Chemical Process Engineering

Process Development: Pilot plant design and start-up

Process improvements requires a deep study of its chemistry and physics prior to modify equipment set ups. Usually this kind of studies are not carried out and according the American Institute of Chemical Engineers (AIChe) is the main cause of fatal accidents due to chemical runaways.

Drage & Mate offers the technical service for detailed study of process chemistry and physics, laboratory process simulation in small capacity reactors and pilot plants design for continuous or batch processes.

Our especiality is in the field of Circular Economy, Green Chemistry and Clean Energy:

Risk process analysis (including SIL/SIS analysis)
Selection or design of special equipment and its provision
Instrumentation, control and automation of the complete process inclusing SIL levels
Design of monitoring systems, online sensors and analyzers
Preparation of operation and training manuals
Commissioning and start-up of new facilities

Semi-industrial testing

D&M has qualified personnel to carry out activities of testing:

Commissioning and operation of pilot plants
Planning and development of test plans(including Design of experiments DoE)
Staff training
Direct operation of pilot facilities
Renting of test facilities and analyzers
Preparation of results reports
Statistical analysis of experimental data
Preparation of hypotheses and validation of tests
Development of analytical methods for process control in testing phase (simulation)
Compliance with customer site specific Safety, Environment and applicable quality rules and regulations.

Documentation of processes and facilities

D&M can provide the service of documentation of existing processes and facilities coming from the on-site review and inspection. Said service may start from any existing information documents or partial documentation and containt as a reference:

Process analysis to establish installation configuration
Identification of Modes of operation, specifications and list of equipment, pipes…
Operating sequences and any other specific characteristics
Preparation of operating manuals and procedures
Preparation of operator training manuals

Industrialization and Process scale-up

D&M has extensive experience in the industrial scaling-up of processes (starting from its conceptual development or on a laboratory scale). Our complete industrial scaling-up service is developed using our own methodology: QUICUX method. This methodology includes:

Analysis of input data and planning
Detailed description of the scope of the project
Literature review and consultation of databases prior to carrying out activity
Carrying out the necessary tests to define the processto apply and simulate at micro scale
From this simulation, prototype design or pilot installation to validate the process on a semi-industrial scale and its subsequent scaled-up.
Development of the basic engineering once the process has been optimized.

How can we help?

If you do not know how to approach a process change, please contact us to discuss options.