PROCESS TECHNOLOGY SOLUTIONS
Driving operational excellence using our process industry expertise.
Innovation is change that unlocks new value.
InnoVent is a technology and consulting company providing turnkey Process Technology solutions as well as Asset Management solutions to the process and manufacturing industries.
InnoVent was established by executives with 25+ years of experience in Asset Performance Management (APM), process simulation, Automation and Control, MES (Manufacturing Execution Systems), and Concept-to-commissioning (turn-key) process plants.
We implement advanced digital solutions and engineering softwares such as AspenTech and ChemCAD simulation and engineering Suite, data historians, and leading Automation & Control systems (PLC/SCADA/DCS). Our engineering team provides “Concept to Commissioning” solutions from conceptual design, simulation, scale-up and safety studies, engineering, fabrication, and commissioning of the plant. Our industry focus is chemical, pharma, energy, gas processing and refining.
PROCESS TECHNOLOGY SOLUTIONS
Driving operational excellence using our process industry expertise.
Our process scheme uses a proprietary design for the regeneration column that results in 25% lower steam consumption. In addition, our refrigeration and liquefaction steps include an innovative cryogenic distillation scheme that reduces power consumption by over 20%.
InnoVent team has decades of experience in developing rigorous simulation models using Aspen Engineering Suite, ChemCAD, Unisim, Petrosim, etc. We develop steady-state and dynamic models for design, optimization, scale-up and transient analysis, and Operator Training Simulators (OTS).
Every purpose needs a platform.
About Digital Solution
Our VIP is a cloud-based software platform to convert “hard copy” based Standard Operating Procedures (SOP’s), manuals, operations checklists, and training content in to interactive and digital versions, with embedded photos, process flow diagrams, datasheets, and video learning tutorials.
VIP takes real-time/historical asset information (Control systems, ERP, historians) and provides KPI monitoring dashboards deploying AI/Analytics/simulation to provide actionable insights, and predict equipment and asset performance. AI/Machine learning algorithms include regression analysis, decision trees, pattern recognition and other predictive techniques.Read More
At XL Byte, innovation is a way of life. We think, connect and hatch new ideas to build innovative platforms that solve real-world problems. Being visionaries, what we see is our soul in things aiming to develop products that benefit millions.
XL Byte is a team of software addicts, conveniently headquartered in Bangalore (the garden city of India), Karnataka. We are smart and committed and our passion and creativity is unmatched.
UNIVERSAL RENEWABLE INTEGRATED ENERGY LOGICS.(URIEL) is a professional turnkey consulting organisation set up by first line professional entrepreneur with the objective to provide high quality value driven industrial and environmental services to commercial, industrial, private, governmental and non-governmental sectors.
Chemstations’ integrated suite of intuitive process simulation software fuels productivity for chemical engineering projects.
We created CHEMCAD to empower the role of chemical engineers across industry. To enhance their design, analysis, and testing capabilities so they can drive productivity throughout their organizations. Our outstanding technical support engineers make your CHEMCAD experience all the more seamless.
AspenTech was born out a joint research project between the Massachusetts Institute of Technology (MIT) and US Department of Energy—called the Advanced System for Process Engineering (ASPEN) Project. It is a provider of software and services for the process industries headquartered in Bedford, Massachusetts.
Chemical engineer with 22 years’ experience in the oil & gas, chemical, and pharma industries. Prior to InnoVent, Vibhu was the Vice President of Advanced Applications at Wood PLC, a $10 billion engineering and automation company. Earlier in his career, Vibhu was CEO of Ingenious Inc, a technology and consulting firm, that was acquired by Wood in 2016.
Chemical Engineer with about 27 years of process engineering experience in Oil & Gas, Refinery, Petrochemicals, Ethanol and Terminals, utility and off-site units. Gautam has held senior positions in many reputed companies like Wood Plc, Aspen Tech, Distichemi, Ingenious Inc., Triangle Simulation and Grasim Industries Limited
Chemical Engineer with over 35 years of experience in refining and petrochemical plants. Previously Executive Director at Indian Oil (IOCL), $90 billion national oil company. Experience in implementing capital projects, engineering systems, project management, energy optimization, hydrocracker, crude and vacuum units, FCC, gas processing plants, and advisory services.
Senior Advisor IT
Chemical engineer with deep IT background and over 25 years of experience in developing complex data management systems, custom software applications, mobile apps, and cloud based deployments.
