Advanced programming calculations.
New high-efficiency unit.
New system design.
Original unit for replacement.
VOC Emissions Compliance - Chemical Sector
Challenge
A polymer manufacturer in the Montsià region faced regulatory pressure after its existing scrubber system failed to meet new VOC (volatile organic compound) emission limits.
The company required a cost-effective solution that would ensure compliance without disrupting production.
Approach
Pronespa’s engineering team conducted an on-site assessment with management and the quality department to analyse processes and identify the specific VOCs out of range.
Engineering
Using advanced modelling tools, we designed a tailor-made scrubber and integration solution:
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Stainless steel construction.
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Optimised dimensions, filling type, flow rate and recirculation liquid.
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Detailed P&ID and 3D models to validate the design pre-installation.
Outcome
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Compliance with EU emission limits for VOCs.
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Reliable SCADA-controlled operation with full staff training.
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Delivery on schedule with a complete turnkey service.
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Improved efficiency and reduced environmental footprint and risk.
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Comprehensive technical documentation to support future maintenance.
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Reinforced reputation for quality and innovation in the chemical sector.
Dosing system.
Installed park.
2D & 3D CAD modelling.
Site planning.
Growth - Detergent manufacturing
Challenge
Long established detergent manufacture requiring new production facility due to increased demand requiring increased raw material storage.
Approach
Working alongside the clients, architects and construction teams, we planned, designed and installed all production related systems, including the re-design of all transportation logistics to and from the site.
Engineering
Using advanced modelling tools and calculations, we developed a bespoke storage park:
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FRP reinforced polyester construction.
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Fast tanker discharge, precise dosification to reactors.
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Detailed P&ID and 3D models to validate the design pre-installation.
Outcome
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Increased production capacity.
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Reliable SCADA-controlled operation with full staff training.
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Delivery on schedule with a complete turnkey service.
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Improved efficiency and reduced environmental risk.
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Comprehensive technical documentation to support future maintenance.
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Compliance with APQ-6.
Installed dosing system.
CAD Dosing system.
Sled during testing.
Interactive 3D CAD.
Sulphuric Acid Dilution Skid
Challenge
To cope with increasing demand, a Spanish fertiliser manufacturer urgently required a new dilution system to increase production capacity. The system was specified to dilute from 98% to 75%, although it can do more significant concentrations if needed.
Approach
Due to the highly corrosive nature of the process, the challenge of a low-energy refrigerated system with extreme exothermic reactions, limited space, tight timelines and the need for direct monitoring, a ‘plug & play” solution would provide flexibility for installation, a quick turnaround and be cost effective for the client.
Engineering
Due to the corrosive & exothermic challenges, accurate material selection was paramount: PPH, PVC, PVDF, FKM, Teflon, Stainless Steel and Graphite were specified.
Using the most advanced 3d modelling allowed us to optimise the skid diameters and functionality for the narrow installation location, while ensuring safe working practices were maintained.
Prior to shipping, the unit was subjected to a full range of tests by our engineers including joint integrity, flow rates, dosing and web-monitoring exceeded specification and fully functional.
Outcome
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Full turnkey project; on-time and to-budget.
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Precise sulfuric acid concentration output.
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Increased production capacity to meet demand.
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Web-monitoring provides instant controls to optimise production.
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Detailed online schematics for maintenance and full training for staff.
{nkaptur} nutrient recovery
Challenge
A local pig farmer’s water shortage in 2015 led to the development of a breakthrough recovery system for livestock slurries and digestates.
In response to growing limits on water use, nutrient application and farm expansion, and in line with EU directives, the {nkaptur} process converts raw slurry into high-value outputs — clean water and nutrient concentrates — supporting both NRR and RENURE initiatives.
Engineering
Combining Pronespa’s long experience in gas and water treatment with advanced chemical R&D, the patented {nkaptur} FQ-C physicochemical unit forms the core of a modular, containerised system.
Integrated with leading dewatering and membrane technologies, it offers remote 24/7 monitoring and full automation — turning slurry management from a compliance burden into a resource opportunity.
Outcome
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Produces four commercial products: C:N solid, nutrient rock, nk-liquid and clean water.
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Reduces land, storage and environmental impact.
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Complies with EU and regional regulations, including Environment Agency discharge approvals.
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Fully modular for easy integration with existing farm or AD infrastructure.
Independent analytics & 3 years of data.
On-farm FQ-C systems.
Variable modular design.