Pilot plant design
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Transcript of Pilot plant design
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Demonstration Plant TestingPilot Plant Design: Steps for Successful Process Scale-up
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Process Scale-up Challenges
Reaction Kinetics & Chemical EquilibriumEquilibrium = the point at which your reaction becomes productive Increased chemical volume = longer time to chemical equilibriumKinetics = how efficiently molecules are mixing which effects how fast equilibrium is reached
Non-linear sizingMultiplying required output by five does not require a five-fold increase across the boardSystem sizes for equipment, chemical inputs and other factors do not increase in a 1:1 fashion
Material PropertiesMaterial selection for equipment & instrumentation must avoid corrosion, erosion & excess expense
Fluid & ThermodynamicsFlow should be kept at the correct Reynolds number for efficient heat transfer and molecule mixingControlled reactions = good thermodynamics that balance heat loss with reaction speed
Agitation ChallengesLarger mixing tanks = more required horsepower to achieve the same turbulence and flowCosts may be reduced through baffles, angled agitators or other agitation equipment
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Basic Pilot Plant Design
Design Documents & DeliverablesScope and boundary limit descriptionProcess flow diagrams (PFD’s) & general arrangement drawingsCost estimate (accuracy between +/- 5-25%) Base Piping and Instrumentation Diagrams (P&ID’s)Estimated project timelinesEquipment, instrumentation and valve listsTechnical peer reviewContingency planProcess simulation (see next slide for deliverables from this)
Pilot plant design stepsFind a process system engineering & design firm Discuss details of your process technology with potential partnerGet a refined quote by paying a small percentage for a base design effortReceive design deliverables and process simulation resultsCommit to full project development, including fabrication effortPartner firm completes process, electrical and controls designFabrication and assembly of pilot plant begin
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Demo Plant Modeling
3D Modeling & SimulationsChemical similitude studiesAspen/HYSYS modelingFinite Elemental Analysis (FEA)Computational Fluid Dynamics (CFD)CADworx Plant & AutoCAD modeling
Deliverables from ModelingIncreased accuracy of budgetary numbers (+/- 5-15%) Complete Piping and Instrumentation Diagrams (P&ID’s)Mass (material) and energy balancesMaterial compatibility & corrosion studiesModule size form factorsPlan and elevation drawings
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Fabrication & Testing
Installation & Startup
Steps Following Design
Modular process system fabricationFactory Acceptance Testing (FAT)
Pilot plant shipment
Installation and plant commissioning
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Demonstration Plant Testing
MODULAR PROCESS SYSTEMS
Looking for a pilot plant design & fabrication company? Speak with an expert pilot plant designer today: 314-845-0077Learn more about pilot plants at: www.epicmodularprocess.com/pilotplant