3D Layout Engineering for Environmental Solutions in Paper Mills

3D layout engineering uses digital plant modeling to visualize, design, and integrate new meri equipment in the environmental process facilities within a mill for green field plants or upgrades.

It ensures that piping, cabling, equipment, and structures fit together seamlessly before manufacturing and on site assembly begins.

Key functions

  1. Equipment Placement & Layout
    • Positioning meri WSR, Material Handling ant ETP – equipment, auxiliaries  tanks, reactors, pumps, blowers, gangways scaffolding and support steel works
    • Optimizing space in tight and crowded brownfield sites.
  2. Piping & Cable Routing
    • Designing process piping, water distribution, chemical lines, sludge pipelines, conveyor tracks, tank arangements in 3D.
    • Planning cable trays, power lines, and instrumentation cabling alongside piping to avoid clashes.
  3. Clash Detection & Interference Checks
    • Identifying conflicts between piping, ducts, cable trays, and structures before site execution.
    • Reducing costly rework and delays.
  4. Construction & Maintenance Accessibility
    • Designing layouts for safe operator access, maintenance clearance, lifting/hoisting paths.
    • Ensuring compliance with safety norms.
  5. Integration with Existing Mill
    • Overlaying environmental systems (ETPs, odor control, sludge handling) with existing production facilities.
    • Minimizing downtime during retrofits or expansions.

Importance & Advantages

  • Accuracy & Efficiency → Reduces errors by visualizing the complete system in 3D before fabrication.
  • Cost Savings → Early clash detection avoids rework, which can save up to 10–15% of project cost.
  • Time Optimization → Faster installation thanks to pre-fabrication drawings and exact routing data.
  • Better Coordination → Facilitates collaboration across process, civil, piping, mechanical, electrical, and automation teams.
  • Safety & Compliance → Ensures adherence to ergonomic standards, maintenance clearances, and environmental safety norms.
  • Enhanced Communication → 3D models are intuitive for operators, managers, and regulators—improving project buy-in.
  • Lifecycle Benefits → The model becomes a digital twin for operation, maintenance, and future upgrades.

Typical Scopes of 3D Layout Engineering in Paper Mill Environmental Projects

  1. 3D Modeling
    • ETP structures (clarifiers, aeration tanks, sludge thickeners, digesters).
    • Sludge handling units (belt presses, centrifuges, dryers).
    • Air emission systems (scrubbers, chimneys, ducts).
    • Pipe racks, pump houses, and cable trays.
  2. Piping Engineering
    • Process and utility piping (water, chemicals, sludge, steam, compressed air).
    • Stress analysis and support design.
    • Isometric drawings for fabrication.
  3. Electrical & Instrumentation
    • Cable tray routing in 3D, avoiding clashes with piping.
    • Equipment layouts for MCCs (Motor Control Centers).
    • Instrument location and junction box layouts.
  4. Civil/Structural Coordination
    • Concrete tank structures, foundations, steel pipe racks, platforms, walkways.
    • Integration of equipment loads and access requirements.

Typical Documents & Deliverables

3D Deliverables

  • Full 3D Plant Model (environmental system integrated into mill).
  • Clash detection reports.
  • NAVIS Works Walkthrough simulations for client/operator review.
  • Bill of Materials (BOM) directly extracted from 3D model.
  • Digital Twin (optional) for operations and maintenance.

2D Deliverables (extracted from 3D)

  • General Arrangement (GA) Drawings.
  • Equipment Layouts.
  • Piping Isometrics with MTO (Material Take-Off).
  • Cable Routing Layouts.
  • Civil Interface Drawings (tank foundations, pipe rack footings).
  • Sectional Drawings for installation guidance.