Chemical Projects Scale Up: How to go from Laboratory to Commercial

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 upOutlines how a reactor can be sized from batch kinetic dataDiscusses how the plant performance of a new catalyst can be evaluatedPresents how the economics of a new product/process can be developedDiscusses the necessary evaluation of recycling in commercial plants Cover Page Front Matter Copyright Introduction Chapter 1 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 Chapter 2 2 - Equipment Design Considerations Introduction 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 Problem Statement Given Pilot Plant Data Required Commercial Operating Needs Problem Approach Pilot Plant Calculations and Comments Commercial Calculations Chapter 3 3 - Developing Commercial Process Flow Sheets Chapter 4 4 - Thermal Characteristics for Reactor Scale-up Chapter 5 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 Chapter 6 6 - Recycle Considerations Why Have a Recycle System in a Pilot Plant? Impurity Buildup Considerations Chapter 7 7 - Supplier’s Equipment Scale-up Agitator and Mixer Scale-up Indirect Heated Dryer Summary of Working With Suppliers of Specialty Equipment Chapter 8 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 Chapter 9 9 - Project Evaluation Using CAPEX and OPEX Inputs Introduction CAPEX and OPEX Project Timing and Early Design Calculations Chapter 10 10 - Emerging Technology Contingency (ETC) Application Contributors/Reviewers References Chapter 11 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 Summary Chapter 12 12 - Scaling Up to Larger Commercial Sizes Summary Chapter 13 13 - Defining and Mitigating Risks Techniques for Definition and Mitigation of Risk Required Manpower Resources Reasonable Schedules Cooperative Team Spirit and Culture Chapter 14 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 Epilogue: Final Words and Acknowledgments Index Content.pdf 1 2 3 4 Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page Blank Page