2 PRELUDE PRELUDE A Medium sized Engineering Consultancy Company serving the Chemical and Petrochemical Industry. Founded in1986 by four experienced Chemical Engineering Professionals, viz. Mr. C.P.Saranathan (Late), Mr. P.N.Srinivasan Mr. R.Narasimhan Dr. N. Rangaprasad Registered in the Directory of Industrial consultancy by IDBI Successfully Commissioned several Process Plants in India and also abroad Located in Chennai DIRECTORS P.N. SRINIVASAN A Chemical Engineer having over 40 years experience in Chlor Alkali & fine chemical Industries. He has wide experience in project execution, installation and commissioning R. NARASIMHAN A Chemical Engineer having over 37 years industrial experience. He has wide experience in Chlor Alkali, technical grade Pesticides & formulation and implementing projects. Dr. N.RANGAPRASAD A Chemical Engineer with PG from IIS, Bangalore and Doctorate from University of Oklahama, USA having over 35 years experience in plant & process design, supervision of erection and commissioning. He has specialized in developing engineering concepts for various projects.
3 OFFICE OVERVIEW ReceptionEngineering Department Conference RoomCAD Department
4 PROTECH has About Process/ Project Engineering Hours per annum. About Mechanical Engineering Hours per annum About Piping Engineering / drafting Hours per annum. About 7000 Electrical Engineering Hours per annum. About Civil Engineering Hours per annum. About Instrumentation Engineering Hours per annum. Pre-investment Studies Basic Engineering Detailed Engineering Project Management Procurement Assistance Construction and Commissioning assistance Turnkey supply of systems Engg. Services Offered Engineering Capacity
5 Know-How & Proven Technologies Available for… Complete Chlor-Alkali plant (except Electrolyser Membrane cell process and design). Chlorine Drying, Liquefaction & Vaporizer Unit. Chlorine Di-oxide solution plant for Pulp & Paper Industry - R2 process and modified Hydrogen Peroxide process Stable bleaching powder plant Salt up-gradation and Iodization plant Extraction of Bromine from Sea Water Bittern. Calcium Chloride Plant Strategic Alliance With ERCO worldwide, Canada For setting up of Chlorine Dioxide plants using R8 and R10 process. Strategic Alliance With ERCO worldwide, Canada For setting up of Chlorine Dioxide plants using R8 and R10 process.
6 Lines of Business Lines of Business Chlor-Alkali plant inclusive of: Primary Brine & Secondary Brine Unit Caustic Evaporation Chlorine Cooling, Drying, Compression, Liquefaction & Storage. Hydrogen Gas Cooling & Handling Hydrochloric Acid Synthesis Unit Sodium Hypo Unit Engineering of Utilities Stable Bleaching Powder Salt Handling, Washing & Up-gradation Calcium Chloride Soln. Preparation – continuous process Chlorine Di-Oxide plant Hydro-chlorination of Methanol Petrochemical Fine chemicals
7 Process Engineering Process Engineering Preparation of process description for the plant. Developing Material and energy balance for the processing unit. Developing process and instruments diagrams (P & ID's) for Process & Utility Sections. Developing quantity of utilities required for the plant Pipe line sizing. Preparation of line list, valve list, equipment list etc. Submission of Plant Operating Manual. Assistance during Pre-commissioning & Commissioning Carrying out Hazop Study for addressing safety related issues of the plant.
8 Mechanical Engineering Mechanical Engineering Preparation of Data sheets, Enquiry specification sheets for fabricated equipment including detailed sketches. Preparation of Enquiry specification sheets for bought-out items like pumps, blowers, filters, etc., Preparation of Enquiry specification sheets for package items like boilers, compressors, chillers etc. Plot plan. Equipment layouts (plan and sections). Scrutiny, checking and approval of fabrication drawings for fabricated items prepared by vendors and Inspection. Preparation of load data drawing including foundation and pocket details for carrying out the civil work. Review of vendor documents / drawings for the bought - out items. Preparation of Enquiry specification for equipment/piping erection work, insulation and painting work etc. Preparation of drawings for submission to government bodies. Supervision of Mechanical erection
9 Piping Engineering Piping Engineering Piping specification. Piping drawings - plan and elevation. Pipe support layouts with details. Stress analysis of piping. Isometric drawings with BOQ. Bulk / Final Bills of Quantities for procurement. Supervision of Piping Erection
10 Civil Engineering Civil Engineering Architectural drawings for all the buildings. Detailed civil drawing for all plant buildings, utility area, adjoining roads, drains, equipment foundations, pipe/cable racks etc. Preparation of bill of quantities, technical specifications, piling design and layout. Preparation of Civil tender. Floating of civil tender to various vendors, including terms & conditions. Preparation of Bid analysis for the civil construction work. Supervision of civil construction.
