Process Design and Development

• Process Simulation: Using software tools like Aspen Plus, HYSYS, or Promax to model chemical processes. Simulate reactions, separations, heat exchangers, and other unit operations to optimize them before implementing in real plants.

• Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams (P&IDs): PFDs outlining the major equipment and flow paths. P&IDs showing detailed control systems, instrumentation, and piping layouts.

• Pilot Plant Operations: After developing a process at a laboratory scale, we can scale up to pilot plant size to evaluate feasibility before full-scale industrial production.

Fluid Dynamics

• Pumps and Compressors: Designing and optimizing the operation of pumps and compressors to handle fluid flow at industrial scales.

• Piping Design and Flow Optimization: Selecting appropriate piping sizes and layouts to ensure minimal pressure drop and energy consumption. Analyze flow regimes to optimize process efficiency.

Safety and Risk Management

• Process and Dust Hazard Analyses (PHA / DHA): Identifying potential hazards associated with chemical processes and designing processes to mitigate them.

• Relief Devices: Designing pressure relief systems such as relief valves, rupture disks, and vent systems to prevent overpressure scenarios that could lead to equipment failure or explosions. These devices provide a safeguard against excessive pressure in vessels, reactors, or piping.

• Explosion and Fire Prevention / Protection : Implementing safety measures to prevent incidents involving flammable materials or reactive chemicals. Additional safety measures include relief and venting systems, flame and detonation arresters, isolation, and protection mechanisms for liquids, gases, solids, and hybrid mixtures.

Reaction Engineering

• Reactor Design: Design of chemical reactors such as Continuous Stirred Tank Reactors (CSTRs), Plug Flow Reactors (PFRs), and fluidized bed reactors. Work to optimize temperature, pressure, and catalyst use to maximize conversion and selectivity.

• Kinetics and Thermodynamics: Understanding reaction kinetics (rates) and thermodynamics (equilibria) to design efficient reactors. Knowledge in this area helps to predict how fast reactions occur and how much product will form.

Heat Transfer Operations

• Heat Exchanger Design: Designing heat exchangers (like shell-and-tube, plate heat exchangers) for efficient heat transfer between process streams.

• Thermal Management: Optimizing heat integration to conserve energy by using waste heat for other process stages (e.g. heat recovery).

• Jacketed Vessels: Managing temperature in reactors and other equipment through cooling/chilled water loops, hot oil systems, and insulation.

Separation Processes

• Distillation: Design distillation columns for optimal performance in refining, petrochemicals, and other industries.

• Absorption and Stripping: Remove undesired components for process or environmental purposes.

• Filtration, Membrane Technology, and Crystallization: Purify liquids and solids by separating unwanted components.

• Extraction (Liquid-Liquid or Solid-Liquid): Involves separating a compound from a mixture by selectively dissolving it in a suitable solvent.

Bulk Solids Handling and Processing

• Storage and Flow: Design storage systems (silos, bins, and hoppers) for bulk solids, ensuring smooth flow by preventing issues like bridging, arching, or rat-holing through techniques such as bin mass flow design, aeration, vibration, and fluidization.

• Conveying and Transport: Transport bulk solids using pneumatic conveying systems, belt conveyors, screw conveyors, and bucket elevators. Selection of the proper method depends on material characteristics and processing requirements.

• Size Reduction and Classification: Processing bulk solids involves operations like grinding, milling, crushing, and sieving to achieve the desired particle size distribution for further use in manufacturing.

• Mixing and Blending: Efficient mixing of bulk solids is critical for ensuring homogeneity in products, which is essential in industries like pharmaceuticals, food processing, and chemical manufacturing.

• Dust and Safety Management: Handling fine particles can generate dust, which poses health risks and safety hazards (e.g. dust explosions). We can design dust collection systems and use filtration, ventilation, and explosion prevention/protection techniques to ensure safety.

• Bulk Solids Characterization: Evaluate flow properties, particle size distribution, moisture content, and compressibility to optimize handling, processing, and storage operations.