OUR SERVICES
Process Chemical Engineering Thermal Design
Green field manufacturing plant / Extension of manufacturing plant – Design
- Review the plant capacity requirement in terms of total equipment volume i.e. reaction volume as per the inputs shared by clientele.
- Estimation of utility load based on optimal equipment / reaction vessel occupancy
- Equipment sizing such as condenser, heating and cooling required for the reaction vessel, cooling flow requirement for the condenser, type of the cooling media required estimation based on process conditions i.e. atmospheric / vacuum, utility pipe sizing, vacuum pump capacity sizing.
- Preparation of summary utility loads for all the manufacturing and effluent treatment plants.
- Preparation of utility capacities to be installed i.e. steam boiler, cooling tower, chilled water plant, chilled brine, thermic fluid system, hot water system, Nitrogen plant, Air compressor, Process water and utility make up water.
- Preparation of pipe line sizing and distribution drawings.
- Preparation of equipment list process and utility and preparation of specification of each equipment
- Preparation of equipment layout
- Preparation of P&I diagrams
Solvent Recovery System
- Solvent mixture separation capacity.
- Collection of data regarding the separation possibility using fractional distillation, azeotropic distillation, extractive distillation, salting out process, molecular sieve adsorption
- Design of the process equipment capacity – Diameter of the distillation column, packing height estimation using the vapor liquid drawing and number of theoretical plates estimation. Selection of the distillation column packing based on the solvent mixture. Condenser capacity, vapor line sizing, interconnection pipe sizing, utility requirement such as steam, cooling water and chilled water, utility pipe sizing, condensate transfer to boiler feed water tank.
- Preparation of GA drawing and P& I diagram
Effluent Treatment Scheme
- Effluent collection, Segregation & treatment scheme as per the pollution control board EC, CFE and CFO conditions
Detailed Engineering Design and Execution
- Review of the fabrication drawings of individual equipment shared by equipment manufacturers with respect to finalized equipment specification
- Site inspection of the equipment fabrication at different stages i.e. nozzle orientation check, dimension check, MOC check, hydraulic leak test
- Plant equipment erection monitoring as per the GA drawing and process, utility pipe line arrangement as per P&I diagram
- Verification of instrumentation as per process requirement such as temperature sensor, temperature indicator, pH meter, TDS meter, on/ off control valves, flow measurement devices such as rotameter, magnetic flow meter, level sensor.
- Leak test of the process and utility equipment
- Dummy trial with water distillation and cooling trails
- Process trials and demonstration and training of the user for the operation of the equipment
- Assisting the team for user requirement specification, design qualification, installation qualification, operational qualification and performance qualification.
Trouble shooting & Technology transfer
- Observation of the existing process at commercial scale or laboratory scale
- Identification of the problem and suggest way forward to avoid the problem
- Design of the suitable remedy for the observed trouble / problem.
- Demonstration of the revised process to overcome the observed trouble / problem such as higher distillation time cycles, loss of product during distillation, higher cooling time cycles, presence of higher boil / low boil impurities during product distillation, loss of product into mother liquor, loss of product into residue, loss of product into low boils fraction, higher filtration time cycles.
Contract Manufacturing Services
- Identification of the suitable manufacturing facility for the proposed product as per the process equipment requirement and utility requirement for the contract giver.
- Equipment mapping and utility mapping as per the product capacity, critical utility and safety requirements at the manufacturer site.
- Costing proposal for the product manufacturing to contract giver and coordination for commercial agreement between the manufacture and contract giver
- Monitoring of the facility arrangement at manufacturer site as per the process requirement of the contract giver
- Arrangement of analytical test requirement as per contract giver.
- Assisting manufacturer during the audit of the facility readiness by contract giver at the manufacturer site
- Assisting the manufacturer to meet any shortcomings of the equipment, utility, EHS requirements as identified by contract giver during the facility audit for readiness
- Assisting the contract giver for raw material transfer
- Participation during technology transfer of the product and during initial trail batches execution.
- Evaluation of batch time cycle, yield, quality as per the requirement of contract giver
- Manufacturing and commercial dispatch monitoring
- Evaluation of the final cost sheet and assisting in smooth closure of the ledger balance
- Assisting and coordination for campaign closure and returning of the left-over raw materials, intermediated and any spent solvents or any other equipment support given by the contract giver.
- Contract Manufacturing Activity arranged for the following companies for critical reactions such as hydrogenation at 10 kg/cm2 and 100 deg centigrade temperatures and POCl3 reaction quenching and ethyl mercaptan and hydrogen peroxide oxidations
- M/S Bheema fine chem
- M/S Bhagirada chemicals and industries
- M/S Nichino India
Trading, Import and Export of the process and utility equipment, chemicals, intermediates and bulk drugs
- Laboratory vacuum pumps supply i.e. value vacuum pump
- Laboratory vacuum pump lubrication oil supply
- Dry vacuum pump with booster pumps supply
- Falling film evaporator
- Rising film evaporator
- Multiple effect evaporator
- Stripper
- PTFE extension blades for the glass lined reactors to reduce minimum stirring
- Hot water systems
- On/off solenoid valves
- Temperature controllers
- Distillation column and its ancillary equipment such as condensers, reboilers
- Laboratory distillation column setup for atmospheric and vacuum distillation. Reflux under atmospheric and reflux under vacuum setup.
- Laboratory vacuum pump low boil solvents trap with dual utility provision to capture the solvents escaping into vacuum pump which results in reduction of vacuum or contamination of vacuum oil. Separate outside jacket for cooling media circulation and inside sump for charging ice salt cooling mixture or dry ice + solvent cooling mixture.
- Design and fabrication of heat transfer equipment, phase separation equipment at OEM as per design and supply. Demonstration of the use of the equipment at the clientele site.
- Trading of vacuum oil, chemicals, intermediates and bulk drugs