PLANT ENGINEERING DESIGN
Engineering design validated by simulation
jimmylea is one of the most capable and insightful firms in plant engineering design. Our plant engineering design services encompass process engineering, mechanical engineering, instrumentation and control systems, delivering integrated solutions for complex industrial facilities. Our multidisciplinary team has successfully delivered process plant consulting and comprehensive plant engineering design services for chemical plants across Australia and Singapore, including greenfields and complex brownfield upgrades.
We recognise that successful plant engineering design begins well before construction, at the critical stage of process technology selection, assessment and validation. Our process plant consulting approach integrates advanced simulation, engineering analysis and practical project experience to optimise safety, operability and long-term performance. Every plant engineering design project is developed to minimise technical risk and maximise operational reliability.
Specialised in multiphase flow, reactive systems and integrated controls
Our in-house chemical process plant consultants bring decades of experience in validating the viability, safety and efficiency of proposed plant designs. Backed by advanced simulation tools and engineering expertise, our plant engineering design services address multiphase flow challenges, reactive systems and integrated control strategies. Through practical process plant consulting, we deliver plant engineering design solutions optimised for functionality, regulatory compliance and sustained performance in demanding environments.
Proven track record, successful delivery across greenfields and complex brownfield upgrades
elow are the plant engineering design projects we have successfully delivered, demonstrating our proven capability in process plant consulting across the full lifecycle of chemical plant development, from concept and technology assessment through detailed design, validation and handover.
By partnering with jimmylea, you engage experienced process plant consultants who combine deep engineering insight with practical, buildable delivery. Our plant engineering design services ensure your plant engineering design project advances with confidence, clarity and minimised technical risk.
[1] Detailed Engineering Design of a Chemical Plant
This project encompassed the front-end engineering design (FEED) and detailed engineering design (DED) of a chemical plant, requiring close collaboration between process, mechanical, instrumentation and control, and drafting disciplines. The objective was to deliver a fully functional and optimised facility that complied with all regulatory requirements while meeting operational performance targets.
The scope of work included developing the conceptual process design, creating PFDs and P&IDs, and performing mass and energy balances along with detailed process calculations. Mechanical engineering activities covered equipment selection, sizing, and layout design, ensuring mechanical integrity during transport and operation. Instrumentation and control tasks involved designing monitoring and regulation systems, integrating automation, and preparing control philosophies and alarm matrices. Advanced simulation was used to optimise fluid flow and assess dynamic performance, while drafting produced comprehensive engineering drawings, layouts, and diagrams to support construction and commissioning.
[2] Detailed Engineering Design of a Polymer Chemical Plant
This project involved a multidisciplinary engineering team comprising chemical, mechanical, instrumentation and control, simulation, and drafting specialists. The team was responsible for the detailed engineering design (DED) of a buoyancy riser plant for the oil and gas industry, with a focus on manufacturing various polymers as raw materials. The objective was to deliver an optimised, high-quality production facility that met stringent industry standards for performance, safety, and reliability.
The scope of work included developing the design basis, performing process simulations, preparing PFDs and P&IDs, and conducting rigorous process calculations to optimise reaction conditions, material and energy balances. Mechanical engineering activities covered the design and specification of equipment such as reactors, mixers, and storage tanks. Instrumentation and control tasks involved designing the control system architecture, specifying instrumentation, developing functional specification and alarm matrices. Drafting produced comprehensive 2D drawings and 3D plant layouts.
[3] Detailed Engineering Design of Inkjet Ink Chemical Plant
This project involved the design of an inkjet ink chemical manufacturing plant. A multidisciplinary engineering team was mobilised to deliver a state-of-the-art facility, covering the entire design lifecycle from conceptual studies through front-end engineering design (FEED) to detailed engineering design (DED). The objective was to create an optimised and fully integrated production plant that met both technical and economic performance targets.
The scope of work included conceptual design tasks such as feasibility studies, development and evaluation of multiple design options, preparation of high-level PFDs, preliminary engineering calculations, and cost estimation. The FEED phase refined the chosen concept into detailed process designs with P&IDs, process calculations, datasheets, OEM vendor recommendations, and conceptual layout drawings. The detailed engineering design phase delivered 2D and 3D plant layouts, detailed arrangements, thermal and fluid mechanics calculations, procurement specifications and tender documents.
[4] Detailed Engineering Design of Waste Heat Recovery Plant
This project involved the multidisciplinary detailed engineering design (DED) of a heat recovery energy plant, drawing on expertise in chemical, mechanical, instrumentation and control, simulation, and drafting disciplines. The work spanned both conceptual and detailed design phases, with the objective of delivering a safe, efficient, and reliable facility to maximise heat recovery and utilisation.
The scope of work included developing the design basis, performing chemical process design, and selecting suitable materials to ensure efficiency and safety. Mechanical engineering tasks covered the design and specification of equipment such as heat exchangers, boilers, and turbines, to integrate equipment within the plant layout. Instrumentation and control activities involved preparing functional specification and integrating automation components. Simulation work included heat transfer modelling and process dynamics simulation. Drafting deliverables comprised 2D and 3D engineering drawings, PFD, P&IDs and detailed layouts for optimal equipment placement and integration.
[5] Process Flow Diagrams (PFDs)
We have delivered process flow diagrams (PFDs) across a range of industrial projects in the chemical, energy, resources and water sectors. These high-level diagrams outlined the sequence of operations, material and energy flows and major process equipment such as reactors, distillation columns, pumps and storage tanks.
Developed in collaboration with project stakeholders, our PFDs served as conceptual blueprints that guided feasibility studies, design reviews and plant operations.
While they do not detail instrumentation or control logic, which we address in our P&IDs, they provide a clear and structured view of process architecture. Our work in this area has supported clients through concept development, regulatory approvals and the transition into detailed engineering and construction.
