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CIO Review >> Magazine >> November - 2014 issue

Synergy Process Systems: Offering Total Solutions in Separations and Thermal Techniques


The market for Engineering Design Tools (EDT) for plants and infrastructure continues to be strong globally. Projects in both plants and infrastructure have become immensely large, exceedingly complex, of long duration and highly expensive. Beyond the project phase, asset owners are now seeing the additional value that engineering design tools can provide during the much longer operations phase of assets in both plants and infrastructure. Synergy Process Systems, headquartered in Pune, brings value by leveraging the Engineering Design Tools to offer reliable and cost effective engineering solutions/systems to Chemical and allied industries.

“We use best design tools that are available worldwide for designing process. The software we use includes Aspen One Engineering Suite of Aspen tech and ChemCAD of Chemstations.” says Avinash Patil, Managing Partner, Synergy Process Systems. “An example is when a heat exchanger design is done in a conventional way; it involves thermal design, followed by mechanical design and drawing/drafting fabrication drawing. With EDR software of AES the same can be accomplished effectively in few hours.” he adds. Synergy Process Systems has also standardized its AutoCAD drafting by customizing AutoCAD. The company uses AutoCAD plant design suite product like PID that has several built-in standards.

Synergy has wide experience in isomer separations, Recovering Solvents and Product Purifications using distillation, fractional crystallization and other separation techniques. The company has also revamped several units that were not running at best operating conditions or facing issues like higher energy consumption, not getting desired purity or capacity etc. The company got into menthol production technology in 2005 and has since made significant contribution to its evolution. The company has pioneered true Continuous Operations that keep running at good efficiencies in place of conventional batch operations. It has replaced FFEs with thermosyphon Reboilers for continuous processes as well as batch operations. Compared to standard L-Mcrystals that take 25 day crystallization technology cycle, obtaining the direct purity of 99.5 percent of L-Menthol out of Distillation has resulted in the liquid menthol product.

Synergy Process Systems focuses on distillation and has engineered several heat integrated plants that have resulted in Opex savings of about 20 to 40 percent even at small scale plants involving Capex less than INR 20 Crore. The company uses an AES tool called Aspen Energy Analyzer and Column Analysis tool to identify possible changes in heat exchanger network and columns to reduce capital as well as operations cost. Pinch technology provides guidelines to tap the hidden potential within the process. It helps in identifying the sources from where the energy, power and water can be effectively utilized via various integration techniques in heat exchanger network design (HEN), combined heat and power (CHP), combined cooling, heating and power (Tri-generation) system design, water network design and distillation system design.

Marching forward, SPS plans to increase its geographical foot print and operate in niche areas like delivering energy efficient systems. The company is in the process of establishing a laboratory of its own and is looking to license few processes worldwide for which it has an Indian patent. Working with few associate companies, SPS aims at offering total turnkey solutions leading to higher value for its services.