Chemical projects scale up : how to go from laboratory to commercial / Joe M. Bonem.

Format:

Book

Author/Creator:

Bonem, Joe M.

Language:

English

Subjects (All):

Chemical engineering.

Chemical industry.

Physical Description:

1 online resource (234 p.) : ill.

Edition:

1st ed.

Place of Publication:

Amsterdam : Elsevier, 2018.

Summary:

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.

Contents:

Cover

Title Page

Copyright Page

Contents

Introduction

1 - Potential Problems With Scale-up

Equipment Related

Mode Related

Theoretical Considerations

Thermal Characteristics

Safety Considerations

Recycle Considerations

Regulatory Requirements

Project Focus Considerations

Take Home Message

2 - Equipment Design Considerations

Reactor Scale-up

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

Reactor Scale-up Example

Problem 2-1

Summary of Considerations for Reactor Scale-up

Supplier's Scale-ups

Volatile Removal Scale-up

Example Problem 2-2

Problem Statement

Summary of Key Points for Scale-up of Volatiles Removal Equipment

Other Scale-ups Using the Same Techniques

Solid-Liquid Separation

Example Problem 2-3

Given

Pilot Plant Data

Required Commercial Operating Needs

Problem Approach

Pilot Plant Calculations and Comments

Commercial Calculations

3 - Developing Commercial Process Flow Sheets

4 - Thermal Characteristics for Reactor Scale-up

5 - Safety Considerations

Use of New Chemicals

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

Step-Out Designs

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

Indirect Heated Dryer

Summary of Working With Suppliers of Specialty Equipment

8 - Sustainability.

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

Summary

9 - Project Evaluation Using CAPEX and OPEX Inputs

CAPEX and OPEX

Project Timing and Early Design Calculations

10 - Emerging Technology Contingency (ETC)

Application

Contributors/Reviewers

References

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

Reasonable Schedules

Cooperative Team Spirit and Culture

14 - Typical Cases Studies

Successful Case 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

Index

Back cover.

ISBN:

9780128137284

0128137282

9780128136102

0128136103