Process Engineering Calculators
Verified engineering algorithms for equipment sizing, PDS generation, vendor procurement, and process calculations.
AHU Design
Perform psychrometric calculations for AHUs.
Batch Reactor Scale-Up
Scale-up reactors based on P/V, tip speed, etc.
Breathing Air Supply
Estimate service duration for SCBA cylinders.
Civil & Structural Design & Costing
Multi-tier API synthesis block structural design basis: equipment loads, RCC column sizing (IS 456 / ACI 318), MTO density, and turnkey CAPEX.
Cleaning Validation Surface Area & MACO Sizer
Calculate equipment wetted surface areas (Reactors, ANFDs, Multi-Mills, Centrifuges, Piping), Maximum Allowable Carryover (MACO per APIC/FDA), swab limits, and cleaning solvent volume.
Control Valve Sizing (Cv / Kv & Flow) Calculator
Calculate Control Valve Flow Coefficient (Cv), Metric Flow Factor (Kv), choked sonic flow conditions, and required flow rates for liquid and gas media.
Cooling Tower Design & Thermal Rating
Calculate cooling duty (TR/kW), Merkel transfer units (NTU), PVC fill surface area, fan static power, and water balance.
Design & Sizing of Acid Gas Scrubbers
Size packed column scrubbers, exhaust blowers, recirculation pumps, and caustic neutralization demand for acid gas liberation (HCl, SO2, Cl2, H2S, NH3) from POCl3, SOCl2, and thiol batch reactions.
Drying Rate
Estimate drying time based on constant/falling rates.
Electrical Cable Sizing & Load Sizer
Multi-criteria cable sizing (continuous ampacity, derating factors, running & starting voltage drop, and short-circuit fault withstand), plant-wide electrical load list, and turnkey BOQ in ₹ INR.
Emergency Vent Sizing
Vapor, liquid, and two-phase (DIERS) relief sizing.
Filtration Designer
Size filter presses using cake filtration theory.
Heat Exchanger Design
LMTD method for shell-and-tube heat exchangers.
Hot Water System (HWT) Sizing
Size closed-loop hot water utility skids for distillation, contact vacuum drying, and jacketed reactor heating.
MEE & VOC Stripper ZLD Sizer
Size 100 KLD Multiple Effect Evaporators (MEE), 10% VOC stripper condensers, TVR steam economy, LRVP vacuum pumps, and 40% TDS ATFD brine feed.
MOC Corrosion Rate & Coupon Study
Calculate corrosion rates (mm/yr & mpy), alloy suitability ratings, and vessel service life per ASTM G1/G4.
NFPA 68 Explosion Vent Sizing
Size deflagration explosion vents for dusts (Kst) & gases (Kg), fluid bed dryers, ANFDs, cyclones, and spray dryers per NFPA 68:2023.
Overall Equipment Effectiveness (OEE) Calculator
Calculate Availability (A), Performance Rate (P), Quality Rate (Q), 6 Big Losses breakdown, MTBF & MTTR reliability metrics for batch reactors and packaging lines.
Packed Column Design
Calculate diameter and height for absorption/stripping.
Pharma Equipment Heat Exchange Area Sizer
Calculate required and available heat transfer area, overall U-values, LMTD, and process cycle times across Glass-Lined & SS Reactors, ANFDs, and Industrial Dryers (RCVD, Nauta, VTD, ATD/ATFD, FBD).
Pipe Line Sizing
Calculate pressure drop and velocity in pipes.
Pressure Vessel Sizing
Calculate wall thickness for shells and heads (ASME).
Pump Sizing
Calculate TDH, NPSHa, and power for centrifugal pumps.
Reactor Shaft Mechanical Sizing
ASME / DIN agitator shaft diameter, torque, dynamic bending, deflection, seal runout, and critical speed.
Shortcut Distillation Column Calculator
Perform shortcut mass-basis (kg/h) and molar distillation column calculations using Fenske-Underwood-Gilliland and Souders-Brown hydraulic sizing.
Single Fluid System (TCU) Sizing
Size Monofluid Temperature Control Unit (TCU) skids: pump hydraulics, N2 expansion tank, and 3 PHEs (Steam, CW, Chilled Glycol).
Solvent Dehydration & Molecular Sieve Sizing Calculator
Calculate molecular sieve quantity (3A, 4A, 5A, 13X), bed volume, column dimensions, Ergun pressure drop, and recirculation loop kinetics for solvent moisture removal (IPA, Acetone, Methanol, EtOH, THF, Toluene).
Static Electricity Sizing
Calculate streaming currents, relaxation times, and spark energy for liquids and powders.
Tank & Reactor Inertization Calculator (N₂ Purging & LOC)
Calculate nitrogen consumption, vacuum swing cycles, continuous sweep purge rates, vacuum pump sizing, and inertization cycle times from atmospheric O2 (20.9%) to target LOC (e.g. 2%) per NFPA 69.
Unit Converter
Convert various engineering units for pressure, flow, viscosity, and more.
Vacuum Pump Sizing
Advanced sizing for vacuum pumps considering evacuation, leakage, and process loads for drying or distillation.
Vapor Pressure (Antoine)
Estimate vapor pressure using Antoine equation.
Disclaimer
The sizing results, parameters, and algorithms provided by these calculators are for preliminary design screening and educational purposes only. They do not constitute formal engineering advice. All safety-critical systems, pressure reliefs, and fluid dynamics designs must be verified by a licensed professional engineer (PE) and comply with all local safety standards, process hazard analyses (PHA), and statutory regulations.