Abstract
It is of interest to study not only the fundamental behavior of catalysts and reactors but also to ensure that they can be scaled up in size. This paper investigates the scale-up of a glycerol-to-propane process starting from fundamental laboratory data from micro-reactor testing to the kilogram scale. The process is described in detail and consist of the use of design documents and computer simulations for determining the sizes of the unit operations involved. The final design included a vaporizer section for a glycerol/water mixture, four reactors in tandem with subsequent dehydration and hydrogenation reactions, a flash vessel to separate the excess hydrogen used, and a compressor for recycling the excess hydrogen with additional light components. The system was commissioned in a linear fashion, which is described, and operated for more than 3000 h and more than 1000 h in the final operating mode including recycle. The major results were that no catalyst deactivation was apparent aside from the slow build-up of carbonaceous material in the first dehydration reactor. That the system design calculations proved to be quite close to the results achieved and that the data generated is believed to be sufficient for up-scaling the process into the 1000 to 10,000 tonnes-per-annum range.
Highlights
There are several aspects to consider when it comes to scaling up processes
The first step in scaling up is normally moving from a small test set-up to a pilot plant, even though the piloting step may be skipped
The pilot plant is operated to study critical process features; it should be large enough to be relevant with respect to results, small enough to keep cost reasonable, it should be concerned with engineering and economic problems and involve several unit operations
Summary
There are several aspects to consider when it comes to scaling up processes. There is a clear distinction between the scientists advocating the approach where every process should stem from the investigation of said process in small-scale studies. Others believe that the only effective method is to construct a large plant and work out the errors by empirical trial and error [1]. This is not distinct, but a sliding scale. There are, several distinctions between a normal test set-up and a pilot plant. The pilot plant is operated to study critical process features; it should be large enough to be relevant with respect to results, small enough to keep cost reasonable, it should be concerned with engineering and economic problems and involve several unit operations
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