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Oneira Corporation, an EPCM company, has provided process engineering and technology solutions to leading industrial companies around the world for more than 30 years.
Focused on Specialty Chemicals, Chemicals, Oil & Gas, Mineral Processing and Process Control, Oneira solves the toughest process challenges by listening to clients, understanding their business requirements and partnering on solutions.
From concept to completion, Oneira delivers on time and on budget. Project after project, clients return to Oneira for reliable execution and measureable results.
In the complex industrial world, Oneira offers a simple formula:
BUILD... DELIVER... DRIVE...
BUILD Relationships: Build long-standing relationships with clients through responsiveness, commitment, accountability and staff continuity.
DELIVER Solutions: Deliver inventive solutions for clients through experience, knowledge and collaboration.
DRIVE Results: Drive measureable results for clients through scalable design, engineering and project management and on-time, on-budget performance.
Oneira’s long-term relationships with leading international Specialty Chemical organizations results in extensive experience and a global perspective within the coatings, inks, resins, adhesives, sealants, lubricants and miscellaneous specialties industries.
Oneira’s knowledge in designing specialty chemical processes makes the firm one of the most innovative servicing the sector today. Oneira has delivered a multitude of engineering services to the sector, from Safety Audits and Plant Retrofits to Greenfield Plant design.
Our Expertise includes:
• Batch Processing• Cycle Time Reduction• Plant and Process Safety• Waste Minimization• Hazardous Materials Storage and Handling• Plant Layout• Process Control and Automation• Regulatory Requirements• Risk Management
Specialty Chemical
Oneira Gated Engineering Process
Through gated engineering phases, Oneira develops clients’ visions from concept to completion.
Decision Support: Analyze data, develop concepts and estimate costs to support stakeholder decision making.
• Lab Testing and Pilot Plants• Process Technology Selection• Scoping Studies• Process Flowsheet Development• Capital Cost Estimation• Optimization Studies• Process Performance Monitoring• Operation Audits• Process Debottlenecking• Safety Audits• Acquisition Due Diligence
Front-End Engineering Design (FEED): Develop strategic information that enables stakeholders to estimate risk, support decisions and commit resources.
• Process Engineering• Mechanical Design• Electrical and Instrumentation Design/Engineering• Process Automation and Controls Design• Civil/Structural Engineering
Detailed Engineering: Final engineering details that capture design requirements and provide a firm basis for budgets, risk assessment and execution.
• Final Engineering Design• Equipment and Instrument Tendering and Selection• Controls Integration• Construction Packages
Construction, Commissioning and Start-Up: Support services for construction, commissioning and start-up.
• Shop Drawing Review• Inspections• Factory/Site Acceptance Testing• Troubleshooting
Case Study
Client: Leading Specialty Chemicals Company, HQ USALocation: Worldwide locationsProject: Multiple Projects Relationship: For over a decade Oneira has provided consulting and engineering services to this world-leading specialty chemicals company representing some of the most recognized brands in the world. The projects have spanned more than a dozen operating companies on four continents, and services have ranged from safety audits, capital planning and acquisition due diligence to retrofits of existing facilities and development of new plants. Result: Project after project, Oneira's inventive solutions and scalable execution have driven results for this specialty chemicals client across its worldwide assets.
Case Study
Client: Global Paint, Coatings and Specialty Chemicals ManufacturerLocation: North America / AsiaProject: Multiple ProjectsBudget: $50 Million (multi-year) Relationship: Oneira has a long-standing relationship with this market-leading paints and coatings company providing multi-discipline engineering solutions to its global facilities. Over a period of 15 years, Oneira has developed solutions to challenging business opportunities in North America and Asia. The projects cover all aspects of specialty chemicals manufacturing from raw material storage to product filling lines and plant retrofits to new facilities. Result: Oneira's extensive experience in this industry and collaborative approach to every project has resulted in the successful execution of over $50 million of project capital.
Case Study
Client: Fortune 500 Business Process and Document Management CompanyLocation: USABudget: $150 Million Relationship: For more than a decade, Oneira has supported this Fortune 500 company in its roll-out and expansion of a revolutionary chemical-based colour toner product. Oneira worked with the client to develop the pilot plant, full-scale plant and several subsequent expansions. Result: Oneira provided conceptual and front end engineering as well as detailed design and construction support.
Case Study
Client: Automotive OEM Primer PlantLocation: CanadaBudget: $35 Million Challenge: The client required additional capacity to meet the demands of the automotive industry. The design objectives included reducing dwell time and adjustments per batch while maximizing repeatability.
