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Experience

Process Scale-Up Capabilities

Transitioning from lab-scale chemistry to a pilot plant facility requires expertise in process modeling, process module design, system scale-up, power and controls integration and  fabrication. Using your lab scale process technology, EPIC will help make your pilot plant concept a reality.

Pilot plant scale up is best designed and implemented by qualified engineers to ensure:

Factors That Effect Process Scale up 

When a process technology increases in size many of the factors related to that system often do not change in a liner manner. For this reason, it requires an experienced team of process engineers.

Factors that influence non-liner scale-up:

  • Fluid dynamics
  • Effective heat transfer area
  • Mixing
  • Foaming and rag layers
  • Safety considerations

Just because a technology is proven in lab scale, it does not mean it will translate into a viable pilot solution or production plant.

We use Aspen/HYSYS and other modeling tools to address the challenges of process scale-up throughout front-end engineering of your pilot plant.

 

Pilot Plant System Design

EPIC ensures your process technology is designed correctly from the start, using our Front End Engineering and scale-up design process. Our process engineers go beyond a classroom understanding of process scale up, all engineers at EPIC have first hand plant experience.  We assess the scalability of your chemical technology and provide a reliable skid design estimate. Our design engineers emphasize: easy maintenance of equipment, ergonomics during operations, employee safety, reducing counter intuitive controls

Codes We Follow 

Our pilot plants are designed and manufactured to meet all standard industry codes, including but not limited to:

  • (NEC) – National Electrical Code
  • (ASME) – American Society of Mechanical Engineers
  • (NFPA) – National Fire Protection Association
  • (AWS) – American Welding Society
  • (IBC) – International Building Code
  • (CE) – European Conformity
  • Almost any unique client specifications provided

Materials of Construction and Equipment/Instrumentation Selection

Non-linear scale-up effects can be managed with the proper equipment, component sizing and materials of construction. We take a pragmatic approach when it comes to component and instrumentation selection.

Design Engineers must balance the customers budgetary restrictions during equipment selection while still proving viability of final scale-up. While data collection is vital to pilot scale projects, EPIC selects the appropriate about of instrumentation to meet your technical and budgetary goals.

Project Management

A seasoned engineer with experience in your type of process will serve as your single point of contact. This engineer will manage your project through skid design to plant fabrication, installation and commissioning. Our project managers have an average of 17 years experience and are well qualified to guide your turnkey pilot plant project.

Your pilot plant is designed, fabricated and programmed in-house by a team of engineers and craftsman under the close supervision of the project manager.  Client participation in Factory Acceptance Testing (FAT) is encouraged and will be completed prior to shipment.  Your plant will arrive fully assembled and tested, ready for installation and start up.

Start-up and Final System Turnover 

After skid fabrication and factory acceptance testing at EPIC’s facility our Start up team will ensure your system is running as specified with punch list items complete – before we consider the job complete. Complete O&M manuals and training of plat staff are an integral part of every project, and are completed before the of commissioning.  Once we consider the project 100% complete the same team who managed your project are available for continued support.

HAZOP Studies

The EPIC safety team examines each part of the original process design, to verify the pilot plat will maintain the highest level of safety. We do this by conducting complete Process Safety Analysis (HAZOP) studies.

Unit Ops

EPIC designs, engineers and fabricates pilot plats for both continuous and batch applications.

EPIC designs and builds modular process systems for batch and continuous process technologies. We build both industrial and sanitary applications. Unit operations we have experience designing modular systems for include: dense phase and dilute phase conveying, batch reaction, particle sizing and separation, continuous reaction, centrifugaion, agglomeration, distillation, drying, In-line blending, gas absorption, liquid extraction, emulsion handling, hot oil glycol systems, ion exchange, high viscosity materials, water de-ionization,water purification, heat transfer, refrigeration, packaging and mass transfer systems.

Case Studies: See More Examples of Past Projects

case-studiesDetailed descriptions of turnkey pilot plants, demonstration modules and commercial plants that EPIC has built.

Video Gallery: Watch Clips of Projects, Methods & More

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Pilot plant videos of turnkey projects and the proven design & construction process EPIC follows to successfully create them.

Press Releases: Read the Latest News from EPIC

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Completed pilot plant projects, company accolades and job openings – read about them all here.

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