Process Engineering

The Process Engineering Division of KITCO has an expert team of chemical, mechanical, electrical and instrumentation engineers capable of extending a wide range of services from conceptual design, Front End Engineering Design (FEED) , Basic engineering design package (BEDP) Detailed engineering, to project management consultancy services during construction, fabrication and setting up of various plants. A competent team of engineers from various branches have proved their mettle in installation and commissioning of complex chemical plants with expertise in process design, selection of process plant equipment & machinery, process control & instrumentation, associated civil, instrumentation & electrical designs, This division deals with various engineering sectors like oil and gas, petrochemical, refineries, chemicals & mineral processing, metals, pharmaceutical, food, manufacturing etc.. the division has many achievements to its credit such as setting up of India first Titanium Sponge Plant for Kerala Minerals and Metals, evolving the concept of food parks in India by setting up Spices Parks all over India for Spices Board and also revolutionizing the Ayurvedic pharmaceuticals manufacturing sector by infusing modern technology and automation. with Major clients under this division include Hindustan Petroleum Corporation Ltd. (HPCL), Bharat Petroleum Corporation Ltd (BPCL), Indian Oil Corporation Ltd (IOCL), Oil and Natural Gas Corporation Limited (ONGC), Indian Rare Earths Limited (IREL), Kerala Minerals & Metals Ltd. (KMML), Spices Board, National Dairy Development Board (NDDB), Oil Palm India Ltd, , Kerala Feeds Ltd. (KFL), Hindustan Latex Limited (HLL), Pharmaceutical Corporation Kerala Ltd. (Oushadhi).

Area of focus

Oil and Gas

KITCO offers its full range of services to India’s major Oil PSUs such as Oil and Natural Gas Corporation, Indian Oil Corporation, Bharat petroleum Corporation, Hindustan Petroleum Corporation Ltd, etc. KITCO’s process engineers have a proven capability in all engineering and construction management services relating to the complex demands of the present Oil and Gas industry.

Chemicals and Mineral Processing

KITCO is one of the established players in the field of metals and mineral processing in the country. The strong interdisciplinary technical knowledge has aided in KITCO in setting up complex and strategic chemical and mineral processing plants. KITCO’s process engineers have proved their capability in setting up many chemicals and mineral processing plants some of which are the country’s first of its kind.

Industrial Manufacturing Complexes

KITCO has been pioneers in accelerating the process of industrialization in the state as well as national level. KITCO has set up many industrial parks and manufacturing complexes in varied fields such as spices processing, electronic component manufacturing and even defense component manufacturing complexes.

Food & Drugs

KITCO has emerged as one of the key players in the food and drugs consultancy sector having provided its range of services in setting up modern pharmaceutical plants, meat processing plants, juice filling plants etc.

AREAS OF OPERATION
  • Metals and Mineral Processing
  • Oil & Gas Sector
  • Chemical Industries
  • Industrial Manufacturing Complexes and Industrial Parks
  • Food Processing Industries
  • Pharmaceutical and Ayurvedic Plants
  • Spices processing and Extraction
  • Coir and Rubber Products
  • Agro Based Industries
  • Feed Mill Plants
Services Offered
  • Basic Engineering and Front End Engineering Design including preparation of Material Balance, PFD, P& IDs.
  • Preparation of Techno-Economic Feasibility Reports, Detailed Project Reports, Selection and Transfer of Technology
  • Master Planning of PESO/OISD compliant Oil storage Terminals, Industrial parks and Integrated Manufacturing complex, Detailed Engineering including Plant Layout, Piping and Equipment Layout, Equipment G.A Dgs
  • Design, Cost Estimation, Tendering Assistance including preparation of Bid documents and Bid Evaluation
  • Debottlenecking, Retrofit and Revamp of Existing plants
  • Project Planning, Project Management Services and Quality Control including Inspection services
  • Pre commissioning and Commissioning Assistance for Chemical, Mineral processing plants, Oil storage Terminals
    Contact Us

    Email: bp@kitco.in

    Phone: +91-484-4129000 / 6129000

    Fax: +91-484-2805066

Key project under execution and undertaken
Oil and Gas

Revamp & Refurbishment of Storage Terminal at Butcher Island Hindustan Petroleum Corporation Ltd (HPCL)

KITCO played a pivotal role in completing assessment and design for refurbishment of the existing storage and bunkering terminal at Butcher Island located off the Mumbai Coast. The terminal attains strategic importance as it enhances the bunkering services of HPCL as well as aid Mumbai Port in its refueling activities. The team was able to undertake comprehensive assessment of the existing tanks, redesign the Storage terminal compliant with PESO/OISD norms, high pressure pumping systems capable of pumping back oil to Mumbai Refinery through a 7-km sub-sea pipeline with all required safety protocols.

