Automated control system

The unit is implemented as part of the construction of a new enterprise in Bashkiria for the production of a cetane improver additive for diesel fuels.

The plant’s design capacity is 30 thousand tons per year. This is the first Russian plant specializing exclusively in the production of cetane improver additives for oil refining enterprises.

Production start-up is scheduled for 2025.

Scope of supply:

1. Technology development
2. Development of working design documentation
3. Manufacturing and complete supply of equipment
4. Supervision of installation works
5. Commissioning works

The reverse osmosis concentrate polishing unit is located in a prefabricated building, common for three lines, and includes:

• Reagent softening unit for concentrate;
• Mechanical dewatering unit for sludge No. 3;
• Evaporation unit:
  • First stage – evaporation with production of a concentrated product in the form of a liquid salt concentrate;
  • Second stage – further evaporation of the salt concentrate from the first stage to obtain a salt suspension;
  • Third stage – centrifugation (separation of crystalline salts from the liquid phase, obtaining waste with moisture content up to 40%).

Scope of supply:

1. Pre-project surveys
2. Development of basic and detailed engineering
3. Process and general design
4. Development and implementation of APCS (Automated Process Control System)
5. Supply of process equipment
6. Supervision of installation works
7. Commissioning works

The installations are equipped with mechanical vapor recompression (MVR) and forced circulation technologies, which contribute to resource saving, improve energy efficiency and profitability of production, and ensure environmental safety.

The equipment was implemented within the framework of a project for landfill reclamation and industrial waste processing.

Scope of supply:

1. Development of working design documentation
2. Manufacturing and complete supply of equipment
3. Installation works
4. Commissioning works

Technology video overview

Installation video overview

Installation model

Scope of supply:

1. Technology development
2. Development of design documentation
3. Equipment procurement
4. Manufacturing and supply of equipment
5. Supervision of installation works
6. Commissioning works

On January 22, 2020, ALVIZ JSC together with ZAVKOM-ENGINEERING LLC successfully commissioned a plant for the production of aromatic alcohols (alembic).

Scope of supply:

1. Design, manufacturing, and supply of the alembic complete with control cabinet and shut-off and control valves
2. Development of software
3. Supervisory installation and commissioning works

Project implementation results:

The successful commissioning of the plant made it possible to provide the ALVIZ distillery with the required amount of aromatic alcohols and improve the quality of the produced products.

Currently, equipment is being manufactured, power and control cabinets are being assembled within the framework of a project with JSC "Ion exchange technologies" for JSC "Gazpromneft ONPZ".

Within the framework of this project, implemented / planned:

1. the technology,
2. working design documentation was developed,
3. the equipment was completed,
4. the equipment was manufactured and supplied,
5. installation supervision and commissioning were carried out.

The project implemented:

1. Equipment supply
2. Development and delivery of process control systems
3. Commissioning work

The project was implemented in 2023.

The equipment was put into operation in 2021. As part of the implementation of this project, a design documentation has been developed, a roll-type crystallizer with a capacity of 4000 kg / h has been supplied, installation supervision and commissioning have been carried out.

In 2020, ZAVKOM-ENGINEERING LLC  carried out a technical re-equipment of the sulfuric acid storage warehouse in order to organize a site for the preparation and dosing of 30% sulfuric acid into the decalcified molasses pipeline of the desugarization production unit and the extract pipeline.

The production process is fully automated; the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of design and working documentation.
2. Development of a plan for the localization and elimination of the consequences of accidents (PMLA).
3. Development of technological regulations.
4. Complete delivery of technological Equipment.
5. Development of automated process control systems.
6. Installation work.
7. Commissioning.
8. Personnel training.
9. Putting into operation.
10. Registration of the Object in Rostekhnadzor (Federal Environmental, Industrial and Nuclear Supervision Service).

At the current time, commissioning works are being carried out.

The projected unit is intended for the production of urea-formaldehyde resin (PKFT) and melamine-formaldehyde resin (MPST) with a total capacity of up to 42,240 tons per year.

Within the framework of this project, implemented / planned - the design and working documentation was developed, the equipment was completed, the manufacture and supply of equipment, installation supervision and commissioning were carried out.

In 2020, ZAVKOM-ENGINEERING LLC  launched production area and filling of vegetable oils and fats into tanks, eurocubes and flexitanks.

The production process is fully automated, the most modern technological equipment from leading Russian and world manufacturers has been supplied.

As part of the project, our company performed the following types of work:

1. Development of working documentation for the brand Production Technology and Process Automation Systems.
2. Complete delivery of technological Equipment.
3. Development of automated process control systems, including the creation of a database of recipes.
4. Complete delivery of the refrigeration machine.
5. Design and manufacture of control cabinets.
6. Installation work.
7. Commissioning.
8. Personnel training.
9. Start-up operations.

