Industrial Process Scale-up

1 Industrial Scale up Content and Context

1.1 Purpose and Set-up

1.2 Scale-up Definition Methodology and Risks

1.2.1 Scale-up Definition

1.2.2 Scale-up Methodology

1.2.3 Stage-gate Innovation Method

1.2.4 Scale-up and Design role

1.2.5. Scale-up Behavior and Risks

1.3 Process industry Systems

1.3.1 Value and Life Cycle Chains

1.3.2 Industrial Complexes

1.3.3 Processes

1.3.4 Unit Operations

1.3.5 Major Process Equipment

1.3.6 Dispersed System Level

1.3.7 Chemistry Level

1.4 Partners and Stakeholders for Innovation

2 Discovery Stage

2.1 Obtaining Process Ideas

2.1.1 Obtaining Ideas in General

2.1.2 Obtaining New Process Routes

2.2 Assessing Process Ideas

2.2.1 Assessing and Ranking many Ideas

2.2.2 Technology Readiness Level method

2.3 Process Design Sketch

2.3.1 Process Concept Design Essentials

2.3.2 Reference Case for Comparison

2.4 Proof of Principle

2.5 Discovery Stage-gate Evaluation

2.5.1 Discovery Stage-gate Purpose

2.5.2 Reporting Discovery Stage

2.6 Pitfalls Discovery Stage

3 Concept Stage

3.1 Detailed Assessment of Ideas

3.1.1 New Process Routes Assessments

3.1.2 Detailed Assessment Best Ideas

3.1.3 Co-operation with External Innovation Partners

3.2 Identifying Potential Showstoppers

3.3 Proof of Concept

3.4 Concept Design

3.4.1 Purpose Concept Design

3.4.2 Concept Design

3.4.3 Break-through Concept Design by Function Integration

3.4.4. Process Modelling and Simulation

3.4.5 Essential Property Determination

3.4.6 Concept Stage Reporting

3.5 Concept Stage-gate Evaluation

3.6 Pitfalls Concept Stage

4 Feasibility Stage

4.1 Purpose of Feasibility Stage

4.2 Process Equipment Scale-up

4.2.1 Introduction to Process Equipment Type Selection

4.2.2 Critical Performance Phenomena

4.2.2.1 Overview Critical Performance Phenomena

4.2.2.2 Feed Distribution

4.2.2.3 Residence time distribution

4.2.2.4 Mixing

4.2.2.5 Shear Rate Distribution

4.2.2.6 Mass transfer

4.2.2.7 Heat transfer

4.2.2.8 Impulse transfer

4.2.3 Process Equipment Scale-up Methods

4.2.3.1 Overview Process Equipment Scale-up Methods

4.2.3.2 Brute Force Scale-Up and Scale-Down

4.2.3.3 Model-Based Scale-Up

4.2.3.4 Empirical Scale-Up

4.2.3.5 Hybrid Model-Empirical Scale-up

4.2.3.6 Dimensionless numbers Scale-up

4.2.3.7 Direct Scale-Up

4.2.4 Scale-up Characteristics Process Equipment Tpes

4.2.5 Process Equipment Type Selection in View of Reliable Large Scale Performance

4.2.6 Historic Case of Process Equipment Type Selection Shell Gas-To-Liquid Development

4.3 Process Scale-up by Design

4.3.1 Purpose Commercial Scale Design in Feasibility Stage

4.3.2 Design Choices in View of Development Cost.

4.3.3 Design Base

4.3.4 Purchasing a Complete Process Technology

4.4 Risk Assessment for Decision Mini-Pant

4.4.1 Mini-plant Choice

4.4.2. Mini-plant Cost Estimate

4.5 Decision on Integrated Down-Scaled pilot plant

4.5.1 Pilot Plant Purposes

4.5.2 Decision on having a Pilot Plant

4.5.3 Industry Project Statistics of not having a Pilot Plant.

4.5.4 Value of Information Approach for Development Plan Decisions

4.5.5 Pilot Plant design

4.5.6 Pilot Plant Cost Estimate

4.6 Decision and Design of Cold-Flow Test Units

4.7 Feasibility Stage Study Pharmaceuticals Agrochemicals and Fine Chemicals

4.7.1 Pharmaceuticals Feasibility Stage

4.7.2 Agrochemicals Feasibility Stage

4.7.3 Fine chemicals Feasibility stage: Unit Operations Choices in View of Scale-up

4.8 Planning for Concurrent Development and Commercial Scale Design

4.9 Feasibility Stage-gate Evaluation

4.10 Pitfalls Feasibility Stage

5 Development Stage

5.1 Mini-Plant Engineering, Procurement, Construction and Testing

5.2 Pilot Plant Engineering, Procurement, Construction and Testing

5.3 Cold-Flow Plant Engineering, Procurement, Construction and Testing

5.4 Front End Engineering Design (FEED)

5.5 Development Stage-Gate Reporting and Evaluation

5.6 Pitfalls Development Stage

6 Scale-up from Existing Pilot Plant

6.1 Scale-up from Existing Pilot Plant to Existing Commercial Scale Process

6.1.1 Scale-up Continuous Process from Existing Pilot Plant to Existing Process

6.1.2 Scale-up for Batch Process from Pilot Plant to Existing Commercial Scale Process

6.2 Scale-up from Existing Pilot Plant to New Process

7 Implementation Stage

7.1 Introduction to Implementation Stage

7.2 Rationale Demonstration Scale Decision

7.3 Engineering Design, Procurement and Construction

7.3.1 Contractor selection

7.3.2 Detailed Design

7.3.3 Procurement, Construction and Commissioning

7.4 Start-Up Commercial Processes

7.4.1 Start-Up Time Prediction

7.4.1.1 Start-up time Merrow Industry Correlation

7.4.1.2 Critical Success Factors Reducing Start-up time

7.4.1.3 Fulfilling critical success factors

7.4.1.4 Start-up time and Critical Success Factors Shell GTL Case

7.5 Pitfalls Implementation Stage

8 Industrial Scale-Up Cases

8.1 Liquid- Liquid Extractive Reaction by Taguchi model-based product quality control

8.2 Start-up Bulk Chemical Product Conventional Process

8.3 Start-up Conventional Process in South Korea

8.4 Purchasing Novel Process

8.5 Polymerization Process

8.6 Wastewater Novel Design and Implementation

8.7 Carilon Engineering Polymer: New Product, Process, Market and Strategy Change

8.8 Purchasing a Commercially Proven Rotating Filter

8.9 Fermentation Scale-up

8.10 Fine chemicals Discovery stage

8.11 Summary of Learning points from Industrial Cases