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Optimizing of TT Cycle Time at strategic Oil Terminals across India for Hindustan Petroleum Corporation Ltd(HPCL)

KITCO completed assessment of existing Storage terminal, adequacy analysis and subsequent design and engineering of required Pumping and Piping systems along with and design of Pumps, Piping, Tank Nozzles to optimize the filling rate to a minimum of 1200 LPM per Loading arm. KITCO undertook this massive project spanning 11 locations all over India like Coimbatore, Jammu, Guwahati, Bharatpur. HPCL is currently implementing the modifications proposed as part of the study. With commencement of operations after proposed modification, the Oil major intends to save revenue as part of faster TT loading time and reduced idling time. The locations included:

  • Coimbatore
  • Madurai
  • Jammu
  • Sangrur
  • Haldia
  • Balasore
  • Rajamundry
  • Ramagundam
  • Manglore
  • Bharatpur
  • Guwahati
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Setting up of Bulk Storage and Bunkering Facility at Cochin Port Trust for Hindustan Petroleum Corporation Ltd

KITCO undertook the preliminary feasibility study for setting up of a Bulk storage and Bunkering terminal at Cochin Port for Hindustan Petroleum Corporation Ltd. The study included Basic and detailed engineering of storage tanks, bunkering facilities, financial analysis, etc. The study concluded with a comprehensive report detailing out the various parameters and financial aspects of setting up of such a terminal and its strategic importance.

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Setting up of Independent Storage Tank and Pumping Systems for Bitumen at Vizag Terminal for Hindustan Petroleum Corporation Ltd

KITCO was entrusted with the feasibility study for setting up of Independent Storage and Pumping Systems for Bitumen Grade VG-40 at Vizag Terminal for HPCL. HPCL Vizag Terminal plays a vital role in the East coast maritime sector as fuel supplier for major vessels berthed at Vizag Port. The study included assessment of existing space availability, design and planning of storage tank compliant to latest PESO/OISD standards, design of high temperature bitumen pumping systems with temperature controlled pipelines.

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Setting up of Automated Bitumen Drum Stacking Facility for Bharat petroleum Corporation Ltd.- Kochi Refinery

KITCO was entrusted with the detailed study of a one-of-a-kind bitumen drum stacking facility for BPCL- Kochi Refinery as part of modernizing the bitumen storage and transport facility. The study included revamp proposals for existing high temperature pumps and piping systems. The unique system develop0ed by KITCO included a grabbing mechanism moving on electrical overhead travelling cranes. The system was designed for a throughput of 500 drums per day with automatic filling and stacking controlled by a PLC based server.

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Over Dimensional Consignment Route Study for Bharat petroleum Corporation Ltd – Kochi Refinery

The problem of transporting huge columns and reactors for the expansion projects of Bharat petroleum Corporation Ltd presented a unique challenge in itself due to location specific constraints in transporting these ODCs to the Site. KITCO’s expert team completed a detailed study elaborating on alternate routes and infrastructure modification proposals for safe movement of these consignments. The study gained vital importance as it was crucial in deciding limiting dimensions of modular structures which would act as major timesavers for the expansion projects

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Chemicals and Mineral processing

10,000 TPA Monazite Processing Plant (MoPP) for Orissa Sands Complex, Indian Rare Earths Limited (IREL)

KITCO successfully completed the construction and commissioning India's only monazite processing plant (MOPP) at Orissa Sands Complex (OSCOM). This unit of Indian Rare Earths Limited (IREL), kicked off its commercial production in 2015. KITCO range of services included detailed engineering, project management services, construction and commissioning support. The plant gained strategic importance in India’s nuclear power generation as a major producer of Thorium. The plant is also capable of producing TSP,RE-Chloride, Thorium Oxalate, Di-Ammonium Uranate.

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Setting up of India’s first Titanium Sponge Plant for Kerala Metals and Minerals Limited (KMML)

KITCO embarked on an ambitious project of setting up India’s first Titanium sponge plant. Titanium sponge has very useful applications in space program and other strategic areas like aeronautics, light defense vehicles etc. KITCO successfully commissioned the plant which is the only one in the world which can undertake all the different activities of manufacturing aerospace grade titanium sponge under one roof.

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PRYNCE and THRUST Project for Indian Rare Earths Limited (IREL) at Udyogmandal

PRYNCE (Praseodymium, Yttrium, Neodymium and Cerium) and THRUST (Thorium retrieval, Uranium Recovery and Storage) were two projects set up at the IREL complex at Udyogmandal. KITCO implemented the above projects for IREL enabling them to separate lighter and leaner rare earths by extraction.

