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With a six-part modular skid currently being prepped for shipping in the EPIC fabrication shop, safety the number one priority. What does it take to...
Safe practices used in our module fabrication shop often parallel the procedures used in the field, our offices, & our everyday lives. Read about the critical steps EPIC uses to ensure shop safety
As a skid fabricator EPIC has a lot of modules coming in and out of our shop every year. Here are a few examples of what we have going on in our shop currently. We have been working on a large run of industrial safety shut down modules in our carbon steel shop. This is …
The steps needed for proper pilot plant design
Want to build a pilot plant to test process technology, but not sure how to get started? What does a pilot plant cost? What steps are involved?
The steps of pilot plant design are outlined in the slideshare below. The six basic steps are:
Consultation with a professional process engineering company
Design – creating process flow diagrams, P&ID’s and specifying the basic system components
Advanced 3D modeling and process simulation – the process technology and proposed pilot plant equipment are run through an engineering simulation to ensure proper equipment sizing, system controls, and to find the optimal pilot plant design.
Controls engineering – automation and controls are developed for the pilot skid, installed, and tested during fabrication and assembly.
Fabrication and assembly of the process module(s) begins after final design is completed. Factory acceptance testing (FAT) is conducted at the end of fabrication to ensure proper module function.
Installation – after testing is completed, pilot plants are shipped to their final destination and installed. Typical installation only takes a few days, with minimal plant interruption.
Startup – modules are fully commissioned with punch-list resolution. Training for operators and maintenance personnel is conducted and the pilot plant is turned over with complete documentation.
When it comes to pilot plant cost, the specific price depends on many factors, for example:
What is the required output? What processing time maximizes output while ensuring the process stays in control?
How toxic or volatile are substances involved? Will they require special equipment, alloys, or safety considerations?
Where is the pilot module going? Are the special design requirements or compensations for existing plant layout?
How many pieces of data must be collected or monitored? How many sampling points will be required? How often must data be collected and logged, and by what method?
The specific list of considerations is unique to the application being scaled. These are the types of questions that are explored and answered in partnership with a professional pilot plant design firm. 3D modeling and simulation will help provide optimal equipment and system arrangements, run-times and process parameters. To discuss a pilot plant design project, contact an engineer today.
Pilot Plant Design Proves Viability of Chemical Processes
Pilot plants are designed to prove production capabilities for new processes or test viability of an established process on a larger scale. A higher than average number of sampling points and instruments are typical in pilot plants, and are used to measure process parameters and results.
Design of pilot skids is not straight forward. Scale-up of chemical processes is not linear and you cannot simply increase the ingredients of a successful process system proportionately. With increased scale, surface area to mass ratios change. Laminar and turbulent flow patterns alter, due to the new surface ratio. Reaction kinetics, fluid mechanics and thermodynamics also change non-proportionally.
Through process ASPEN/Hysys process modeling, a successful pilot plant can be designed. Process flow diagrams (PFD’s), piping and instrumentation diagrams (P&ID’s), material balances and equipment layout are developed by process system experts based on the process modeling results.
A variety of chemical processes and applications can be proven with a pilot plant. A few examples of recent pilot plants developed by EPIC include:
A CO2 absorption column pilot skid
This large absorption column – similar to a distillation column – strips CO2 out of flue gas at refineries. A new technology by Akermin, this pilot plant skid was installed at a test facility in Alabama. Data from the test plant was used to prove to investors and the US Government the viability of the new process, and has since led Akermin to build multiple units with evolved versions of the technology.
Liquid biofuel from biomass process
Needing to prove full-production feasibility, this challenging biomass to liquid fuel application had several unique challenges. Traditional electric heating sources were not sufficient for the process. There were no pre-existing utility systems in the lab where the demonstration plant would be installed. The skid would also have to be fully enclosed to be installed in it’s final destination, and safety rated for an earthquake zone.
Agricultural fertilizer formed through ion-exchange reaction process
A highly corrosive process was proven through a demonstration plant with a high number of sampling points. Production level equipment and an after-process effluent processing system were tested and vetted. After several months of testing the highly corrosive batch process, the parent company was ready to build a full-scale production facility for the product.
If you have a chemical process you would like to scale-up to a pilot plant or demonstration module, contact one of our process system experts today.
