In addition to our services in project development and planning, we offer process engineering services. Our cross-industry expertise enables us to implement individual solutions based on various projects in different industries.
Our services in process engineering include:
Piping and Instrumentation Diagrams (P&IDs) are the centerpiece of successful plant design in the field of process engineering. These detailed graphical representations not only provide a visual overview of industrial processes but also serve as an indispensable tool for the control, monitoring, and optimization of facilities.
P&IDs are detailed diagrams that map out all pipelines, instruments, and control elements of a facility. These flowcharts offer a comprehensive depiction of the process structure, considering both the physical layout of pipelines and the integration of sensors, valves, pumps, and other components. By clearly labeling process fluids, instruments, and controls, P&IDs facilitate precise communication among various teams involved in the planning, construction, and operation of the facility.
“Carbon Dioxide Capture and Utilization” (CCU) and “Carbon Dioxide Capture and Conversion” (CCC) are approaches aimed at reducing CO2 emissions by capturing carbon dioxide (CO2) and utilizing or converting it into other products. These technologies play a crucial role in efforts to mitigate anthropogenic CO2 emissions and address climate change.
CCU refers to the process of capturing CO2 from industrial processes or directly from the atmosphere, followed by using this CO2 to manufacture useful products.
CCU and CCC technologies contribute to viewing CO2 as a resource rather than merely considering it as a waste product. Ongoing research and development in this field aim to enhance these technologies and broaden their applications. ICB is focused on the application of CCC technology, which we will briefly introduce to you as follows:
CO2 Capture and Conversion (CCC):
CO2 Capture and Conversion focus on transforming captured CO2 into other chemical compounds or forms of energy. This process can occur through various methods, including chemical reactions or electrochemical conversions. Some examples of CO2 Capture and Conversion are:
Technologies in focus:
The Amine Solvent Technology is employed in the field of CO2 capture to remove carbon dioxide from industrial processes or exhaust gases. In this technology, a solvent based on amines, often Monoethanolamine (MEA) or other amines, is used to selectively absorb CO2 from gas streams. The process takes place in an absorption unit where the gas flows through the amine solvent. The amine molecules react with the CO2, forming stable compounds. Subsequently, the loaded solvent is directed to a desorption unit where the CO2 is released again by increasing the temperature or reducing the pressure. This cycle allows for continuous separation of CO2 from gas streams. The Amine Solvent Technology plays a crucial role in reducing greenhouse gas emissions in industrial processes and improving environmental sustainability.
The Pressure Swing Adsorption (PSA) technology is employed in the field of CO2 capture to efficiently and selectively remove carbon dioxide from gas mixtures. In this process, the gas mixture is passed through an adsorption unit under elevated pressure, which is filled with a specialized adsorbent. The adsorbent selectively binds CO2, temporarily retaining other gas components. After a specific period, the pressure in the system is reduced, relieving the adsorbent and releasing the captured CO2. This cyclic shift between pressure increase and reduction enables continuous CO2 separation. PSA technology is characterized by its flexibility and adaptability, making it attractive for various applications, including the reduction of CO2 emissions in industrial processes. Continuous advancements in this technology aim to enhance its efficiency, positioning it as a significant component in the pursuit of more sustainable environmental impacts.
The Temperature Swing Adsorption (TSA) technology has emerged as a significant method in CO2 capture, especially in industrial processes. This advanced technology utilizes temperature fluctuations to efficiently separate carbon dioxide from gas mixtures. In a TSA system, the gas mixture passes through an adsorber filled with a suitable adsorbent. The adsorbent captures CO2 at low temperatures. Subsequently, the temperature is increased, releasing and regenerating the adsorbent. The cyclic transition between adsorption and regeneration allows for continuous CO2 separation. TSA technology offers the advantage of thermal regeneration, making it particularly effective and energy-efficient. This advanced method plays a crucial role in efforts to reduce CO2 emissions and has the potential to make a sustainable contribution to combating climate change.
Membrane Technology has emerged as a promising approach in CO2 capture, particularly in the context of gas processing and separation. In this process, semi-permeable membranes are utilized to selectively separate CO2 from gas mixtures. The membranes allow CO2 to pass through while retaining other gas components. This process offers the advantages of simplicity, cost-effectiveness, and a compact plant design. There are various types of membranes, including polymeric, ceramic, or metal-organic membranes, each with its own specific properties. Membrane technology is well-suited for applications with low CO2 concentrations, often found in industrial exhaust gases. Its flexibility and scalability make it a promising option for CO2 capture, with ongoing research and innovation aimed at improving the efficiency and applicability of this technology.
Hazard and Operability Analysis (HAZOP) is a critical tool in the field of process safety, holding a central position at [Company Name]. Our HAZOP risk analyses are designed to identify, assess, and minimize potential hazards in industrial plants, ensuring safe operation and efficient process management.
