Division 2 Capabilities

Engineering Consultancy & Plant Design

Providing end-to-end basic and detailed process blueprints, piping layouts, structural coordinates, and HAZOP assessments.

Thermal & Fluid Core

Process Design & Formulation Blueprints

The foundation of any high-performance chemical or pharmaceutical processing plant lies in its process engineering parameters. Tech-Sol Services employs advanced process models to balance mass transfers, determine heat integration values, and chart optimal flow velocities.

  • PFD & P&ID Development - Drafting full Process Flow Diagrams and Piping & Instrument Diagrams with detailed valve, tag, and bypass parameters.
  • Material & Energy Balances - Modeling dynamic mass limits and heat inputs across reactors to ensure stable thermodynamic pathways.
  • Batch Sizing & Scale-up Support - Designing fluid transfers from pilot laboratory scale-ups to full capacity manufacturing output.
  • Solvent Recovery Engineering - Sizing fractional distillation systems and estimating energy-saving column heat integrations.

Calculations Built on Safety

Our detailed chemical calculations cover fluid hydraulics, NPSH checks for pumps, control valve CV sizing, and vent relief parameters, preventing operational bottlenecks before construction starts.

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Spatial Layouts

3D Plant Layout & Mechanical Routing

Conflict-Free Piping Layouts

Utilizing advanced 3D engineering software to map physical constraints and mechanical overlaps.

Routing process fluid lines across massive steel layouts requires absolute conflict-free coordination. We build complete, physical-fidelity 3D mockups of process machinery, structural supports, and piping racks to optimize operator reach, process pathways, and utility connections.

Equipment Layout

Sizing equipment spacing to ease maintenance and allow quick exit routes.

Piping Routing

Detailed lines routing with expansion loops and optimized pressure drops.

HVAC Planning

Zoning air handler units and filter housings for sterile pharma spaces.

Civil Coordination

Mapping structural dynamic loading points for massive equipment anchors.

Sizing & Selection

Premium Equipment Sizing & Selection

Reactors & Mixers

Sizing glass-lined (GLR) and stainless steel (SSR) vessels with dynamic agitator configurations.

Distillation Columns

Engineering packed or tray towers for solvent purification and recovery lines.

Heat Exchangers

Sizing shell-and-tube, spiral, and plate coolers for high-efficiency heat integration.

Industrial Dryers

Selecting fluid bed (FBD), vacuum tray (VTD), and rotary cone vacuum dryers (RCVD).

Plant Utilities

Utility Thermal Design & Sizing

Industrial processing relies heavily on stable, efficient utility backbones. Our thermal engineers calculate exact consumption profiles and select high-performance systems to support reactor cooling, product drying, and sterile cleaning loops.

  • Boiler Systems - Boiler capacity sizing with fuel combustion assessments and steam header layouts.
  • Cooling Towers - Evaporative cooling selection based on peak local humidity levels.
  • Chilled Water Systems - Dynamic refrigeration systems providing water at +5°C, -10°C, or brine down to -30°C.
  • Nitrogen Generation - PSA nitrogen generators delivering high-purity inert gas for blanket reactor safety.
  • Thermic Fluid Heaters - Sizing closed-loop oil boilers for high-temperature synthesis steps.

Optimizing Energy Recovery

By analyzing utility waste streams, we design energy recovery networks like condensate flash drums and air pre-heaters, cutting operating costs by up to 22%.

Risk Mitigation

Safety Engineering & HAZOP Compliance

HAZOP Studies

We facilitate comprehensive Hazard and Operability studies, utilizing node analysis to identify process deviations and implement safety interlocks (SIL).

Fire & Explosion Safety

Zoning explosive gas environments (hazardous area classifications), designing pressure release vents, and structural fire protection.

GMP & FDA Guidance

Ensuring layout plans completely isolate sterile and raw zones, map clear personnel airlocks, and satisfy USFDA, WHO, and Schedule M standards.

Expert Advice Desk

Inquiry Form - Plant Engineering & Design

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