Additive Chemical Injection Package

Verito Engineering Private Limited’s Additive Chemical Injection Package, developed for Tata Chemical Limited, is an advanced and high-precision system designed to dose and regulate chemical additives in various processes within chemical production. This system is engineered to meet the demanding requirements of industrial dosing, ensuring accuracy, efficiency, and safety across a wide range of applications.

Overview: The Additive Dosing System is a critical component in the chemical production process, where it ensures the precise addition of various chemical additives to achieve desired reactions, product qualities, or process optimization. Tailored to meet the specific needs of Tata Chemical Limited, this system is designed for accuracy, consistency, and long-term reliability, even in harsh industrial environments.

 

Advanced FEA Analysis & Engineering Calculations for Skid-Mounted Chemical Injection Packages

At Verito Engineering Private Limited, we specialize in providing comprehensive engineering analysis and calculations for Skid-Mounted Chemical Injection Packages, ensuring superior performance, reliability, and compliance with global industry standards.

Our expertise covers Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), Structural, Mechanical, Hydraulic, and Thermal Calculations for all critical skid components, including:

Key Engineering Capabilities

Pressure Vessel Calculations API 675-Compliant Dosing Pump Selection & Sizing Agitator & Mixing Calculations (For Chemical Preparation Skids)
  • Pressure Vessel Design & Shell Thickness Calculation as per ASME Sec. VIII Div. 1 & 2.
  • Vessel Internal Component Load Analysis (Baffles, nozzles, internals, etc.).
  • Stress Analysis for Pressure Retaining Components to ensure longevity.
  • Nozzle Reinforcement & Load Analysis to prevent failures under operational loads.
  • Flow Rate & Pressure Drop Calculation for precise chemical metering.
  • Pump Stroke Length, Plunger/Diaphragm Sizing & NPSH Calculation to prevent cavitation.
  • Pulsation Dampener Sizing for flow stability & reduced pressure fluctuations.
  • CFD Analysis for Flow Optimization in complex piping networks.
  • CFD Analysis for Flow & Performance Optimization.
  • Impeller Selection & Torque Calculation for effective chemical mixing.
  • Structural & Fatigue Analysis of Agitator Shaft & Blades for extended service life.
  • Vortex Prevention & Baffle Sizing for improved mixing efficiency.
Automation & Instrumentation for Optimized Operations Piping Stress & Pressure Calculations Structural & Skid Frame Analysis
  • PLC, HMI, SCADA-Based Automation for precise control & reduced human intervention.
  • Smart Flow Meters, Pressure Transmitters & Level Sensors for real-time monitoring.
  • Automatic Dosing Adjustment & Data Logging to optimize chemical consumption & efficiency.
  • Pipe Wall Thickness Calculation as per ASME B31.3.
  • Flange Sizing/rating, Leakage & Weld Joint Strength Assessment for high-pressure applications.
  • Surge & Transient Flow Analysis to prevent pressure spikes.
  • FEA-based validation for skid stability, seismic loads, and lifting conditions.
  • Baseplate & Pump Mounting Deflection Study to prevent misalignment.
Strainer Calculations Safety & PSV Sizing Calculations Injection Quill
  • Strainer Mesh Sizing & Pressure Drop Calculations for filtration efficiency.
  • Pressure Safety Valve (PSV) Sizing per API 520/521.
  • Overpressure & Surge Analysis for emergency scenarios.
  • Injection Velocity & Jet Penetration Analysis for precise chemical dispersion.
  • Wake Frequency Calculation to prevent vibration-induced failures.
Material Selection & Corrosion Analysis Operational Efficiency & Cost Reduction
  • Material Compatibility Assessment (SS316, Duplex, Super Duplex, Alloy 20, Hastelloy).
  • NACE MR0175/ISO 15156 Compliance for sour service applications.
  • Optimized Equipment Layout for Compact Skid Design - reduces footprint & installation cost.
  • Automated Operation to Reduce Manpower Requirements.
  • Remote Monitoring & Troubleshooting for reduced downtime & maintenance costs.

 

Key Features and Benefits

 

High-Precision Dosing Pumps

  • The system is equipped with high-accuracy metering pumps, including plunger, diaphragm, and hydraulic pumps, depending on the application. These pumps provide precise flow control to ensure the correct amount of additive is introduced into the process.

Corrosion-Resistant Materials

  • All wetted parts of the system are made from corrosion-resistant materials like SS316L, Hastelloy, and PTFE, ensuring compatibility with aggressive chemicals and long-lasting performance.

Advanced Flow Monitoring

  • Real-time flow measurement and monitoring through integrated flow meters ensure that the system maintains consistent dosing rates, with options for adjustable flow rates to meet changing process requirements.

Automated Control System

  • The system features a PLC-based control system with an HMI (Human-Machine Interface) for easy operation and monitoring. The automated control allows for precise dosing adjustments, data logging, and remote operation capabilities.

Multiple Dosing Channels

  • The system can be customized to handle multiple dosing points, making it adaptable for various additive dosing applications, including simultaneous dosing of different chemicals.

Safety and Compliance

  • The system is equipped with safety features such as leak detection, pressure relief valves, and emergency shut-offs, ensuring compliance with industry safety standards and protecting operators from exposure to hazardous chemicals.

Temperature Control

  • In applications where temperature-sensitive chemicals are used, the system can include integrated temperature control units to maintain additives at optimal conditions for dosing.

Easy Maintenance

  • Designed for minimal downtime, the system includes easily accessible components for maintenance, such as quick-release couplings, self-cleaning filters, and modular pump designs, making repairs and replacements straightforward.

 

Applications in Chemical Production

 

The Additive Dosing System is critical for controlling the introduction of chemical additives in processes such as

 

  • Water Treatment : Precise dosing of coagulants, flocculants, and disinfectants.
  • Fertilizer Production : Controlled introduction of nutrient-rich additives to enhance product quality.
  • Industrial Chemical Production : Accurate dosing of catalysts, inhibitors, and reactants to optimize chemical reactions and improve process efficiency.

 

Technical Specification & Capabilities

 

Material of Construction SS316L, Hastelloy, PTFE (depending on the chemical properties of the additive)
Pump Types Plunger, Diaphragm, Hydraulic Diaphragm (customized as per application needs)
Flow Rate Customizable to meet process requirements (ranging from 0.1 LPH to 1000 LPH)
Pressure Range Capable of operating at pressures up to 100 bar
Control System PLC-based with HMI interface, remote monitoring capabilities
Temperature Range Up to 150°C (optional with temperature control)
Accuracy ±0.5% to ±1% depending on process requirements
Electrical Requirements 230V/400V, 50Hz, 3-phase

 

Advantages

 

Precision

  • Delivers highly accurate dosing, essential for maintaining product quality and consistency.

Safety

  • Equipped with extensive safety features to ensure protection against leaks, over-pressurization, and exposure to harmful chemicals.

Low Maintenance

  • Modular components and corrosion-resistant materials ensure low maintenance costs and long-term reliability.

Versatility

  • Capable of handling a wide range of chemicals, flow rates, and pressure levels, making it adaptable to various industrial applications.

Automation

  • Full control over dosing parameters through PLC automation, reducing human error and allowing for remote monitoring and adjustments.

 

Applications Beyond Chemical Production

While developed for Tata Chemical Limited, the Additive Dosing System can also be used in other industries such as pharmaceuticals, petrochemicals, food processing, and wastewater treatment, where precise and reliable chemical dosing is essential.

 

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