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PROCESS ENGINEERING

Businesses perform only as well as the manufacturing processes they rely on - so we help clients with process design, applied chemical engineering, and process safety solutions to unlock vision and unleash performance.  

 

Our highly motivated process personnel have a track record of delivering successful process-driven projects in manufacturing industries for chemicals, polymers,  adhesives, coatings, paper, and semiconductors.

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CAD design

Unit Operations
Experience Includes:

  • Fermentation

  • Reaction

  • Distillation

  • Heat Transfer Absorption / Adsorption

  • Crystallization

  • Slurry Handling

  • Centrifugal Separation

  • Degassing

  • Filtration

  • Extrusion

  • Material Handling

Process Engineering
Experience Includes:

  • Product Development

  • Process Scale-UP

  • Captial Project Dev. (FEL -1,2,3)

  • Alternatives Evaluations

  • Process Improvement Cost Estimates

  • Debottlenecking

  • Process Staff Augmentation

  • Process Safety Support

  • Relief Systems Evaluation + Sizing

  • PFDs + P&IDs

  • Material + Energy Balances

  • Process Data Sheets

  • Hydraulic Analysis

  • Equipment, Line, + Instrument Sizing

  • Detailed Design

  • Equipment Arrangements

  • Safety Systems Analysis

  • Vent Flare Header Analysis

  • Process Safety Management / Plant Safety Programs

Process Modeling + Simulations

​We team with our clients to develop process models and process engineering simulations to quantify alternatives, reduce risk and maximize ROI. 

 

From debottlenecking an existing process to evaluating economic alternatives on the front-end our process modeling team can reduce investment risk and optimize performance. 

Process Design Services

We maximize our clients' return on the process investment by integrating business objectives, process goals and establishing the technical options available to achieve them.

 

Our process design services start with a front-end loading (FEL) approach that is designed to significantly improve project delivery.  

 

Conceptual + Preliminary Process Design Services

 

  • Process Feasibility Studies

  • Process Flow Diagrams (PFDs)

  • Process Modeling and Simulation

  • Process Alternatives Evaluations

  • Basis of Design (BOD) Development

  • Technical and Economic Evaluations

  • Capital Cost / Operating Cost Estimates

  • Conceptual (FEL-1, FEL-2) Process Design Packages

  • Preliminary (FEL-3, FEED) Process Design Packages

 

As process design evolves we aim to minimize risks while achieving the level of efficiency, reliability, and safety required by the project owner. 

 

Detailed Process Design Services 

 

  • Process Controls Design

  • Equipment Specifications

  • Equipment, Line, and Instrument Lists

  • Equipment Layout Drawings

  • Process Control Diagrams (PCDs)

  • Capital Cost / Operating Cost Estimates

  • Hazard and Operability Studies (HAZOP)

  • Relief Device Sizing + Flare System Design

  • Piping and Instrumentation Diagrams (P&IDs)

Process Development +

Process Scale-Up Support

To successfully move from the small scale to the large, one must understand how size changes impact a number of physical and chemical phenomena.  

 

We perform process scale-up support services to ensure clients can profitably and reliably manufacture from pilot plant to commercial-scale production. 

Technology Transfer

From production reshoring to the use of contract manufacturing organizations (CMO), our process-led multidisciplinary teams specialize in technology transfer solutions for complex capital projects.

 

Using a holistic quality by design approach (QBD) we provide clients with robust tech transfer packages that support the executive mission. 

Process Safety + Risk Management 

We provide process safety and risk management services to ensure quality and safety standards are met. 

 

Our process team helps clients with local, state, and federal regulations to ensure compliance and mitigate hazards. 

 

From OSHA and NFPA regulations on combustible dust to FDA and ICH guidelines on Highly Potent Compounds, our extensive industry experience enables us to deliver the best process safety solutions for your operations.

 

We recognize our clients’ commitments to safety and we team with them routinely to:

 

  • Facilitate Process Hazards Analysis (PHAs) 

  • Hazards Assessments (including HAZOPs)

  • Conduct Process Safety Compliance Audits

  • Perform Layer of Protection Analyses (LOPA)

  • Conducting Safety Integrity Level (SIL) selection analyses for Safety Instrumented Systems (SISs)

  • Develop Process Safety Information

  • Develop Process Safety (PSM) Programs

  • Size new pressure relief devices (PRDs),

  • Validate existing PRD installations

  • Evaluate vent and flare headers

  • Verify and update P&IDs 

  • Perform Dust Hazard Analysis (DHA)

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