Case Study: Hatch achieves 100% paperless delivery and six-week schedule cut with Bentley's digital twin

Hatch Sets Industry Benchmark Using a Digital Twin to Deliver Sulfuric Acid Plant in the DRC

Hatch was retained as the EPCM contractor to deliver a USD 245 million, 1,400‑ton‑per‑day sulfuric acid plant in remote Katanga, DRC to supply nearby copper mines. The project faced a constrained supply chain, environmental risks, limited grid power, complex integration with existing electrical systems, and an aggressive, fast‑tracked schedule with engineering teams spread across five global offices. To meet these challenges Hatch partnered with Bentley, leveraging Bentley’s applications such as ProjectWise, OpenPlant, OpenBuildings Designer and STAAD to digitalize workflows.

Bentley implemented a connected data environment and a 3D digital twin, enabling a 100% paperless delivery, real‑time field access via Navigator, and upstream fabrication and procurement from the model. The approach cut six weeks from the construction schedule, reduced material purchasing costs by 10–15%, lowered capital expenditure by 20% and delivered the project in under 24 months, and shortened production ramp‑up from six months to one week — all while improving coordination, reducing rework and slashing transport and fabrication costs.

Hatch

Randy McMeeki

Global Managing Director