Our Services
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Process Simulation Services
Process Simulation is performed in Chemika using industrially recommended software.
Our Simulation modules are as follow:
Distillation Column Absorption and Stripping Operation
Liquid-Liquid Extraction
Batch Distillation
Batch and Continuous Reactors
Heat Exchangers
Complete Plant Simulation
Petroleum Refinery Process Simulations
Crystallizer, Filter, Granulator & Dryer
Cyclone separators, Scrubber Centrifuge and ESP
Blowdown/Depressurization
Compressor Dynamic Simulation/ Surge Analysis
Properties Estimations
Flow Assurance (Predict hydrate formation,
slugging, wax deposition & corrosion rate)
Flare System Analyzer and Design
Oil Blend Properties Estimation
Process Control Study Using Dynamic Simulation
Equipment Design
Distillation Column Design
Heat Exchangers
Reactors
Venturi Scrubber
Spray Column
Two-Phase Separator
Three-Phase Separator
Vacuum System Design
Condensate System Design
Batch Heating & Cooling System Design
Storage Tank Heating/Cooling System Design
Falling Film Reactor
Evaporator Design
Adsorber System
Piping and Instrumentation System
Pump Sizing
Agitator Design
Gas-Solid Cyclone Separator
Pressure Relief Valve Sizing
Control Valve Sizing
Thickener and Clarifier
Liquid-Liquid Extractor
Solid -Liquid Extractor (Leaching)
Cooling Pond Design for Heat Transfer
Dust and Fume Control System
Basic & Detailed Engineering Services
Basic and Detailed Engineering Services plays an important role in greenfield and brownfield projects, for the Refinery, chemical & petrochemical industries. Chemika's Process engineers and experts have many years of experience in preparing Basic and Detailed Engineering package (BEDP). Chemika has worked independently or jointly Basic and Detailed Engineering package (BEDP) to HAZOP preparation.
Basic Engineering Design services: the most important Process engineering design activity for working on any Greenfield or Brownfield projects. Chemika is providing engineering design and several Process Engineering related services. Also, offering Basic engineering design packages (BEDP) for various sectors of industry to its clients. Chemika has many years of experience in the preparation of Projects for Basic Engineering Design Packages (BEDP) that enable new project & process technology to be commercialized for the first time. The conceptual design services involve the development of various plot plans or diagrams that have a great concept regarding the task a particular project needs. Conceptual engineering design services help to create various engineering packages that can provide various designing services to the clients without any delay. Chemika has availed a team of skilled and knowledgeable process engineers who uniquely identify such packages and formulate them in the most efficient manner.
Engineering document developed during this course of a project provides comprehensive process design report useful for preparing detailed engineering design service package and Preliminary site layouts.
FEED
Process design basic development,
Heat & Mass balances.
Process flow diagrams,
P&ID development.
Material movement analysis
Equipment duty specification
Datasheet development.
Instrumentation design approach
Equipment, piping, & utility evaluation for use in the new process.
Utility system evaluation.
Initial risk assessment & Process HAZOP studies.
Establishment of an overall design basis for new or expansion projects at an integrated design approach.
Safety designs
Effluent generation and disposal mechanism for ETP.
Cost estimation and CAPEX evaluation up to 10% accuracy.
Computational Fluid Dynamics (CFD)
Process engineers are familiar with plant design software and general mathematical modeling tools for process optimization. The physics of fluids with or without heat transfer, mass transfer and chemical reactions, and is used for the design and analysis of equipment and unit processes. The idea is to predict, and design around, transport related problems using detailed numerical solution methods prior to physical testing. Alternatively, CFD simulations can provide operational support for troubleshooting, throughput improvement, process scaleup (and scaledown), and improving product quality and plant yield. The simulation can be steady or dynamic - 2D or 3D - and subjected to initial, boundary and flow operating conditions. CFD enables engineers to maximize throughput, innovate on new products, enhance process stability across the plant, drive sustainability and develop new processes more efficiently. The CAE/CFD/1D(system engineering) can be done.
Flow distribution. Most chemical companies do not design their own plant equipment; rather, they own assets and operate them. The key issue is throughput and finding new ways to push more material through production. Can they get more from their assets than they already have? How can they manage flow distribution to avoid erosion, corrosion and extra pressure drops? How will existing assets behave under different products or materials?
Scaleup. CFD is also instrumental for supporting the scaleup process, especially in the chemical and pharmaceutical industries. During this process, engineers run experiments inside a laboratory on a much smaller piece of equipment to be tested. This bench- or laboratory-scale equipment is used to develop the product. Then, through the scaleup process, questions of how this product can be manufactured on the commercial scale are answered. CFD is used to estimate how the commercial-scale process will perform and the corresponding outcome on the product.
Process stability. CFD also helps drive process stability. Chemical engineers must manage problematic issues, such as rust buildup in pipelines and fouling, erosion, hotspots, dead spots and cold spots in chemical plants. Through CFD modeling, engineers can predict and identify these issues before they materialize in the plant and deal with them to deliver an enhanced level of efficiency, reduce downtime and help ensure safety. Also, the stability of the process against process or material variability can be simulated using CFD.
Process intensification. While engineers want production to run cheaper, better and more reliably, they also are focused on process intensification that allows greater energy efficiency and the creation of more sustainable products through reuse or product redesigns.
Enhanced efficiency. Companies that employ CFD have better insights into their processes. This enables them to operate their equipment at lower cost, potentially reduce emissions and delay unwanted maintenance. Using the additional insight from CFD, plant operators can reduce material waste tremendously.
