Pressure vessel and process equipment design compliant with ASME Section VIII and PED standards.
Finite element analysis and computational fluid dynamics verification for every critical equipment design.
Extensive materials database covering corrosion-resistant alloys, duplex steels, and exotic materials for chemical service.
Chemical Processing
Equipment Design
Chemical plants handle volatile, corrosive, and toxic substances under demanding conditions. Our engineers design distillation columns, mixing vessels, reactors, and specialised equipment using advanced corrosion-resistant materials and ATEX-compliant configurations — ensuring process safety, regulatory compliance, and long-term operational reliability.
Equipment Challenges
in Chemical Processing
Corrosive media, explosive atmospheres, and complex reaction conditions demand precision engineering.
Distillation Columns
Multi-component separation columns require precise mechanical design for tray hydraulics, packing support, and thermal expansion — while handling corrosive vapours and high-temperature operation.
Mixing & Agitation Vessels
Reactor and blending vessels with agitators require careful analysis of shaft dynamics, seal selection, baffle design, and torque loading to ensure uniform mixing and process consistency.
Corrosion-Resistant Equipment
Chemical processes involve acids, alkalis, and solvents that attack standard materials. We specify duplex steels, Hastelloy, glass-lined vessels, and PTFE-lined equipment for long service life.
ATEX & Safety Compliance
Equipment in explosive atmospheres must comply with ATEX directives. Our designs incorporate explosion-proof fittings, proper earthing, and hazardous area classification from the design stage.
Our 11-Step
Methodology
A systematic approach adapted for chemical processing safety and regulatory requirements.
Initial Consultation
Meet with the customer to define project objectives, operational challenges, and process-specific requirements through structured technical workshops.
We capture detailed process parameters such as operating pressures, temperatures, flow rates, fluid properties, and site constraints. This scoping phase produces a formal requirements specification that aligns all stakeholders on performance targets and project milestones.
Conceptual Design
Develop initial design concepts through feasibility studies, trade-off analyses, and preliminary process flow modelling.
Our engineers produce concept layouts, P&IDs, and high-level equipment sizing to compare competing approaches on cost, thermal efficiency, and footprint. Each concept is scored against weighted criteria so the preferred option is selected with full transparency.
Detailed Engineering Design
Create comprehensive 2D and 3D engineering drawings specifying dimensions, materials, tolerances, and manufacturing processes using industry-standard CAD platforms.
Deliverables include general arrangement drawings, fabrication details, bills of materials, and nozzle schedules. Every design decision is traceable to the requirements specification, ensuring the equipment will perform reliably across its full operating envelope.
Simulation & Analysis
Apply advanced computational techniques including CFD, FEA, and thermal-hydraulic modelling to validate design performance across the full range of operating conditions.
Simulations target critical phenomena such as stress distribution, fatigue life, heat transfer coefficients, and flow-induced vibration. Results are iterated until all safety margins and efficiency targets are met, reducing the need for costly physical rework.
Prototype Development
Build functional prototypes or scaled test rigs to validate design concepts, material compatibility, and manufacturing feasibility before committing to full-scale production.
Prototypes are subjected to controlled test campaigns covering performance, pressure integrity, and wear resistance. The empirical data collected is compared against simulation predictions to close any gaps and de-risk the final design.
Design Review
Conduct structured design reviews with multidisciplinary teams and client stakeholders to challenge assumptions, identify risks, and optimise the design.
Reviews follow a formal gate process covering HAZOP, constructability, and value engineering. Action items are tracked to closure, ensuring every aspect from weld accessibility to maintenance clearance is addressed before sign-off.
Compliance & Standards
Ensure every aspect of the design complies with applicable international codes, safety regulations, and environmental legislation relevant to the operating jurisdiction.
Our compliance engineers verify conformance against ASME, API, PED, ATEX, BSI, and EN standards through detailed code calculations and third-party review coordination. This proactive approach prevents costly non-conformances and accelerates certification timelines.
Documentation
Prepare a comprehensive documentation package including design basis memoranda, technical specifications, certified drawings, and calculation reports.
The package encompasses manufacturing procedure specifications, inspection and test plans, welding procedure qualifications, and quality control protocols. All documents are revision-controlled and delivered in formats ready for fabricator and third-party inspector use.
Design Validation
Perform factory acceptance testing and field validation to verify that equipment meets specified performance, durability, and reliability criteria under real-world conditions.
Tests include hydrostatic pressure trials, performance curve verification, vibration monitoring, and leak detection. Any deviations from design intent are root-caused and corrected, with results formally documented in a validation report.
Feedback & Iteration
Incorporate feedback from testing, validation, and client review to refine geometry, materials, or operating parameters for optimal performance.
Design iterations are tracked through a formal change management process that evaluates each modification for impact on cost, schedule, and compliance. This closed-loop approach ensures continuous improvement while maintaining full traceability of every change.
Finalisation
Finalise the design with formal customer approval, closing out all review actions and confirming every requirement has been verified before release to manufacturing.
The final deliverable set includes approved-for-construction drawings, material requisitions, and a design dossier. A structured handover meeting ensures the fabrication team has complete clarity on intent, tolerances, and quality expectations.
What You
Receive
ATEX-conscious engineering deliverables for chemical processing equipment.
Process Design Package
Complete P&ID, PFD, and equipment specifications with heat and mass balance integration for the designed equipment.
Mechanical Design Calculations
Wall thickness, nozzle reinforcement, wind/seismic loading, and skirt/saddle design per ASME VIII and EN 13445.
Material Selection Report
Detailed corrosion assessment with material recommendations including compatibility testing data and corrosion allowance calculations.
CFD Simulation Results
Flow distribution, mixing efficiency, heat transfer, and residence time analysis using Computational Fluid Dynamics.
ATEX Documentation
Hazardous area classification, equipment marking, and Declaration of Conformity per ATEX Directive 2014/34/EU.
Fabrication & QC Package
Detailed drawings, welding procedures, NDE requirements, and inspection plans for fabrication oversight.
Proven Results in
Chemical Processing
Based on equipment design projects across petrochemical, specialty, and fine chemical facilities.
Chemical Processing
Equipment FAQ
Common questions from chemical plant operators about our equipment design service.
Ready to
Design?
Our chemical processing engineers deliver ATEX-compliant equipment designs that ensure process safety and operational reliability.
- Comprehensive engineering design & documentation
- Chemical Processing-specific CFD & FEA simulation
- Full compliance with ASME, API, BSI & EN standards