Overview In 2025, Phoenix Equipment successfully completed the sale and full relocation of a 2,300 BPD recycled oil refinery from Florida, USA to Indonesia—a complex, multinational project completed in under nine months from initial due diligence through delivery at the buyer’s site overseas. This turnkey assignment showcased Phoenix Equipment’s unique ability to manage the entire lifecycle of a plant redeployment: commercial negotiation, engineering review, precision dismantling of installed equipment, heavy haul transport of uninstalled assets, international export packing, port operations, and ocean freight logistics.   The Result: A fully delivered recycled oil refinery Over 4,300 CBM of equipment successfully exported 955,000+ kg of machinery in total 48 break-bulk pieces plus 20 x 40' sea containers Significant cost savings for the buyer vs. purchasing new equipment Timeline far faster than new-build alternatives  The Challenge The buyer required a complete used oil recycling plant — available immediately, priced competitively, and relocatable across the world. The plant in Florida fit their technical needs perfectly and was similar to their existing facility but large portions of the plant: Had been fully installed, requiring precise reverse-engineering of connections Included oversized, heavy vessels and columns Needed to be extracted from a tight operating site Required specialized rigging and multi-axle transporters Had to be packed, staged, and loaded within strict port schedules Needed to be shipped to Indonesia without damage or delay Coordinating these activities simultaneously across engineering, dismantling, permitting, heavy haul, and ocean freight required an experienced turnkey partner. See the plant block diagram to see the full scope of this project. Phoenix Equipment’s Solution 1. Due Diligence & Transaction Management Phoenix Equipment managed: Technical evaluation of all the plant Commercial negotiations Documentation and contract finalization A complete project schedule compressing engineering, dismantling, logistics, and ocean transport into < 9 months Our ability to handle both the asset sale and the relocation streamlined execution and minimized cost and risk for the buyer.   2. Precision Dismantling of Installed Equipment Many refinery components—including large distillation columns, vessels, heat exchangers, and skids—were fully installed and integrated. Phoenix Equipment coordinated: Engineering of lift plans Isolation and disconnection of utilities and tie-ins Rigging and removal using heavy cranes (see photos) Cutting and separation where required Marking, tagging, and documentation for reinstallation Our dismantling team ensured the plant could be reassembled efficiently in Indonesia, preserving piping configurations, skid layouts, and vessel orientations.   3. Heavy Haul Transport of Uninstalled and Oversized Assets Several refinery sections had never been installed and were located in storage areas. These included very large ASME vessels requiring: Multi-axle SPMT or dual-lane trailers Route surveys and permitting Police escorts and controlled movement Specialized saddles and supports during transport   4. Export Packing, Containerization & Break-Bulk Preparation The refinery components were staged, packed, and prepared for ocean export, including: 20 x 40’ containers of skids, controls, and auxiliary systems 48 break-bulk pieces for oversized equipment Custom crating VCI preservation Saddle fabrication Lashing and securing plans Moisture protection for long-duration sea transport Total shipment volume exceeded 4,300 CBM and 955,000 kg.   5. Port Operations & Ocean Freight to Indonesia Phoenix Equipment acted as single-point logistics coordinator, including: Contracting with a major port and ocean carrier Supervising port receiving, staging, and loading Managing tandem-lift heavy crane operations (as shown in photos) Ensuring proper stowage for long-haul transit Final delivery to Indonesia Our integrated approach ensured schedule adherence and minimized demurrage and port charges. Outcome Within just nine months, the buyer received a fully packaged refinery ready for reassembly. By purchasing a used plant and leveraging Phoenix Equipment’s turnkey relocation capabilities, the buyer: Saved millions vs. new-build cost Avoided 30+ months of new construction lead time Received a complete, functioning refinery delivered to their country This project underscores Phoenix Equipment’s reputation as a global leader in: Complete plant acquisitions Industrial asset redeployment Dismantling & rigging Heavy haul and project cargo logistics Turnkey international relocation Whether a project requires a few truckloads or an entire refinery like this one, Phoenix Equipment delivers speed, expertise, and end-to-end accountability.

