Skip to Content
Kalidris Products & Solutions  Deep Technical Insights

1. Heat Exchangers Technical Details​

• Thermal performance is calculated using HTRI, Aspen HYSYS, or proprietary simulation tools.
• Heat duty, approach temperature, fouling factors, and allowable pressure drop are modeled for each client scenario.
• Advanced features include multi-pass tube arrangements, removable bundles, and “U” tubes for thermal expansion.
• Designs account for thermal cycling, vibration, and differential expansion.

​

• Pressure vessels engineered to ASME Sec VIII Div. 1 or 2, PED, or GOST as required.
• Tubesheet, baffle, and support design optimized for high-flow, high-pressure, and corrosive environments.
• Materials: From carbon steel and 316L/904L stainless to Incoloy, Hastelloy, and duplex superalloys.
• Non-destructive testing: radiography, dye penetrant, ultrasonic, and hydrotesting.
• Automated tube-to-tubesheet welding, eddy current tube inspection.
• Shell-side and tube-side corrosion allowance, expansion joints for stress relief.
• Modular skids available for compact sites or quick deployment.
• Integrated cleaning (CIP/SIP), bypass circuits, steam tracing, and insulation.
• Instrumentation: thermocouples, flowmeters, pressure transmitters for real-time monitoring.


2. Emission Control Systems – Technical Details​

• SCR reactors sized via kinetic modeling, ensuring >90% NOx reduction at design throughput.
• Catalysts: honeycomb or plate, vanadium/titanium or zeolite for ammonia slip tolerance.
• Ammonia/urea dosing skids with automated control and NOx analyzers.


• Wet (limestone/gypsum), dry (spray dryer), or semi-dry configurations to match fuel sulfur content.
• Recycle loops, forced oxidation, and byproduct handling (gypsum dewatering, saleable sulfur).
• ESP sizing for sub-micron dust capture (>99% efficiency), baghouse pulse-jet cleaning.
• Filter media: PTFE-coated, acid/alkali-resistant, high-temperature capable.
• Claus process with thermal and catalytic stages; oxygen enrichment for >99% recovery.
• Tail gas treatment: SCOT, Amine-based, or SuperClaus, with online sulfur analyzer integration.


• Full suite of CEMS (NOx, SO₂, CO, O₂, PM) with real-time DCS/SCADA links.
• Self-diagnosing field transmitters, remote calibration, and automated compliance reporting.


3. SCADA & Digital Automation Solutions – Technical Details​

• Distributed redundant servers, hot standby failover, and industrial cybersecurity (IEC 62443).
• Protocols: OPC-UA, Modbus TCP, Profibus, Ethernet/IP, IEC 61850 for power grid applications.
• Hierarchical architecture: field device layer (RTU/PLC), plant control layer, enterprise/business integration layer.


• Sub-millisecond sampling rates for fast processes.
• Edge analytics: data preprocessing at field level to reduce network load and enable local alarms.
• Time-series database with long-term archiving, historian integration.
• Custom dashboards, KPIs, alarm/event management, digital twin overlays.
• Remote access via secure VPN, web portals, or mobile applications.
• Multi-language, role-based GUI for operators, engineers, and managers.
• Seamless links to ERP/digital business platforms (via REST API, SQL, or MQTT brokers).
• Advanced analytics: predictive maintenance, anomaly detection, AI-based optimization.


4. Civil Engineering & Construction Solutions – Technical Details​

• Detailed geotechnical surveys (CPT, borehole, lab soil testing) inform all foundation choices.
• 3D topographic modeling, drainage, and stormwater management.
• Earthworks planned for minimal disturbance, with erosion control and compaction testing.


• Structural steel and concrete designed to Eurocode/ACI/ASTM/BS standards.
• Seismic, blast, and wind load calculations for process-critical structures.
• Fatigue analysis for dynamic/vibrating machinery supports.
• Underground pipe rack engineering for chemical/steam/oil/water with leak detection.
• Cable trenches, earthing grids, lightning protection, and fire water systems.
• Access roads, heavy vehicle loading zones, modular building assembly.
• 4D/5D BIM for clash detection, schedule optimization, and cost tracking.
• Lean construction techniques to minimize waste and downtime.
• Digital HSE management: smart PPE, IoT site monitoring, electronic permit-to-work.


5. Energy Recovery & Optimization Systems – Technical Details​

• Pinch analysis for optimal heat integration.
• Heat exchangers, economizers, and HRSG units sized via dynamic simulation.
• Steam turbines and ORC (Organic Rankine Cycle) modules for low-grade heat recovery.


• Model predictive control (MPC) adjusts process variables for maximum efficiency in real-time.
• Energy management systems (EMS) compliant with ISO 50001.
• Integration with utility grid, microgrid, or district heating/cooling networks.
• High-accuracy flow, pressure, and temperature instrumentation for performance tracking.
• Data logging for process audit trails and government reporting.
• Waste-to-energy: integrating with waste incinerators, biogas plants, or landfill gas systems.
• CO₂ capture and reuse as part of the energy recovery suite.


6. Integrated Business Management Platform (ERP) – Technical Details​

• Modular, service-oriented architecture (SOA) for scalability and reliability.
• Cloud, on-premises, or hybrid deployment; containerized with Docker/Kubernetes support.
• Full API layer for RESTful integration with plant automation, suppliers, or customer portals.


• Procurement: multi-stage approvals, supplier rating, e-auctions
• Inventory/Warehouse: batch/lot tracking, barcode/RFID, stock optimization
• Asset & Maintenance: predictive maintenance, spare parts, CMMS integration
• Production: scheduling, OEE tracking, real-time job cost analysis
• Quality: inspection plans, lab data, ISO/GMP traceability
• HR & Payroll: workforce planning, time management, competency matrix
• Finance: multi-currency, tax compliance, IFRS reporting, BI dashboards
• Workflow automation, escalation, and document management
• Custom KPI dashboard builder, drill-down analytics, real-time alerts
• Cybersecurity: role-based access, encryption, audit trail
• SCADA and plant historian integration for asset health, production stats, and loss analysis
• EDI/E-Invoicing for seamless supplier/customer interactions
• Mobility: mobile apps for inventory, maintenance, and approval workflows


7. Custom Engineering & Turnkey Projects  Technical Details​

• Conceptual, FEED (Front End Engineering Design), detailed engineering, procurement, construction, commissioning, and O&M.
• Risk management using HAZOP, SIL/LOPA safety assessments, and constructability reviews.


• Multidisciplinary 3D modeling (PDMS, SmartPlant, Revit, Tekla).
• Clash detection and constructability analysis.
• Digital twins for construction progress and future O&M planning.
• Prefabrication/modularization for off-site assembly, reducing site labor and risk.
• Commissioning with digital punch lists and automated turnover packages.
• Performance guarantees: throughput, emissions, safety, and uptime.
• Remote monitoring, predictive diagnostics, and on-call technical support
• Training programs and digital manuals for operators and maintenance staff