Fumed Silica Burner Train project image
Key Statistics
Cabot Carbon
PM Group Office

Cabot Corporation is a leading global, speciality chemicals and performance materials company. Their product portfolio covers areas such as rubber and speciality carbons, activated carbon, inkjet colorants, cesium formate drilling fluids, fumed silica, aerogel and elastomer composites.

The project

Cabot Corporation developed a new fumed silica burner train to increase production capacity its facility in Barry, South Wales.

The team (formerly PM Projen) was first appointed to conduct a Front End Engineering Design study. Following this, the execution phase was awarded as an EPCM contract.

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Peter Farrelly
Peter Farrelly


Scope of work included full detailed design plus equipment specification and project execution and included:

  • Burner/Cooling tube layout including PED work
  • Main Unit Filter
  • Feedstock, Air and Hydrogen supplies
  • Environmental Emissions Abatement
  • Process Utilities
  • DCS migration from legacy system

The challenge

This was quite a complex project with a large number of subcontractors that differed greatly in terms of size and experience. An integrated project team was established at an early stage that included all the critical suppliers. Key project team members from across the supply chain were involved from the outset in the development of the execution plan.  

Focus on Health and Safety

A high emphasis was placed on the Safety, Health and Environmental performance of the project with over 90,000 safe work hours recorded. Underpinning this success was the behavioural safety training provided for all those engaged on the project.

The project was successfully delivered on time and on budget. It was commissioned and put into full production with the expected capacity and product quality targets met.

The project was recognised by the European Construction Institute (ECI) as an exemplar of how working collaboratively and promoting shared responsibility can bring real benefits.

Peter Farrelly