We offer technological and energy audit for chemical enterprises with 3 levels of study depending on specific tasks of the company and the budget.
Technological audit and optimization
СВЯЗАТЬСЯ С НАМИ
THE ENGINEERING CHEMICAL TECHNOLOGY CENTRE
YOU GET PROFESSIONAL TECHNICAL RECOMMENDATIONS AND THE OPPORTUNITY TO SIGNIFICANTLY INCREASE THE COMPANY'S REVENUE
What we do is a detailed survey of existing production facilities, modeling and calculation of all technological processes and search for bottlenecks
We provide services of the composite optimization of production flux in several areas:
1. Statistical optimization of the existing equipment operation.
2. Technological audit of production process.
3. Development of technical offers for optimization of energy losses and costs.
4. Development of technical offers for the implementation of R&D results.
1. Statistical optimization of the existing equipment operation.
2. Technological audit of production process.
3. Development of technical offers for optimization of energy losses and costs.
4. Development of technical offers for the implementation of R&D results.
Statistical optimization is preferred as the first step, because it requires minimum costs. The methodology is based on analysis of the archive data of automated process control system and on-line analytical control of the technological process. It is recommended for receiving 'quick profits' in the shortest possible time. On average, the project implementation allows to increase the annual revenue up from 150 000 USD.
The goals of statistical optimization are to increase the quality and amount of the product and reduce the costs of 'processing' (reducing consumption, both in the main and in auxiliary reactants, as well as in energy).
As a result, our client receives technological roadmaps with the optimal technological modes of operation of the equipment.
The goals of statistical optimization are to increase the quality and amount of the product and reduce the costs of 'processing' (reducing consumption, both in the main and in auxiliary reactants, as well as in energy).
As a result, our client receives technological roadmaps with the optimal technological modes of operation of the equipment.
The methodology of statistical optimization has proved itself in the world and in Russia. SIBUR, RUSAL, Sberbank and other leading companies use this technique on a regular basis to reduce the number of claims to the quality of product.
Benefits of technological audit
Optimization of existing production through technological audit is the optimal solution of the issues of reducing costs and increasing revenue of an enterprise without a global restructuring of the production process.
Two key issues of the technological audit:
Two key issues of the technological audit:
From our experience, the economical effect of technological audit for medium and large chemical enterprises makes the value ranging from 100 000 to 1 500 000 USD, superior to the cost of technological audit.
- identification of bottlenecks
- detection of losses of raw materials, products, energy resources
Technological audit includes professional analysis and verification of the operating mode of individual units and processes in general, computer modeling of technological processes, optimization of material and energy balance, calculation of technological and economic effect.
The result of such a project is the elimination of sources of financial and material losses.
Why is it profitable?
Two years from the date of the inspection
THE RESULT IS QUICK SOLUTIONS
Inspection
Continuation of work
From year and beyond
PREPARATION
INSPECTION
IMPLEMENTATION OF RAPID ACTIONS
IMPLEMENTATION OF MIDTERM ACTIONS
IMPLEMENTATION OF LONG TERM ACTIONS
1
PREPARATION
2
WORK ON THE SITE
3
WORK IN THE ENGINEERING CENTER
1
WORK IN THE LABORATORY
2
WORK IN THE ENGINEERING CENTER
3
WORK ON THE PILOT SITE
THE RESULT is justification of investments and baseline data for the project
Stages of technological audit of the enterprise
1
We conclude confidentiality agreements (NDA) as a guarantee that all secrets of the technological process will remain inside the company.
2
The preparatory stage consists of collecting detailed information about the production and acquaintance with the technological and design documentation at the enterprise.
3
Sampling and measurements of technological parameters (temperature, pressure, reagent costs, etc.) are carried out as agreed.
The information is taken at control points.
4
There are carried out visual and physical examination of the technological chain of the enterprise, distribution of flows, assessment of losses, search for 'bottlenecks'.
The whole analysis algorithm is discussed with the client.
5
Construction of an accurate computer model of production in real time, statistical processing of data, analysis of samples. Development of proposals and technical and economic assessment of the necessary changes and economic effect on the items:
- material balance of the process;
- heat balance process;
- quick, profitable actions;
- actions requiring technical and scientific study.
According to the results of the audit, the client receives a report and a list of actions, including detailed recommendations for optimizing and debugging the production process, energy consumption with reference to economy. The technical and economic assessment of the proposed changes is given in different depths of work depending on the requirements of the client.
Quick
actions
actions
THERE ARE A NUMBER OF QUICK ACTIONS THAT DON'T REQUIRE COMPLEX TECHNOLOGICAL SOLUTIONS AND CAN BE IMPLEMENTED 'HERE AND NOW'
Implementation period
РАЗРАБОТКА НАУЧНЫХ РЕШЕНИЙ
1
2
3
4
MATCHING OF THE OPTIMAL TECHNOLOGICAL MODE OF THE EQUIPMENT OPERATION
MATCHING OF THE OPTIMAL WAY OF PACKING ABSORBENTS
6-12 months
MODERNIZATION AND REPLACEMENT OF OUTDATED TECHNOLOGICAL EQUIPMENT (FEASIBILITY STUDY, SEARCH FOR NEW SUPPLIERS, ETC.)
Revenue
Risk level
from 25 000
to 500 000 USD per year
to 500 000 USD per year
low
4
MODERNIZATION OF THERMAL INSULATION
СВЯЗАТЬСЯ С НАМИ
РАЗРАБОТКА ТЕХНОЛОГИЧЕСКИХ РЕШЕНИЙ
>>
>>
ЗАПРОС
РЕЗУЛЬТАТ
РАСПРЕДЕЛЕНИЕ ЗАДАЧ
Optimization of energy costs will identify heat and cold losses, as well as develop solutions for heat recuperating based on 'pinch-analysis'. This actions do not require a long shutdown of the technological process and can be realized in a shutdown maintenance.
Result of works:
- Optimized equipment operation
- Recommendations for the replacement of insulating materials on economic basis
- Baseline data for the design
Services for the introduction of research results (R&D). Quite often scientific developments come to the enterprise without proper engineering study. We offer services in developing an implementation plan for R&D and assessing the economic impact of the results of implementation.
Terms and Conditions
The depth of development and the level of consulting support in technological and energy audit:
Basic
Analysis of technological processes and energy consumption in the enterprise. Development of basic recommendations.
Advanced
Working out and the detailed analysis of technological process on the chosen units and devices. Proposals for technological, energy and economic optimization without large process changes.
Expert
Subtle adjustment of the processes of the technological chain. Replacement or modification of key chemical processes. Selection of catalysts, process conditions, etc. Development of detailed recommendations and feasibility study considering market conditions, production partners, logistics chains, etc
Duration of works: information gathering and primary conclusion – 2-3 months, detailed recommendations – 3-8 months.
We are looking forward to collaboration!
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