Solution: Oneira began the project with cycle time and material flow analysis for the anticipated product mix. The design incorporated sophisticated automated batch control, state-of-the art pipeline pigging and enhanced safety features. Result: Oneira's innovative design and seamless project execution resulted in an unprecedented ramp-up to full capacity.
Project Profile
Client: AKZO NOBEL
Project: Strontium Chromate Slurry System Columbus, Ohio
Value: $1.0 million
Services: Preliminary Engineering Detailed Engineering Equipment & Instrument
Description:
• Designed a system suitable for handling suspect carcinogens
• Strontium chromate bag breaking, and bulk bag unloading station
• New mezzanine
• Bulk liquid transfer system
• Solids dispersion
• Slurry distribution system to batching vessels
• Dust-tight construction
Project Profile
Client: BASF Canada Inc.
Project: Safety Upgrade – Miscellaneous Debottlenecking Windsor, Ontario
Value: $4 million
Services: Process Design Preliminary Engineering Capital Cost Estimating Detailed Engineering
Description:
• Designed a system suitable for handling suspect carcinogens
• Study of existing building for code compliance
• Relocation of metallic slurring operations
• Relocation of solvent tank farm truck unloading bay
• New intermediate bulk distribution systems
• White paste manufacturing and distribution systems
• Emergency power system for fire water and building ventilation
• Solvent tank farm upgrade for compliance with all codes
• Mill conversion from pass to recirc
At BASF’s request Oneira conducted a safety audit of the existing production building. The study identified a lack of explosion venting resulting in non-compliance to the code. Oneira worked with local authorities and designed an innovative solution to comply with the codes, avoiding costly structural changes to the building.
Project Profile
Client: BASF Canada Inc.
Project: Solvent Borne Rationalization Windsor, Ontario
Completed: 1998
Services: Project Management Capital Cost Estimating Process Design Preliminary Engineering Detailed Engineering Procurement Construction support
Description:This project involved adding substantial capacity to the existing primer plant designed by Oneira in 1995. For details see primer plant profile.
Project Profile
Client: BASF Canada Inc.
Project: Grass Roots OEM Primer Plant Windsor, Ontario
Value: $35 million
Services: Process Design Preliminary Engineering Capital Cost Estimating Detailed Engineering Procurement Construction Management Commissioning
This plant, claimed by BASF as their international “flagship” automotive paint production facility, employed many new technologies. Oneira’s innovative design and application of the technologies resulted in an unprecedented, short startup reaching full capacity in 6 months. Despite growth in engineering scope, Oneira managed to complete the detailed design and procurement on schedule.
Description:
• Raw materials receiving system• Batch cycle time and material flow analysis • Flammable liquid warehouse expansion• New resin tank farm• Flammable liquids manufacturing including large and small batch areas• Flammable liquids storage building• Pigment prestaging operation• Air emission analysis• Process equipment layouts
• Site redevelopment plan including demolition of several buildings, relocation of maintenance facilities and future upgrades to other facilities. • DCS based batch control system on a fibre optical network with 9 PLCs and 27 weigh scales• Pigging system to clean common transfer header and manifold system• Metered bulk liquid distribution system
Project Profile
Client: Flint Ink Corporation
Project: Greenfield Liquid Centre Lebanon, Ohio
Value: $15 million
Services: Project Management Process Design Preliminary Engineering Capital Cost Estimating Detailed Engineering Procurement Construction Management
This Greenfield packaging ink production facility included the following highlights:
This project involved a tight timeline, with Oneira executing the project from detailed engineering to start-up in an unprecedented 9 months. Despite this, the engineering was brought in under budget and the overall project cost under our estimate.
Description:
• Warehouse design and modelling • Material flow analysis • Manufacturing including small batch, large batch and fill-off• Bulk liquids tank farm• Flammable liquids processing building• Pigment handling• Cellulose Nitrate Handling
• Site traffic analysis• DCS based batch control system• EPA emission modelling• Metered bulk liquid distribution system• Industrial ventilation system• Site plan development• Building layouts including, offices, lab, manufacturing, and utilities
Project Profile
Client: NALCO
Project: New Tank Farm and Batch Blending Facility
Value: $8 million
Services: Detailed Engineering
Description:
• Equipment Layout
• Process Design
• Civil and Structural Engineering
• Outdoor Tank Farm
• Truck Unloading Station
• Blender Layout
• Pipe Pigging System
• Piping Design
• Equipment Specifications
Project Profile
Client: Tremco Ltd.
Project: Aerosol Filling Line Toronto, Ontario
Value: $3 million
Services: Process Design Detailed Engineering Code Review Government Liason
Description:
• Building modifications
• Code compliance
• New solvent storage
• Solvent blending and transfer
• Paint transfer to filling line from blending
• Liason with vendors
Oneira’s design performance and project management resulted in less than 1% contract extras.