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Modernization Projects - Copperas Recovery Project, Fibre Grade Plant, Neutralization plant for Travancore Titanium Products Ltd.(TTPL) at Thiruvananthapuram

KITCO is currently undertaking three modernization projects for TTPL at their existing TiO2 pigment plant at Kochuveli, Thiruvanthapuram. KITCO’s expertise in the metals and minerals sector has ensured the planned execution of these three projects.. KITCOs services start from basic engineering, detailed engineering, developing technology for up gradation from Lab level process to commercial production (Fibre Grade Plant), identification of different work packages, tendering assistance, technical evaluation and ends at commissioning and completion support activities. These projects are vital for the growth and future of TTPL and currently execution is underway for these projects

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Industrial Manufacturing complexes

Defense Systems Integration Complex, Palasamudram for Bharat Electronics Ltd

KITCO was awarded the Comprehensive consultancy services including the preparation of Master plan of factory complex at Palasamudram, Ananthapuram District, Andhra Pradesh The scope of work included the Master planning as well as detailed engineering of all buildings. Including Strategic Business Unit, Hardstands, Administration and canteen buildings. The plant will have state-of-the-art infrastructure such as Assembly Hangars and Hard Stands for Radars and Weapon integration, System Integration, Missile Electronics development, UAV Test Range, EW Test Range, HLS Test, Torpedo Mfg, Explosives Handling, RF radiation sources for target simulation, Automatic Test Equipment, Clean Rooms for electronic assembly, Explosive Integration Buildings, Missile Storage buildings, Environmental Test Chambers, Fire Stations, Solar Power Plant, Estate and Admin buildings. The proposed Complex will be a world-class facility with Automated Guided Vehicles and Industrial Robots for material movement and handling.

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Manufacturing Facility Complex for OEN India Ltd at MIDC Chakan, Pune

OEN India Ltd, a leading manufacturer of relays entrusted the consultancy services for setting up of an integrated manufacturing complex in Pune KITCO’s engineers developed the master plan for plot including architectural concept development, industrial planning along with utilities. The project with a manufacturing capability of 1.5 Crore relays per year was one of the first to be implemented as part of the ‘Make in India’ initiative of the Government of india.

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Setting up of Spices Parks at various locations all over India for Spices Board, India

Spices Parks, a concept developed to enhance spices processing in various parts of India was developed in the country for Spices Board India with the help of KITCO’s engineering expertise. KITCO set up spices parks in the states of Kerala, Tamil Nadu, Rajasthan, Madhya Pradesh which had facilities for pre cleaning, dehydration, steam sterilization, extraction plants for red chilly and ginger. Spices park in Chindwara, Madhya Pradesh was the first of its kind in India. Advanced Quality evaluation Labs for testing of spices and spice extract was also set up in major cities like Kolkata, Kochi, Delhi , Tuticorin.

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Setting up of Cattle Feed Plants at various locations in Kerala for Kerala Feeds Limited (KFL)

KITCO has successfully constructed and commissioned cattle feed plants in the state for Kerala Feeds Limited at various locations. These include the 650TPD Cattle Feed Plant at Kallettumkara, Thrissur, 300 TPD Cattle Feed Plant, Karunagappally, Kollam, Mineral Mixture Plant, Athavanad, Malappuram (1200 MT per Annum, Densified Fodder Block Unit, Muthalamada, Palakkad (15000 MT per Annum), 300 TPD Cattle Feed Plant, Chemmanchery, Kozhikode. KITCO is also currently involved in the construction and setting up of a 500 TPD plant at Thodupuzha, Idukki for KFL.

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Strategic Technology Advancement in the Coir Sector

The coir sector in Kerala has hugely benefitted from the technology advancement initiatives of KITCO. KITCO successfully commissioned the Automatic PVC/Latex Tufting plant for Coir Corporation at Adoor. KITCO also set up the first of its kind coir composite board manufacturing plant. The major clientele in the coir sector includes Coir Board of India (Coirfed) Kerala state Coir Corporation, Foam Mattings Limited (FOMIL).

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Food and Drugs

Modernization projects of Pharmaceutical Corporation (I.M) Kerala (Oushadhi)

KITCO started its association with Oushadhi in the early part of last decade beginning with the modernization of its existing traditional Ayurvedic manufacturing units. The successful implementation of this project paved way for future modernization projects of Oushadhi. The Centre of Excellence (CoE) for Lehyam and Choornam medicines at Kuttanalur, thrissur is a testimony on its own of KITCO’s prowess in the pharma sector. This modern Ayurvedic plant was the first of its kind in India. KITCO still continuous its esteemed association with Oushadhi on a wide variety of services ranging from Setting up of new units, technology up gradation of existing unit, strategic advices on manufacturing processes. Studies on implementing WHO-Good Manufacturing processes (GMP) is also underway .

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Dairy projects for National Dairy development Board (NDDB)

KITCO was instrumental in setting up the Dairy Plant at Villupram for National Dairy Development Board (NDDB). This plant was one of the first World bank project in India with a processing capacity of 1 Lakh litres of milk. KITCO’s engineers also set up the Mangalore dairy project in Karnataka. These developments in Karnataka gave a major impetus to the dairy development in South India with KITCO playing a major role. KITCO is currently studying various possibilities in the development of a dairy sector on a pan India basis.

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Modern Abattoir for Meat Products of India (MPI)

KITCO has successfully constructed and commissioned a 200 bovine and swine per day processing and rendering plant at Edayar, Kerala. This project was jointly funded by the Ministry of Food Processing Industries (MoFPI) and Government of Kerala (GoK). The plant employs most modern meat processing techniques and is slated to improve the performance of the meat processing industry sector in the state. KITCO’s range odf services in this project included basic engineering, detailed engineering, tendering, project management support and commissioning support activities.

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