HAZOP is a systematic method for risk analysis that aims to identify potential hazards and operational issues in a process system. Our experienced engineers conduct HAZOP analyses by critically examining every aspect of a process, uncovering potential deviations from normal operation. This involves considering not only technical aspects but also operational, human, and organizational factors.
Thermodynamic simulation using specialized software is an essential component of modern engineering practices. At [Company Name], we leverage advanced simulation tools to analyze, comprehend, and optimize complex thermodynamic processes. This simulation software enables precise predictions and detailed insights into the behavior of liquids, gases, and solids in various industrial applications.
Process engineering plays a key role in the implementation and optimization of new technologies in energy generation and industrial processes. Innovation areas such as renewable energy, fuel cells, and asset optimization require advanced process engineering approaches to develop sustainable and efficient solutions.
Through precise modeling, simulation, and continuous process improvements, process engineering enables the integration of new technologies into existing industrial processes. This contributes to increasing efficiency, reducing emissions, and promoting the transition to a sustainable energy future.
In the context of green energy, which focuses on sustainable forms of energy, process engineering plays a crucial role in converting renewable resources into usable energy. Whether it’s the efficient conversion of solar energy into electricity, processing biomass into biofuels, or optimizing the use of wind energy, process engineering shapes processes to ensure maximum efficiency and environmental friendliness. Through continuous research and development, process engineering contributes to fully harnessing the potentials of green energy, making a significant contribution to the global energy transition.
Technologies in Focus:
“Power-to-Gas-to-Power” is an energy concept that combines two main processes: the conversion of electrical energy into gaseous energy storage (Power-to-Gas) and the reconversion of this gas into electrical energy (Gas-to-Power).
Energy is stored in the form of gas over a period of about 8 hours, preferably during an off-peak period such as at night, to be later converted back into energy from gas. This technology is particularly interesting in industrial areas with defined production times, for operators of energy networks, and for bridging time gaps in wind and solar energy installations.
This approach plays a crucial role in the integration of renewable energies and addressing challenges related to the intermittent nature of certain renewable energy sources such as solar and wind energy.
This concept is increasingly important in the creation of a sustainable and flexible energy ecosystem based on renewable resources, addressing the challenges of integrating fluctuating energy sources. It provides an approach to bridge temporal and spatial discrepancies between supply and demand in energy systems.
The “Solid Recovered Fuel to Power” (SRF-to-Power) technology refers to a process in which waste, through methods such as gasification or pyrolysis, is converted into energy in the form of so-called “Solid Recovered Fuels” (SRF). This technology plays a crucial role in waste management and renewable energy, particularly in reducing waste, recycling resources, and simultaneously generating clean energy.
“Waste Heat to Power” refers to the utilization of waste heat generated as a byproduct of industrial processes or other applications to produce electrical energy. Many industrial processes generate significant amounts of waste heat that is typically released into the environment. By converting this waste heat into electrical energy, the efficiency of plants can be increased, while simultaneously saving energy.
“Hot Water – Chill Water” refers to a building air conditioning system that combines heating and cooling functions within an integrated system. This system is often referred to as “Heating, Ventilation, and Air Conditioning” (HVAC) and uses water as the medium for heat or cold transfer.
The use of water as a heat transfer medium allows for efficient transfer of heat or cold within the building. Additionally, the “Hot Water – Chill Water” system enables centralized control and regulation of room temperatures.
The process of “UCO to Biodiesel” refers to the conversion of used cooking oil (UCO) into biodiesel. Used cooking oil is generated through the cooking of food and is often considered a waste product. By converting UCO into biodiesel, this waste material can become a sustainable and renewable source of biodiesel.
“Gas to Biowax Technology” refers to a process in which gas, typically synthesis gas (syngas), is converted into biowax through Fischer-Tropsch processes. This approach combines the utilization of gases, often sourced from renewable or sustainable sources, with the production of biowax, a versatile material with various applications.
This technology represents an innovative approach to producing biowax as an environmentally friendly and sustainable product, using renewable gases as the starting material. Progress in this technology can help reduce dependence on fossil resources in wax production while contributing to a more sustainable chemical industry.
“Waste Steam to Power/Hydrogen/Methane Technology” refers to technologies that convert waste heat or steam generated as byproducts in various industrial processes into clean energy sources. These technologies contribute to the efficiency improvement of industrial processes by transforming otherwise unused heat into electrical power, hydrogen, or methane.
Excess Steam to Hydrogen:
“Waste Steam to Hydrogen” refers to how waste heat or steam is utilized to produce hydrogen. This can be achieved through high-temperature electrolysis or other thermochemical processes where steam is converted into hydrogen and oxygen. The produced hydrogen can be used as a clean fuel or for storing renewable energy.
Excess Steam to Methane:
“Waste Steam to Methane” involves using waste heat or steam to produce methane. This can be done through methanation, where hydrogen reacts with carbon dioxide (CO2) to form methane. The produced methane can be injected into existing gas infrastructures or used as a clean fuel.
