scale-up of chemical engineering process chapter 1...
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Scale-Up of Chemical Engineering
Process
Chapter 1: Introduction of
Scale-Up Processes by
Nurul Sa’aadah Sulaiman
Faculty of Chemical and Natural Resources [email protected]
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Definition of Scale-up
“The successful startup and operation of a commercial size unit whose design and
operating procedures are in part based upon experimentation and demonstration at a smaller
scale of operation”
(Source: Bisio & Kabel, 1985)
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Definition of Scale-up
“Indeed, to a very significant extent, scale up is Chemical Engineering”
-Prof. G. Astarita
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Why Scale-Up
Scale up is basically needed for:
• Market growth
• Introduction of new processes
• Reduction in making expensive errors in design
and operation
• Concentrate on addressing areas of doubts and
uncertainty
• Economic feasibility
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Scale-up
How to scale up from small scale to large scale?
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Scale-Up theory and Calculation
There are three categories of scale up:
1. WELL-DEFINED, EASY AND QUANTIFIABLE
(e.g. distillation, heat exchanger, absorption etc.)
2. DIFFICULT BUT QUANTIFIABLE (e.g. reactors)
3. VERY DIFFICULT AND RARELY CAN BE QUANTIFIABLE (e.g. particulate processes)
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Scaling up Step by Step
• Product and process development for scaling up is typically move in small steps.
• For instance, the development is initially from lab scale to bench scale then move to pilot scale and finally to commercialization scale.
• By performing scale up step by step, the risk with large investments could be lessen.
• The following figure illustrates the conventional scale up procedure for bio fuel.
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Conventional Scale-up Procedure
(Source: Biofuels International Magazine, November 2012)
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Conventional Scale-up Procedure
1. Bench or laboratory scale- This is an early-stage tools to assess and scaling new
product or technology
2. Pilot Scale- Pilot scale is a first view into continuous processing of a
product
3. Demonstration scale- In this step, the process flowsheet is closely resemble commercial scale operations.
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ESSENTIAL STEPS
BASIC DATA
PROCESS ANALYSIS
TECHNOLOGY CHOICE PROCESS
MODELLING
INDUSTRIAL UNIT
VALIDATION OF MODEL SCALE
UP
MOCK-UPS
PILOT PLANT
LABORATORY
(Source: Euzen et al. 1993)
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Production Capacity
Scaling factor Typical production capacity
Bench/ Laboratory 0.001 – 0.1 kg/h
Pilot Plant 10 – 100 kg/h
Demonstration Plant 100 – 1000 kg/h
Commercial Plant > 1000 kg/h
Table below shows the general production capacity of each scaling up step in the process industries.
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STEPS IN DEVELOPMENT OF A PROCESS
Exploratory Stage
Process Concept; Conceptual Design
Development of individual steps
Evaluate
Preliminary plant flowsheet
Miniplant & pilot plants
Evaluate
Integrated pilot plant
Evaluate
Design of Commercial Plant
Abandon Development
Abandon Development
Abandon Development
(Source: Vogel, H. 1992)