11 Electrical Engineering Electrical Engineering Single line diagrams. Preparation of Cable & Cable Tray Routing drawing and selecting location of Push Button Stations. Enquiry specification sheets for the electrical equipment including Transformer, MCC, Cables, Switches, Lighting etc. Power / Earthing / Lighting Layouts for the process and utility buildings. Bill of material for electrical items like cable, cable tray etc. Enquiry specification for electrical erection. Supervision of electrical erection
12 Instrumentation Engineering Instrumentation Engineering Instrument Summary. Enquiry specification sheets for all instruments. Process control and interlock description. Preparation of I/O list for analog and digital signal for DCS. Preparation of control loop schematic diagrams, wiring diagrams, process graphic diagrams for DCS graphics, interlock/ladder logic diagram Instrument Cable & Cable Tray Routing Drawing Instrument layout. Specifications for air headers, instrument cables, junction boxes and cable trays. Instrument cable schedule. Loop Diagrams & Hook up diagrams. Enquiry specification for instrument erection along with instrument erection MTO. Supervision of Instrument Erection.
13 Project Management Project Management Collate Basic Data Bar / Pert Chart Coordination with client Review of data provided by client and arrange to obtain missing information Procurement Assitance Prepare Activity Schedule and Highlight Client on the critical activities and steps that need immediate execution, to achieve target schedule Conduct review meetings amongst - Client - Lead Engineers - Vendors and Contractors Pre-assess the activities which are likely to be delayed and assist client in taking necessary steps in advance to take care of any slippage. Prepare progress report highlighting the activities completed, activities to be planned & completed for the next 2 months, slippage etc. Arrange for meetings with all vendors for the Techno-Commercial meetings and assist client in finalizing the orders.
14 HP SERVER 2003 with Extensive LAN network A0 Size Inkjet Printer A3 & A4 Size Inkjet Printers Broadband Internet Connectivity Library housing the necessary technical codes & standards and reference books Subscribed to leading technical journals & magazines. PROCESS, MECHANICAL, INSTRUMENTATION & ELECTRICAL: AutoCAD Release 2011 – Network Version (10 users) for Drafting Designers Desktop for mechanical design of vessels, heat exchangers and tall columns – Based on ASME & TEMA. CV Spec for Control Valve Sizing. MS Project (2003) for project management TALLY – for accounting CIVIL & STRUCTURAL: STADD 2008 for Structural Design STRAP 2004 for Structural Detailing REVIT 2009 for Architecture Infrastructure Facilities Software Tools Used
15 Special Designs Carried Out Special Designs Carried Out Chlorine Liquefier Chlorine drying tower Chlorine Vaporizer Ion Exchange Unit for Brine Purification Calcium Chloride Solution – continuous process Reactors Single effect, Double effect and Triple effect Caustic evaporators
