The Role of a Chemical Process and Plant Design Consultant

In today’s rapidly evolving chemical industry, the role of a Chemical Process and Plant Design Consultant has become more critical than ever. Whether it’s a greenfield project, plant expansion, process revamp, or digital transformation, an experienced consultant ensures that the design is efficient, cost-effective, and sustainable.

With over 25 years of experience in chemical plant design, process optimization, and digitalization, I have witnessed firsthand how expert consulting can bridge the gap between technology and profitability. Let’s explore the key responsibilities and value additions that a consultant brings to chemical process industries.

1. Feasibility Studies & Conceptual Design

A successful project begins with a robust feasibility study. This involves:

• Process Selection: Evaluating raw materials, reaction pathways, and technology options. So that capex investment is safe and provide highest possible returns to the investors.
• Techno-Economic Analysis: Assessing CAPEX, OPEX, and ROI to determine economic viability. Selecting best possible technology in terms of initial capital requirement. Choosing contemporary technology which is providing highest product yield, lowest cost of manufacturing and generating low waste which is not toxic and hazardous.
• Process Flow Development: Creating initial Process Flow Diagrams (PFDs) and performing mass & energy balances. This will help to understand the process at macro level to the stockholders and enables to estimate cost of production data for financial feasibility study.
• Risk Analysis: Identifying potential challenges related to safety, sustainability, and regulatory compliance. Assessment of the safety equipment requirement, process controls, material handling, selection of effluent treatment, required provision during plant design & engineering.

2. Process Design & Engineering

Once feasibility is established, the consultant plays a pivotal role in detailed process design:

• PFDs & P&IDs: Developing block flow and process flow diagram, carryout the material and energy balance for the process. Subsequently designing of process control system with process and instrumentation diagrams.
• Equipment Sizing & Selection: Designing and preparation of specification sheets of unit operation such as reactors, distillation columns, heat exchangers, pumps, and separators.
• Process Simulations: Using advanced tools like ChemCad, HYSYS, and other simulators to optimize process conditions. The detailed design of heat exchangers, distillation & absorber columns.
• Safety Considerations: Conducting HAZOP studies, SIL assessments, and relief system design to mitigate risks.

3. Detailed Engineering & Project Support

A chemical process consultant collaborates with multidisciplinary teams to ensure smooth project execution:

• Material & Equipment Specification: Providing detailed guidelines and equipment specification data sheets for procurement and fabrication. This includes all the required details including equipment operating parameters (i.e., flow rate, capacity, pressure, temperature), design parameters and material of construction, applicable codes & standards for equipment design and testing, sketch of the equipment with nozzle schedule, site conditions, etc.
• Process Control & Automation: Defining instrumentation requirements, control schemes, and digital monitoring solutions. After detailed study of the chemical process, we design a control philosophy for the smooth and efficient plant operation. In this course of work we take into consideration emergency plant shutdown requirements to avoid any hazardous conditions.
• Vendor & Licensor Evaluations: Analysing technology proposals for proprietary processes, identify optimal solutions, assess technological options to minimize variable production costs, and study effluent generation, treatment methods, and environmental impact.

4. Process Optimization & Troubleshooting

Even well-designed plants require continuous optimization and this is imperative for businesses to remain competitive. To meet this objective, a consultant applies tools like Six Sigma & Lean and can provide solutions for:

• Energy & Yield Optimization: Applying DMAIC & Lean methodology, Implementing heat integration, advanced process controls, and AI-driven analytics.
• Debottlenecking & Capacity Expansion: By process mapping and using Lean methodology to Identify the constraints or debottleneck stages. This way improving throughput without major capital investment.
• Operational Issues: Analysing process data using six sigma tools and troubleshooting quality, yield, or equipment performance problems.

5. Sustainability & Green Chemistry

With increasing regulatory pressure and environmental concerns, sustainability is at the core of modern plant design. To meet this objective we need to work upon below line items:

• Waste Reduction & Byproduct Recovery: Enhancing material efficiency to minimize waste. Finding the possibilities of recycling & reusing the effluent streams inside the plant. Working upon options to convert the waste into wealth so that final product can more economical and sustainable.
• Carbon Capture & Green Energy Integration: Exploring alternative energy sources and emission control strategies. We can study the process and work upon the methods to recover waste heat available from heat of reaction, distillation column condensers, high temperature streams and flue gases. This way we can reduce the overall energy requirement for the plant and can reduce the carbon foot prints.
• Eco-Friendly Processes: To design a sustainable and green process, evaluation of renewable feedstocks, green solvents, and low-carbon production methods.

6. Commissioning & Startup Support

Consultants play a hands-on role in plant commissioning and startup. Since he or she has complete knowledge of process technology and plant, therefore can anticipate the possible hurdles and problems during commissioning. Also, previous experience gives hands of solutions to resolve the issues which helps to expedite the plant start up:

• Pre-Startup Safety Reviews (PSSR): Ensuring that the plant meets all design and safety criteria. This step help to avoid any unforeseen issues which can lead to accident or equipment breakdown before commissioning. This includes to check the issues like missing of gaskets, bolts, welding joint failure, electric motor direction, any blind availability, NRV fitting, strainer or filter chocking, safety valves, vents & drain provisions, etc.
• Operator Training: Conducting workshops on plant operation, troubleshooting, and digital tools. This is an important step before plant handover to the production team. Also, preparation and review of the plant standard operating procedures before actual plant commissioning is very crucial.
• Performance Validation: Analysing startup data to confirm that the plant is operating as per design expectations. In case there is any gap in plant performance then conducting brainstorming to fix the problems so that design parameters can be achieved.

7. Compliance & Regulatory Support

Navigating the complex landscape of industry regulations is another critical aspect:

• Environmental & Safety Regulations: Ensuring compliance with OSHA, EPA, REACH, and other global standards.
• Documentation & Permitting: Preparing necessary reports and technical documentation for regulatory approvals.
• Risk Management: Conducting safety audits and implementing best practices for chemical handling.

How a Consultant Adds Value

• Independent & Unbiased Perspective: Unlike in-house teams, consultants provide objective insights.
• Cost Savings: Optimizing CAPEX & OPEX through smarter engineering and technology choices.
• Innovation & Digitalization: Leveraging real-time analytics, AI, and machine learning for better plant control.
• Risk Mitigation: Proactively identifying and resolving potential failures.

Conclusion

In an industry where margins are tight and efficiency is key, the right consulting expertise can mean the difference between success and failure. Whether you are planning a new project, troubleshooting an existing plant, or looking for digital transformation solutions, expert consulting can help unlock new levels of productivity and sustainability.

If you are looking for a consultant with deep experience in chemical plant design, process improvement, and digital transformation, feel free to reach out. Let’s work together to build the future of chemical manufacturing!

Thanks for reading,

Kailash Mehra