Project Profile
Client: Schenectady Canada Ltd.
Project: Phenol Distribution and Effluent Collection Systems Scarborough, Ontario
Value: $0.5 million
Services: Preliminary Engineering Capital Cost Estimating Process Design Detailed Engineering Procurement Project Management
Description:
• Tank farm dyke expansion
• New MDI tank farm dyke
• Mass metered phenol distribution system to 8 resin reactors
• Phenol effluent collection system
• Incorporated phenol system into existing Fisher DCS
• Emission analysis
Oneira’s design performance and project management resulted in less than 1% contract extras.
Project Profile
Client: Cytec Canada Inc.
Project: Bulk Tanks Replacement Niagara Falls, Ontario
Value: $1.4 million
Services: Preliminary Engineering Capital Cost Estimating Project Management Detailed Engineering Equipment and Instrument Specifications
Description:
• Removal of existing underground storage tanks
• Process piping, Instrumentation
• New above ground tank farm for the storage of flammable and pyrophoric materials
Specialty Chemical Experience
Stepan Canada – Orillia, OntarioEthylene Oxide Storage Safety Study; Sulphonation process upgrades; Flammable liquids storage design review.
Akzo Nobel – Pontiac, MichiganFlammable liquid storage design and construction management. Colour blending building design. Automated dosing machine specification. High speed dispersion tank specification. Small batch production process design and layout. Plant expansion planning and capital cost estimation. Letdown and intermediate tank storage system. Warehouse building structural review.
Akzo Nobel – Suzhou, ChinaChromate handling process design and plant layout. Filling line automation upgrade. Akzo Nobel – Toronto, OntarioLatex pigging system. Tank farm and truck unloading upgrades. Ammonia storage.
Eucomex – Querétaro, MexicoGreenfield concrete admixtures plant.
BASF Canada Inc. – Brantford SiteSafety Upgrade Project for the existing automotive refinish paint facility. Regional Flammable Liquids warehouse.
BASF Canada Inc. – Windsor Site‘Grass Roots’ automotive OEM Primer Plant and New Resin Tank Farm.
BASF Canada Inc. – Windsor SiteSafety Upgrade to the existing automotive Water Borne OEM Paint Plant & Solvent Tank Farm.
BASF Canada Inc. – Constellation CourtMDI unloading & transfer system. Upgrade of laboratory for handling & storage of flammable liquids.
BASF Corporation – Greenville, OhioUpgrade and relocation of E-Coat Facility from West Virginia.
Specialty Chemical Experience
BTL Specialty Resins Resin Reactor System Relocation.
Schenectady Canada Ltd.MDI Tank Farm Dyke. Phenol Distribution and Phenol Effluent Collection System.
AOC Resins New tank farm and railcar unloading system for maleic anhydride and other raw materials.
Ashland Chemicals CanadaLatex Emulsion Plant.
Industrial Adhesives – A Division of Timminco LimitedPlant wide industrial ventilation system and waste treatment process development.
Henkel Canada Ltd. – Emery GroupMajor plant expansion. New Continuous Process Unit for Fatty Acid and Glycerine Production, Glycerine Ion Exchange Purification, Fatty Acid Hydrogenation, Emtrol Production, Energy Conservation Project
Suncor – Mississauga, OntarioMotor Oil Blender Upgrade Concept, feed and detailed engineering. Pail filling line optimization.
Cytec Canada Inc.New tank farm for the storage of pyrophoric. Plant upgrades and debottlenecking.
Akzo Nobel Coatings Inc. – Columbus, OhioPreliminary engineering and capital cost estimate for planned plant expansion.
Akzo Nobel Coatings Inc. – Columbus, OhioChromate handling, slurrying and distribution system.
Specialty Chemical Experience
PPG Industries – Delaware, OhioPaint plant.
Manders Premier, Inc. – Lebanon, OhioGreenfield Liquid Packaging Ink Plant.
Flint Ink Corporation – Lebanon, OhioGreenfield Liquid Ink Plant.
Hostmann Steinberg – Brampton, OntarioDesign/Build Paste Ink Filtration and piggable transfer system.
Tremco Mameco – Cleveland, OhioNew closed vessel sealants production processes.
Tremco – Toronto, OntarioNew closed vessel sealants production process. Installation of colour and catalyse on fill. Filling machines. Tank Farm expansion.
Xerox Canada – Mississauga, OntarioEA Toner Plant.
Xerox Corporation – Webster, New YorkGrass Roots EA Toner Plant. Expansion of EA Toner Plant for additional production.
Nalco – Burlington, OntarioBrownfield Tank Farm and Batch Blending Facility.