In 2020, ZAVKOM-ENGINEERING LLC  completed work on the supply of equipment to Metadynea LLC in the city of Gubakha.

Within the framework of this project, the following equipment was implemented - designed, manufactured and supplied: reaction equipment (synthesis reactor, condenser and hopper), scrubber, capacitive and filtering equipment.

The unit was put into commercial operation in 2020.

In 2018, ZAVKOM-ENGINEERING LLC completed work on the project for obtaining technical naphthalene with a concentration of at least 97% at Magnitogorsk Metallurgical Plant JSC (MMK JSC) in Magnitogorsk.

In February 2020, employees of ZAVKOM-ENGINEERING LLC successfully launched the brewing department of the Azeri brewery in Baku.

In the process of modernization, the filter tank was reconstructed and enlarged.

This allowed us to increase productivity and automate the filtration process.

The local wastewater treatment plant is part of the thermoplastic elastomer production at JSC "Voronezhsintezkauchuk" and allows purification of wastewater from lithium ions to a level below 0.08 ppm, ensuring environmental safety of the main production for the entire region.

Scope of supply:

1. Technology development
2. Development of working design documentation
3. Manufacturing and complete supply of equipment
4. Supervision of installation works
5. Commissioning works

The unit was put into commercial operation in 2019.

In 2019, ZAVKOM-ENGINEERING LLC  successfully completed work on the construction of a urea-formaldehyde resin production unit with a capacity of 33,000 tons per year in Pavlovsk, Altai Territory.

Within the framework of this project, it was implemented — the technology, design and working documentation was developed, the assembly, manufacture and supply of equipment, installation supervision and commissioning were carried out.

In 2019, within the framework of the implemented project with Gambrinus OJSC, the employees of ZAVKOM-ENGINEERING LLC  performed the following work package:

1. Turnkey delivery of the fermentation department (design, manufacture and supply of capacitive equipment, process pipelines, instrumentation and control cabinet, control cabinet; installation supervision and commissioning).
2. Turnkey delivery of the pure yeast culture department (design, manufacture and supply of capacitive equipment, process pipelines, instrumentation and control cabinet, control cabinet; installation supervision and commissioning).
3. Development and implementation of a unified automatic control system for the fermentation department, yeast department, pure yeast culture department and CIP washing department.

The reconstruction made it possible to increase the volume and improve the quality of products, as well as to increase the overall level of automation of the brewery plant.

In 2018, the company ZAVKOM-ENGINEERING LLC  successfully carried out work on the implementation of the project for the technical re-equipment of the raw material warehouse for CJSC Murom in Murom.

The storage warehouse for receiving, storing and supplying the production of UFC-85 and 37% formalin contains 6 containers. The process is fully automated, practically does not require human intervention, and the project contains the most modern energy efficient equipment.

As part of the project, our company performed the following types of work:

1. Development of design and working documentation;
2. Complete delivery of equipment;
   • 6 tanks, 75m3 each;
   • instrumentation sensors;
   • control cabinet;
   • computer hardware and software;
3. Installation supervision;
4. Designer supervision;
5. Start-up and adjustment works;
6. Personnel training.

In 2018, ZAVKOM-ENGINEERING LLC  successfully completed a project for the construction and commissioning of a new brewhouse for HANSEN BREWERY LLC, Stavropol.

This unit, with a capacity of 5 tons of wort from one brew, was developed and designed taking into account the latest design and technological solutions developed by ZAVKOM-ENGINEERING LLC. The operation of the brewing department is carried out in a fully automatic mode, which made it possible to achieve a stable mode of operation of the equipment with a minimum number of staff.

The specialists of the ZAVKOM group of companies performed a full range of services, including:

• Development of project and design documentation,
• Manufacturing of the main technological equipment,
• Assembly of control cabinets,
• Software development,
• Supply of equipment,
• Installation supervision and commissioning,
• Training,
• Warranty service.

As part of this project, a set of works was completed for PJSC "Vasileostrovskaya brewery" to supply a brewhouse with a capacity of 13 tons of wort from one brew. Due to the high automation of the technological process, it was possible to achieve a productivity of 12 brews / day.

The scope of delivery included:

1. Development of a technological project;
2. Equipment manufacturing;
3. Supply of a set of piping, instrumentation and control cabinets;
4. Execution of supervision and commissioning works.

Scope of completed work

1. development of engineering documentation taking into account the technological requirements of the facility and local regulations;
2. development and implementation of an automated process control system (APCS) ensuring stable management of technological processes and control of production parameters;
3. development and manufacturing of control cabinets adapted to the operating conditions of the enterprise;
4. supply of components, including instrumentation, control valves, cable products and related accessories;
5. performance of supervision of installation works with participation of the company’s specialists;
6. commissioning works, as well as training of the Customer’s personnel to operate the automation system.