Industrial Process Scale-up

Description

Industrial Process Scale-up: A Practical Innovation Guide from Idea to Commercial Implementation, Second Edition helps industrial process innovators in research, development and commercial start-ups assess the risks of commercial-scale implementation, also providing them with practical guidelines and methods to reduce the risks to acceptable levels. In addition, the book can be used in cooperation with industrial R&D people and academic researchers to shape open innovation programs, and in education as a reference book. This updated edition has the latest literature and has been expanded with a scale-up of pharmaceutical processes and their history in both academia and the process industries. Key Features -Offers easily accessible, step-by-step and concise guidelines for industrial process scale-up -Explains each stage of the innovation funnel, from research, development, demonstration and commercial implementation for any process type and branch -Based on industrial experiences and practices that reduce the risks of commercial scale implementation of new processes to acceptable levels and reduce cost and time of process innovation Front Cover......Page 1 Front Matter......Page 3 Copyright......Page 5 Dedication......Page 6 Table of Contents......Page 8 Preface......Page 10 Acknowledgement......Page 12 Purpose and set-up......Page 13 Scale-up definition......Page 14 Scale-up methodology......Page 15 Stage-gate innovation method......Page 16 Scale-up behaviour and risks......Page 18 Value and life cycle chains......Page 19 Processes......Page 20 Major process equipment......Page 21 Partners and stakeholders for innovation......Page 22 Obtaining ideas in general......Page 27 Assessing and ranking many ideas......Page 29 Technology readiness level method......Page 30 Process concept design essentials......Page 31 Discovery stage-gate purpose......Page 32 Reporting discovery stage......Page 33 Pitfalls discovery stage......Page 37 New process routes assessments......Page 39 Detailed assessment best ideas......Page 40 Cooperation with external innovation partners......Page 41 Identifying potential showstoppers......Page 42 Purpose concept design......Page 43 Break-through concepts by function integration......Page 44 Process modelling and simulation......Page 46 Essential properties determination......Page 48 Concept stage reporting......Page 49 Pitfalls concept stage......Page 50 Introduction to process equipment type selection......Page 51 Feed distribution......Page 52 Residence time distribution......Page 54 Mixing......Page 55 Shear rate distribution......Page 57 Mass transfer......Page 58 Heat transfer......Page 59 Overview process equipment scale-up methods......Page 60 Model-based scale-up method......Page 61 Empirical scale-up......Page 62 Dimensionless numbers scale-up......Page 63 Scale-up characteristics of major process equipment types......Page 64 Process equipment type selection in view of reliable large-scale performance......Page 67 Purpose commercial scale design in feasibility stage......Page 68 Design choices in view of development cost......Page 69 Design base......Page 70 Purchasing a complete process technology......Page 71 Mini-plant choice......Page 72 Pilot plant purposes......Page 73 Decision on having a pilot plant......Page 75 Industry project statistics of not having a pilot plant......Page 76 Value of information approach for development plan decisions......Page 77 Pilot plant design......Page 80 Decision and design of cold-flow test units......Page 82 Pharmaceuticals feasibility stage......Page 83 Fine chemicals feasibility stage: Unit operations choices in view of scale-up......Page 85 Pitfalls feasibility stage......Page 87 Mini-plant engineering, procurement, construction, and testing......Page 89 Pilot plant engineering, procurement, construction, and testing......Page 90 Front-end engineering design......Page 91 Development stage-gate reporting and evaluation......Page 92 Pitfalls development stage......Page 94 Scale-up for batch process from pilot plant to existing commercial scale process......Page 95 Scale-up from existing pilot plant to new process......Page 97 Rationale demonstration scale decision......Page 99 Contractor selection......Page 101 Detailed design......Page 102 Start-up time Merrow industry correlation......Page 103 Critical success factors reducing start-up time......Page 105 Start-up time and critical success factors Shell GTL case......Page 112 Pitfalls implementation stage......Page 115 Liquid-liquid extractive reaction by Taguchi model-based product quality control......Page 117 Bulk chemical product start-up conventional process......Page 120 Start-up conventional process in South Korea......Page 122 Purchasing novel process......Page 124 Polymerisation process start-up......Page 125 Wastewater novel design and implementation......Page 126 Carilon engineering polymer new product, process, market, and strategy change......Page 128 Purchasing a commercially proven rotating filter......Page 129 Fine chemicals discovery stage......Page 130 Summary of learning points from industrial cases......Page 131 References......Page 135 E......Page 139 I......Page 140 S......Page 141 W......Page 142 Back Cover......Page 143