
Support Projects
Implementing a secure, uniform site-wide system for enhanced safety and emergency response.
Challenge
OMYA, Inc., a global leader in calcium carbonate production, required modernization and optimization across several critical systems in their automated production facilities. They faced challenges in scaling their control systems with over 1,000 I/O points, upgrading their SCADA system to enhance operational efficiency, and integrating new production equipment like milling, drying, and evaporator systems. These upgrades needed to align with OMYA’s high standards for precision and scalability, while accommodating evolving production needs and ensuring seamless implementation within operational facilities.
Solution
Hallam-ICS delivered comprehensive engineering and design solutions tailored to OMYA’s needs.
Control System Design: Hallam-ICS has provided control system design for OMYA facilities that include over 1000 I/O points. The design includes process and instrumentation drawings (P&ID), control panel layout, wiring details and loop sheet generation for over 500 field devices.
SCADA System Selection: OMYA was interested in upgrading their existing Supervisory Control and Data Acquisition (SCADA) system. Hallam-ICS provided evaluation and testing of possible upgrade solutions. This included defining the needs of the system, developing prototypes and testing the scalability of the proposed solution. Hallam-ICS was able to develop a solution that included off-the-shelf technology customized to OMYA’s specific requirements.
Milling and Drying System: Hallam-ICS provided structural and mechanical engineering services to perform the detailed design associated with this project. Our work included meeting with the owner’s engineering and operations staff to develop an equipment general arrangement plan. Once an acceptable plan was developed, we designed all necessary structural foundations, equipment support structures, and equipment access/service platforms including catwalks, ladders, and stairs. Beyond the general arrangement, our mechanical work included product piping and utility piping design and interconnecting ductwork and dust collection system for a fluid energy mill, flash dryers, and an impact mill.
Evaporator System Installation: Hallam-ICS provided mechanical, electrical, and control design services for the process design of a prototype evaporator system for a calcium carbonate production facility. Our scope of services included the preparation of equipment general arrangements, process piping design, electrical power distribution, and process instrumentation and controls. System components included flash vessels, heat exchangers, 500 hp turbo fans, and several pumps. During installation of the project we attended construction progress meetings and made field inspections on the owner’s behalf.
Rotary Dryer Installation: Hallam-ICS provided structural and mechanical engineering services for layout and design/analysis of a new rotary dryer circuit for an existing calcium carbonate production facility. System components included feed hoppers, belt and screw conveyors, dust collection, a screen plant, a rotary dryer, interconnecting ductwork, equipment support structures, access platforms, and catwalks.
The team also supported construction oversight to maintain quality and timeline adherence.
Results
Our team accomplished the following:
- Designed and implemented a control system with over 1,000 I/O points, supporting precise production control.
- Evaluated and upgraded OMYA’s SCADA system using scalable, off-the-shelf technology tailored to their operations.
- Delivered structural, mechanical, and process designs for complex systems, including rotary dryers and evaporators, improving facility efficiency.