Praj Industries Limited

Manufacturing Capabilities

Design Codes and Standards

Metallurgy

Quality Systems

Health safety and environment

Industries Served

Praj’s capabilities are leveraged across industries. With India emerging as a sourcing hub for the world, we have established ourselves as a reliable partner for our global clients. We meet clients’ expectations with affordable, safe solution of highest quality.

We offer customized equipment namely columns, towers, shell & tube heat exchangers, reactors, pressure vessels, separators, storage vessels for a variety of applications in the oil and gas and the downstream industries. Other than that, we have a proven track record in the food, pharma and biotech sectors.

Together for Sustainability at Kandla manufacturing facility

As a project engineering and manufacturing organization, Praj is a stakeholder in the global chemical industry. Our state-of-the-art manufacturing facility at Kandla caters to our international clients in the oil & gas, petrochemical, chemical and related sectors. It is of utmost importance that our equipment meet all the safety norms and we conduct ourselves in a manner consistent with the sustainability requirements of the industry.

Together for Sustainability (TfS) is a joint initiative of chemical companies for sustainable supply chains, founded in 2011. It is a major initiative of the global chemical industry to bring sustainability in the supply chain. TfS has developed and implemented a global program to assess, audit and improve sustainability practices within the supply chain of chemical industry. Its members include AkzoNobel, Arkema, BASF, Bayer, Clariant, Covestro, DSM, Eastman, Evonik, Henkel, IFF, Lanxess, Merck, Sanofi, Solvay, Syngenta, Wacker, Brenntag and DuPont.

Our prestigious clients encouraged us to carry out the TfS audit for Kandla facility. This involved rigorous assessment on parameters like management, environment, health & safety, labor & human rights and ethics & governance.

All the positive observations and areas of improvement have been recorded, with a time bound corrective action plan. The holistic learning from TfS Audit is valuable and is helping us improve the sustainability performance.

A modular process skid is a system within a frame that allows easy transportation. Individual skids can contain complete process systems or multiple skids can be combined to create a larger process system or an entire portable plant.

Process skids are an alternative to traditional stick-built construction where system parts are shipped individually and installed incrementally at the manufacturing site.

This execution philosophy has several advantages over the conventional methods as it organizes a manufacturing process into logical units to minimize risk, saves cost and time and is useful in case of process operations in difficult geographical terrains.

Leveraging its expertise across multiple engineering disciplines and manufacturing capabilities, Praj provides

 modular process skids
 and packages. We have developed and fine-tuned in-house capability of designing skids using 3D design softwares like Plant 4D and PDMS. We specialize in –

Overall plant layout to minimize site erection time and cost
Layout optimization for proper access and operation with equipment engineering to suit skid mounting and operation
Utmost importance to health, safety and environment
Integration of pipe routing with attached equipment
Instrumentation assembly and cabling with cable trays
Insulation and cladding of equipment and piping
Factory Acceptance Test (FAT)
Supporting and lashing of equipment with suitable lifting provisions for handling and shipment

The latest wastewater treatment & recyclingtechnologies likebiomethanation,recycle, reuse and zero liquid discharge have been mastered at Praj. Being a knowledge based company with over 30 years of experience, we have the ability, technology & facility to design the most effective solutions as per the client’s requirements to meet the environment norms pertaining to the region.

Zero Liquid Discharge Solutions
Solvent Recovery and Scrubbing
Scrubbing
Evaporation
Combination of Evaporation
Crystallization
Drying Technology

Praj’s business lines are supported by its world-class manufacturing infrastructure. Praj has 4 manufacturing facilities in India. All the facilities have the capability to manufacture equipment in compliance with the most stringent requirements of various countries viz. CE, EN, DOSH, MOM, GOST – TR. The facilities are also ISO 9001 - 2008 and ASME (U, U2, R, H, S) certified.

Salient features
High thick rolling machine (upto 150 mm)
CNC plasma cutting machines
CNC vertical lathe machine
CNC Drilling machines
Electroslag strip cladding machine
Dish end pressing - press of 1000 MT capacity
High tonnage rotators as well as positioners
Shot blasting and painting facility
Column and boom automatic SAW and PAW
Electro-polishing machine

Manufacturing Capability - Metallurgy
Carbon steel – all grades, including NACE, HIC etc
Alloy steel – various grades & combination of Cr, Ni, Mo, Ti etc
Stainless steel – Austenitic, Ferritic, Duplex
Clad steel – CS and LAS with Cu-Ni, Monel, Inconel, SS, Ni cladding
Non-ferrous – Cu, Ni, Ti, Monel, Inconel, Brass, Hastelloy
Other materials - Lining - Rubber, FRP, PTFE

Engineering is the backbone of Praj’sintegrated offerings.More than 70% of the employee strength consists of engineers of various disciplines – mechanical, chemical, electrical, civil, instrumentation etc.

Knowledge and experience coupled with the latest design software, engineering team ensures accuracy and smooth interfacing between various modules of an integrated plant. With global presence, comes the expertise in various global codes and standards.

