Manrochem - Gas Cleaning, Pollution Control and Emission Abatement

Manrochem Limited offers specifically tailored environmental and safety solutions to the pharmaceutical, fine chemicals and allied industries. We have developed extensive expertise in the fields of gas cleaning and pollution and emission control, including scrubbers, absorbtion and Integrated Pollution Prevention Control (IPPC).

Our wide range of services also includes plant design (batch reactors, polymerisation, fermenters, etc.), solids handling and drying (conveying, blending and bulk storage), heat exchanger design and instrumentation and control. We are actively involved with Axion Recycling to provide services in the fields of biodiesel and plastics recycling, and can offer unique cryogenic technology applications in partnership with Arencibia Associates and Kelvin Cryo Systems.

PROCESS ENGINEERING AND NATURAL EXTRACTIONS

We specialise in traditional process engineering design, product development and process development for both new and existing products. Our Indian office has great expertise in natural extractions; processes/products derived from natural sources.

In the field of construction we perform detailed design across all disciplines. The work extends from mechanical completion through handover to process commissioning. As well as this we have a secondment service that will supply engineers from all disciplines to work on client sites to specific client instructions. Engineers for the Middle East and Far East market are provided from our Indian office.

RISK ASSESSMENT, HAZOP, ZONING AND BLOWDOWN STUDIES

Safety related activities include risk assessment for the process, product and project. Project risk assessment covers both the project risks and the construction activity as defined by the CDM Regulations in the UK. We also carry out studies for basis of safety, relief and blowdown, hazard and operability and zoning.

MANAGING ENVIRONMENTAL AND POLLUTION CONTROL PROJECTS

Our expertise in gas cleaning and pollution and emission control allows us to offer complete project management to our clients. Our services include:

• Programme planning
• CDM regulation compliance
• Specification, bid analysis and procurement
• Expediting and inspection
• Cost-control, forecasting and reporting
• Site supervision
• Sub-contractor management
• Process commissioning

Some of our projects that have involved the improvement of environmental processes follow below.

VOLATILE ORGANIC COMPOUND (VOC) EMISSION ABATEMENT PLANT

The scope of work undertaken by Manrochem in the planning and construction of an emission abatement plant for BIP Ltd included: integration of the bio reactor design into plant P&ID, plant arrangement drawings, the procurement of equipment and contracts, supervision of installation and pre-commissioning checks.

Special features of the project included outline design for phases two and three, full project documentation and implementation of CDM regulations.

GAS CLEANING PLANT CHROME OXIDE KILNS

For Elementis Chloride Teeside, we undertook process development, developed Flowsheets and equipment specs, selected the main equipment vendors, performed HazOp studies and commissioning assistance.

Special features of the project included the elimination of the persistant plume from the plant and improved production times on kilns.

PROCESS INTENSIFICATION

We are actively involved in process intensification; re-engineering a process to avoid scale-up. This allows a maximised return on investment for clients by driving down lifecycle costs. An example of this is a gas cleaning plant being designed to recover valuable feedstock where we took equipment and ideas from one industry sector and applied them to another.

This approach has seen cryogenic techniques applied to reactor design, plastics industry equipment modified for the pharmaceutical sector, modular construction for pharmaceutical/fine chemical manufacture and replacing sequential batch reactions with small-scale continuous plant.

The technique can be applied to new and existing processes when the drive to do something different is present. In our experience the limiting constraint is the ability to recognise there are alternative methods available. With this in mind the greatest benefits accrue when our involvement starts during the development laboratory stage.

ABOUT MANROCHEM LIMITED

Based in Stockton-on-Tees, we have additional offices in Huddersfield and Chennai, Southern India. Founded in 1990, we can offer services from feasibility studies to full-design and turnkey projects. We have successfully executed 400 projects to date, ranging in value from £20,000 to £7million.