Improved profitability through proven operations and maintenance approaches

Chemicals are of major significance in any modern economy and there are thousands of bulk and specialised chemical products that contribute towards our quality of life.  These include pharmaceuticals, consumer formulated chemicals, cement, fertilisers, rubber, plastics, mining reagents and many more.  Upstream industrial processes are more capital intensive and typically produce intermediate and bulk products.  Downstream processes can convert these intermediates into final products.  Downstream processes are generally less capital intensive, smaller, more varied and more labor intensive.  The processes can be continuous or batch, and a typical process company can produce as few as one product or up to thousands of products in various specifications, packaging or forms.

Despite the variety of products; there are several things in common across the process industry. Process industry companies often face very similar business and technical challenges.  There are many opportunities for productivity improvements and innovation.  Tackling these challenges is best achieved with a multidisciplinary, experienced partner such as OTC.

How we help Process Industry clients

We work with established owners, project developers and financiers to identify opportunities, develop and implement successful,process chemical projects that deliver the necessary return on capital investment and that result in an efficient, competitive, sustainable and environmentally responsible business.

Our depth of experience and expertise in the entire energy, gas, xTL, process chemical value chain is unique. OTC consultants each have over 30 to 40 years’ experience typically in owner/operator roles in project and business development and operations.

How we work

Our approach has evolved over many years being hands-on involved in strategy, business development, operations, profitability improvements as well as community relations.  and our methodology is adaptable to meet our clients unique requirements.  

Our aim is to optimise businesses through detailed analyses of business and operations performance and identification of improvement opportunities. Opportunities are translated into either interventions ( organisational, procedural) or capital projects.

We will always ensure that business objectives are translated into project outcomes.  We take on the role of owner representative and/or as members of a project team together with developers, financiers, EPC contractors and operators to optimise and deliver on shared business objectives.    We also have an extensive network of strategic partners and alliances which can be quickly drawn on to ensure the best possible outcomes.

We have developed a comprehensive knowledge base of proven best practices which we use in assignments.

Related services and offerings

  • Operations and business due diligence.
  • Technical due diligence.
  • Benchmarking studies.
  • Business Valuations and Economic Evaluations.
  • Earned Value Management Systems.
  • Qualitative and Quantitative Risk Analysis.
  • Enterprise Risk Management.

Value assurance including:

  • Project Lifecycle Process – Quality Peer Reviews
  • Gate Readiness Review- Framing up to Board Application
  • Value Engineering

Internal audits:

  • Operational Processes 
  • Project and Portfolio Processes


Third Generation Modularisation

Third Generation Modularisation

The development of modularisation in the process industry, from Generation 1 (G1) to Generation 3 (G3), was discussed in an earlier Insight Article. In this article we focus on the more salient and practical issues during the development of a modular approach and...

read more
Effective Process Safety Management

Effective Process Safety Management

"Keep it in the pipe!" This paper addresses the elements of a process safety framework through the stages of a project from concept design, to detailed design, to operations; and translates these into elements of a process safety management programme. Introduction...

read more
Site Selection for Process Plants

Site Selection for Process Plants

In this article, we’ll discuss the site selection process, we’ll see how facility objectives influence site selection, we’ll spend time on site selection criteria and discuss the site selection decision matrix. Introduction Selecting a site for a process plant is far...

read more