Bentley > Case Studies > Hatch Sets Industry Benchmark Using a Digital Twin to Deliver Sulfuric Acid Plant in the DRC

Hatch Sets Industry Benchmark Using a Digital Twin to Deliver Sulfuric Acid Plant in the DRC

Technology Category

Analytics & Modeling - Digital Twin / Simulation
Sensors - Temperature Sensors

Applicable Industries

Metals
Transportation

Applicable Functions

Maintenance
Procurement

Use Cases

Digital Twin
Virtual Prototyping & Product Testing

Services

System Integration
Testing & Certification

About The Customer

Hatch is a global professional services company that was retained as the engineering, procurement, construction, and manufacturing contractor to deliver a sulfuric acid plant in Katanga, a remote province located in the southern part of the Democratic Republic of the Congo (DRC). The DRC is a resource-rich area with abundant reserves of copper and cobalt, with copper accounting for 50% of all DRC exports. The sulfuric acid plant is being built to sustain one of the largest copper mining operations in the DRC, as the copper mines require sulfuric acid to leach copper oxide minerals. The plant will manufacture thousands of tons of acid daily and will exceed world standards for sulfur dioxide emissions, optimizing environmental sustainability.

The Challenge

Hatch, a global professional services company, was tasked with delivering a $245 million sulfuric acid plant in the remote region of Katanga, Democratic Republic of the Congo (DRC). The plant was critical to sustain one of the largest copper mining operations in the DRC, as the copper mines required sulfuric acid to leach copper oxide minerals. The project presented several challenges, including the remote location, logistical and environmental difficulties, and a fast-tracked schedule. The plant was to feature a 1,400 ton-per-day manufacturing facility and an electrical waste heat power generation system with a steam turbine unit, which was critical due to the limited power grid supply in the area and complex integration with the existing electrical network. Hatch needed to overcome these complexities and accommodate the accelerated timeline with a team of engineers distributed globally across five offices. The company sought a sustainable technology solution, digitalizing all workflows and deliverables.

The Solution

Hatch implemented a collaborative digital strategy using Bentley’s open applications, which streamlined workflows and facilitated quality engineering processes that saved time and costs. The project team used STAAD to model and analyze the structural steel components, and OpenPlant and OpenBuildings Designer to create a digital twin model of the entire acid plant. ProjectWise served as the collaborative platform to establish an open, connected data environment to manage and share information across five globally dispersed engineering offices. Bentley’s open applications provided flexibility within the design environment, enabling a single 3D model to be used for layout, analysis, design, and fabrication. This flexibility also optimized coordination throughout all stages of engineering and construction, as well as presented opportunities to capitalize on digitalization to improve efficiencies. The interoperable digital technology allowed operations teams to interact in the model environment for hazard and operability study checks, improving operations reviews and enhancing operational safety.

Operational Impact

The digital solution allowed geographically dispersed teams to jointly move the discrete paper isometric drawing production process into continuous digital delivery sets for site fabrication. This capability optimized coordination between global delivery teams and site fabrication to accommodate the aggressive schedule. By working in the connected data environment with Bentley’s open applications, Hatch was able to accelerate project delivery, streamlining workflows to cut six weeks from the schedule and resulting in substantial return on investment for the client. The digital twin facilitated shipping of bulk pipe materials rather than prefabricated piping spools, reducing transportation costs by four times. The 100% digital solution accelerated operational readiness, reduced capital expenditure costs by 20%, and enabled Hatch to deliver the fast-paced project in under two years, from feasibility to startup.

Quantitative Benefit

Working with a digital twin streamlined workflows and eliminated paper deliverables, cutting six weeks from the project schedule.
Using the digital twin model for material extraction and procurement saved 10% to 15% in purchasing costs.
Hatch completed the fast-paced project under budget in less than 24 months, saving 20% in capital expenditure costs.