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Process Design
Based on numerous site assessments, one plant design does not fit every situation. Our engineering services determine exactly what is needed for your facility. Services include process design (front-end engineering design; FEED), trouble-shooting and optimization, feasibility studies, computer simulations, detail design, construction management and startup.

Chemical Plant Design

chemical engineering 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.


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


  • Ammonium Nitrate

  • Diammonium Phosphate

Sour Gas Processing

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

  • Sulfur Recovery Plants

  • Sour Water Strippers


  • 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.

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]

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