Shutting down a chemical plant is rarely the hard part. Making the site ready for its next use is where the real work begins. For the former Vertellus castor oil facility in Bayonne, New Jersey, that meant removing decades of industrial infrastructure while safely managing residual process materials, environmental requirements, and a complex dismantling effort. The objective was to prepare the property for permitting, resale, and redevelopment.   Project Overview             The project combined demolition, environmental preparation, and infrastructure removal across nearly every major outdoor process area on the site. The scope included: Two process buildings A sebacic acid processing area Four storage tanks exceeding 250,000 gallons each, located near live power lines Two outdoor tank farms containing more than 90 storage tanks Thousands of linear feet of process piping Three boiler stacks approximately 150 feet tall   The work also included draining process systems, cleaning tanks and equipment, asbestos abatement, dismantling, and demolition.                Project Challenges       Although the plant owner had begun draining and cleaning the facility after shutdown, substantial quantities of product and residual materials remained inside tanks, piping, and process equipment. The shutdown created another practical challenge. The operating personnel who normally managed these systems were no longer available to complete the work. Before dismantling could begin, the remaining materials had to be identified, removed, contained, and prepared for disposal. Several of the largest storage tanks were positioned beneath live power lines, requiring careful planning throughout the dismantling process. The waterfront location also meant material handling and demolition activities had to be aligned with the site's existing stormwater control plan.   Dismantling Approach       Before demolition could begin, every vessel was opened and inspected. The contents were identified, quantities were assessed, and a removal plan was developed for each tank. Rather than applying a single dismantling method across the site, each vessel was evaluated individually. The condition of the remaining materials determined how the work would proceed. Where liquid product could be recovered, vacuum trucks removed the remaining material before cleaning was performed. Not every tank could be emptied conventionally. Some contained heavy residual heels that vacuum trucks could not remove. Those tanks were cleaned from the top down before being cut back to the level of the remaining material. Depending on the condition of the contents, the remaining tank sections were either disposed of with the heels in place or the residual material was removed before the steel was recovered for scrap. This staged approach allowed dismantling to continue while safely managing the materials that remained inside the equipment.   Safety, Environmental Compliance, and Logistics       Permitting, utility isolation, equipment mobilization, and environmental planning all had to be completed before field work could begin. Phoenix obtained approximately 90 permits for the removal of the outdoor tanks and two demolition permits for the buildings. The site owner completed the required sewer, water, and electrical disconnects before demolition activities started. Excavators equipped with grapples and shears, cranes, bobcats, and lulls were mobilized to support the dismantling effort. Throughout the project, Phoenix worked with Vertellus to significantly reduce overall project costs by recovering value where practical. Scrap metal was recycled, and dozens of pieces of process equipment were resold rather than demolished. The work was completed by a 10-person crew in approximately four months.   Preparing the Site for Redevelopment Industrial demolition involves much more than taking structures down. Remaining process materials, environmental controls, permitting, and work sequencing all influence how quickly a property can move to its next phase. By the end of the project, the outdoor process areas, storage tanks, buildings, piping, and boiler stacks had been removed. The site was left in a condition that allowed the owner to move forward with permitting, resale, and redevelopment.

