Engineering services

Planning services of small plants

Design and engineering of costumized mixing plant modules (Laboratory Scale, Industrial Scale, Large Scale)

  • Feasibility studies (Valuation of theoretical approaches)
  • Plant optimization
  • Plant extension / new construction
  • approval planning
  • Layout planning
  • Piping design
  • Process planning
  • ATEX-Certifications
  • Debottlenecking

Testing technology / Mixing and agitation tests

  • Mixing and agitation tests
  • Determination of mixing times
  • Local velocity profiles
  • Optimization of the impeller selection
  • Setting / adjustment of temperatur profiles
  • Solid draw down / stirring in of solids
  • Dissolving tests
  • et cetera

Research and developement

Research projects, e.g.

Process development:

  • Enzymatic cleavage of oil
  • Montan wax extraction from coal substances
  • Bioethanol ligninous renewable raw materials that 
  • Highly loaded shear thinning substances of bio gas production
  • Liquefaction of coal slurry and red mud

Process improvement:

  • Wax melting
  • Bitumen and thick matter paint
  • High vicous flame retardants
  • Adhesives / glues

    CFD – Computational Fluid Dynamics

    By means of the innovative method CFD – Computational Fluid Dynamics – predeterminations of mixing results are possible without complex and expensive trails and tests. Those data help to optimize difficult mixing and heat transfer tasks.

    Calculation example:

    • Local flow velocities
    • Energy dissipation / power consumption
    • Wall velocities
    • Dead bands / dead spaces
    • Concentration profile
    • Mixing time
    • Temperature distribution in the reactor
    • Flow stress / load of installation components
    • Heating-/ cooling time
    • Heating load/ - cooling load calculations

    FEM – Fenite Element Method

    FEM – Finite Element Method – is a modern method which is used by STC for the mechanical design of equipment with regard to stress and vibration behaviour, as well as for resonance problems by means of complex modal analysis, if analytic methods are not precise enough.

    Calculation example:

    • Deformation of the system, e.g. agitator on vessel top
    • Local stress maxima e.g. by shock-cooling of tube bundle heat exchanger
    • Dynamic stress analysis e.g. impellers
    • Vibration behaviour e.g. natural frequency of agitator on vessel top
    • Baffle loads
    FEM-Analyse - Deckelverstärkung / FEM - analysis - reinforcement of the vessel top

    Process calculations

    We perform calculations of:

    • Agitator- and mixing technology

      • Mixing time
      • Solid sedimentation velocity
      • Solving time
      • Power consumption
      • Power drop under gassed conditions
      • OTR-Oxygen transfer rate
      • kLA –Volumetric mass transfer coefficient
      • Impeller flooding point
      • Pumping rate of draft tube applications
      • Density distribution in the vessel
      • heating- / cooling technology

    Strength calculations

    We perform calculations of:

    • Machine components, e.g.

      • Bolts
      • Bearings (life time)
      • Pins, studs
      • Springs
      • Couplings
      • Belts, chains

    • Machine dynamics / vibration analysis
    • Notch root stress analysis

    • Critical Speed

    • Starting behaviour of agitator systems

    • Traverse / support frames

    • Nozzle loads while operation

    • Baffle

    • Verification of stability of vessels

    • Pressure vessels

      • AD 2000 / EN ISO
      • BS 5500
      • ASME, ...

    Up-scaling from laboratory to production scale

    Laboratory ScaleIndustrial ScaleLarge Scale
    1 Litre – 1.000 Litre1 m³ - 100 m³>100 m³ - 5.000 m³
    0,25 kW – 3 kW4 kW – 1.000 kW55 kW – 2.500 kW

    Failure analysis

    • Wear analysis
    • Material analysis
    • Stress analysis
    • Vibration analysis
    • Load analysis
    • Welding engineering
    • Production technology / surface engineering
    • Mixing technology

    CE- / Atex-certification / technical documentation

    • Detailled operation and maintenance manual
    • QA-documentation
    • Risk analysis according machinery directive 2006/42/EG
    • Atex - risk analysis  according regulation 2014/34/EU
    • Atex- and CE-certification for the whole system
    • Assembly declaration for incomplete machines
    • Declaration of Conformity for complete machines
    • Certifications / registrations according to law for costums union Russia, Kazakhstan, Belarus
    • Manufacture Licensing SELO China (Approval in China regarding steam boilers, pressure vessel, and their accessories with safety device)
    • SCC-Certification (HSE-Examination for operational Supervisors)
    • others on request
    STC Dokumentation / STC documentation

    Design / Technical Drawings

    We prepare technical drawings in 2D as well as in 3D.

    Our services contain:

    • P + I
    • Installation planning
    • Piping isometry
    • Assembly drawings
    • Sectional drawings
    • Fabrication drawings
    • Explosion drawings

    For design support the following software is applied:

    • Autodesk Plant 3D 2013
    • Autodesk Mechanical 2013
    • Autodesk Inventor 2013
    • Solid EdgeSolid Works (Possible migration of MicroStation)
    Technische Zeichnungen

    Video animation

    • Function processes
    • Vibration and tension visualisation
    • Assembly / Disassembly processes
    • Collision considerations