1 Conventional scale-up method: challenges and opportunities
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Abstract
This chapter covers the application of scale-up in chemical process industries, which has been the core of certain industrial successes where the size of the pilot plants was large enough to allow for an appropriate extrapolation of the processes. The design and operation of the pilot plant are therefore central to its success. Nonetheless, the limitation of monetary resources has forced companies to substantially decrease the size of pilots and that has created a knowledge gap between these units and the industrial-scale units leading to process failure. There are, however, some challenges and opportunities surrounding the conventional scale-up. Statistical data reported in this chapter show the importance of taking a fresh look at pilot plants and ways to replace them for future scale-ups. The proper design and use of scaled-down pilot plants, process simulation, and a return to lab experiments would be considered alternative solutions to pilot plants in the path of conventional scale-up. With the information reported in this chapter and the power of information technology, it seems, in some cases, we can avoid piloting before design, and other tools can be employed for the benefit of scale-up to a large extent.
Abstract
This chapter covers the application of scale-up in chemical process industries, which has been the core of certain industrial successes where the size of the pilot plants was large enough to allow for an appropriate extrapolation of the processes. The design and operation of the pilot plant are therefore central to its success. Nonetheless, the limitation of monetary resources has forced companies to substantially decrease the size of pilots and that has created a knowledge gap between these units and the industrial-scale units leading to process failure. There are, however, some challenges and opportunities surrounding the conventional scale-up. Statistical data reported in this chapter show the importance of taking a fresh look at pilot plants and ways to replace them for future scale-ups. The proper design and use of scaled-down pilot plants, process simulation, and a return to lab experiments would be considered alternative solutions to pilot plants in the path of conventional scale-up. With the information reported in this chapter and the power of information technology, it seems, in some cases, we can avoid piloting before design, and other tools can be employed for the benefit of scale-up to a large extent.
Chapters in this book
- Frontmatter I
- Preface VII
- About the Editors XI
- Contents XIII
- 1 Conventional scale-up method: challenges and opportunities 1
- 2 Iterative scale-up method: concept and basics 21
- 3 Process extrapolation by simulation 57
- 4 Transition from e-pilot to full commercial scale 91
- 5 Life-cycle assessment and technology scale-up 125
- 6 Case study I: n-Butane partial oxidation to maleic anhydride: VPP manufacture 147
- 7 Case study II: n-Butane partial oxidation to maleic anhydride: commercial design 167
- 8 Case study III: Methanol to olefins 191
- 9 Case study IV: Hydropotash from potassium feldspar 221
- 10 Case study V: Lactide production process development 251
- 11 Case study VI: CO2 sequestration in microalgae photobioreactors 279
- 12 Discussion and concluding remarks 305
- Index 327
Chapters in this book
- Frontmatter I
- Preface VII
- About the Editors XI
- Contents XIII
- 1 Conventional scale-up method: challenges and opportunities 1
- 2 Iterative scale-up method: concept and basics 21
- 3 Process extrapolation by simulation 57
- 4 Transition from e-pilot to full commercial scale 91
- 5 Life-cycle assessment and technology scale-up 125
- 6 Case study I: n-Butane partial oxidation to maleic anhydride: VPP manufacture 147
- 7 Case study II: n-Butane partial oxidation to maleic anhydride: commercial design 167
- 8 Case study III: Methanol to olefins 191
- 9 Case study IV: Hydropotash from potassium feldspar 221
- 10 Case study V: Lactide production process development 251
- 11 Case study VI: CO2 sequestration in microalgae photobioreactors 279
- 12 Discussion and concluding remarks 305
- Index 327