Selective Dismantlement Within an Active Industrial Facility Industrial facilities rarely become obsolete all at once. More often, changing markets leave individual process units without a future while the rest of the site continues operating. Removing those assets without disrupting the plant that remains requires careful planning long before dismantlement begins. That was the situation at Dyno Nobel's facility in Donora, Pennsylvania. Market conditions made the site's nitric acid plant and ammonium nitrate neutralizer no longer necessary, while other portions of the facility continued operating. Dyno Nobel needed the obsolete process units removed while preserving the infrastructure that still supported active production. Phoenix Equipment purchased the nitric acid plant and ammonium nitrate neutralizer, creating an opportunity to recover value from reusable equipment, precious metals, and recyclable materials while preparing the site for its next phase. Project Overview The project involved dismantling a fully integrated nitric acid plant and ammonium nitrate neutralizer. Major components included an absorber tower, compressor house, heat train, storage tanks, extensive pipe racks, and supporting utilities. Only selected portions of the facility were scheduled for removal. Pipe racks, utilities, and other infrastructure supporting ongoing operations had to remain in place throughout the project, making selective dismantlement the defining challenge.   Planning Around an Operating Facility Successful selective dismantlement begins with understanding what stays. Before work started, the team documented equipment layouts, structural conditions, and process systems to develop a detailed removal plan. Infrastructure supporting active operations was identified early, allowing obsolete piping and equipment to be removed while preserving the pipe racks and utility systems that remained in service. That planning established the sequence for every phase of the project and allowed dismantlement to proceed without affecting adjacent operations.   Precision Dismantlement With the removal plan in place, crews systematically dismantled the nitric acid plant and ammonium nitrate neutralizer using specialized lifting methods and heavy equipment. Major towers, process vessels, structural steel, piping, and associated equipment were removed in a controlled sequence while protecting nearby infrastructure that remained part of Dyno Nobel's operating facility. The project was completed without a safety incident.   Recovering Value Throughout the Project Dismantlement was only one part of the project. Recovering value from the facility was equally important. Reusable process equipment was evaluated for resale before being designated for recycling. Phoenix also partnered with PGM Technologies, led by David Kelley, to identify and recover precious metals from selected process equipment, increasing the value recovered from the project. Remaining metals were responsibly recycled, while construction debris was segregated, placed into site-provided containers, and removed throughout the project to maintain a clean and organized work area.   Preparing the Site for Future Use As dismantlement progressed, the site was prepared for its next phase without affecting ongoing operations. The obsolete process units were removed while designated infrastructure supporting the active facility remained in service. Concrete foundations and selected infrastructure were left in place for future redevelopment, while operations elsewhere on the site continued uninterrupted.   Project Outcome The project combined selective dismantlement, equipment recovery, precious metal recovery, and responsible recycling within an active industrial facility. Dyno Nobel removed process units that no longer supported its business while preserving the infrastructure needed for ongoing operations. Equipment remarketing, precious metal recovery, and responsible recycling helped improve the project's overall economics while reducing material sent for disposal. Industrial facilities continue to evolve as markets, products, and production priorities change. Those changes often affect only part of a facility rather than the entire operation. Projects like this demonstrate that selective dismantlement can safely remove obsolete process units, recover additional value from industrial assets, and prepare a site for its next use without disrupting the operations that remain.  

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

