We take this step very sincerely and give highest regard to operating team at client’s premises. Understanding status quo on process equipment performance and operating philosophy is a must. It forms the basis for further action. It further clarifies requirement of upstream & downstream systems and any changes if required.
It is prudent to “not re-invent the wheel”. Once the action path has been decided, we undertake thorough screening of published literature in the forms of technical journals, patents etc. to see if we get the exact solution or early leads. We engage academic experts from premier institutes who are in our circle to get their opinion as per project need. This step clarifies the action and timeline. We are ready to give a quote for our services.
Modelling a physical phenomenon or any equipment gives lot of insight about it at reasonable cost compared to experiment. Every model is as accurate as are the assumptions used in making it. Sound assumptions taken on the basis of discussion with client can make the model a tool of high value. We can simulate several cases to see what is best for the equipment performance. The model can be shared to the customer to train his internal team.
Laboratory experiments can be undertaken to create the “proof of the pudding” of a concept. They are also of immense value in measuring parameters on physical or chemical properties needed in the model developed for the system. We undertake these experiments with proper planning and under the concept of design of experiment (DOE) to minimize the cost and maximize the information outcome.
Computational fluid dynamics a.k.a. CFD is a valuable tool to decipher the interrelation between equipment internals and their effect on physical phenomena of heat, mass or momentum transfer. CFD helps us in simulating the hydrodynamics in the full scale equipment. This helps in choosing several variables e.g. for stirred tank we can use CFD to decide about impeller type and its dimensions , number of impellers, location, RPM, velocity and temperature profile, mixing quality and time etc.
Pilot scale testing is important to bridge the gap between the controlled testing in the laboratory and variability expected at full scale. Pilot scale should be viewed and designed as scale down version of full scale plant to generate maximum information and confidence. Pilot testing becomes important for new processes for which no operating data is available. It is costly; hence its usage should be justified. It is preferred to do pilot testing for the most critical aspect of the plant. We undertake pilot tests after careful consideration for value and cost.
Mock-up tests are add-on to pilot test for measuring the hydrodynamics in full scale equipment made of transparent polymeric material. As water and air are the usual fluids handled in mock up test under atmospheric condition, it gives lot of flexibility. However proper design of these tests is must for getting correct data on the hydrodynamics in the full scale plant.
Large volume of data is generated during fabrication and operation of chemical process equipment. This data is valuable. Data analytics is the tool to collect the process data and sift it through statistical tools to get deeper insights about the process, equipment and their interrelation. This can be used to optimize performance or the equipment and generate prescriptive and predictive analytics for it.
Process control and automation are used to minimize human error. It also helps in reducing off spec product or unsafe conditions. This results in maximum output from the employed hardware without compromising about safety of personnel or environment. We promote and employ efficient process control and automation in chemical process equipment.