Are Hidden Inefficiencies
Draining Your Acid Plant?
With 40+ years of acid plant experience, GEC is your partner in optimizing every aspect of plant performance.
From converter beds to cooling water systems, every process step hides opportunities for improvement.
25+
plants audited
worldwide
$0.5M-$1M
savings identified
95%
Our audits uncover performance, reliability, profit and losses through deep process and energy analysis.
Why should you use GEC as your Audit Partner?
Without GEC Audit
- Frequent unplanned downtime due to hidden equipment failures
- High energy costs from inefficient heat exchangers
- Corrosion and material degradation go unnoticed
- Poor absorption efficiency → mist emissions
- Lost production due to process bottlenecks
- Decisions based on assumptions
With GEC Audit
- Reduced downtime via early risk detection & preventive maintenance
- Lower costs via optimized heat recovery
- Extended equipment life through corrosion checks & validation
- Improved compliance & mist capture
- Increased throughput with process improvements
- Data-driven engineering insights
How a GEC Audit Benefited a Major Sulphuric Acid Manufacturing Facility
25%
Plant Availability
30%
Power Generation
₹2 Cr
Annual Power Savings
<1 Yr
ROI
Challenge:
Unstable power recovery and energy losses driven by equipment inefficiencies.
Outcome:
Targeted modifications improved system reliability and power recovery efficiency.
A GEC audit helped a 300 TPD Sulphuric Acid plant enhance uptime, efficiency, and profitability achieving ROI within a single operating cycle.
Recover Waste Heat. Reduce Energy Load. Enhance Plant Profitability.
Our energy audits identify where your plant loses valuable heat and energy from converter heat recovery to cooling water optimization. We quantify these losses, benchmark against best available technology, and design actionable recovery strategies.
Did you know?
In a typical double absorption plant, around 28% of energy is lost to cooling water and about 4.5% to inefficiencies. That is value leaking from your operation every day.
Energy Distribution in Typical Double Absorption Plant
Without regular audits, plants waste energy, face unplanned downtime, and lose competitive advantage.
Typical recovery potential:
Audit payback
< 12 months
Verified savings up to
$0.5M annually
Our Proven Audit Workflow
Data Review & Benchmarking
Evaluate process data & set performance baseline
On-site Energy & Equipment Assessment
Field inspection, efficiency testing, and instrumentation audit
Actionable Recommendations + Support Execution
Detailed report and assistance for implementation
What You’ll Receive from a GEC Audit
A complete audit package designed for measurable improvement combining deep process diagnostics, performance analytics, and actionable implementation support.
Comprehensive Audit Report
Detailed documentation of plant and energy performance, including quantified loss mapping and efficiency data.
Benchmarking Analysis
Comparison of your current KPIs against global sulphuric acid plant standards and best available technologies.
Root Cause Diagnosis
Identification of hidden inefficiencies, fouling, and process deviations impacting throughput or energy recovery.
Optimization Roadmap
Actionable plan with process modifications, equipment recommendations, and improvement priorities.
Energy & Cost Savings Estimation
Quantified potential savings, payback calculations, and ROI projections for each recommended measure.
Implementation Support
On-ground engineering assistance to help execute audit recommendations effectively.
Follow-Up Performance Review
Post-audit assessment to validate improvement results and fine-tune performance parameters.
What Our Clients Say
We requested Goliakotwala Engineering to Audit our Acid Plant due to vast experience in this field. We wanted to understand the reasons for few plant parameters to be below expected values. Galiakotwala Engineering did a thorough review and gave us some invaluable suggestions and furthermore plained ow we can execute this solution along with the names of vendors.
Bhageria Industries
Managing Director
Don’t Let Inefficiencies Drain Your Profits
A single audit can uncover millions in savings. Take control of your plant’s performance today.