From Surplus Brewery Equipment to Whisky Distillery Expansion Every process improvement leaves something behind. Sometimes it is an outdated procedure. Sometimes it is a process system that no longer fits the operation, even though it still has years of useful service ahead of it. That was the situation at the Coors Brewery in Golden, Colorado. Changes to the brewery’s production process eliminated the need for a 1.5 MMGPY ethanol recovery unit that reclaimed ethanol from waste beer and other alcohol-containing process streams. Although it no longer fit Coors’ operations, the lightly used system still had years of useful service ahead of it. Finding the right buyer became the critical step. The system needed a manufacturer whose production process and expansion plans aligned with its capabilities. Phoenix Equipment began identifying potential buyers while discussions to acquire the unit were still underway.   Why Phoenix Purchased the Unit Specialized process systems rarely have a broad market. Their value depends on identifying manufacturers whose production processes and expansion plans align with the equipment, often before it ever reaches the open market. Phoenix began identifying potential buyers while discussions to acquire the unit were still underway. That early market knowledge gave Phoenix the confidence to purchase the unit outright, remove it according to Coors’ project schedule, relocate it to Texas, and begin marketing it to qualified buyers worldwide.   Project Overview Built in 2018 and operated until 2019, the unit recovered ethanol from waste beer and other alcohol-containing process streams, allowing valuable product to be reclaimed rather than discarded. Because it had seen relatively little service, the system presented an attractive opportunity for manufacturers looking to expand processing capacity without purchasing a comparable new unit.   Finding the Right Buyer Selling a complete process system is fundamentally different from selling individual pieces of equipment. The pool of potential buyers is much smaller. Success depends on identifying manufacturers whose production requirements closely match the system being offered. That search ultimately led to an established whisky distillery in Ireland that was expanding production capacity. For the distillery, acquiring an existing unit provided a faster and less expensive path to expansion than purchasing a comparable new system. New fabrication would have cost more than twice as much and required a lead time of more than one year. The buyer moved quickly. After placing a deposit to secure the unit, representatives traveled to Texas to perform due diligence and inspect the equipment. A purchase order followed immediately after the inspection. From acquisition through sale, the transaction was completed in approximately four months.   Preparing the Unit for Relocation Following the sale, Phoenix managed the unit’s relocation to Ireland. The project included dismantlement at the brewery, transportation to Texas, export packing, inland and ocean freight, and delivery to the destination port in Ireland. The buyer then assumed responsibility for installation and commissioning. Throughout the project, Phoenix met Coors’ removal schedule while coordinating the international logistics required to deliver the system overseas.   Project Outcome The transaction created value for every party involved. Coors recovered value from a process system that no longer supported its manufacturing strategy while meeting its project timeline. The buyer acquired additional processing capacity at significantly lower capital cost and with substantially less lead time than purchasing a comparable new unit. Phoenix’s understanding of the market for specialized process systems made the transaction possible by connecting a seller with surplus equipment to a buyer ready to expand production. Industrial facilities constantly evolve as products, processes, and business priorities change. Those changes create surplus assets that still have years of productive service ahead of them. The challenge is identifying where those assets fit next and putting them back to work.  

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.

Western Electric’s plant in Kearny, New Jersey was closed and sold for re-development years ago. The developer determined that the site’s main powerhouse/substation buildings would be obsolete in the site’s future and over the years removed all boilers, ducts and miscellaneous equipment from the powerhouse’s interior. In April of 2015, the developer decided to completely demolish the powerhouse and substation buildings. The powerhouse was a 100’ x 100’ x 100’ high steel framed structure with brick exterior walls, a poured in place concrete floor supported  by steel approximately 18’ above grade and a concrete/steel coal bunker running east to west and hung from the roof steel approximately 25’ wide by 90’ long. Atop the powerhouse’s roof were (2) 20’ diameter by 200’ high redial brick chimneys. The main substation was a 65’ x 120’ x 2’ steel frame structure with brick walls and concrete and steel arches. The substation’s south wall was a party wall with the powerhouse’s north wall. A 28’ wide driveway, east of the (2) buildings, separated the buildings from an active warehouse structure (the driveway was the emergency exit for the warehouse). North of the substation, a 45’ wide driveway separated another warehouse from the project.  90’ west of the buildings was the Hackensack River while underground water and gas lines serving the site were south of the powerhouse. Implosion was not an option for this project.   Solution Phoenix Equipment Corporation was selected because:   Our experienced management personnel devised a demolition methodology that greatly reduced the project’s cost. Phoenix’s ability to obtain and manage safe/competent subcontractors for the project (i.e. Asbestos abatement, manual demolition of chimneys, site production (i.e. roof coverage, sidewalk bridges, scaffolding, etc.). Phoenix’s ability to deal with local, state and federal agencies which might get involved with the project.   