Chemical Pilot Plant Design Overview
Your chemical pilot plant combines your process chemistry with EPIC’s expertise in system scale-up to create a module that will prove your process technology at a commercial level.
To say that the scale-up of a chemical process is a non-linear process is an understatement. Predicting differences in flow, reaction rate, kinetics, fluid dynamics, and thermal dynamics between a beaker and a full-scale production system is difficult without extensive scale-up experience and often done incorrectly.
Our proven scale-up methods use a mixture of simulation, modeling, and hard-earned experience in real-world chemical pilot plant applications. We consistently deliver pilot modules that prove ROI, output significant levels of product and exceed client expectations.
CASE STUDIES: Chemical Pilot Plant Examples
Chemical Process Scale-Up Proves Product Market Viability
Our client needed to test and prove the potential market for a new powder agri-chem product. Using chemical engineering and process design tools, EPIC built a chemical batch reactor pilot skid that processed, dried and packaged the product for distribution. After a successful market test the client will be able to expand the existing pilot facility into a larger commercial operation using revenue generated from the current operation.
Key Features: Batch reaction, chemical drying, bulk bagging, demonstration skid.
Management and production of over 100 different chemical additives was automated and streamlined with a flexible pilot module from EPIC. The legacy system that was replaced with the upgraded chemical batching module was manual and difficult to track batch storage with. The new system tracked batches from mixing through storage and use within other parts of the plant and increased production rates.
Key Features: Chemical treatment dips, automated mixing system, batch mixing, Wonderware InBatch Software, Class 1, Group D, Division 1, hazardous area
Common Types of Chemicals Worked With
We offer chemical engineering and pilot plant design for the following products. If your product is not listed below, please contact us to discuss your application.
- Aluminum chloride
- Automotive chemicals
- Barium salts
- Fluorine & flourochemcials
- Food additives
- Household chemicals
- Hydrogen peroxide
- Industrial chemicals
- Inorganic chemicals
- Organic chemicals
- Phosphoric acid
- Rare-earth compounds
- Salts and sodium compounds
- Soaps and detergents
- Sugars and starches
- Sulferic acid
How to Scale Up Your Chemical Process
To start the process of your custom pilot plant equipment design, reach out to an EPIC pilot plant engineer. We will discuss the technical, commercial and operational goals for your specific industrial scale-up project. Our process is:
- EPIC’s Front-End Engineering
- Demonstration plant design
- Process controls engineering
- Modular fabrication and testing
- System installation
- Start-up and commissioning