Optimizing Modular Layout for a Petrochemical Plant

Assessing Modularization Potential for Cost and Efficiency Gains

A leading petrochemical company aimed to adopt modular construction for a new facility. The objective was to maximize efficiency, minimize land use, and reduce costs, but the company needed a structured evaluation to determine the best modular approach.

Identifying Cost Savings and Feasibility with OptiMod Execution

DyCat Solutions applied the OptiMod Execution Process to assess modularization feasibility and financial impact. Key actions included:

• Conducting a Class 5 estimate to determine cost advantages.

• Comparing modular vs. traditional construction to evaluate potential savings.

• Assessing logistics, transportation, and site constraints to define modularization limits.

Determining the Right Level of Modularization for Maximum Efficiency

Through a structured evaluation, DyCat Solutions determined that:

• 75% of the facility could be modularized while maintaining constructability and transport feasibility.

• Very Large Modules (VLMs) were the optimal choice to maximize off-site fabrication and minimize on-site labor.

• A balance between modularization and site assembly was required to optimize efficiency and execution.

Developing an Optimized Modular Layout to Reduce Plot Space

To refine the facility's footprint, DyCat Solutions:

• Designed an optimum modular plot plan that significantly reduced site congestion.

• Compared the modular layout vs. a traditional layout to identify inefficiencies.

• Ensured that logistics, assembly, and operations were fully integrated into the design.

Achieving Cost and Land Savings with a Smarter Modular Approach

By implementing the optimized modular layout:

• Plot area was reduced by 40%, cutting unnecessary land use and improving site accessibility.

• Total installed cost was lowered by 20%, primarily due to reduced on-site labor and more efficient material usage.

• Execution planning was streamlined, ensuring seamless integration between off-site fabrication and on-site assembly.

Delivering a Scalable, Cost-Effective Petrochemical Facility

Through DyCat Solutions’ expertise in modular construction and the OptiModLayout Process, the petrochemical company successfully:

• Increased modularization to 75%, minimizing construction risks and labor challenges.

• Reduced overall costs while maintaining safety, quality, and operational efficiency.

• Optimized facility layout to support long-term scalability and streamlined execution.

Looking to improve efficiency and reduce costs with modular construction? Contact DyCat Solutions today.