Capacity Optimisation and Debottlenecking
We measure the gap between what your plant could make and what it actually makes, then engineer the changes that close it
Capacity Optimisation
and Debottlenecking
Most plants run well below the capacity they were designed for, and the difference is usually trapped behind a handful of fixable bottlenecks. Our team quantifies the gap between theoretical maximum, demonstrated maximum and the capacity you operate at today, then engineers the interventions that close it through intensification, parallel installation, control upgrades and tighter supply integration. We carry out the work alongside a fresh process hazard analysis, safety integrity level and hazardous area review so your safety envelope keeps pace with the extra throughput.
Our implementation model
A practical, phased delivery approach that runs from gap assessment through operational embedding and is built around your regulatory context.
Quantify current capacity, demonstrated maximum, theoretical max, build capacity utilisation curve and constraint map.
Test bottleneck hypothesis through capacity step up trials, equipment vendor consultation, and process simulation.
Generate debottlenecking options, equipment upgrade, parallel installation, intensification, operational change, supply integration.
Engineer the selected option through detailed engineering and MOC, integrate with PHA / SIL / HAC re review where required.
Commission per PSSR discipline, structured ramp up with daily performance tracking, capture lessons learned.
Validate capacity uplift against business case, document for next cycle benchmarking, integrate into asset register.
Capacity Optimisation in full scope
Value of Capacity Optimisation and Debottlenecking
- A fresh process hazard analysis and safety integrity level review run alongside the debottlenecking
- Your safety envelope is updated for the new throughput
- Pre startup safety review discipline at every startup
- Integrity operating window limits refreshed in line with API RP 584
- Management of change handled in line with CCPS RBPS Element 14
- Permit to operate kept current
- Environmental clearance refreshed
- Insurer reporting kept up to date
- Capacity typically rises by 10 to 40 percent
- You avoid the capital cost of a greenfield build
- You reach the extra throughput faster
- Your assets are utilised more fully
- You avoid the capital cost of building new
- Payback is fast and usually under two years
- Extra revenue comes at marginal cost
- Working capital is used more efficiently
Codes & standards we work to
Triggers that signal the need
Where Capacity Optimisation and Debottlenecking applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- Capacity diagnostic report
- Bottleneck and option register
- Debottlenecking portfolio ranked by net present value
- Engineering and management of change package
- Commissioning and ramp up plan
- Post investment learning report
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.