Expertise

PatersonChemE® offers process engineering consulting services. With nearly 40 years of experience in process development, scaleup, and optimization of manufacturing processes we can advise you in the following areas:

Process Design: From concept to commercial, we help you achieve your production and product specification goals by assisting in the development, scaleup, operation, and troubleshooting of your manufacturing process. We utilize our experience in chemical reaction engineering, materials handling, separation technologies, and chemical engineering unit operations to help optimize your process.
Scaledown & Scaleup: We ensure a successful process scaleup by first considering the commercial process end-in-mind. We then define lab-scale equipment and operating conditions which maintain the critical parameters that must be kept constant upon scaleup, taking into account geometric and dynamic similarity.
Membrane Separations: We help you design and optimize tangential flow filtration (TFF) processes taking into account the molecular weights of the species to be separated, the solvent matrix, hydraulic limitations, cleaning requirements, membrane lifetime, and membrane material and format.
Chromatographic Purification: We help you achieve your final product or intermediate purity specifications by assisting with ion exchange, size exclusion, and hydrophobic interaction chromatography steps. Process optimization includes charge conditions, elution (gradient, isocratic), resin regeneration, column size and type, flow rate/residence time, resin preparation and packing operations.
Reaction Engineering: We can improve reaction rate and yield by assisting with reactor design (batch, fed-batch, continuous), heat transfer, mass transfer, mixing/agitation, order of additions, and the potential benefit of developing a kinetic model to speed laboratory development.
Debottlenecking: We identify and eliminate bottlenecks in your multi-step manufacturing process to increase throughput by utilizing a model of each step’s capacity and the linkage between steps. We use Monte Carlo simulation to identify and minimize the effects of variability (measurement uncertainty, time delays, human factors) on plant output.
Process Control: We minimize process variability by ensuring appropriate computer control of your process. We can review your Piping & Instrument Diagrams to ensure optimum application of instruments, controllers, valves, and logic necessary to bring about uniform control.
Data Mining and Analysis: We help identify and eliminate the root cause of process problems by analyzing process data and analytical results, and applying first principles to form and test hypotheses.
Technical Writing: We draft, review, edit, and finalize technical publications such as development history reports, investigation reports, process narratives, and educational materials for engineers, scientists, operations, maintenance, and management.