Pilot Plant Scale-up Techniques & Examples

Challenges of Pilot Plan Scale UpReaction Kinetics – Efficiently mixing solution elements together to reach equilibrium

Chemical Equilibrium – Reactions aren’t efficient until equilibrium. Increased quantities = more time required

Material Properties – Materials shouldn’t influence reactions, erode over time or make systems unduly costly

Fluid Dynamics – Fluids should be kept at correct Reynolds Number for thermal transferring

Thermodynamics – Reaction temperature must be controlled and monitored to keep the process in control

Agitation Issues – The correct amount of turbulence requires more power to achieve as chemical amounts increase

Equipment Selection – Correctly sized equipment, piping and instrumentation is key to a controlled reaction

Pilot Plant Modeling MethodsFinding the Optimal Pilot Plant Design

Aspen/HYSYS Modeling

Finite Element Analysis (FEA)

Computational Fluid Dynamics (CFD)

With the use of these modeling methods one can determine the limitations of

a pilot plant process through scale-up modeling,

predictably reducing cost and removing the need to

build addition systems.

Chemical Simulated Studies

Mathematical Modeling

Successful Pilot Plant Examples

Proprietary Ion-Exchange Technology Modular ion exchange pilot system upgraded a proprietary process to a commercial level. Key features of the pilot plant: modular plant design, highly corrosive chemical and detailed piping specifications.

Dual Skid Design Enables 91% EthanolA two-in-one skid allowed a large system to fit into limited space. A complicated installation path required a design that could be split into two modules for installation that worked as one system upon start-up.

Pilot Plant Validates Alternative Energy Technology

An R&D process that converted biomass through a multi-stage process. Extensive process testing, proprietary technology protected with indoor fabrication/testing, and a self-contained system featuring: exhaust, drainage and spill management system.

Speak with an expert pilot plant designer today: 314-845-0077Learn more about pilot plants at: www.epicmodularprocess.com/pilotplant

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