While waiting for the actual permits to demolish the buildings, our team performed the following work:   Abate remaining asbestos in both buildings. Covered roofs of both warehouse operations with insulation board, covered by tires and topped with 2” thick decking. Erected a sidewalk bridge in north and east driveways to protect emergency exits from warehouses. Opened bottoms of both 200’ high brick chimneys.    Once the demolition permits had been obtained, Phoenix performed the following work:   Demolish both radial brick chimneys to the powerhouse’s roof, using a scaffold attached to the chimneys as a work platform and the chimneys as their own chutes. Using excavators attached with shears and grapples, the substation was demolished to grade. Using manlifts as work platforms, we sectionalized the powerhouse and dropped or pulled sections into our work area.  The largest pulled section weighed approximately 800 tons. Set up an owner revised dewatering set-up at the site (Baker tanks, 6” pumps and hoses). Removed building basement slabs and foundations as low as possible based on the dewatering set-up’s ability to handle ground and river water. Crushed masonry materials to 1”+ and left on site.   The project yielded: 2,500 Tons Scrap Steel 50,000 Pounds copper cable 23,000 Tons - masonry (crushed and left on-site)

History Calpine decided to close, for business reasons, its 56MW cogeneration plant in Newark, NJ.  Phoenix acquired the site and committed to perform the total demolition, returning it to a parking lot, at no cost to Calpine. The plant, built in the early 1990’s, was compromised of a 40 MW GE Frame 6B Gas Turbine Generator, a 20 MW ABB Alstom Steam Turbine Generator, an HRSG and all associated equipment. Its main building was a 90’ x 150’ x 45’ high (1) story structure. The HRSG had an 8’ diameter x 215’ high steel stack. The site was located on a pad 4 to 6 feet above adjacent grades and surrounded by a paper recycling operation to its south and west; the site access road/railroad tracks to its north and an active street to its east. Further complicating the salvage/demolition project, the energy company had already terminated electric power to the site and the soils below the plant had to be left undisturbed in place and capped.   Solution  Phoenix Equipment Corporation was chosen to perform the contract because:   Phoenix’s ability to market/sell equipment to re-users, lowering the project’s cost to the energy company. Phoenix’s ability to devise a safe and efficient demolition work plan for the project in a confined/congested work area. Phoenix’s ability to deal with Newark, NJ’s various governmental agencies, obtaining the necessary permits for the site. Phoenix’s ability to coordinate/manage its necessary subcontractors to provide a safe and smooth running project    While waiting for the demolition permit to be issued for the project by the City of Newark, Phoenix had to salvage portions of the (2) turbines (a crane would be need to lift sections), portions of the water filtration units, the transformers and the cooling towers.  Using an outside crane for the turbine and water filtration unit salvage would have cost too much and taken to long. Phoenix reactivated the building’s overhead crane for the project to capture the maximum benefit for the equipment salvage value, speed the salvage process and maximize the site’s minimum available space. The 215’ high steel stack had to be taken down with cutting torches. The surrounding paper recycling facility had to be protected. Phoenix and its subcontractor sealed the scaffolding around the stack and contained all the sparks emitted by the torch cutting operation and used the chimney itself to chute the cut sections to the ground. After Phoenix demolished the stripped building to its slab using hydraulic excavators equipped with shears and grapples, our site contractor sealed openings in the site’s concrete walls with rebar and concrete, processed on site masonry to level the site and covered the entire .75 acre site with a 3” base and 3” of asphalt. Phoenix completed the project ahead of schedule garnering the maximum bonus available to it under the contract and a minimal cost to the energy company.   The project generated sales of: Portions of the gas and steam turbines Cooling towers (2) Tanks (2) Transformers Portions of the water filtration units   The scrap materials generated at the site were: 2,500 Tons scrap 50,000 Pounds of copper 5,000 Tons masonry

