Chemical Plant Design

Chemical Engineering Services

Our team of seasoned Process Design Engineers customize front-end engineering packages (FEED) for bench scale, pilot plant & full scale chemical plants. Costello's other expertise include trouble-shooting and optimization, feasibility studies, computer simulations, detail design, construction management and startup for your chemical plant.

• Chemical plant design and construction

• Chemical plant modifications and troubleshooting

• Chemical plant equipment specification and selection

• Process control and instrumentation

• Distillation and Evaporation

• Process modeling/simulation and custom computer applications

   

IN HOUSE PROCESS EXPERIENCE

Bulk Industrial Chemicals

• Chlorine / Caustic (Cl₂ / NaOH)

• Sulfur

• Sulfuric Acid (H₂SO₄)

• Sodium Bicarbonate (NaHCO₃)

• Titanium Tetrachloride (TiCl₄)

• Titanium Dioxide (TiO₂)

• Hydrogen Sulfide / Sulfur (H₂S / S)

• Aqueous Ammonia (NH₄OH)

• Anhydrous Ammonia (NH₃)

• Phosphoric Acid (H₃PO₄)

Specialty Chemicals

• Vanadium Oxytrichloride (VOCl₃)

• Vanadium Tetrachloride (VCl₄)

• Antimony Trichloride (SbCl₃)

• Titanium Trichloride-Aluminum Trichloride Complex (TiCl₃)* 3AlCl₃))

• Ethyl Silicate and Polymers of Ethyl Silicate (Si(OC₂H₅)₄)

• Dichloro Benzyl Chloride (C₆H₃Cl₂CH₂CL)

• Hydrogen Peroxide (High Purity 90% H₂O₂)

• Sulfur Chlorides

• Lubricating Oil Additives ( Sulfonates Used As Detergent Additives)

Pharmaceutical Intermediates

• Thiophene-2-Acetyl Acid (For semisynthetic Penicillin Production)

• Thiophene-2-Acetyl Chloride (For semisynthetic Penicillin Production)

• Benzyl Chloride (C₆H₅CH₂CL)

• Benzyl Alcohol (C₆H₅CH₂OH)

Plastics and Resins

• Unsaturated Polyester Resins

• Phenolic Resins

• Halar (Ethylene-Chlorotrifluoro Ethylene Co-Polymer) 

• Polyethylene

Agricultural Chemicals

• Captan

• Folpet

• Difolatan

• Orthene

Fertilizer

• Ammonium Nitrate

• Diammonium Phosphate

Sour Gas Processing

• Amine Units for the Removal of Carbon Dioxide and Hydrogen Sulfide

• Sulfur Recovery Plants

• Sour Water Strippers

Petrochemicals

• 1,2-Dichloroethane

• Vinyl Chloride Monomer

• Styrene

• Ethylene

• Benzene

• Cumene

• Poly-Alpha-Olefins

• Normal-Alpha-Olefins

Petroleum Refining

• Crude and Vacuum Distillation

• Hydrotreating

• Reforming

• Coking

• Hydrogen Plant

• Selexol Process for removing Carbon Dioxide

• Fluid Catalytic Cracking Unit (FCCU)

• Lo-Cat Sulfur Recovery Process

• Selexol Sulfur Recovery Process

• AquaClaus Sulfur Recovery Process

• Pipco Sulfur Recovery Process

• Sulfamol Process for the removal of Hydrogen Sulfide and Carbon Dioxide

• Beavon Stretford Tail Gas Unit

• Merox Process

Recent Publications By Rocky C. Costello, P.E.

• Recovering the Past - Aquaclaus^® Sulfur Recovery April 2019

• Playing it Safe, Biofuels International, May 2010

• Squeeze More From Your Process, Chemical Processing Magazine, September 2008

• Getting Serious about Safety, Biodiesel Magazine, September 2006

• Reflux and Recovery Biodiesel Magazine, November 2006

• Tiny reactors aim for big role, Chemical Processing Magazine, December 2006

• Process Intensification: Think Small, Chemical Engineering April 2004

• Process Intensification: Think Small, Innovations in Pharmaceutical Technology, June 2002

• Flashback prevention helps cure thermal oxidizer explosions, System redesign improves safety and productivity, Chemical Processing January 1997

• Pipeflow - A Pressure Drop Calculator, Chemical Engineering August 1996

• Improving performance and safety of thin film evaporators, Configuration and control enhancements boost effectiveness, Chemical Processing February 1996

Please call for further information

R.C. Costello & Assoc., Inc.
1611 S. Pacific Coast Highway, Suite 302
Redondo Beach, CA 90277
Tel: (310) 792-5870, Fax: (310) 792-5877
E-MAIL: rcca[at]rccostello.com