Vishnu Chemicals — CO₂ & NH₃ Dual-Line PRS Skid

A custom-engineered, compact PRS skid delivering zero-leak CO₂ and NH₃ pressure control for R&D operations — scalable to full production.

The Challenge

Vishnu Chemicals Limited is a leading Indian manufacturer of specialty chemicals — particularly chromium-based compounds and barium carbonate — exporting to more than 60 countries across pharmaceuticals, glass, ceramics, pigments, and metallurgy. Established in 1993, the company operates ISO-certified facilities and maintains stringent safety and environmental standards.

R&D Gas Handling Requirements

Vishnu's R&D unit required a pressure regulation solution for CO₂ and NH₃ — two gases with fundamentally different handling requirements and significant safety implications. The system needed to fit within an existing R&D footprint while remaining scalable to production volumes.

• Precise pressure control at experimental scale — even small deviations affect pilot batch reliability
• High-integrity containment for ammonia (NH₃): a toxic, corrosive gas requiring zero leak tolerance
• CO₂ handling at accurate low pressures for controlled R&D reactions
• Compact footprint — the system had to integrate into existing R&D infrastructure without extensive pipework changes
• Compatibility with existing DCS/SCADA for pressure monitoring, alarms, and remote control
• Clear scalability path from R&D to full production without a system redesign

Nirmal's Solution

Nirmal engineered a custom CO₂ and NH₃ Dual-Line Pressure Reducing Station (PRS) Skid specifically for Vishnu's R&D application. Every element of the design addressed the client's stated constraints.

Key Engineering Features

• Dual-Line PRS: Independent regulation circuits for CO₂ and NH₃ with high-precision control valves — no cross-contamination risk
• SS316L construction with compatible elastomers: full corrosion resistance for both gas chemistries
• Integrated safety package: pressure relief valves, non-return valves, and purge systems for zero-leak operation
• Compact modular skid: plug-and-play installation into the existing R&D layout with no major piping changes
• Automation-ready instrumentation: pressure monitoring, DCS/SCADA alarm integration, and data logging capability
• Scalability designed in from day one: the modular architecture supports expansion to production-scale throughput

Outcome

The CO₂ and NH₃ PRS Skid has operated at Vishnu Chemicals with zero leak incidents. The dual-line architecture delivers the precise, independent pressure control required for reliable experimental results. Integration with the existing DCS/SCADA system was achieved without modification to surrounding infrastructure.

The modular, scalable design has laid the groundwork for Vishnu's production-scale expansion. When the R&D phase concludes, the same engineering principles — and Nirmal's support — will carry the system into full-volume manufacturing.

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