How Asset Recovery Reduced the Cost of Redeveloping a Former Chemical Plant When Cardolite, a major producer of Cashew Nut Shell Oil (CNSL), ceased manufacturing at its Newark, New Jersey facility, the property's new owner planned to redevelop the site into a warehouse and distribution center. Rather than treating every asset as scrap, Phoenix recovered and sold surplus process equipment through the secondary process equipment market, helping offset the owner's redevelopment costs. The new owner purchased the property as-is, inheriting a chemical manufacturing facility that still required extensive cleaning before redevelopment could begin. Product left in tanks, piping, and process equipment had solidified after the shutdown, while other systems still contained liquids that had to be safely removed. Phoenix stepped in to plan and execute the cleanup, preparing the site for equipment recovery, demolition, and redevelopment. Beyond the cleanup effort, the property contained three major tank farms, more than 30 storage tanks, thousands of linear feet of process piping, and a wide range of process equipment. While portions of the facility would be demolished, much of the equipment still retained value for continued industrial use. Identifying and recovering those assets became an important part of the redevelopment strategy. Project Overview The former manufacturing site contained approximately 20 buildings. Nine production buildings accounted for roughly 50,000 square feet, while eleven office and warehouse buildings totaled approximately 100,000 square feet. Redeveloping the property required selective demolition, utility separations, hazardous material removal, equipment recovery, and regulatory coordination across the site while preparing it for its next use.   Why Phoenix Was Selected The owner was not simply looking for a demolition contractor. Recovering value from surplus process equipment was an important part of the redevelopment strategy. Phoenix managed the demolition, utility separations, environmental work, subcontractor coordination, and regulatory requirements under one project. At the same time, Phoenix's established position in the secondary process equipment market provided a practical outlet for equipment that still retained industrial value. Usable tanks and process equipment could be identified, removed, cleaned, and marketed to industrial buyers rather than being treated as scrap. This equipment selling capability helped offset the owner's overall project costs and was a major factor in choosing Phoenix.   Project Execution Before demolition could begin, electrical, water, and sewer utilities were separated so buildings scheduled for demolition could be isolated without interrupting service to structures being retained. Phoenix removed remaining CNSL from process equipment and six bulk storage tanks while safely identifying, removing, and containerizing hazardous materials, including sulfuric acid, caustic, ethylenediamine (EDA), and triethylenetetramine (TETA). Asbestos abatement and regulatory requirements were completed before dismantling progressed. Process piping, tanks, and equipment were then thoroughly cleaned and evaluated. Equipment with remaining market value was removed first and prepared for resale. Equipment and materials no longer suitable for continued use were directed toward recycling or demolition. Six process buildings were demolished to grade. Process equipment was removed from the remaining three production buildings, which were gutted as required for their new use. Site tanks and diked containment areas were also removed as part of the property's reconfiguration.   Recovering Value Through Asset Recovery Equipment that still has industrial value is fundamentally different from scrap. A stainless steel tank, heat exchanger, mill, or process dryer may continue operating for years in another facility. Recovering these assets before demolition preserves considerably more value than recycling them solely for their raw material content. Phoenix evaluated the facility's equipment before demolition to determine what could be preserved for continued industrial use.   Assets recovered for resale included: 25 stainless steel tanks ranging from 1,000 to 15,000 gallons 10 heat exchangers 2 Rotex screeners 2 Hosokawa mills 1 Witte fluid bed dryer 1 V-blender 1 Ribbon blender   Phoenix's access to the secondary process equipment market allowed these assets to be marketed based on their remaining industrial value rather than their scrap value. The resulting equipment sales helped offset the owner's site reconfiguration costs. After reusable equipment was removed, the remaining materials were evaluated for recycling or beneficial reuse. The project recovered approximately 1,350 tons of scrap steel and 150,000 pounds of stainless steel. Approximately 10,000 tons of masonry were crushed and left on site for reuse, reducing disposal requirements while preparing the property for redevelopment.   Preparing the Property for Its Next Use The Newark project required far more than demolition. It involved cleaning a former chemical manufacturing facility, safely removing residual products and hazardous materials, recovering equipment with remaining industrial value, recycling materials wherever practical, and preparing the site for redevelopment. By combining industrial redevelopment services with direct access to the secondary process equipment market, Phoenix helped reduce the owner's redevelopment costs while returning valuable equipment to productive service instead of scrap. The result was a redevelopment-ready property and industrial assets that continued operating elsewhere rather than being lost to recycling.