Electrolyzer Supplier: UHDE 1. Kothari Petrochemicals Ltd., Karaikal Capacity: 60 TPD (Expandable to 100 TPD) (Year of Completion: 1997) 2. Chemplast Sanmar Ltd., Karaikal Capacity: TPD (Year of completion: 2004) 3. Chemplast Sanmar Ltd., Karaikal Capacity: 52.5 TPD (Year of completion: 2006) 1.Primary Brine Unit: Consisting of saturation, chemical preparation, precipitation, clarification, brine filtration including anthracite filters & Precoat filters. 2.Secondary Brine unit, Brine Dechlorination unit and Chlorate Destruction unit 3.Chlorine Handling Unit: Consisting of Chlorine cooling, drying, compression, liquefaction, storage & tonner handling. 4.Hydrogen cooling & distribution to flaker unit, bottling plant & Hydrochloric Acid synthesis unit. 5.Caustic handling unit: Consisting of Caustic distribution & Caustic Concentration Unit (CCU): 6.Sodium Hypo Unit 7.Storage, Loading & unloading systems 8.Utilities consisting of Cooling water, Chilled water, DM water, Raw water, Plant air, Instrument air, Padding air, Nitrogen generation unit & Steam. 9.Instrumentation (including DCS) 10.Civil & Electrical engineering was also carried out for Kothari & Chemplast Sanmar Karaikal unit. BASIC/DETAILED ENGINEERING AND PROJECT MANAGEMENT EXPERIENCE IN CHLOR-ALKALI PLANTS SCOPE Electrolyzer Supplier: AKCC 1. Chemplast Sanmar Ltd., Mettur Dam Capacity: 200 TPD (Year of completion: 2007) 2. ASM Chemical Industries, Bangladesh Capacity: 60 TPD (Expandable to 100 TPD) (Year of completion: 2008) Note: Detail Engineering only 3. TCI Sanmar Chemicals, LLC, Egypt Capacity: 281 TPD (Year of completion: 2009) Electrolyzer Supplier: UHDENORA 1. Malay-Sino Chemical Industries Sdn. Bhd., Malaysia Capacity : 180 TPD (Expected Year of completion: 2011)
UNITS DESIGNED BY PROTECH FOR CHLOR-ALKALI PLANTS (Partial List) CAUSTIC EVAPORATION PLANTSSODIUM HYPO UNIT GUJARAT ALKALI & CHEMICALS LIMITED, DAHEJ WASTE HEAT RECOVERY SYSTEM BY ADOPTING DOUBLE EFFECT EVAPORATION – 200 TPD (31.5 TO 49% CONCENTRATION) GUJARAT ALKALI & CHEMICALS LIMITED, DAHEJ – 100 TPD (48 TO 58% CONCENTRATION) SPIC HEAVY CHEMICALS, MANALI, CHENNAI – 165 TPD (TRIPLE EFFECT EVAPORATION) KOTHARI PETROCHEMICALS LTD., KARAIKAL – 60 TPD (DOUBLE EFFECT EVAPORATION) HINDUSTAN ORGANIC CHEMICALS LTD., RASAYANI, MAHARASHTRA – 60 TPD (TRIPLE EFFECT EVAP.) CHEMFAB ALKALIES LTD., PONDICHERRY – 120 TPD. CHEMPLAST SANMAR LTD., KARAIKAL – TPD (TRIPLE EFFECT EVAPORATION) CHEMPLAST SANMAR LTD., KARAIKAL – 52.5 TPD (SINGLE EFFECT EVAPORATION) CHEMPLAST SANMAR LTD., METTUR DAM – 200 TPD (TRIPLE EFFECT EVAPORATION) ATUL PRODUCTS, VALSAD PUNJAB ALKALIES & CHEMICAL LIMITED, PUNJAB GRASIM INDUSTRIES LIMITED, NAGDA DCW LTD., SAHUPURAM TRAVANCORE CHEMICAL LTD..KERALA DCM SHRIRAM CHEMICAL LTD., RAJASTHAN. CHEMFAB ALKALIES LIMITED., PUDUCHERY
19 VARIOUS OTHER PROJECTS - PARTIAL LIST SALT & MARINE CHEMICAL PLANTS INTERNATIONAL COUNCIL FOR CONTROL OF IODINE DEFICIENCY DISORDERS,SRI LANKA (ICCIDDSL), 15 TPH & 8 TPH SALT WASHERY (YEAR OF COMPLETION: 2007) HINDUSTAN SALTS LIMITED, SAMBHAR LAKE, RAJASTHAN 10 TPH SALT UP-GRADATION (YEAR OF COMPLETION: 2006) TAMILNADU SALT CORPORATION LTD., VALINOKKAM, TPA IODIZED SALT & 9810 TPA DOUBLE FORTIFIED SALT (YEAR OF COMPLETION: 2004) CHEMPLAST SANMAR LTD., SALT WORKS, VEDARANYAM. 40 TPH SALT UP-GRADATION PLANT (DOUBLE EFFECT EVAPORATION) PREM NAMAK UDYOG PVT. LTD., DHARANGHDRA.., 72,000 TPA FREE FLOWING IODIZED SALT INORGANIC CHEMICAL PLANTS ATOFINA CATALYST INDIA LIMITED, NAGDA ALUMINIUM CHLORIDE MANUFACTURING PLANT BILASPUR BARYTES (P) LTD, BILASPUR, M.P. BARIUM CARBONATE PLANT KOTHARI SUGARS & CHEMICALS LTD., CHENNAI., CONCENTRATED NITRIC ACID SPIC HEAVY CHEMICALS DIVISION, MANALI, CHENNAI. ALUMINIUM CHLORIDE PLANT EXPANSION GUJARAT ALKALIES & CHEMICALS LIMITED, RANOLI, CALCIUM CHLORIDE SOLUTION PREPARATION (CONTINOUS PROCESS) & EVAPORATION (33 TO 46%) CAPACITY: 26.5 TPD OMAN CHLORINE, SOHAR, OMAN TURNKEY SUPPLY OF CALCIUM CHLORIDE SOLUTION PREPARATION UNIT CAPACITY: 37 TPD.