PhD Chemical engineer from MIT with 35 years of experience in process simulation, modeling, asset optimization systems, kinetic models, training programs for refining, petrochemical, chemical and polymer companies.
InnoVent Technology LLC
4002 Arnold St,
Houston, TX 77005
Innovent Process Solutions Pvt. Ltd
Office No. 304 & 305, Power one condominium, Pingale Wasti,
Near Passport office, Mundhva,
Pune – 411 036, Maharastra.
CARBON CAPTURE AND STORAGE (CCS) TECHNOLOGY
The CCS technology can help oil & gas, power, and other industries achieve Net Neutral carbon, reduce carbon intensity, and meet stringent greenhouse gas abatement regulations by removing CO2 from their exhaust streams
InnoVent Technology LLC is a USA based technology and consulting company providing process technology expertise, engineering, automation and digital solutions with offices in Houston, Texas, USA; Pune, India; and Mexico. InnoVent provides “Concept to Commissioning” solutions from conceptual design, engineering, fabrication and commissioning. Our industry focus is chemical, refining, renewable energy, and gas processing. InnoVent has access to world class software for rigorous process simulation, design, optimization, capital cost estimation, engineering and scale-up.
InnoVent’s process scheme uses a mixture of amines to absorb CO2 from flue gas or any CO2 containing gaseous streams. Amines have been used for this process in various areas ranging from natural gas production to the food and beverage industry for over sixty years. There are multiple classifications of amines, each of which has different characteristics relevant to CO2 capture. InnoVent has designed an optimal formula of mixed amines that provide the best recovery results.
Our process scheme uses a proprietary design for the regeneration column that results in 25% lower steam consumption. In addition, our refrigeration and liquefaction steps include an innovative cryogenic distillation scheme that reduces power consumption by over 20%. These innovative steps, in addition to an energy integrated and optimized design, allow for an efficient and affordable system.
Part A: CO2 Recovery
A continuous scrubbing system is used to separate CO2 from a gaseous stream. The system consists of two main elements, an absorber, where CO2 is absorbed into a sorbent and a regenerator (or stripper), where CO2 is released (in concentrated form) and the original sorbent is recovered. Chemical absorption systems tend to be more efficient than the other systems, as the process is accompanied by a chemical reaction that enhances the overall mass transfer from gas phase to liquid phase.
The Amine mixture reacts chemically with the CO2 in the flue gases to form a weakly bonded compound (carbamate). The scrubbed gases are then washed and vented to the atmosphere. The CO2 rich solution leaves the absorber and passes through a heat exchanger, then further heated in a reboiler using low-pressure steam. The weakly bonded compound formed during absorption is broken down by the application of heat, regenerating the sorbent, and producing a concentrated CO2 stream. The hot CO2-lean sorbent is then returned to the heat exchanger, where it is cooled, then sent back to the absorber. Some fresh Amine mixture is added make up for losses incurred in the process. The CO2 product is separated from the sorbent in a flash separator, and then taken to the drying and compression unit. It is compressed to high pressures so that it is liquefied and bottled and easily transported. For different Streams of CO2 containing gaseous mixture with different compositions and process conditions, different absorbers with common regeneration may be used. InnoVent team have decades of experience in developing optimized process schemes customer specific requirement.
Part B: Compression, Purification and Bottling
Recovered CO2 is compressed in two stage compressors. After each stage, the compressor discharge is cooled and condensed water is separated using knock out drum. Compressed CO2 at around 18 barG pressure and 38 0C is fed to the bottom of cryogenic distillation column. Overhead vapor from the column is condensed using refrigerant liquid from the chilling plant. The condenser is a partial condenser with total reflux. Uncondensed gases along with small part of CO2 is purged to atmosphere /stack. Pure CO2 liquid is drawn as a side draw from middle of the column. Small quantity of CO2 with some heavier impurities is purged from the bottom of the column.
A variety of flexible process schemes are available to reduce power consumption and/or use Low pressure steam in lieu of electrical power. Please contact us for more details, or for a quotation
Process Simulation is one of the core expertise of InnoVent. We have decades of experience in developing high fidelity models for diversified industries and applications using leading commercial simulation software – Aspen Engineering Suite, Chemcad, Hysys, Unisim, Petrosim etc. We develop steady-state, unsteady state and dynamic simulation model for a specific plant area or for entire plant.
Coupled with simulation, our safety and risk management services allow clients to meet their safety, health, and environmental (EHS) compliance requirements (PSM, PHA).
