Industries · Flexera Consulting
Industries we serve
Our process engineering expertise spans a broad range of industrial sectors — from established bulk chemical manufacturing to emerging green energy technologies. Each industry brings its own process challenges, regulatory environment, and engineering standards. We bring deep, sector-specific knowledge to every engagement.
Sector-specific process depth.
Chemicals · renewables · water · biofuels
6
core sectors
28+
years experience
Global
India & remote
01
01
Chemical & Petrochemical
The chemical and petrochemical industry demands precise process design, strict safety standards, and continuous pressure to improve efficiency and reduce emissions. We have extensive experience delivering engineering solutions across both bulk and specialty chemical operations.
Areas of expertise
- Gas absorption and stripping systems — packed and tray columns
- Sulfonation and chlor-alkali process design
- Solvent recovery systems — toluene, IBB, MDC, organic mixtures
- Emission control systems for SO₂, CS₂, and fugitive VOCs
- Heat exchanger design and thermal optimization
- Process intensification and hydraulic studies
Representative project experience: SO₂ recovery plants, CS₂ recovery plants, acrylonitrile solvent recovery plant, dichloromethane (MDC) recovery plant, VOC vent recovery systems across IBB, NPB, DMS, and crotonaldehyde plants.
02
02
Fine Chemicals
Fine chemical manufacturing involves complex, multi-step processes where product purity, yield optimization, and waste minimization are paramount. Small process inefficiencies can have significant impact on product economics. We apply rigorous process engineering to help fine chemical producers improve performance and reduce environmental footprint.
Areas of expertise
- Batch and continuous process design
- Distillation column design and optimization
- Solvent recovery and recycling systems
- Vent mapping and VOC recovery
- Effluent minimization and treatment
- Scale-up from laboratory and pilot trials
Representative project experience: ATBS plant solvent recovery for Vinati Organics; vent recovery and emission control for specialty chemical intermediates; process intensification studies for multi-product chemical plants.
03
03
Renewable Fuels
The transition to low-carbon energy demands robust, bankable engineering for green fuel production systems. We have hands-on engineering experience in green hydrogen, green methanol, and compressed biogas — three of the most important renewable fuel pathways being deployed today.
Green hydrogen
- Production system design via alkaline water electrolysis and PEM technology
- Balance of plant engineering — hydrogen separation, cooling and purification, water treatment, compression, storage interface
- Integration with renewable power sources
Green methanol
- CO₂ hydrogenation to green methanol as an alternate fuel
- Biomass gasification route for bio-methanol synthesis
- Process simulation and heat integration studies
Compressed biogas (CBG)
- Feedstock-flexible design — rice straw, municipal solid waste (MSW), spent wash and Napier grass
- Basic engineering, RFQ preparation, and technical evaluation
- H₂S removal, gas purification, compression systems and cascade systems
Representative project experience: green hydrogen and green methanol process development; CBG plants — 80 TPD and 185 TPD rice straw-based project FEED and residual engineering, 275 TPD MSW-based, and 150 TPD distillery spent wash-based; 2G ethanol pilot plant from bagasse feedstock.
04
04
Electrochemical Processes
Electrochemical manufacturing — including chlor-alkali, water treatment, and organic electrochemical synthesis — presents unique process engineering challenges at the intersection of chemistry, electrical systems, and mass transfer. We bring specialized knowledge of membrane-based electrochemical processes and their downstream integration.
Areas of expertise
- Membrane-based chlor-alkali plant design
- Caustic evaporation systems — single and multi-effect
- Brine preparation, purification, and recirculation systems
- Downstream derivative product units
- Sewage treatment plant (STP) process design
- Organic electrochemical synthesis support
Representative project experience: 18 TPD caustic evaporation plant integrated with a 30 TPD membrane-based caustic soda plant, 2 TPD chlorine equivalent commercial hypo plant; multiple downstream derivative product unit designs for chlor-alkali complexes.
05
05
Biofuels & Distilleries
India's rapidly growing biofuels sector — driven by ethanol blending mandates and energy security priorities — requires engineering partners who understand both the fermentation front-end and the complex distillation and utility systems at the back-end. We have delivered complete distillery engineering across grain-based and lignocellulosic feedstocks.
Areas of expertise
- Grain-based ethanol distillery design (multi-pressure distillation)
- 2G ethanol from lignocellulosic feedstocks — bagasse, rice straw
- Fermentation system process support
- Distillation column sizing and optimization
- Evaporation and ZLD integration for stillage treatment
- Complete project support from RFQ through commissioning
Representative project experience: grain-based ethanol distilleries; 2G ethanol pilot plant basic engineering from bagasse feedstock.
06
06
Water Treatment & Zero Liquid Discharge (ZLD)
Industrial water scarcity and tightening effluent discharge regulations are driving rapid adoption of advanced water treatment and ZLD systems. We have strong expertise in the process engineering of evaporation-based ZLD systems and industrial effluent treatment across multiple sectors.
Areas of expertise
- Zero liquid discharge (ZLD) plant process design
- RO reject treatment and volume reduction
- Evaporation technology selection and design — MEE, MVR, TVR
- Technical comparison studies for technology selection
- Crystallizer and salt recovery system interface
- Potash and resource recovery from incineration ash
Representative project experience: 500 m³/day ZLD plant and technical comparison of direct steam vs TVR-based vs MVR-based MEE systems; potash recovery from incineration ash (60 TPD) for specialty chemical plant.
Cross-industry capabilities
When your process crosses sector boundaries
Many of our most impactful engagements involve processes that cut across industry boundaries — for example, ZLD systems for chemical plants, biogas upgrading for refinery applications, or solvent recovery for pharmaceutical intermediates. If your process sits at the intersection of sectors, we are well equipped to handle that complexity.
We have additionally served
- Pharmaceuticals
- Refining
- Pigments
- Inorganic chemicals
- Specialty chemicals
- Environmental engineering
Reach
Based in Chennai. Working across India & internationally.
We have delivered projects for clients across multiple Indian states and are equally available for remote consulting engagements for international clients who need India-based process engineering expertise.
Tell us about your project- Tamil Nadu
- Andhra Pradesh
- Karnataka
- Maharashtra
- Odisha
- + International
Working in one of these sectors?
We would welcome a conversation about your process engineering requirements — whether you have a defined project scope or are still exploring your options. All enquiries are treated in strict confidence.
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