20 VARIOUS OTHER PROJECTS - PARTIAL LIST FINE CHEMICALS PLANTS BAYER INDIAN SYNTANS LTD., MADURAI LEATHER PROCESSING MANUFACTURING UNIT SPIC PHARMA, CUDDALORE, TAMILNADU. LEATHER FINISHING CHEMICAL UNIT STAHL INDIA PVT. LTD., RANIPET. LEATHER FINISHING CHEMICALS UNIT INNOVASYNTH TECHNOLOGIES INDIA PVT. LTD., KHOPOLI, MAHARASTRA, SPECIALTY CHEMICAL PLANT ATC CHEMICALS INDIA PVT. LTD., PUDUCHERRY., SYNTANS PLANT PETROARALDITE LTD., MANALI, CHENNAI EXPANSION OF SOLID RESIN PLANT CHLORINE DIOXIDE PLANTS BINDAL PAPERS LTD., MUZZAFFARNAGAR, UP CAPACITY: 5 TPD (H PROCESS) KR PULP & PAPERS LTD, SHAHJAHANPUR, U.P. CAPACITY: 4 TPD (H PROCESS) SESHASYAEE PAPER & BOARDS LIMITED, ERODE, TAMIL NADU CAPACITY: 10 TPD (R-8 PROCESS) RUCHIRA PAPERS LIMITED, KALA-AMB (HIMACHAL PRADESH) CAPACITY: 1.5 TPD (H PROCESS) JK PAPERS LTD, SURAT, GUJARAT CAPACITY: 1.5 TPD (H202 PROCESS) BALLARAPUR INDUSTRIES LTD, SEWA, ORISSA CAPACITY: 4.5 TPD (CONVERSION FROM R-2 PROCESS TO H 2 O 2 PROCESS) AND 1.5 TPD (R-2 PROCESS) KEMIRA PULP & PAPER, ARGENTINA CAPACITY: 7 TPD (R-8 PROCESS) RIA PULP, INDONESIA CAPACITY: 30 TPD (R-10 PROCESS) ITC BHADRACHALAM PAPERBOARDS LTD., ANDHRAPRADESH CAPACITY: 7.0 TPD (R-8 PROCESS)
21 VARIOUS OTHER PROJECTS - PARTIAL LIST PETROCHEMICALS PLANTS MANALI PETROCHEMICALS LTD., CHENNAI, TAMIL NADU Detailed Engineering Services for setting up of Propylene Oxide Reactor Unit - Plant-II SUPREME PETROCHEM LIMITED, MANALI, Engineering Services for revamping of their existing Expanded Polystyrene (EPS) Plant INDIAN ADDITIVES LTD., MANALI, TAMIL NADU. Detailed Engineering Services for installation of Batch Reactor, Blending Vessels and 100 KL Liquid Storage Tanks CETEX PETROCHEMICALS LTD., MANALI, TAMIL NADU Consultancy services for Debottlenecking of Secondary Butyl Alcohol (SBA) & Methyl Ethyl Ketone (MEK) plant. SRF LIMITED, MANALI, CHENNA Detailed Engineering of Nylon plant for capacity expansion. Basic Engineering by Polymer Engineering, Germany STAHL INDIA PRIVATE LIMITED, RANIPET, TAMIL NADU Detailed Engineering for cooling & blending system & pressure control system for existing reactors of their acrylic plant DCW LIMITED, SAHUPURAM, TAMIL NADU Basic & Detailed Engineering Services for 12 TPD Tri Chloro Ethylene (TCE) Plant - ONGOING SREE RAYALASEEMA ALKALIES ALLIED & CHEMICALS LTD., KURNOOL, ANDHRA PRADESH Basic & Detailed Engineering Services for Hydro Chlorination Section of Chloromethanes Plant - ONGOING FEASIBILITY & HAZOP STUDY DEEPAK NITRITE LIMITED, VADODARA. Preparation of detailed project report for 60 TPD Caustic Soda plant. ANDHRA PRADESH PAPER MILLS LTD., HYDERABAD Feasibility report for Caustic Soda Plant ADITYA BIRLA CHEMICALS (THAILAND) LTD., THAILAND Hazop Study of P & I Diagrams for existing Chloralkali plant. CHEMFAB ALKALIES LTD., PONDICHERRY Engineering Services for carrying out the study of thermal balance of the existing Caustic Concentration Unit, for carrying out technical safety audit for existing Chlorine plants and for carrying out the feasibility study for enhancement of Liquid Chlorine production.
