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Plant Design


TCGroup provides a wide range of design engineering and construction management services addressing all phases of plant and process development.


Our effort is characterized by a balanced blend of plant experience and consulting engineering skills, a background in plant operations, coupled with multi-disciplined design and consulting expertise. Rigorous management has earned us a reputation for reliable capital construction budgets and tightly controlled implementation costs. Our assignments have encompassed a wide range of plant mill processes, in projects ranging from feasibility studies to all facets of design, engineering and management for large integrated complexes and greenfield plants. We have completed numerous modernization projects, and supplied conceptual engineering and capital cost evaluations for new plants, expansions and process unit installations. We have assisted clients in identifying and implementing improvements - large or incremental - that can help secure competitive advantage, including optimizing fiber use, debottlenecking production, upgrading to higher value-added papers, or reducing energy costs through process modeling. TCGroup's process modeling application can both balance flowsheets and portray dynamic conditions. It gives our client a crystal clear view of process bottlenecks, potential quality control problems, process waste management, or process inefficiencies. Imagine being able to easily predict what will happen to paper quality in the hours following a change in wood fiber species, or being able to tell the next shift about predicted effluent loading on the waste treatment plant.


Project Experience


Tissue Machine Rebuild                                                                                 

Clearwater Paper



Wastewater Treatment Plant  

Clearwater Paper



Biomass Plant Studies




Biomass Co-Combustion Study

Confidential Client



Wood Pellet Plant Upgrades

Zikha Biomass



New 15 Ton/Hour Pellet Line Study

Anheuser-Busch (BARI)



New Converting Lines

Cellu Tissue



Malthouse 6 CO2 System Upgrade

Anheuser-Busch (BARI)



Boilers No. 1, 2, 3, and 4 Rebuilds, Charter Street Station




New 250,000 PPH Steam & Condensate Distribution System




TM1 Production Increase Projects

Cellu Tissue



UW-Madison - Main Steam Stress Analysis

State of Wisconsin



Electrical Distribution Study

Madison Gas & Electric



Main Steam Thermal Stress Analysis

Calpine Corporation



New Tissue Converting Plant

Cellutissue Holdings



New Multi-Layer Blown Film Line

Appleton Performance Packaging



Barley Work House Systems Upgrade

Anheuser-Busch (BARI)



New 99 MW Cogen Plant Study

Azco Inc.



New 24TPH Coal Pulverizer Study

Confidential Client



New 15 & 35 MW Cogen Plant Study

Confidential Client



150,000 PPH Package Boiler Study

Manitowoc Public Utilities (MPU)



Coal Conveyor Platforms Edgewater Generating Station

Alliant Energy



Malt House 6 Aspirator Addition

Busch Agricultural Resources Inc.
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