Studies :

• Project Quality Plan
• assessments (material, heat, utility, power)
• Implementation of PFDs (process flow diagram) and then PIDs (piping and instrumentation diagram)
• Sizing of new equipment and storage capacities
• Elaboration of project lists (equipment, motors, piping, valves, cables)
• Implementation of the whole project in the existing workshop
• Preliminary security analysis
• Drafting of new functional analyses
• Drafting of preliminary technical specifications for preliminary design consultation: equipment and works contracts (civil engineering, structure and framework, piping, electricity / instrumentation / automation, “centralized dust collection” package)
• CAPEX and implementation planning

Completion of the industrial transfer of a nanosphere and polymer microsphere manufacturing unit.

Location : Meyzieu, Rhône FRANCE
Project phases : Detailed design and implementation (studies and monitoring of the transfer)
Project duration : 3-month detailed design and 18-month implementation

Within the MERCK group, the ESTAPOR division has been designing and manufacturing nanospheres and microspheres of polymers, magnetic or not, since 1993.

MERCK wanted to regroup ESTAPOR’s premises, initially in Pithiviers, on its Meyzieu site. For this purpose, MERCK had decided to rely on the services of an industrial engineering team to confirm the preliminary design studies and manage the complete transfer, from the shutdown of the units and the management of the stocks before transfer to the complete reassembly on the host site. The transfer concerned the two ESTAPOR businesses: laboratory (clean rooms) and production (grey rooms). The reception site was completely dismantled since the previous activity was still in place on the floors.

Total amount of the project :

Range A < €10 million
Range B: between €10 and €20 million
Range C: between €20 and €50 million
Range D > €50 million

You can find our different realizations on chemistry and innovative materials by clicking on the following link.

Specialty Industry – New Production Line for Silicon Carbide Nanoparticles

Location: Rambouillet (78)
Project phase: Engineering studies
Project duration: 18 months

Project background: the start-up NANOMAKERS called on EMDELEN to strengthen its capacity to produce nanoparticles, which are generated from a laser pyrolysis process. Main applications: reinforcement of polymer or composite materials, lithium-ion batteries.

• Review of the production rate to increase the plant’s productivity
• Assessment, sizing of equipment and drafting of technical specifications
• Implementation of the new production line in the existing workshop
• Work specification (piping, EIA)
• Writing of the functional analysis and HAZOP
• Writing a process book

Unit for manufacturing bromine from used bromine brines

Location: Plaine de l’Ain Industrial Park – Saint-Vulbas (01)
Project Phase: Preliminary Project-Summary studies necessary to determine the amount of investment and obtain operating costs.
Study period: 2 months

Tredi, a company specialising in the treatment of industrial waste, is planning to build a bromine manufacturing unit (Br2, 30,000 t/year) using used bromine brines (sodium bromide and/or potassium bromide in aqueous solutions of varying concentrations.

Project background: Tredi has the technology to extract bromine from brine for lower production and wants to obtain a Capex for 30,000 t/year based on this technology.

Emdelen Mission : 

• Definition of the block diagram of the unit defining the main functions
  • Used brine disposal area
  • Storage of used and purified brines
  • Static furnace and hardening
  • Oil discharge area and oil storage for furnace combustion
  • Treatment of combustion fumes
  • Bromine extraction and storage
  • Various utilities (Soda, hydrochloric acid, natural gas, compressed air)
• Development of PDF schemas (Process Flow Diagram) after validation of the block schema
• Technical specification and consultation of the main packages: static furnace, quenching, smoke treatment and bromine extraction
  • Vertical static brine combustion furnace, dual-fuel natural gas/oil burners 3 MW
  • Smoke quenching system for cooling from 800 °C to 70 °C (graphite quench and water spray)
  • Purification of flue gases by venturi and spray column, devesicator and scrubber with activated carbon filling, extraction of purified bromine brines
  • Bromine extraction columns with steam and chlorine injection
• Realization of the overall plans of the installations for internal costing of the civil engineering, structural, piping and electrical/instrumentation/automation lots
• Realization of utility diagrams
• Establishment of the electrical balance sheet and list of motors
• Estimate of CAPEX (at +/-25%) and OPEX

Redesign of effluent treatment

Location: Saint-Auban (04)
Project phases: Feasibility studies
Study period: 6 months

Studies :

• Study and definition of the segregation of effluent flows:
  • Acidic flows without TSS or COD that only require pH adjustment
  • Flows loaded in TSS and/or COD
  • Fluxes loaded with adsorbable organic halogen and aromatic organochlorine
  • Neutral flow without any need for treatment
• Pilot laboratory tests
  • Neutralization
  • Physico-chemical treatment
  • Adsorption on activated carbon
  • Ozone oxidation
• Based on the results of laboratory tests:
  • Definition of the physico-chemical treatment process
  • Definition of the size of the structures
  • Audit of the existing station
  • Validation of existing recoverable equipment
  • Creation of new works
  • Definition of activated carbon filters
• Implementation of PIDs, functional analysis, implementation plans
• CAPEX, OPEX and planning

New effluent treatment plant for the vaccines business

Location: Neuville-sur- Saône (69)
Project Phases: Detailed Preliminary Project Study
Study period: 2 months

Emdelen Mission :

• Flow balance, material balance and definition of the treatment chain
  • Water channel (biological) including the following steps:
    • Homogenization of effluents in buffer tanks
    • Neutralization of effluents
    • Biological cultures on mobile media with syncopation to alternate nitrification and denitrification sequences
    • Separation of the bio-mass by pressurized float
    • Coagulation of effluents leaving the floater
    • Filtration of effluents on rotating screens
    • Counting and discharge of effluents in the natural environment
  • Sludge filter comprising the following steps:
    • Storage of sludge coming out of the floater
    • Sludge conditioning
    • Sludge dewatering on filter presses
  • Definition and preparation of reagents: lime milk, polymer, ferric chloride
  • Treatment of tank vents on activated carbon filtration
• Realization of PID schematics
• Writing of the Functional Analysis, definition of the PLC inputs/outputs and the automation architecture
• Single-wire electrical diagram and power balance
• Implementation of implementation plans
• Allocation of the project
• Specifications and consultation of equipment batches
• Specification and consultation of work packages
• Analysis and comparison of offers
• Drafting of control documents and operation of the station
• Listing of laboratory equipment required for operation
• Planning, Capex (€2.5m) and Opex

Revamping and refurbishment of catalyst production lines

Location: Kentucky, USA
Project phase: Studies
Project duration: 30 months

Feasibility / Basic design studies:

• Carrying out balances (material, heat, utility, power)
• Implementation of PFDs (process flow diagram)
• Sizing of equipment and storage capacities
• Implementation in the existing workshop
• Preliminary security analysis
• CAPEX, planning

Detailed design study (Process part):

• Realization of PIDs (piping and instrumentation diagram)
• Writing the functional analysis
• Participation in HAZOP (Hazard and Operability analysis)
• Drafting of technical specifications for equipment