MamkoTech

On Technology front from Space to Information India is progressing very fast. Mamko's efforts are in Process Technology.

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COMPACT PLANTS BY SMART DESIGNS


‘Process Intensification’ is the recent ‘Mind Set’ of the Process Industry.

Process Intensification means : “A set of often radically innovative principles (“paradigm shift”) in process and equipment design, which can bring significant (min. factor 2) benefits in terms of process and chain efficiency, capital and operating expenses, quality, wastes, process safety, etc. (European Roadmap of Process Intensification, 2007)”.

(Taken from Presentation of Prof. A. Stankiewicz EUROPIC Director, Tu Delft)

You can bring this ‘Mind Set’ to the ‘Water’ Industry. We are there in the background to assist you with our ‘Equipment and System’.

Water Treatment Plants are traditionally ‘large’. There are huge Tanks for Mixing, Aeration, Methanation, Separation etc. Many of these Plants can simply be made smaller and achieve the benefits as noted above by using our‘Equipment and Systems’. Some of these are elaborated in our website www.mamko.co

JET MIXING SYSTEMS


Foundation of mamkotechis mixing in Process Industry. Most of the Mamko manufacturing has been for Specialized Mixing Equipment. For example:

Around these Mamko has developed several mixing systems.Some of these are elaborated in our Website www.mamko.co Mixing systems are often engaged in Tank Mixing . Large Tanks it becomes more relevant.

Jet Mixing systems have been very much useful in large tanks where varying liquid heightsis a normal event. In such a situation designing of a proper mixing system which equally gives good performance at various liquid levels demands special and specific Designs. Mamko offers the same

Industrial Application of Mixing systems are :

A typical Mixing Patterns in follwing slideshow

EMUSIFICATION TECHNOLOGY


Water and Oil do not mix. Process industry however wants them together for several of their products. Formulation industries like Pharmaceuticals, Cosmetics, Toiletries, Process Foods and even Explosive do need emulsions.

Emulsion is a ‘liquid form’ where Water and Oil coexists, depends upon whether it is Oil droplets in Water continuum and Water in Oil emulsion is other way round. The Technology that achieves this is Emulsion Technology.

In emulsification process chemical emulsifiers play an important role. By choosing proper chemical emulsifier emulsification process can be made that much easy. Emulsifiers are often accompanied by stabilizers together they play big role in emulsion technology.

Here, Oil represents all non-polar liquids and Water represents all polar liquids. Generally one or both the phases have active material. Which is kept separate in emulsified form. Formulations play around such phenomenon. Oil in Water emulsions are more common both in Cosmetic and Pharmaceutical industries. They constitute most of the products called lotions, creams, moisturizers, bleach etc. Water in Oil emulsions however, have typical applications. One such application is in Explosive Industry. Where Explosive is in water phase and wax acts as a protective material which holds the water droplets. This makes the emulsion form of explosive safe to handle and only explodes when wanted (detonated).

Mamko has actively participated in developing Emulsion Explosives for IEL Ltd (one ICI company). Where a lab scale process was first scaled up to a pilot plant and thereafter to a successful commercial plant.

Emulsion Technology was also used by Mamko for Parle Industries in preparation of concentrates which are used in bottling of Colas.

Wax emulsions may also be processed with this Technology. The process steps for this would be as follows:

  • Melt the wax above 60oC.
  • Mix the Emulsifier and other Additives.
  • Emulsify.
  • Cool immediately to Room Temperature.
  • Wax emulsions may be used in several products. One of such use is in ‘Investment Casting’.

These are few examples of Success of Emulsion Technology of Mamko.

LIQUID EXTRACTION SYSTEM


LIQUID/LIQUID EXTRACTION SYSTEM


‘Here intensity in Extraction is achieved where the contact area between the phases is increased and convective mass transfer is enhanced. The smaller the droplet size, large is the contact area per unit volume. However, the smaller droplets may create another problem of separation. That is the emulsion shall be so stable that it will not separate. A proper balance is the skill of the designer

Extraction here is achieved in properly designed "Static Mixers". This operation is followed by any Equipment to give extra residence time (if required) and then a "Hydrocyclone" where the phases are separated.

ACID/ALKALI DILUTION SYSTEM


Chemical Industry has a regular requirement of Dilute Acid and/or Alkalis Acids may be Sulphuric Acid, Nitric Acid, Hydrochloric Acid or any other strong Acid. Alkali may be Sodium, Potassium or any other Water dissolving Hydroxide. Why do you need a ‘Process System’ for Acid or Alkali dilution?

There are two intrinsic problem with Acid/Alkali dilution such as :

  • Exothermicity
  • Corrosivity

Exothermicity should be dealt with appropriate by creating flow system and cooling (or chilling) so that the temperature do not shoot up and also the cooling (or chilling) medium is used economically.

Corrosivity of these is so complex that the choice of Material of Construction depends upon the concentration. Most Chemical Engineers know the problem specially about Sulphuric Acid. Therefore, economic choice of Material of Construction can only be achieved by designing an appropriate Process System. Both the above criteria, when addressed by an Technical expertise, you get an optimal solution both for CAPEX and OPEX.

Once you understand these problems and are able to collect appropriate data you then need to set your objectives that may be

  • Not to cross the maximum allowable Temperature.
  • Keep the cost at the lowest.
  • Keep the operation simple..

Each System is different. And Mamko has acquired enough insight in this field to give you the best system.

