We provide both on- and off-site plant unit debottlenecking on short notice – worldwide.
In-depth assessment of estimated benefits, cost and return on our recommendations on optimization of your running unit or retrofit or revamp is provided at a nominal charge. Most often the benefits and quick returns strongly justify the move.
We provide prompt plant reactor area de-bottlenecking. From our past experience most of such tasks can be accomplished within a few days’ time (1-3 days in most cases) once we are on-site or upon receipt of a clear problem definition directly from the involved operating team – provided the problem is not due to a fundamental flaw in the original design. An example of such a flaw is under-design an internal or external heat exchanger (inadequate heat transfer surface or coolant flow capacity) that leads to reactor temperature run away. This was diagnosed as the cause of effluent line plugging by product polymerization that was unstoppable despite all operational controls. We experienced such and other problems in operating plants and were able to fix them quickly unless there was a fundamental flaw/ limitation in the design.
Field Unit Optimization: After a period online an operating reactor in a plant may be at far from optimum conditions causing unintended loss of yield or product quality. This may be because of preset conditions that require resetting due to altered feed-stock composition or quality, catalyst degradation, altered heat transfers, fines/pressure build-up, line blockage/fouling or other reasons. We can help diagnose the ills of an Underperforming reactor and promptly bring it back to its optimum performance. Increased revenue resulting from this should more than justify the cost incurred in our unit optimization service.
Retrofit & Revamp: For many decades-old operating reactors a retrofit or revamp can lead to dramatic improvement of productivity or product quality or environmental friendliness. We can minimize both risk and downtime in reactor retrofit or revamp and maximize your net profit from making these changes. Add that polishing reactor/ reactor extension, that inexpensive S/ Hg/ de-NOx device, flare gas converter (to liquid fuel?) or simply tune up your reactor – which you have been postponing. The reactor tune-up involves optimization or re-optimization of the operating mode for the changed feed-stock or new product specification or simply to compensate for the age-spots (that may include fouling, partial plugging and deactivation)