Description
Chemical Projects Scale Up: How to Go from Laboratory to Commercial covers the chemical engineering steps necessary for taking a laboratory development into the commercial world. The book includes the problems associated with scale up, equipment sizing considerations, thermal characteristics associated with scale up, safety areas to consider, recycling considerations, operability reviews and economic viability. In addition to the process design aspects of commercializing the laboratory development, consideration is given to the utilization of a development in an existing plant.
- Explains how heat removal for exothermic reactions can be scaled up
- Outlines how a reactor can be sized from batch kinetic data
- Discusses how the plant performance of a new catalyst can be evaluated
- Presents how the economics of a new product/process can be developed
- Discusses the necessary evaluation of recycling in commercial plants
Chapter
1 - Potential Problems With Scale-up
Theoretical Considerations
Project Focus Considerations
2 - Equipment Design Considerations
Laboratory Batch Reactor to Larger Batch Reactor (Pilot Plant or Commercial)
Laboratory Batch Reactor to a Commercial Continuous Stirred Tank Reactor
Laboratory Batch Reactor to a Commercial Tubular Reactor
Laboratory Tubular Reactor to a Commercial Tubular Reactor
Summary of Considerations for Reactor Scale-up
Volatile Removal Scale-up
Summary of Key Points for Scale-up of Volatiles Removal Equipment
Other Scale-ups Using the Same Techniques
Required Commercial Operating Needs
Pilot Plant Calculations and Comments
3 - Developing Commercial Process Flow Sheets
4 - Thermal Characteristics for Reactor Scale-up
5 - Safety Considerations
Change in Delivery Mode for Chemicals
Impact of a New Development on Shared Facilities
Reaction By-Products That Might be Produced
Storage and Shipping Considerations
6 - Recycle Considerations
Why Have a Recycle System in a Pilot Plant?
Impurity Buildup Considerations
7 - Supplier’s Equipment Scale-up
Agitator and Mixer Scale-up
Summary of Working With Suppliers of Specialty Equipment
Long-Term Changes in Existing Technology
Long-Term Availability and Cost of Feeds and Catalysts
Long-Term Availability and Cost of Utilities
Disposition of Waste and By-Product Streams
Operability and Maintainability of Process Facilities
9 - Project Evaluation Using CAPEX and OPEX Inputs
Project Timing and Early Design Calculations
10 - Emerging Technology Contingency (ETC)
11 - Other Uses of Study Designs
Identifying High Cost Parts of CAPEX and OPEX
Identifying Areas Where Unusual or Special Equipment Is Required
Identifying Areas for Future Development Work
Identifying the Size-limiting Equipment
Identifying Areas Where There Is a Need for Consultants
12 - Scaling Up to Larger Commercial Sizes
13 - Defining and Mitigating Risks
Techniques for Definition and Mitigation of Risk
Required Manpower Resources
Cooperative Team Spirit and Culture
14 - Typical Cases Studies
Unsuccessful Case Studies
Production of an Inorganic Catalyst
Development of a New Polymerization Platform
Utilization of a New and Improved Catalyst in a Gas Phase Polymerization Process
Inadequate Reactor Scale-up
Utilization of a New and Improved Stabilizer
The Less Than Perfect Selection of a Diluent
Epilogue: Final Words and Acknowledgments
Chemical Projects Scale Up
：How to go from Laboratory to Commercial
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