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
Average Annual Savings Identified
95%
Audits Find Significant Savings Opportunities
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
300 TPD
Central India
Challenge
Unstable power recovery and energy losses driven by equipment inefficiencies.
Results
25%
Plant Availability
30%
Power Generation
₹2 Cr
Annual Power Savings
<1 Yr
ROI
Outcome
Targeted modifications improved system reliability and power recovery efficiency.
Why Do You Need an Energy Audit?
efficiency and profitability.
Did you know?
In a typical double absorption plant, around 27% of energy is lost to cooling water and about 3% is lost due to inefficiencies. That is value leaking from your plant operation every day.
Energy Distribution through a Sulphuric Acid Plant
Without regular audits, plants waste energy, face unplanned downtime, and lose competitive advantage.
Typical Recovery Potential:
10–18% Reduction in Utility Costs
Audit Payback
< 12 Months
Verified Savings Up To
$0.5M Annually
Our Proven Audit Workflow
Data Review & Benchmarking
Evaluate process data and 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 Will Receive From a GEC Audit
Benchmarking Analysis
Root Cause Diagnosis
Optimization Roadmap
Implementation Support
Energy & Cost Savings Estimation
Follow-Up Performance Review
Comprehensive Audit Report
What Our Clients Say
We requested Galiakotwala 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 explained how we can execute this solution along with the names of vendors.
Confidential Client
Don't Let Operating Inefficiencies Drain Your Profits
A single audit can uncover millions in savings. Take control of your plant’s performance today.