“Zero Liquid Discharge” (ZLD) refers to an environmentally friendly approach in industrial processes where no wastewater or sludge is discharged into the environment. The goal is to design the entire process in such a way that no liquid waste remains, and instead, all liquids are reused or treated in some other manner. The term “Zero Liquid Discharge” implies not only the reduction of wastewater emissions but complete avoidance.
“Zero Liquid Discharge” is applied in industries such as the chemical industry, mining, electronics production, food processing, and other water-consuming sectors. It represents an advanced approach to addressing environmental impacts and efficiently utilizing water resources in industrial processes.
Process engineering in the field of hydropower encompasses various technologies aimed at efficiently utilizing water while employing various process engineering techniques.
Key Technologies Include:
“Chemical Conditioning” refers to the use of chemical substances to alter or improve specific properties of water. This may include controlling deposits, providing corrosion protection, or adjusting the pH level, for example. In hydropower plants, careful chemical conditioning is crucial to extend the lifespan of plant components and enhance overall efficiency.
“Reverse Osmosis” is a water treatment technology where water is forced through a semi-permeable membrane to remove undesirable contaminants such as salts or organic substances. This can be utilized in hydropower plants to provide drinking water for operational needs or to reduce unwanted minerals in the water.
“Thermal Desalination” involves heating water to vaporize it and subsequently condensing the steam to obtain drinking water. This process can be employed in hydropower plants to desalinate saltwater and convert it into usable water, particularly in regions facing water scarcity.
“Ion Exchange” is a process in which undesirable ions in water are exchanged for other ions to improve water quality. This can help reduce the accumulation of harmful substances in the water, thereby supporting the operation of hydropower plants.
In the oil and gas industry, process engineering is crucial to ensure not only efficient but also sustainable processes. The focus here is on innovating new technologies to optimize processes, efficiently utilize waste heat, and eliminate pollutants from production.
Process Optimization for Higher Efficiency:
Our process engineers specialize in optimizing the entire value chain from extraction to processing. By utilizing state-of-the-art simulation tools, we analyze complex process workflows, identify bottlenecks and weaknesses, and develop tailored solutions to enhance overall efficiency. This not only enables cost savings but also reduces energy consumption and environmental impacts.
Utilization of Waste Heat and Process Waste:
Waste heat and process waste represent valuable resources. Our process engineers implement innovative heat recovery systems to extract waste heat from various processes and use it for heating, cooling, or energy generation. This not only reduces operating costs but also lessens the ecological footprint.
Pollutant Cleanup for Clean Production:
Environmental protection is at the core of our process engineering in the oil and gas industry. We implement advanced technologies for pollutant cleanup to minimize emissions and ensure compliance with increasingly stringent environmental regulations. From removing sulfur compounds to reducing CO2 emissions, we rely on innovative processes to enable sustainable and environmentally friendly production.
Key Technologies Include:
The formation of black powder in pipelines can have various causes, including corrosion, hydrogen and sulfur compounds, as well as other chemical reactions. Black powder can compromise the efficiency of facilities, reduce the lifespan of equipment, and lead to operational disruptions. Therefore, it is crucial to implement effective strategies for the removal and prevention of black powder.
Hydrocyclone technology, also known as centrifugal separator, is a method for separating solids and liquids or classifying particles in a suspension. Hydrocyclones are commonly used in industrial applications, including the oil and gas industry, mineral processing, water treatment, and other processes where efficient particle separation is required.
In the oil and gas industry, for example, hydrocyclones are used in the pretreatment of drilling muds, water treatment, and the separation of solids from liquids.
Technologies:
“Gas scrubber technology”, also known as gas washer or absorption column, is a technology employed in various industries to remove gaseous pollutants and contaminants from exhaust streams. The primary purpose of gas scrubbers is to improve air quality, meet environmental regulations, and reduce harmful emissions.
The selection of suitable gas scrubber technology depends on the specific requirements of the application and the types of pollutants to be removed. Gas scrubbers are a crucial component of modern environmental protection and emission control systems.
An Upstream 3-Phase Separator is a piece of equipment used in the oil and gas industry, specifically in the “Upstream” segment. The Upstream sector refers to the phase of the oil and gas production chain that involves the exploration, drilling, and extraction of raw materials at the source.
The Upstream 3-Phase Separator plays a crucial role in the initial processing stage of the raw materials obtained from oil and gas wells. It facilitates efficient separation of the various phases, ensuring that the extracted oil can be processed cleanly and in the correct specifications, while simultaneously treating or disposing of water and gas in an appropriate manner.
“Natural Gas Purification from CO2 with Membrane Technology” refers to a process for cleaning natural gas from carbon dioxide (CO2) using membrane technology. This process is crucial to bring natural gas to specified quality standards while minimizing environmental impacts.
The application of membrane technology for CO2 separation in the natural gas industry helps provide natural gas in a cleaner form while supporting efforts to reduce greenhouse gas emissions. It is important to note that various technologies can be employed depending on the specific requirements and conditions of a facility.