ISO 9001 CERTIFIED · CONSULTANT APPROVED · EXPORTING SINCE 2005
ENGINEERING
The design is decided before
the first ply is laid.
Process simulation, composite FEA, CFD and a proprietary fan design suite, held to the governing international codes, and proved on our own test rigs before anything is despatched.
FABRICATION BAY · MANKOLI, BHIWANDI
01 — HOW A PROJECT RUNS
Six stages, one team, one set of assumptions.
Single-point responsibility means the design basis, the laminate, the fan curve and the commissioning report all trace back to the same engineers.
01
Define
Design basis, process data and site survey reviewed jointly with you and your consultant.
02
Simulate
Process simulation in ChemCAD; flow and structural simulation in SolidWorks.
03
Engineer
Laminate schedules and mechanical design to the governing code, checked by FEA analysis before any prototyping.
04
Manufacture
FRP, dual-laminate and PPH fabrication at Mankoli under documented QA.
05
Test
Laminate testing in house, and fan performance testing to IS 4894.
06
Commission
Installation, start-up, operator training and the commissioning document.
02 — CODES & STANDARDS
What the design is held to.
Almost no Indian FRP fabricator publishes the codes it designs to. We put them on every equipment page, because they are the first thing a specifying engineer looks for.
CODE
SCOPE
APPLIED TO
BS EN 13121
Vessels and tanks in reinforced plastics; GRP tanks and vessels for above-ground use
TANKS · VESSELS · SCRUBBERS
ASME Sec X RTP-1
Fibre-reinforced plastic pressure vessels; reinforced thermoset plastic corrosion-resistant equipment
PRESSURE VESSELS · SCRUBBERS
DVS 2205
Design of thermoplastic tanks and apparatus
PPH TANKS · LINERS
AD 2000-Merkblatt
German pressure equipment design rules
TANKS · VESSELS
IS 4894
Centrifugal fan performance testing
BLOWERS
BS 848
Fans for general purposes — performance
BLOWERS
ACGIH
Industrial Ventilation Manual — hood and duct design
EXHAUST SYSTEMS
03 — SOFTWARE
The tools behind every proposal.
Also in use: Aspen HYSYS and ChemSep for process work, and in-house macros for static head loss to ACGIH.
PROCESS SIMULATION
ChemCAD
Sizing and validation of wet scrubbers, with the inlet stream and recirculation liquor fully defined.
3D DESIGN & LAYOUT
SolidWorks Professional
Parametric layout of exhaust, ventilation, scrubbing and dust collection systems.
COMPOSITE FEA
SolidWorks Simulation
Compares designs and predicts buckling, collapse, drop and fatigue in composite structures.
CFD
SolidWorks Flow Simulation
Flow in exhaust systems and blower rating at different speeds, without a prototype.
PROPRIETARY
In-house fan design suite
Shaft sizing, sheet thickness by material, motor selection and generated performance curves.
STRUCTURAL CHECK
Composite FEA verification
Laminate and structural design verified by FEA analysis before any prototyping for equipment is done.
04 — WHY FRP
An honest comparison with the metals it replaces.
FRP is not the answer to every duty, and we would rather you heard its limits from us. For acid, chloride and wet chlorine service at moderate temperature, it is usually the lowest lifetime-cost option by a wide margin.
PROPERTY
FRP / DUAL LAMINATE
MS RUBBER-LINED
SS 316
EXOTIC ALLOYS
Resistance to HCl, chlorides and wet chlorine
Excellent
Good, until the lining fails
Poor
Excellent
Weight
Light
Heavy
Heavy
Heavy
Capital cost
Moderate
Moderate
Higher
Very high
Maintenance
Low
Periodic re-lining
Low where compatible
Low
Temperature ceiling
Limited by resin
Limited by lining
High
High
Abrasion resistance
Moderate
Good
Good
Good
Repair at site
Straightforward
Specialist re-lining
Welding
Specialist welding
A general guide. The right material always depends on the specific chemistry, concentration and temperature.
05 — MATERIALS
Resin and liner selection, in plain language.
A general guide only. Final selection is made against the resin manufacturer’s chemical resistance data for the actual concentration and temperature.
Isophthalic polyester
Dilute acids, salts, water and general chemical service at moderate temperature.
Bisphenol polyester
Broader acid and alkali resistance than isophthalic grades.
Epoxy vinyl ester
Strong acids, alkalis, oxidising and chlorinated service, and higher temperatures.
Novolac vinyl ester
Elevated temperatures and solvent exposure beyond standard vinyl ester.
PP, HDPE, PVC liners
Dual-laminate construction where the chemistry would attack any resin.
PVDF liner
The most aggressive services — strong oxidisers, HF, high-purity duty.
06 — PROVEN ENVELOPE
The largest ratings and sizes we have handled.
300 m³
FRP and dual-laminate tank, Ø 6,000 × 8,000 mm
165,000
Am³/h blower at 550 mmWC
875,000
CMH largest installation
1,500,000
CMH design capability
112,500
CMH cross-flow scrubber, H₂SO₄ mist
110,000
CMH pulse jet collector, 1,522 m²
21.0 m
Longest process tank, push-pull pickling
10 kg/cm²
Internal pressure, and full vacuum
07 — QUALITY & TESTING
How it is proved before it ships.
ISO 9001 certified quality system. Stage inspection is open to the customer and their consultant.
Raw material inspection
Resin, glass and thermoplastic sheet checked on receipt.
Stage inspection
Lamination and assembly inspected at each stage, open to the customer.
Laminate testing
Destructive and non-destructive testing of FRP laminates and weld joints, in house.
Fan performance testing
Measured curves on our IS 4894 test rig before despatch.
Factory acceptance
Hydro tests and FAT before the equipment leaves Mankoli.
Commissioning record
A documented handover with performance data.
BRING US THE HARD ONE
When the duty sits outside the catalogue, we design for it.
Send the process data and the layout constraint, and an engineer will come back with a sized proposal.
ENQUIRY
Pick the equipment. We will send you the data sheet.
Choose the equipment you need. We will take three details, then send you the enquiry data sheet for that product — the one our engineers use to size and quote.
Already know what you need? Download data sheets directly
ENQUIRY DATA SHEET
Scrubbing systems
The sheet arrives by email immediately. Fill it in and send it back, and an engineer replies with a sized proposal.
Bhavi Plast
FRP and dual-laminate process equipment, engineered, built, installed and maintained under one contract. Established 1977.
EQUIPMENT
APPLICATIONS
HCl fume scrubbing
Cl₂ and NH₃ scrubbing
H₂SO₄ mist removal
Flue gas desulphurisation
Pickling line exhaust
Solar PV and semiconductor exhaust
Cl₂ and NH₃ scrubbing
H₂SO₄ mist removal
Flue gas desulphurisation
Pickling line exhaust
Solar PV and semiconductor exhaust
CONTACT
603 Dev Corpora, Cadbury Junction,
Khopat, Thane (W) 400 601
Maharashtra, India
Plant — Mankoli, Bhiwandi
+91 22 4970 9140
mb@bhaviplast.com / jm@bhaviplast.com
Khopat, Thane (W) 400 601
Maharashtra, India
Plant — Mankoli, Bhiwandi
+91 22 4970 9140
mb@bhaviplast.com / jm@bhaviplast.com
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