Our team can address issues ranging from operational risk, equipment integrity, loading limits or naturally occurring hazards. We use field-proven methods to offer clients practical, holistic risk management systems and solutions. From quantitative and probabilistic software-based risk modeling to qualitative hazard assessment, we can help design an overall risk management strategy.
Modelling and Simulation have become a core part of design, optimization and operations of complex manufacturing facilities. Substantial R&D efforts are being made for developing and commercializing sophisticated computer software tools that are used for fast, accurate and optimized process designs, project cost estimation and plant operations. Developing and validating process simulation models requires experience and expertise.
Process simulation models are used for a variety of applications. For new projects, simulation models are used to generate heat and material balance, equipment sizing, design optimization, evaluating alternative technologies/process schemes and economic feasibility studies. Dynamic simulation models are used for control system design/validation and for operator training. For batch processes, simulation studies are done to optimize batch sizes, batch cycle time, operation steps for batch distillation and batch reactors.
For existing plants simulation studies are done to diagnose and rectify product quality issues, enhance capacity, improve energy efficiency and reduce off-spec products.
InnoVent has in-depth experience in developing and validating process models for variety of processes. Some of our core areas of expertise are:
Steady-State and Dynamic Models of Refinery Separation Processes: Crude Distillation, Vacuum Distillation, Naphtha Stabilizers, FCC Main Fractionator, Coker Columns etc.
Steady-State and Dynamic Simulation Models for Refinery Treatment Process: Amine Treatment, Sour Water Strippers, Caustic Towers etc.
Steady State Simulation Models for Refinery Reactors : These include FCC, CCR, DCU, NHT, DHT, HCU, ISOM, ALKYLATION using Aspen Hysys Petroleum refining (RefSYS). We build, calibrate and validate the process models of these units which in turn are used to optimize the units, predict yields and qualities of products with respect to changes in feed stock quality. The models are also used for generating input (delta vectors) for planning models (PIMS) enhancement and updates.
Rigorous Dynamic Simulation Models for Compressors: InnoVent team has detailed experience of developing rigorous dynamic simulation model for compressor performance analysis including anti-surge control validation, hot/cold bypass requirement, motor thermal limit check. We use first principles rigorous torque balance models to analyze the performance of compressors units during normal operation, turn down operation, emergency shut down, start-up, normal shutdown and other operational scenarios and propose appropriate modification to prevent the compressor from falling into surge and for safe operations.
Rigorous Simulation Models for Batch Reactor/Batch Distillation/Batch Processes: We undertake simulation of batch processes including batch reactors and batch distillation units to optimize designs and operations. For batch reactors, we apply first principles (Arrhenius, Hinshelwood-Langmuir, Fermentation/Biochemical & Catalyst Activity) reaction kinetic models to regress model parameters using variety of experimental data and simulate reactors with various heat transfer arrangement (Jackets, Internal Coil, Limped Coils) and agitations/mixing using variety of impellers geometries. This systematic approach helps in optimized design, maximized yield, minimized batch time and reduce off-spec/undesired side products with better process visibility, shorter product development cycle and faster process development.
Besides the above, we have the capability to build, calibrate and validate process models for virtually all process plants – be it Cement, Steel, Fertilizers, Active Pharmaceutical Ingredients, Polymers, Petrochemicals, Ethanol, Distilleries, Natural Gas, Paper & Pulp, Mining & Metal Industries, Power Generation Plants, Water Treatment and Waste Management facilities. The models we develop not only provide the basis of design, it also provides reliable information and input for equipment selection and sizing, cost estimation, effluent generation & mitigation, control & safety system design and play the pivotal role at all stage of project life cycle – basic engineering, detailed engineering, construction, commissioning and operation.
Our approach to plant performance improvement/ revamp/ modification/ optimization is based on a systematic study through rigorous process simulation, model validation & equipment performance rating. Typical steps involve:
Our approach is based on very detailed engineering analysis and without leaving any loop holes, without compromising on plant safety and any quality constraints. As a result, we have very high rate of success. Many times, the cost of our services including cost of implementation pays back in weeks!
InnoVent team has the expertise to provide process data historian configuration and implementation using Aspen InfoPlus 21 (IP.21), and other leading systems. A process historian allows users to capture data from a plant control system such as DCS, PLC systems, and Historize that data over a period of time, so that you can generate trends, history, performance parameters etc. for environmental and operational excellence purposes, users can track variations, anomalies, and generate KPI monitoring systems with dashboards. Data historian and MES solutions can be integrated with our VIP software for an integrated solution.
