Many process plants are afflicted by excessive consumption of inputs such as solvents, reactants, and utilities. This is due to losses through vents, drains, and effluent, sub-stoichiometric conversion of reactants to products, and process and energy waste. They can flip the plant economics from profit to loss.
In our audits, we examine the mass and energy balances—over the entire plant as well as individual equipment. All input and output flows are studied to locate areas of abnormal loss. Reaction stoichiometry is analyzed to compare ideal versus actual conversions. Process parameters including pressure, temperature, and flows are assessed. Our audit includes an inspection of equipment to evaluate its condition, efficiency, and wear, with a view to upgrading, repairing, or replacing components to ensure optimal performance. Our final recommendations include revisions to operating procedures and parameters, modifications to plant and equipment, and specifications for additional equipment.
Energy consumption is a significant cost in process plants, and optimizing it is crucial for cost savings. We analyze energy usage across various systems—including heating, cooling, and power supply—to propose tailored improvements. These include process heat integration, energy-efficient equipment, and enhanced control strategies. Additionally, our audits serve as a critical tool for enhancing operational efficiency, improving product quality, reducing energy costs, and ensuring compliance with safety and environmental regulations. Through systematic evaluation, we identify inefficiencies and deliver actionable solutions to minimize input waste, streamline workflows, and improve overall sustainability.