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Process Scaleup: Volume 2 — Focus on Equipment

Process Scaleup: Volume 2 — Focus on Equipment

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Safe, cost-effective scaleup is an essential aspect of moving promising developments proven in the lab to full-scale, commercial production. The articles presented in this guidebook focus on specific equipment-related aspects that arise during scaleup efforts.

Articles provide guidance on how to prepare a proper design basis, how to exploit the physical properties of chemicals during scaleup, how to manage heat transfer and mass transfer issue that arise during reactor scaleup, and how to address mixing issues that arise when moving from small-scale to large-scale operations.

There is emphasis on the proper design and operation of pilot plants, and focus on safety aspects such as managing exothermic reactions and eliminating runaway reactions, that need to be reconciled to ensure incident-free scaleup.

Also included are piping-related challenges that need to be reconciled early to manage cost and risk. These practical, how-to articles were originally published in Chemical Engineering.

Delivered in a PDF format, 120 pages.

A Checklist for Safer Chemical Batch Reactions
A good understanding of the reaction chemistry is needed for a safe process design

Designing Safer Process Plants
Several often-overlooked strategies to increase inherent safety are discussed here

Focus on Physical Properties To Improve Processes
Exploiting the physical properties of chemicals can offer pathways to more simplified and elegant processes

Safe Scaleup of Exothermic Reactions

Principles of P&ID Development
The tips provided here will streamline efforts to develop piping & instrumentation diagrams

Ten Things You May Not Know About Liquid Mixing Scaleup

Millichannel Reactors: A Practical Middle Ground for Production
Reactors with millimeter-scale dimensions provide mixing, heat transfer and other advantages over devices with larger dimensions, and increased robustness compared to microdevices. Here are tips to consider for using them

Calculations in Process
Engineering Knowing how specific calculations differ can focus your efforts

Pilot Plant Cost Estimating: Make Intelligent Use of Contingency
In capital cost estimating, provision for contingency is often a misunderstood concept. Here are guidelines for applying it soundly to estimates involving pilot plants.

Adiabatic-Temperature Rise: An Awkward Calculation Made Simple
How to estimate a final temperature after a reaction

Active Management of Pipespool Fabricators
Contractors need to integrate and engage to improve deliveries and shorten project schedules

Design Safety Instrumented Systems with Relevant Data
Laboratory-based data can be too optimistic; some data from the field are too pessimistic. Here is how to deal with that dilemma

How to Prepare a Process Design Basis
Take care not to overlook anything when preparing this document, which is vital for spelling out a wellplanned chemical-process project. The checklists and tables in this article can serve as reminders

Short-Cut Piping Costs
This method saves precious time in preparing estimates for pre-design and other approximated analyses

Mass Transfer in Fermentation Scaleup
As fermenters are scaled up to huge sizes, mass transfer is a key consideration

Preventing Fires and Explosions in Pilot Plants
The issues and complications are different from — and in many ways more challenging than — those for full-scale plants Avoiding Runaway Reactions
Risk analysis is an important tool for thermal safety

Runaway Reactions: Ignore the Chemistry
At Your Peril Proper hazards testing is key to ensuring chemical process safety

“But What Will It Cost?” The Keys to Success in Pilot Plant Cost Estimating
Acceptable capital-cost estimates for pilot plants can indeed be developed. But the pitfalls to be dodged are far more numerous than with estimates for full-scale plants

Piping: Minimizing the Risk of ‘Pre-buys’
Buying too early may risk a surplus; buying too late may impact the schedule and budget

Heat Transfer for Huge- Scale Fermentation
The impact of ten-fold scaleup is explored here

Strategies for Water Reuse
Membrane technologies increase the sustainability of industrial processes by enabling large-scale water reuse

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