Phoenix purchased a 600,000 gallon tank farm and unloading station operation that was closed down. As part of our purchase we removed all assets from site, including a large concrete retaining wall structure, restoring the property to Greenfield. The project was completed in September 2008.  We sold several tanks and scrubber for re-use; we recycled over 1,000,000 lbs of non-ferrous materials and 1,000 tons of ferrous material.   The equipment saved for resale on the project included: (13) 45,000 Gallon 304L Stainless Steel Horizontal Tanks (1) 15,000 Gallon 304L Stainless Steel Horizontal Tanks (2) 7,000 Gallon 304L Stainless Steel Horizontal Tanks  (1) 3,000 304L Stainless Steel Horizontal Tanks

How Phoenix Removed a Petrochemical Plant Without Interrupting Active Operations When Nova Chemicals discontinued production of a polystyrene product at its Pennsylvania manufacturing complex, the shutdown left an entire production unit no longer needed. The rest of the manufacturing complex, however, continued operating. The owner wanted the unused plant completely removed while the remainder of the facility stayed in operation. At the same time, it wanted to maximize the value recovered from surplus process equipment, structural steel, and other materials generated during the project. Phoenix combined industrial dismantlement, demolition, environmental coordination, and equipment recovery under a single contract. By recovering valuable process equipment for resale before demolition began, Phoenix helped reduce the owner's overall project costs while preparing the site for its next use.   Project Overview The project involved removing an entire polystyrene production unit along with other unused portions of the manufacturing complex while surrounding production areas remained operational. Unlike a standalone demolition project, every phase of the work had to be planned around an active petrochemical facility. Equipment recovery, utility isolations, environmental work, demolition, and material handling all had to be carefully sequenced to protect surrounding operations while maintaining a safe work environment.   Why Phoenix Was Selected The owner was looking for more than a demolition contractor. Recovering value from surplus process equipment was an important part of the project's economics. Phoenix managed demolition, equipment recovery, environmental coordination, subcontractor management, and regulatory requirements under a single contract. At the same time, Phoenix's experience in the secondary process equipment market created an opportunity to preserve the value of equipment that remained suitable for continued industrial service. More than 50 major pieces of process equipment were recovered, rigged, and prepared for resale before demolition began, including stainless steel reactors, pellet dryers, vacuum pump systems, ribbon blenders, heat exchangers, pressure vessels, and storage tanks. Recovering these assets before demolition helped offset the overall cost of the project.   Preparing the Plant for Dismantling Preparing the plant for dismantling began well before any structural demolition. Phoenix first coordinated asbestos abatement through a licensed subcontractor while developing safe, cost-effective methods for removing residual styrene and maleic anhydride from the process piping and equipment. Universal waste, including fluorescent lamps, ballasts, transformer oils, and equipment oils, was identified, packaged, and removed in accordance with applicable environmental requirements. Once the process systems had been made safe, equipment identified for resale was systematically disconnected, rigged, and removed before demolition progressed, preserving significantly more value than scrap recovery alone. With reusable equipment removed, demolition proceeded while maintaining safe separation between the project area and the surrounding operating facility.   Complex Demolition Challenges Working within an active petrochemical manufacturing complex introduced challenges beyond those typically encountered during industrial demolition. Including:   Removing a 110-Foot Process Building One of the project's most technically demanding tasks involved dismantling a 110-foot process building that shared a party wall with a one-story warehouse that remained in service. Even more challenging, the building's elevator extended through the warehouse roof to serve the upper levels of the process building, eliminating conventional demolition methods. Phoenix developed a controlled dismantling sequence using a 150-ton crane and elevated work platforms to remove the elevator structure and upper portions of the building before completing the remaining demolition. The approach allowed the process building to be dismantled while the adjacent warehouse remained intact.   Removing a 135-Foot Water Tower A deteriorated 135-foot steel water tower presented another significant challenge. Located between active pipe bridges and an occupied office building, only a 60-foot-wide corridor remained available for removal. Before the lift could begin, Phoenix stabilized portions of the weakened tower by cabling the structure together. A 300-ton crane and elevated work platforms were then used to safely remove the tower within the confined work area.   Recovering Value Through Asset Recovery Industrial process equipment often retains substantial value long after production has stopped. Reactors, vacuum systems, heat exchangers, pressure vessels, and process dryers can frequently be refurbished and returned to service at another facility. Recovering these assets before demolition preserves considerably more value than reducing them to scrap.   Assets recovered for resale during the project included: Five 6,000-gallon stainless steel reactors One 15,000-gallon stainless steel reactor Two Gala pellet dryers Five Nash vacuum pump skid systems One 135-cubic-foot stainless steel ribbon blender Dozens of shell-and-tube heat exchangers, stainless steel pressure vessels and storage tanks   After reusable equipment had been removed, Phoenix recycled structural steel generated during demolition. Masonry from the project was crushed to 2-inch-minus material and reused across the site, eliminating the need to import aggregate and saving the owner substantial cost.   Preparing the Site for Its Next Phase Phoenix completed the dismantlement, demolition, equipment recovery, environmental coordination, and site preparation in just over eight months while working within an active manufacturing facility. The project was completed on schedule, on budget, and without a safety incident. By combining industrial dismantlement with direct access to the secondary process equipment market, Phoenix reduced the owner's overall project costs while returning valuable industrial assets to productive service instead of scrap. The result was a cleared site ready for its next phase, completed safely within an active petrochemical manufacturing complex.  

