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Process design
Process design includes all the elements of a process plant. This is one of Process Engineering’s most important work areas and we perform process design within the four industries Energy & Renewables, Industry, Food & Biotech and Pharma.
Our areas of expertise and services
Process design often takes place in partnership with you because you possess the experience of the process and of which special considerations we must be aware of in a particular process. Our engineers and technicians produce the required documentation to ensure that the design of your process meets your requirements and expectations.
Below you can read about some of the elements that are typically included in the process design.
Process simulation
Process simulation is one of the most important tools for our engineers. It makes it possible to simulate how a process proceeds through a plant in a way where material composition, temperature, pressure as well as flow are mapped. In this way the basis for the plant design is established in an overall documentation package which can be used as the basis for detailed layout of devices and components in the plant.
Our highly trained chemical engineers often use several internationally acknowledged process simulation programmes, and often they are capable of preparing the first assessments of the investment for a new process plant at a Conceptual Design level.
Process Flow Diagrams
One of the starting points for engineering of a process plant is a process flow diagram (PFD) that includes all the fundamental conditions of the processes to be carried out at the plant.
By means of PFD we map all the mass and energy flows and determine pressure and temperature for each of these flows. The mass flow is described with a percentage distribution on various components and in a statement of the mass flow, which can be outlined in kg/h or Nm3/h.
We use the PFD rigorously in the project process, so the design basis of equipment and components is always well-defined. In this way – and also in the case of changes during the project – we ensure a permanent overview of the consequences of these changes.
Process Flow Diagrams
One of the starting points for engineering of a process plant is a process flow diagram (PFD) that includes all the fundamental conditions of the processes to be carried out at the plant.
By means of PFD we map all the mass and energy flows and determine pressure and temperature for each of these flows. The mass flow is described with a percentage distribution on various components and in a statement of the mass flow, which can be outlined in kg/h or Nm3/h.
We use the PFD rigorously in the project process, so the design basis of equipment and components is always well-defined. In this way – and also in the case of changes during the project – we ensure a permanent overview of the consequences of these changes.
Process description
The process flow diagram provides a great overview of the processes that flow in a process plant, and in some cases it can also stand alone in the dialogue between people with experience of process simulation. But when other people in the project team are to program the operating system, it is necessary to make a process description of how the individual process steps should be performed.
We prepare systematic process descriptions, which makes it possible for other people than process people to quickly familiarise themselves with the situation, and we ensure a well-defined process description for use in relation to official approval.
PI Diagram
A PI diagram (Piping and Instrumentation Diagram) is a detailed pipe and component diagram. It is used in the process industry to create a transparent and systematic overview of the process equipment and its context.
PI Diagram
A PI diagram (Piping and Instrumentation Diagram) is a detailed pipe and component diagram. It is used in the process industry to create a transparent and systematic overview of the process equipment and its context.
3D pipe design
Design of pipe systems is not always straightforward. For instance, steam, cooling facilities, extensive systems and sanitary installations with piping in sterile areas are examples of complex installations.
Process Engineering designs and specifies pipe work for all purposes within the process industry based on idea presentations or existing PI diagrams.
Virtual Reality
In addition to 3D drawing of the process plant, we also offer a VR (virtual reality) walkthrough of the process plant.
By using VR glasses to review the 3D drawing of the process plant, the design process is improved, a realistic and lifelike experience is gained, and potential problems are easier to identify. We create the VR model based on the 3D Navis model in which the process plant is drawn. With the VR experience, you can “walk around” the plant and get a sense of the space where the plant will be located.
Virtual Reality
In addition to 3D drawing of the process plant, we also offer a VR (virtual reality) walkthrough of the process plant.
By using VR glasses to review the 3D drawing of the process plant, the design process is improved, a realistic and lifelike experience is gained, and potential problems are easier to identify. We create the VR model based on the 3D Navis model in which the process plant is drawn. With the VR experience, you can “walk around” the plant and get a sense of the space where the plant will be located.
Hygienic Design
Hygienic design of a process plant is crucial in food production and the pharmaceutical industry, where clean and sterile environments are essential for product quality, safety, and compliance with regulations and standards.
We assist in clarifying and determining relevant hygiene standards for specific process plants. We design the plants, prepare tender documents, plan the project, ensure utility clarification, and handle installation, commissioning, and handover.
Energy balance
The purpose of the energy balance is to create an understanding of the energy needs and consumption in a process plant. We list process plant technologies such as machinery, components, and instruments in an Excel template, and record and categorize all installed utilities such as power supply, steam, cooling tower water, refrigeration, compressed air, and chemicals according to specification requirements.
Energy balance
The purpose of the energy balance is to create an understanding of the energy needs and consumption in a process plant. We list process plant technologies such as machinery, components, and instruments in an Excel template, and record and categorize all installed utilities such as power supply, steam, cooling tower water, refrigeration, compressed air, and chemicals according to specification requirements.
Mass balance
The mass balance is one of the key documents in any process design. Its purpose is to provide an understanding of quantities, capacities, and properties within the process plant. Initially, we list the product’s composition and characteristics.
Process integration
Process integration connects the individual technologies so that the process plant operates as a single, cohesive unit. Process integration can account for up to 60% of the total project delivery scope.
We offer this part of the project as detailed process design, enabling customers to purchase directly from the manufacturer and achieve significant CapEx savings.
Process integration
Process integration connects the individual technologies so that the process plant operates as a single, cohesive unit. Process integration can account for up to 60% of the total project delivery scope.
We offer this part of the project as detailed process design, enabling customers to purchase directly from the manufacturer and achieve significant CapEx savings.
Tender documents and requirement specifications
Tender documents and requirement specifications are both documents that describe the commercial and technical scope of delivery. Process Engineering typically handles the technical part, while the customer is responsible for the commercial part.
Cases
Over the years, we have completed many projects for manufacturing companies, system builders, and workshops.
Do you have a project for which you need strong engineering skills?
Contact us and learn how we can assist you as your consulting engineering partner
