2 Iterative scale-up method: concept and basics
-
Jamal Chaouki
Abstract
This chapter covers the basics, tools, and applications of the iterative scale-up method in chemical process industries. In this approach, the piloting, which is central to the conventional scale-up method, will be removed from the scale-up path as the chemical and biological process industries avoid operating uncertain pilot plants due to their minimal benefits, high operational anxieties, and rather significant costs. This leads to direct pre-design of an industrial plant based on the existing data generated from the literature, initial laboratory, bench, and small pilot plants. At this stage, uncertainties will be judiciously identified and wisely reduced to an acceptable level in various iterations through process modeling and simulation, small-scale runs and/or down-scaled piloting within the frame of the feasibility analysis. This approach to scale-up, however, remedies the shortcomings of the conventional scale-up method and fills the knowledge gap created in the wake of the pilot plant removal. The chapter includes the basics of the iterative scale-up method, tools and techniques to minimize the uncertainties and introduce the description of the case studies to be included in the book. With the information reported in chapters one and two, and the power of information technology, it seems we can easily avoid the costly, tedious, and time-consuming piloting before design with the close collaboration of the chemical process industry. The iterative scale-up method would create a paradigm shift in process design and more cases would be available in the future to support its wide applicability. We hope this scaleup can be integrated into design courses to train a new generation for its industrial implementations.
Abstract
This chapter covers the basics, tools, and applications of the iterative scale-up method in chemical process industries. In this approach, the piloting, which is central to the conventional scale-up method, will be removed from the scale-up path as the chemical and biological process industries avoid operating uncertain pilot plants due to their minimal benefits, high operational anxieties, and rather significant costs. This leads to direct pre-design of an industrial plant based on the existing data generated from the literature, initial laboratory, bench, and small pilot plants. At this stage, uncertainties will be judiciously identified and wisely reduced to an acceptable level in various iterations through process modeling and simulation, small-scale runs and/or down-scaled piloting within the frame of the feasibility analysis. This approach to scale-up, however, remedies the shortcomings of the conventional scale-up method and fills the knowledge gap created in the wake of the pilot plant removal. The chapter includes the basics of the iterative scale-up method, tools and techniques to minimize the uncertainties and introduce the description of the case studies to be included in the book. With the information reported in chapters one and two, and the power of information technology, it seems we can easily avoid the costly, tedious, and time-consuming piloting before design with the close collaboration of the chemical process industry. The iterative scale-up method would create a paradigm shift in process design and more cases would be available in the future to support its wide applicability. We hope this scaleup can be integrated into design courses to train a new generation for its industrial implementations.
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
