Services
We Design, Debottleneck , Enhance Equipment and Process Performance
As a first step, we understand the customer’s expectations, issues, pain areas, objectives and constraints very clearly. We believe that the equipment performance can be enhanced by thorough understanding of the process and the operation of the equipment. The process could be extremely complex like polymerization, gas-liquid-solid slurry reactor operating at high temperature and high pressure. Understanding of the process and customers pain can help to lead to the root cause of the issue and hence model the physics of the cause. For example, wide distribution of molecular weight of the polymer chains could be due to inefficient mixing. The inefficiency of the liquid-solid catalytic reaction could be due to improper solid suspension.
The next step involves the selection and application of various tools and techniques based on the nature of the problem statement.
CFD Modeling
To get detailed, local insight of the hydrodynamics and its effect on chemical reaction, heat and mass transfer, we use our experience and expertise of CFD modeling techniques. We have very strong experience in modeling a wide range of equipment with complex physics like multiphase flows, combustion, heat transfer, rotating bodies, external flows.
Multiphysics Analysis
To address the problems that involves structural, thermal and flow coupling, we use FEA and CFD techniques. It is important to access the impact of fluid on structural integrity of the equipment. Fluid-Structural Interactions are studied through multiphysics analysis. Different physics like Electrical, Magnetic, Thermal, Acoustics and Fluids needs to be studied together. We provide our services in the domain of multiphysics analysis and provide design solutions.
Artificial Intellegence
For the complex problems with less insight into the physics and many variables are involved with non-linear relationships, we recommend AI based methodologies. This approach needs historical data over a long period covering variability in the process and parameters involved. More critical is the data of output variables like quality, yield, conversions, composition etc.
Molecular Modeling
If the properties of the materials (solubility, thermal conductivity, density, surface tension etc.) which are determined by the molecular interactions need to be determined, molecular modeling tools and techniques need to be adopted. We have an experienced team to perform molecular modeling simulations to collaborate in your material discovery programs.
Process Modeling
We adopt chemical engineering principles and process modeling techniques to model process flow sheets, individual equipment performance and what-if studies.
Simulation Automation
We can help you to improve your teams productivity and manage your intellectual property. Our team is highly skilled in Java, Python, C, C++, Matlab, etc. and has experience in integrating various platforms/softwares to create automated, simplified, user-friendly interfaces, templates, simulation assistants, and automated workflows.
Process Optimization
We integrate various modeling approaches like process modeling, reactor modeling, CFD and AI techniques along with chemical engineering fundamentals to optimize the process parameters to give higher and consistent yield, conversions and energy efficiency.
Performance Enhancement
We provide our services in improving the individual equipment performance and uptime. With our process knowledge and expertise in various modeling tools and techniques, we have improved the performance of a wide range of equipment over different industry segments.
R&D and Skill Development
Development phase in every big program is very crucial as the results of the next phases depend on the timely, detailed and accurate representation of the physics and the process. We are happy to partner with you in your development stage of modelling, validations and knowledge transfer to your technical teams. We also conduct online training program for corporate and individuals particularly on CFD modeling.
Industries We Serve
Industries
We have around 20 years of experience of providing optimal design solutions and operating conditions for a wide range of industrial sectors
Chemicals
- Design of single phase and multiphase reactors like Stirred tank, bubble columns for effective mixing, uniform gas dispersion, uniform solid suspension, thermal uniformity, uniform mixing, reduce power consumption
- Reactor Scaleup and Scale down
- Optimize internals like sparger, dip tube, coils for higher performance, reduction in batch time, steam consumption reduction
- Design and evaluate Heat Exchangers, Polymerization reactors, Spray drier, Static mixers, Flue gas Desulphurization units, Fluidized bed reactors, Electrolytic Cells to get higher yield, better conversion, consistent quality
Pharmacueticals
- Design and Debottleneck Bioreactors, Fermenters for higher gas holdup, CO2 Stripping, uniform mixing, thermal homogeneity, pH uniformity, longer cell life
- Evaluate Crystallizer Performance and determine the optimal conditions to obtain uniform crystal size distribution.
- Choose right reactor from the available reactors for the given product to achieve the desired quality
- Understand and develop Scaleup and Scale down strategies for effective product development process
- Design mixing tanks and optimize impeller locations, types, speed, dip tube locations.
- Predict Residence time distribution, mixing time in the reactors
- Evaluate designs of reactors for flow chemistry to meet your requirements before procurement
- Evaluate and bottleneck drier designs for particle drying
- Develop and design particle coating systems, optimize spray locations, flow rates for effective coating.
Agro Chemicals
Design Batch reactors, impeller designs, feeding systems, for proper mixing and homogenization
Design heating system and control for thermal homogenization
Paints
Improve paint viscosity consistency and flowability by proper homogenization
Metals
- Evaluate SEN design to reduce mold level fluctuations
- Increase availability of Blast furnace hearth to by reduction in refractory erosion
- Reduction of metal loss during ladle teeming operation
- Analyze the effect of number, location and design of porous plugs on mixing and reduce localized oxidation, and emulsion formation in Basic oxygen furnace
- Improve thermal homogenity and Predict of slag eye, spout in argon stirred ladle
- Reduce Low yield levels in the Tundish when draining the tundish at the end of a sequence due to slag entrainment and vortex formation
Foods and Beverage
Design and Evaluate materials for packaging for food product
Spray Drier Design for improved powder particle size distribution, lower moisture content and quality parameter
Improve Energy efficiency of continuous tray driers
Automobile
- Predict Drag on the outer surface of the vehicle ( external flow aerodynamics)
- Simulate and optimize air flow in car, aero plane cabins.
- Analyze thermal performance of EV Li-ion battery box. Predict thermal runaway. Design efficient cooling systems
Oil and Gas
- Evaluate the Design performance of two phase and three phase separators under different operating conditions
- Enhance the performance of storage tanks with submerged rotating jets to get uniform mixing, without sludge settling issues
- Improve the performance of Catalyst Roaster and Cooler
Cement
- Enhance the collection efficiency and pressure drop in Cyclone Separator. Study the effect of design variables like dip tube diameter, dip tube height, inlet size, cone angle, cylindrical height etc.
- Predict the flame shape and structure in Kiln. Solve the issues like hot spot on kiln shell. Optimize axial, radial and swirl air quantities for lower CO and better flame, heat transfer.
- Improve the calcination efficiency of the Calciner. Enhance coal combustion. Determine optimal location for meal feed and coal feed for better calcination and fuel combustion, reduced NOx
- Analyze flow in Bag House and suggest design changes to reduce bag damage, reduce pressure drop, dust carryover.
- Improve the collection efficiency of Electro Static Precipitator by straightening the flow using suitable design changes.
- Reduce the pressure drop and erosion issues in the Duct Network. Improve the life of the pipes.
- Protect your investment and Evaluate different Burner Designs and ensure the performance.
- Eliminate the design bottlenecks in VRM, reduce pressure drop, improve particle size distribution and separation efficiency
Please visit our Case studies section to get an idea of our capability and experience of modeling of different equipment.