REACTOR SYSTEM


Traditionally large reactors have been a practice in process industry. This has come about from direct scale up of batch scale R&D in laboratories. Mamko from their large range of Process Equipment have converted these into Continuous Reactor Systems. Depending on the process, selection of the process equipment is done. Consequently, there is saving in Space and Power.

The reactions that have already been considered are Carbonation, Chorination and Sulphonation. Suphonation is further elaborated below.


Sulphonation Reaction System


Molecular Level contact is essential in a Reaction. This is achieved by Mass Transfer and Mixing. When we intensify these operation the residence time in the reactor can be substantially reduced.

The reactions are, however, highly Exothermic. The efficient heat transfer is therefore required. The Heat Exchanger is therefore kept in a loop with a high recirculation rate.

Mamko has taken up and resolved many such reaction situations. A typical example on Sulphonation Reaction System is depicted in the picture below.

OSCILLATION REACTOR SYSTEM


“Shaken not stirred” is a concept gaining importance in the Process Engineering. These Contactors are highly efficient, cost effective for Solvent Extraction, Stripping, Reaction and such operations where effective Contact between phases determines the mass transfer and thus the process such as Extraction or Reaction

Oscillating, Pulsating, Vibration or simply, shaking Contactors for Extraction or Reaction have been around for quite some time. Recently, however, there have been a number of studies which have ascertained their usefulness, specifically, in producing product with uniform properties and by consuming less Energy.

There are several types of Oscillating Contactors that Mamko offers. These are

  1. Contactors with internal Static Element design that induces pulsation.
  2. Contactor with mechanical Vibrating device to create pulsation.
  3. Contactor where pulsation are created by compressed air pressure pulsation.
  4. Third and Contactor where pulsation are created in the in Fourth device requires a great deal of Automation.The first one requires high pressure drop and therefore high energy. Therefore the preference goes to the item No. 2.

Advantages:

  • Continuous and multi-stage extraction process
  • Handling of liquids with suspended solids
  • A safer and more environmentally friendly process
  • Free from moving internal parts
  • A fully automated system
  • Lower maintenance and operating costs
  • Dramatically reduces floor space needs

Applications:

  • Minerals processing: uranium, nickel, cobalt, zinc, titanium
  • Chemical industry: nitric, phosphoric and hydrochloric acids
  • Environmental protection: recovery of nitrates, sulfuric acid,cyanides & halides
  • Additional applications include pharmaceutical, food and petroleum industries

[ORS with Static Elements]



[ORS with Vibrating Device]

ROTATING DISC REACTOR SYSTEM


Reaction between Liquid phases with different design can be carried out in Rotating Disc Reactor System. Mamko has enough information on these to be able to design a System for your Process Condition.

REFURBISHING PROCESS PLANT


As Mamko deals in modern Process Engineering Technologies, it will be very useful to engage them in refurbishing your Process Plant with Services from Mamko. Mamko has a number of smart Engineers and Technicians, who will make the required change in your existing Equipment, refurbish them and achieve improvement in product quality. If needed process changes will also be made with the backup from Laboratory experiments.

In summary following objectives will be achieved.

REFURBISHMENT–WHY ?

Process Plant Refurbishment is required generally for one of the following reasons.

  • Obsolescence and Wearing out of an Equipment or a System.
  • To increase Production Capacity.
  • To improve Product Quality.
  • To increase Energy Efficiency.
  • To reduce Production Time.

ROAD MAP

Prior to visualizing the final scenario it is important to establish the reasons for refurbishment for the final scenario based on it. Data necessary to fix the final scenario are

  • What is the reason for refurbishment?
  • What should be the life expectancy of the refurbished product?
  • Is the use of New Technologies welcome?

The Path (Process of Refurbishment)

Once the starting and the end points are established the steps to be followed are as follows :

  • Determination of the scope.
  • Working out the procedure and time schedule.
  • Working out Technical and Commercial proposal
  • Negotiation of the Proposal to a Final Agreement
  • Receipt of an Order from the Client
  • Implementation of Refurbishment

Reasons, approach and benefits of refurbishment

Refurbishment is usually performed due to two basic reasons:

  • obsolescence and wearing out of equipment
  • to increase efficiency.
Generally speaking, refurbishment may result in achievement of multiple effects such as:
  • increased reliability
  • reduced production costs
  • increased power and generation of electric energy
  • increased static and dynamic stability
  • extended service life
  • increased efficiency

Diagnostics of the existing plants condition on the basis of the data obtained from

  • technical documentation
  • documentation on “operation history”
  • operating staff
  • inspections and checking

Analysis of the condition of the main electrical parts related to water flow and output power of HPP:

  • determination of remaining service life
  • determination of possible scope of improvement (increaseof water flow or power) for each component separately.

Harmonisation of the scope of improvement for the main components in accordance with the criterion of technical and economic optimum specialised measurements and testing

 

Necessary financial investment

Determination of the scope of refurbishment

Requirements set by :

  • legal provisions
  • electric power market
  • electric power system
 

Elaboration of basic solution for refurbishment

Working out of feasibility study

Working out of technical and commercial documentation for public bidding

Invitation for tenders, collecting offers,selecting a contractor

Meet our team

The best people formula for Progressive Technology.

We do everything with our core values of Honesty,Hard Work and Trust.

CONTACT

Contact us and we'll get back to you within 24 hours.

D25, MIDC Kudal, Post Waghchoudi, Nerur, Dist. Sindhudurga, Maharashtra 416525, INDIA.

+ 912362-223534/35

+91 9870464627, +91 9821464623 , +91 9870700071, +91 9870700074, +91 8275019600

info@mamkotech.com, vchavan@mamko.co