Re-Engineering, Overhaul & Production Line Development
In heavy industries, particularly thermal pyrolysis processes, every minute of production downtime or reduced thermal efficiency can result in significant costs. With a deep understanding of thermodynamic mechanisms and high-temperature component wear, Kiyan Saze Malahat restores your system to maximum operating capacity with the most cost-effective engineering approach.
Solutions Tailored to the Actual Condition of Your Production Line
From upgrading a single module to completely rebuilding a production line, the scope of services is determined based on equipment condition, the level of wear, and your operational objectives.
Technology Upgrade
Adding engineered modules to reduce energy consumption, control emissions, and increase the number of production cycles.
View Upgrade SolutionsInstallation & Commissioning
Equipment layout, foundation work, assembly, and cold and hot testing for existing or stored production lines.
View Commissioning ProcessLight Overhaul
Preventive maintenance, lubrication, replacement of consumable parts, and calibration of control equipment.
View Maintenance ServicesMajor Overhaul
Technical audit, reverse engineering, structural rebuilding, and final load testing of the system.
View Rebuilding Process
Technology Upgrade & Improved Line Efficiency
Existing systems are upgraded with engineered modules to reduce energy consumption, increase process speed, and control emissions.
Off-Gas Sweetening & Purification
Purification and neutralization of non-condensable gases and their recirculation to the burners to reduce or eliminate auxiliary fuel consumption and optimize energy use.
Energy ManagementCentrifugal Carbon Discharge & Bag Filter
Mechanized carbon black discharge under isolated and pressurized conditions, combined with industrial bag filtration to reduce airborne dust.
Dust ControlHydraulic Movable Thermal Cover
Design of movable insulated covers with a hydraulic lifting mechanism for rapid opening, shorter cooling times, and increased production cycles.
Higher Production CyclesIndustrial Scrubber Package
Design and parallel configuration of gas scrubbing systems to remove acidic compounds and suspended particles in accordance with project environmental requirements.
Emission Reduction
From Equipment Layout to Hot Testing & Operational Handover
Improper installation can damage rotating components, the reactor, and electromechanical equipment. The Kiyan Saze Malahat engineering team takes full responsibility for the installation and commissioning of existing production lines at your facility.
Equipment Layout Plan
Preparing equipment layouts based on required capacity, available project space, and operational access routes
Foundation & Assembly
Foundation construction, precise alignment of rotating components, and assembly of mechanical and electrical sections
Cold & Hot Testing
Performing Cold Commissioning and Hot Commissioning under the supervision of senior engineers
Operator Training
Training in temperature and pressure control, emergency management, and correct system operation
Prevent Failures Before They Stop Production
Periodic monitoring and timely replacement of consumable parts help prevent unexpected failures and prolonged production downtime. Our light overhaul services are designed to maintain stable performance and extend equipment service life.
Specialized Inspection & Lubrication
Inspection of mechanical sections and lubrication of reactor drive and power transmission systems
Replacement of Wear-Prone Parts
Replacement of refractory packing, mechanical seals, gaskets, power transmission chains, and consumable parts
Thermal System Calibration
Burner adjustment and inspection of temperature and pressure sensors to prevent reactor overheating
Restore Worn Systems to Reliable Operating Condition
When a reactor suffers severe wear, thermal deformation, or extensive electromechanical damage, rebuilding should be based on a detailed audit, transparent assessment, and the client’s technical approval before execution.
Decisions Based on Technical & Economic AnalysisTechnical Audit & Detailed Troubleshooting
Identifying damaged sections, investigating the causes of failure, and providing a technical report before any execution work begins.
Cost Estimate & Economic Feasibility Analysis
Providing a detailed cost breakdown and clearly identifying components for which rebuilding is not economically justified, along with recommended alternatives.
Reverse Engineering & Parts Manufacturing
Redesigning worn sections, manufacturing new parts, and carrying out rebuilding work after the client’s technical and financial approval.
Load Testing & Final Handover
Complete system testing under operating conditions, including temperature, pressure, and equipment performance checks, followed by line handover after final approval.
Rebuilding work begins only after the technical report, cost estimate, and formal client approval have been provided.
Choose the Service Level Based on Your Production Line Condition
The appropriate service is determined after an inspection, review of technical documentation, and assessment of the equipment’s operating condition.
Operating Line with Low Efficiency
The system is operating, but its energy consumption, process speed, or emissions require improvement.
Recommended: Technology UpgradeUninstalled or Stored Equipment
The machinery has been purchased, but proper installation, layout, and commissioning have not yet been completed.
Recommended: Installation & CommissioningOperating Line with Periodic Wear
The equipment is operating, but consumable parts, burners, or sensors require servicing and calibration.
Recommended: Light OverhaulStopped or Worn Production Line
The system has lost performance due to structural damage, reactor deformation, or extensive electromechanical failure.
Recommended: Major Overhaul
Before Making a Decision, Assess Your System Accurately
Send us your line specifications, feedstock type, capacity, current issues, and equipment photos so Kiyan Saze Malahat’s technical experts can contact you to coordinate an inspection and recommend the appropriate solution.
Get in Touch for Technical Services
For installation, commissioning, periodic inspections, spare parts supply, or specialized technical consultation, submit your request to our after-sales service team.