[6] Piping and Instrumentation Diagrams (P&IDs)
Our chemical engineers have developed detailed piping and instrumentation diagrams (P&IDs) for a wide range of industrial facilities, providing a comprehensive representation of each plant’s process, mechanical and control systems.
These diagrams captured the precise interconnections between equipment, piping, valves, instrumentation and automation components. Unlike high-level PFDs, our P&IDs contained the technical detail necessary for construction, commissioning, operations and maintenance. They included control loops, sensors, alarms, interlocks and shutdown systems to reflect each plant’s control philosophy.
Our P&IDs were used extensively in HAZOP studies, supporting hazard identification and risk mitigation. They also served as critical tools for functional specification, DCS logic development and regulatory compliance. By providing a clear roadmap for both control and safety systems, our P&IDs have helped clients ensure operational integrity and streamline troubleshooting across chemical, energy, resource and water sectors.
[7] Plant Engineering Design of a Mineral Processing Plant
This project involved a multidisciplinary engineering team comprising chemical, mechanical, instrumentation and control, simulation, and drafting specialists to upgrade the wash plant purge system used in mineral processing. The upgrade aimed to enhance the efficiency and performance of the existing system, ensuring improved operational reliability and compliance with industry standards.
The scope of work included developing the design basis, conducting detailed process engineering calculations, preparing PFDs and P&IDs, and selecting suitable chemical processes and equipment. Mechanical engineering activities covered the design and specification of pumps, tanks, and piping, mechanical stress analysis and detailed fabrication drawings. Instrumentation and control tasks involved upgrading control systems, specifying new instrumentation, developing functional specification. CFD simulation was employed to validate the design. Drafting delivered 2D and 3D plant layouts and GA drawings.
[8] Design Verification of a Gas Plant Pipe Intergrity
This study involved an independent verification to assess the impact of a pressurised oxygen (O₂) pipe rupture and its TNT equivalent on the structural integrity of reinforced 30 MPa concrete bunkers with fortified access steel doors. The objective was to determine the extent of potential damage and ensure the bunkers’ safety and robustness under such extreme conditions.
The scope of work included calculating the TNT equivalent of the rupture to estimate explosive impacts, analysing the structural integrity of seven bunkers of varying sizes and configurations, and evaluating the performance of reinforced concrete under simulated explosion scenarios. The assessment also covered the strength and durability of fortified access doors. A safety evaluation was conducted to determine whether the bunkers’ structural integrity remained intact, identify vulnerabilities, and provide recommendations for reinforcement or design modifications.
[9] Detailed Design of Containerised Coal Seam Gas Water Plant
This project involved the detailed engineering design (DED) of a mobile coal seam gas (CSG) water treatment plant housed within several 40-foot containers. It required close collaboration between chemical, mechanical, instrumentation and control, and drafting disciplines. The key challenge was to develop a fully functional, mobile high-performance treatment system that could be transported as a convoy and operate reliably in varying locations.
The scope of work included developing the design basis, preparing PFDs and P&IDs, and optimising the process for CSG water treatment, including chemical selection and dosing. Mechanical engineering tasks covered the design and selection of pumps, valves, and other equipment, as well as layout planning for secure container integration and mechanical integrity during transport. Instrumentation and control activities involved designing monitoring and regulation systems, integrating automation, and enabling remote operation. Drafting delivered detailed engineering drawings and container layout plans.
[10] Design of High-Purity Chemical Manufacturing Cleanroom
This project involved the process design of a high-purity chemical manufacturing cleanroom, requiring precise environmental control to maintain exceptional cleanliness and operational efficiency. The design needed to ensure optimal airflow, temperature, humidity, and hazardous substance management to meet stringent safety and quality standards.
The scope of work included determining supply, exhaust, and return air flowrates, defining air velocities, and sizing grills for uniform airflow. Cooling and heating design tasks covered coil sizing, air leakage calculations, and make-up air requirements. Hazardous substance management involved calculating flowrates for ammonia, solvents, acids, and other chemicals, designing safe handling and removal systems, and determining desmoke requirements for fire safety. Piping and fluid systems design encompassed chilled water and process piping sizing, layout, and compliance with safety and environmental regulations.
[11] Design Verification of a Renewable Energy Plant
This study involved an independent engineering design verification of a renewable energy plant, with a focus on evaluating major equipment and confirming the accuracy and reliability of the design values provided. The objective was to ensure the proposed design was both technically sound and operationally feasible.
The scope of work included verifying the design of key equipment such as the turbo expander generator, liquid nitrogen (N₂) plant, and vaporiser system, as well as assessing multiple design options for accuracy and feasibility. Process engineering calculations were reviewed and validated to confirm compliance with specifications, along with the thermal and mechanical design aspects of major equipment. ASPEN Hysys was used to conduct process dynamic simulations, evaluating plant performance under varying operational scenarios and testing control strategies for robustness. Findings were compiled into a comprehensive report, complete with recommendations for design improvements, optimisation opportunities, and supporting simulation and calculation data.
[12] Detailed Engineering Design of A Chemical Plant
This project involved providing chemical process engineering services for a chemical plant, with a dedicated process engineering team working closely with the technology provider to deliver both front-end engineering design (FEED) and detailed engineering design (DED).
The scope included leading the chemical engineering activities and coordinating with the technology provider to ensure alignment with the overall design objectives. During the FEED stage, the team established the process design basis, developed PFDs and P&IDs, carried out mass and energy balance calculations, and defined the key process parameters.
During the DED stage, the work expanded to detailed process calculations for the main plant and associated utility systems, preparation of equipment specifications including reactors, development of safety and control systems, and ensuring compliance with environmental and regulatory requirements.