How Asset Recovery Helped Reduce Demolition Costs at an Active Refinery When an industrial process unit is shut down, demolition isn't the only decision to make. Determining what equipment can be recovered before dismantlement begins can have just as much influence on the overall cost of the project. That was the challenge Marathon Oil faced after electing to cease operations of its lube oil plant at the Catlettsburg Refinery in Kentucky. Although the lube oil plant was no longer needed, the refinery itself remained fully operational. Marathon needed the obsolete process units removed without disrupting refinery operations while recovering as much value as possible from the equipment and materials that remained. Phoenix combined equipment recovery, scrap management, and industrial dismantlement under a single contract. Integrating these services helped reduce the overall cost of removing the plant while maximizing the value recovered from surplus assets. Project Overview The project included dismantling an 18,000-barrel-per-day furfural unit, an 11,000-barrel-per-day methyl ethyl ketone (MEK) extraction unit, and the associated process equipment, utilities, and supporting infrastructure that made up the former lube oil plant. Because the work was performed inside an active refinery, planning extended well beyond demolition activities. Asset recovery, utility systems, demolition sequencing, material handling, and ongoing refinery operations all had to be carefully coordinated to complete the work safely without interrupting adjacent site activities.   Why Phoenix Was Selected Marathon was looking for more than a demolition contractor. Recovering value from surplus process equipment and recyclable materials was an important part of the project's economics. Phoenix contracted to purchase the machinery, process equipment, and scrap while also performing the complete dismantlement of the plant. Combining these responsibilities under a single contract allowed equipment recovery, scrap management, and dismantlement activities to be planned and executed as one integrated project.   Recovering Value Before Demolition One of the most significant opportunities involved the plant's MEK dewaxing equipment. Rather than dismantling individual assets for scrap, Phoenix executed a bulk sale of major process equipment associated with the MEK extraction unit, including rotary vacuum filters and vacuum pumps. Recovering an integrated process package before demolition began helped reduce Marathon's demolition budget while preserving valuable equipment for continued industrial service. That effort required considerably more than simply removing equipment. Phoenix match-marked major components, dismantled and prepared equipment for transport, loaded it for shipment, and relocated assets retained for future resale. Completing this work before dismantlement progressed preserved equipment that otherwise would have entered the scrap stream.   Maximizing Scrap Recovery After reusable equipment had been removed, dismantlement of the remaining plant and supporting infrastructure proceeded. Phoenix recovered approximately 5,000 tons of heavy melting steel (HMS) and approximately 400,000 pounds of non-ferrous metals during the project. Because scrap recovery represented an important part of the project's economics, Phoenix shared proceeds from carbon steel recovery above an established price threshold and documented every shipment through bi-monthly reporting. Jointly verified weight slips and copies of payments received from carbon steel sales provided Marathon with clear visibility into the value recovered throughout the project.   Completing the Project An agreement for the project was reached in July 2009, and Phoenix mobilized to the site the following month. Dismantlement work began in late August 2009 and continued through September 2010, including the complete removal of concrete slabs. By combining asset recovery, scrap management, and industrial dismantlement under a single contract, Phoenix helped reduce Marathon's overall project costs while maximizing the value recovered from surplus process equipment and recyclable materials. This project illustrates how integrating asset recovery into industrial dismantlement can improve project economics while safely removing obsolete process facilities within an active refinery.