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Over the last 18 years of existence, Expert has carried out designs for chemical plants that start with preparation of conceptual flow diagrams, process flow diagrams, mass and energy balance diagrams, P & IDs, General Arrangement drawings for fabricated equipment, equipment layout drawings including piping isometrics, laying down standard operating procedures, etc.

For processes that have been developed through studies in the laboratory scale, Expert has been instrumental in scaling up to the pilot plant scale and finally to commercial levels. Chemical Plant designs are carried out based on well established data that either generated through small scale or bench scale studies or are based on data provided in the literature.

Specific emphasis have been given by Expert to ensure that any reactor that is designed to carry out a chemical reaction which invariably involve exothermicity or endothermicity, perform optimally at the conditions desired. It has been quite a challenge to optimize designs of chemical reactors in the commercial scales, in order to match the yields, conversions, and cycle-times as achieved in the lab or pilot scales of operation. Quite often, batch reactors have been converted to continuous reactors involving the CSTR protocol.

The designs for chemical reactors usually have been arrived through data generation in small scale reactors. Chemical reactors designed by Expert has sometimes followed the principles of micro-reactors where the primary feature has been to increase the surface area to volume ratios.

He has had probably the most satisfying experience that he has gained through his assignments has been the one in UK where an energy efficient drying system has been designed for a coating machine. The heat of combustion in the evaporated organic solvent from the drying system has been utilized to replace 95 % of the natural gas that would have otherwise been used as the source of energy for drying. This assignment has helped the client in securing a few prestigious awards by the Scottish Government for energy conservation.He provided detailed analysis of the heat transfer aspect of a chemical reactor where the organic product, an aroma ingredient, was being co-distilled under high vacuum, resulted in identifying the limiting heat transfer coefficients. Steps were taken to improve the limiting heat transfer coefficients and also the heat transfer area, which ultimately helped in reducing the batch-time which in turn helped in improving the yield due to shorter residence time of the product in contact with the hot surfaces.He worked on the trouble-shooting of a non-performing plant to produce Polyester Resin by analysis of operating data helped in the plant operating with reduced batch time, reduced energy consumption and hence reduced manufacturing cost. This was for a Client in Oman. Expert has recently helped a Global R & D Centre in setting up a high pressure lab to carry out simulated corrosion studies using hydrogen sulphide as one the principal gases. This project involved attaining extremely low leak rates of helium through the gas tubing system. This Project involved designing dry-type absorption system for hydrogen sulphide. In the second phase, the set up is being designed to help tests being carried out with the gas mixtures at 350 bars. He has an assignment to carry out basic design, detailed engineering, project engineering and project management of a plant in Saudi Arabia to produce ground calcium carbonate from limestone.