The constituents of an integrated plant are

All kind of RCC work
Steel Structures
Equipment like columns / heat exchanges / tanks / pumps / PHEs etc.
Package units like boiler, dryer, cooling tower, refrigeration plant, bottling plant etc.
Electrical drives, power distribution systems, lighting etc.
Field and panel mounted instruments, plant control systems etc.
Interconnection piping systems

To design, engineer and integrate all these constituents, we have competent teams for -

Process & utilities
Layouts & piping
Civil & structural
Mechanical (shop fabricated, site fabricated and sourced from suppliers as bought outs)
Electrical
Instrumentation, automation and control

Best of the best design softwares are used for plant designing. To name a few -

ChemCAD for process design
HTRI for heat transfer design
PVElite for mechanical design of equipment like distillation columns, pressure vessels and heat exchangers
PDMS and AutoPLANT for 3D modelling

Praj’s project management team consists of qualified, experienced and PMI certified professionals well versed with the global standards and practices.

A strong backbone of SCM team supports the complexities involved in Praj’s business. With around 50 qualified professionals, the team handles procurement of over 100 categories of commodities, metals, equipment, electrical, automation, piping, structural, rotary equipment like pumps and compressors.

Our SCM team is well versed in global practices and norms viz. ASME, DIN, En, ISO, SMS, ANSI, ASTM, API etc. With a host of efficiency improvement tools like just in time, vendor managed inventory, Kanban, we ensure quality, timeliness, and sustainability to the execution of projects.

Praj’s references in more than 75 countries is a testimony to the extensive network of our logistic partners across the globe. We import from and have delivered to landlocked and challenging terrains in Africa, South America, Asia and Europe, by modes like air and ocean freight, chartering etc.

Procurement Categories

Raw Materials :-

Plates
Heat exchanger tubes
Pipes
Clad plates
Structure
Fittings
Flanges
Unions
Forging

Rotary Equipment :-

Blowers/MVR
Decanters/centrifuge
Process pumps
Dosing pumps & systems
Agitators
Compressors
HRSCC/clarifiers
Vacuum pumps
Filter press
DAF

Equipment :-

Plate type heat exchangers
Valves
Membranes (UF/RO)
Expansion bellows
Cleaning nozzles

Packaged Units :-

Boilers
Turbines
Refrigeration systems
Dryer & conveyers
Column internals
DG Set
Cooling towers
ETP/STP/WTPs
MBR systems

Electrical and Instrumentation :-

Motors
Control valves
Control panels (PLC/MCC/DCS)
Cables
Measuring instruments
Cable Tray & accessories
Luminaries
Transformers

Miscellaneous :-

Fasteners
Paint
Gaskets
Abrasive
Cutting tool
Steam Straps
Welding consumable
Strainers

Areas of ResearchBioenergy

Biochemicals
Health and Wellness
Customized Research Solutions and Services
Analytical Science Center

Infrastructure

Clean Room Facility :-

Class 10000 facility
6 research labs covering 9000 sq ft
Biosafety cabinets
Anaerobic glove boxes
PCR and q-PCR
Electroporator
Sporeplay
Iso Electric Focusing (IEF)
Ultracentrifuges

Bioprocess Development

Sterile fermentation
Multi fermenter systems
SCADA controlled fermenters (1, 2.5, 5, 10, 40, 100 L scale)
Downstream processing
High speed centrifuges
Membrane separation units
Chromatography columns
Liquid-liquid extractors
Crystallizer
Vacuum evaporators
Dryer & leaching apparatus

Chemical Process Development

High pressure stirred tank reactors
(700 ml to 25 l scale)
SCADA controlled Dual Fixed Bed Reactor System
Granulator
Fluidized Bed Drier and Hydraulic press
Continuous Distillation
Liquid-Liquid Extraction and Crystallization
Short Path Distillation (0.02 & 0.5 m2)

Analytical Facility

ISO 9001:2008 certified
4 labs (Wet Chemistry, Instrumentation, Organoleptic & Microbiology Analysis)
Processing capacity of upto 300 samples/day Equipped with
Multiple HPLC, GC, GC-MS
Ion Chromatography,
ICP, TGA, DSC,
FTIR, FTNIR, UV-Vis Spectrophotometer, Rheometer, Cloud & Flash point analyzer, Anton parr, Flash Chromatograph, COD Digester

2nd Generation Ethanol Pilot Plant

1 MT(dry basis) per day processing capacity of
various cellulosic feedstocks
Material handling section
Pretreatment section
500 l (6 nos) enzymatic hydrolysis reactors
1000 l (6 nos) fermenters
Distillation & evaporation sections
Diverse types of S/L separation units

Multipurpose Pilot Plant

Catalytic & fermentation end-to-end process
30bar high pressure reactor
Glass lined reactor
Fermenters (100 -1000 l)
Downstream processing equipment
High pressure IBR boiler
Chilling facility (-20 °C)
High temperature (300 °C) thermic fluid heating facility
High vacuum (0.01 Torr)
RO water & cooling water