Safety & Risk Management Services
InnoVent’s safety and risk management services allow our clients to meet their safety, health, and environmental compliance. We have the experience to address issues ranging from operational risk, equipment integrity, loading limits or naturally occurring hazards. Our engineers use field-proven methods to offer clients practical, holistic risk management systems and solutions. From quantitative and probabilistic software-based risk modeling to qualitative hazard assessment, we can help you design an overall risk management strategy.
Some of the safety management services offered by InnoVent Includes:
EPC AND TURNKEY PLANTS
We provide turnkey engineering, procurement and commissioning solutions, by combining our engineering expertise and our strategic partner capabilities.
Basic & Front-End Engineering Design (FEED) Services
The main objective of the Basic Engineering Package/FEED is to provide engineering and design inputs to estimate the total installed cost of the plant. The project cost and cost overrun is sensitive to the engineering effort and hence it is important to deliberate and invest time optimally during the basic engineering stage of a project to avoid cost overruns and sub-optimal design.
InnoVent can deliver the following engineering documents under Basic and FEED package
From the conceptual design of a facility to the integration of process controls and utilities, we have the resources and experience to ensure to complete the project successfully on time in budget. InnoVent can develop cost-effective solutions for clients.
Utility system design & water management: We have the capability to design utility distribution network (Steam, Cooling Water, Thermic Fluids, Fuel gas, Chilled Water, Instrument Air, Nitrogen, etc.). We undertake detailed studies of water management, effluent treatment and water recycle scheme to minimize water consumption.
Thermal design of heat exchanger: We have in-depth experience in providing vibration free thermal design of shell & tube heat exchangers (Sensible Exchangers, Condensers, Reboilers, Evaporators, batch heating, and cooling systems) using TEMA, ASME, DIN and British Standards, Air Coolers & Double pipe heat exchangers.
Distillation and separation system design: InnoVent offers specialized services for design and optimization of separation schemes including distillation, liquid-liquid extraction and pressure swing adsorption. We have hands-on experience in azeotropic, extractive and reactive distillation schemes for separation of most complex liquid mixtures.
2D/3D Smart Drawings
Our team of experts, develop and implement SmartPlant PID, SP3D, and PDMS, CAD 2D/3D modeling services, Update and digitize plant equipment datasheets, maintenance work order systems, CMMS systems.
Automation and Control Solutions
InnoVent team has deep expertise in implementing automation systems from leading vendors. Our integrated automation and digital solutions can provide an IIOT friendly solution for operational excellence. Our capabilities include
KPI Monitoring System
KPI Dashboard, with reports on Production, Sales, Performance, Efficiency of the equipment and resources. Data Analytics, AI/ML are incorporated using regression, pattern recognition and predictive models.
Asset Monitoring Steps :
Case Studies :
Digital SOP's and User Manuals
Our platform provides digital secure repository for Manuals, SOP’s and Media Files which can be accessed from anywhere by using a browser.
Our industry experts can perform comprehensive review of content, conduct site interviews for knowledge capture with experienced operators and experts, and updated SOP (Procedures), and Operations documents.
We create an interactive digital operations Checklist using videos, equipment images, engineering drawings, etc.
Our digital Operations checklist ensures that operators can perform complex startup/shutdown or Routine maintenance activities flawlessly. The Digital checklist works as an instant digital guide for process engineers/operators in the plant.
Smart Systems = Machine Learning + Simulation Models
Deep learning in using historical plant data for curve fitting (by regression analysis) to update reactor kinetic models.
Batch Reactor Systems for Pharma and Speciality Chemicals:
A rigorous reactor model built in a process simulator with machine learning data allows better reaction prediction, soft sensors, property determination, and predictive modeling. In addition, perform rigorous heat transfer modeling, mixing and agitation – all based on rigorous process simulator.
Advantages include reducing batch cycle time, reduced impurities, higher yields, better reaction mechanism prediction, improved safety and reliability.
Smart Decision Tree
Knowledge capture using Smart Decision Tree. Capture what-if and cause and effect plans help to make smart decisions.
eTutorials and Knowledge Capture
Capture knowledge videos of operators and process experts, and use our library of modules for distillation, reactors, unit operations and Process equipment like - Pumps, Compressors, Heat Exchangers, Process Vessels, and Valves. All modules include multiple choice quizzes to grade trainee performance with SCORM compliant links to learning management systems (LMS).