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Year

2023

Hysytech

Biogas & Biomethane, Energy and Automation, Flue Gas Treatment, Hydrogen & CO2 Capture
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Description

Hysytech is an engineering company founded in 2003, specializing in the design, development and industrial implementation of new technologies and turnkey process equipment. Hysytech’s capabilities start from know-how in chemical and process engineering, up to commissioning, monitoring and maintenance.

The company operates mainly in the field of generation, treatment and recovery of industrial gases, organic liquids and energy, according to first level engineering practices in the plant engineering world, also through the implementation of the technologies it has developed for hydrogen, biomethane and bio-LNG.

In 2018 the Hysytech Group acquired Stirling Cryogenics, a global specialist in cryogenic technology, originally founded by technology giant Philips. Stirling Cryogenics designs, builds and supplies cryogenic solutions based on the thermodynamic (reverse) Stirling cycle, with a long history, high efficiency and a reference list of over 3,000 installations worldwide. Stirling Cryogenics’ core products are stand-alone Liquid Nitrogen systems (StirLIN’s), producing Liquid Nitrogen (LN2) on site and bespoke cryogenic cooling systems based on Cryocoolers (Liquid Oxygen, Methane, Argon, Helium and CO2 plus ‘Nitrogen) with Stirling technology.

 

Our path

Hysytech, for the design of its plants, had been using for many years a system which, despite being the market leader among 3D mechanical CAD, was poorly adapted to the peculiarities of plant engineering, with the consequence that the design process was cumbersome and involved a waste of time that seemed objectively excessive.

In 2019 it was therefore decided to materialize the hypothesis, which had already appeared on several occasions, of replacing the product used until then with a specific tool for plant design which would hopefully allow all phases of project development to be managed in an integrated manner , from the development of functional diagrams to construction and assembly documents, simultaneously reducing execution times.

After a careful analysis and comparison of the various products available on the market, both from a functional and economic point of view, in mid-2019 three ESApro P&ID and Instrumentation licenses were purchased, for the management of process and instrumentation schemes, and as many licenses of ESApro 3D Piping and Isometrics for the three-dimensional modeling of the system and the generation of material lists and isometric drawings.

Getting ESApro up and running, including staff training, environment customization and preliminary tests, took about a year, a rather long time due to the fact that the introduction of the software coincided with a critical period for the company both due to external factors, the Covid pandemic, and due to the simultaneous consistent growth of the company.

Once the implementation process was completed satisfactorily, between 2020 and 2021 other module licenses for P&ID and piping were acquired plus new modules for the design of cable routes to complete the ESApro suite.

“At the beginning of 2022” says the Mechanical Design Manager of Hysytech “the company acquired two large orders for two almost twin plants for the purification of Biogas and subsequent liquefaction of the Biomethane obtained.

The project, entirely managed with ESApro, involved approximately four people for process design, five for mechanical design and one person for electrical design, to which were added, when necessary, collaborators from external companies who supported us not only for construction, but also in engineering activities.

In this phase, great help also came from ESApro’s particularly short learning ramp which allowed us to quickly insert new resources into the project, obtaining particularly efficient and effective results.”

“Thanks to the use of ESApro P&ID and Instrumentation in the process design phase and 3D Piping, Isometrics and Cable Trays in the subsequent mechanical and electrical design phases, it was possible to complete the activities within the planned times and with a notable reduction of busy hours” continues the Mechanical Design Manager. “The workflow integrated by the various components of ESApro has improved the efficiency of communicating changes, the ease of tracking them and the consequent communication with the construction.

The integration with the pre-existing project documentation and with the internal management applications was very fluid and without any particular problems to solve.

In particular, compared to the tools used previously, we found greater control and efficiency of the design and hours spent on modifications as well as a clear improvement in data communication between the various departments involved (process engineering and mechanical design) with a consequent reduction of errors.

Furthermore, we achieved a 15/20% reduction in the hours required for issuing sketches towards construction.”

“As regards future prospects,” concludes the Mechanical Design Manager, “we are currently in a phase of significant company growth and consolidation of the procedures and tools currently in our possession, after which we do not exclude the numerical expansion of what is already in use and the addition of further new ESApro modules for supports construction and stress analysis.”

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