Client: North America Construction (1993) Ltd.
Location: Aylmer, Ontario
Delivery Model: Design-Build
J.L. Richards and Associates Limited was retained by North America Construction (1993) Ltd. (NAC) as the Prime Consultant for the planning, design, construction, and commissioning of a two-phase 100-million gallon per year (MGPY) fuel-grade ethanol production facility for the Integrated Grain Producers Cooperative (IGPC) located in Aylmer, Ontario. Both phases were delivered following a design-build contract delivery model.
Phase 1 – Facility Development:
Phase 1 included construction of an ethanol production plant with a rated capacity of a 50 million gallon per year (MGPY) fuel-grade ethanol, grain receiving and bulk storage, ethanol storage tank farm including secondary containment and truck and rail loading, as well as overall site development and utility distribution.
A key part of the contractual agreement for the initial development of the facility was for construction to be completed and ethanol production to begin within 500 days from award. Using a team approach and a sequential building permit process, foundation construction began two months after design was initiated. The modern ethanol production facility was completed 30 days earlier than originally anticipated.
Phase 2 – Facility Expansion:
Phase 2 involved the expansion of the IGPC facility to double the production capacity to 100 MGPY. Unlike the original greenfield plant construction in Phase 1, the expansion required considerable planning and coordination with existing processes and site constraints while limiting the impact on ongoing plant production.
The plant expansion included significant expansions to several existing production buildings, expansion of the bulk tank farm, a new hammermill building with additional space for expansion, a new high-protein product storage building, as well as various other changes and improvements to the site layout and utility distribution to accommodate the increased production capacity.
Sequential building design packages allowed for building permits, design of proprietary production processes by third-party vendors, balance of plant design, and construction to proceed concurrently. Phase 2 was completed approximately 60 days earlier than the construction deadline. A testament to the team effort and collaboration of all involved.
Additional Facility Upgrades and Improvements:
In addition to the two major projects described above, NAC and JLR have collaborated on several additional projects at the IGPC site over the years.