22 INSTALLATIONS OF CAUSTIC SODA PLANT CAPACITY 60 TPD CLIENTASM CHEMICAL INDUSTRIES LTD., BANGLADESH PHOTO VIEWOVERALL PLANT VIEW CAPACITY200 TPD CLIENTCHEMPLAST SANMAR LTD., METTUR DAM PHOTO VIEWDEPLETED BRINE, CAUSTIC, CHLORINE, HYDROGEN & CELL HOUSE
23 INSTALLATIONS OF CAUSTIC SODA PLANT CAPACITY200 TPD CLIENTCHEMPLAST SANMAR LTD., METTUR DAM PHOTO VIEWCELL HOUSE VIEW CAPACITY281TPD CLIENTTCI SANMAR CHEMICALS LLC, PORTSAID, EGYPT PHOTO VIEWCLARRIFIER, TANKS & SLUDGE PIT
24 INSTALLATIONS OF CAUSTIC SODA PLANT CAPACITYDESIGNED FOR 100 TPD CAUSTIC SODA PLANT CLIENTTRAVANCORE COCHIN & CHEMICALS LTD., KERALA PHOTO VIEWOVERALL VIEW CAPACITY`60 TPD CLIENTKOTHARI PETROCHEMICALS LTD, KARAIKAL PHOTO VIEWOVERALL BRINE PLANT VIEW
25 INSTALLATIONS OF CHLORINE DI OXIDE PLANT CAPACITY30 TPD – R10 PROCESS CLIENTRIA PULP, INDONESIA PHOTO VIEWOVERALL VIEW OF THE PLANT CAPACITY10 TPD – R8 PROCESS CLIENTSESHASAYEE PAPER & BOARDS LTD; ERODE PHOTO VIEWA VIEW OF Q-20 LOOP
26 INSTALLATIONS OF CHLORINE DI OXIDE PLANT CAPACITY7 TPD – R8 PROCESS CLIENTITC BHADRACHALEM PHOTO VIEWOVERALL VIEW OF THE PLANT CAPACITY1.5 TPD CLIENTRUCHIRA PAPERS LTD., HP PHOTO VIEWVIEW OF PRIMARY REACTOR
27 INSTALLATIONS OF SALT PLANT CAPACITY5 TPH DOUBLE FORTIFIED SALT PLANT CLIENTTNSCL, VALINOKKAM PHOTO VIEWFLUIDIZED BED DRYER CAPACITY10 TPH SALT UP-GRADATION PLANT CLIENTHINDUSTAN SALTS LTD., SAMBHAR LAKE PHOTO VIEWRAW SALT PLATFORM & CONVEYOR SYSTEM
28 INSTALLATIONS OF CAUSTIC EVAPORATION UNIT CAPACITY200 TPD – TRIPPLE EFFECT CLIENTCHEMPLAST SANMR LTD., METTUR DAM PHOTO VIEWOVER ALL VIEW CAPACITY200 TPD – DOUBLE EFFECT CLIENTGUJARAT ALKALIES & CHEMICALS LTD., DAHEJ PHOTO VIEWOVER ALL VIEW
29 INSTALLATIONS OF CALCIUM CHLORIDE PLANT CAPACITY26.5 TPD CLIENTGUJARAT ALKALIES & CHEMICALS LTD. RANOLI PHOTO VIEWREACTORS & NEUTRALIZING TANK
30 In pursuit of energy saving, renewable resources, using recycled products for a non-toxic world. Thank you!