Pilot Plant Process Research Articles

Antioxidative and antimutagenic activities of healthy herbal drinks from Chinese medicinal herbs.

Twenty-nine Chinese medicinal herbs and three healthy herbal drinks made of those herbs in a food processing pilot plant were tested for their antioxidative, free radical scavenging, mutagenic and antimutagenic activities. Water extracts of herbs (with few exceptions) and herbal drinks showed free radical scavenging activity. All water extracts of herbs and herbal drinks showed no mutagenicity toward Salmonella typhimurium tester strains TA98 and TA100 used in the Ames mutagenic tests. In the antimutagenic tests, the mutagenic activity of 4-nitroquinoline N-oxide (NQNO) toward S. typhimurium TA98 was markedly inhibited by water extracts of herbs and herbal drinks. Based on the results, it is suggested that the herbal drinks manufactured in pilot-plant scale are safe and can be served as health-promoting drinks for the public.

Pilot-Plant Investigation of the Leaching Process for the Recovery of Scandium from Red Mud

A pilot-plant process has been developed based on an innovative laboratory-scale method for the recovery of scandium that exists in economically interesting concentrations in red mud, the main byproduct of alumina production. This method includes acid leaching of the red mud pulp, ion-exchange separation of scandium and lanthanides from the co-leached main elements such as iron, and subsequent liquid−liquid extraction of the eluate for further scandium purification and enrichment. In this work, experimental and theoretical investigation of the pilot-scale leaching process was performed. The following parameters were tested: mode of agitation, solid-to-liquid ratio, acidity of the leachate, number of stages in the process, and pretreatment of red mud with concentrated acids in order to achieve optimum scandium recovery combined with low iron dissolution. Furthermore, by theoretical interpretation of the experimental data, a predictive correlation for the scandium leaching efficiency was developed.

Effect of high-temperature inside-outside spray on survival of campylobacter jejuni attached to prechill chicken carcasses

Prechill chicken carcasses, inoculated with Campylobacter jejuni, were sprayed in an inside-outside birdwasher at 20, 55, or 60 C, with or without 50 ppm chlorine, in a poultry processing pilot plant. Carcasses were sprayed for 12 s at 80 pounds per square inch (psi). Next, carcasses were placed in a chiller filled with 50 ppm chlorinated ice water at 4 C for 50 min. Most probable numbers of C. jejuni were determined based on chicken carcass wash water before and after the spray treatment. The skin color of chicken carcasses was measured. The results of this study showed that the 55 and 60 C water spray treatments significantly reduced C. jejuni by more than 0.78 log cfu/carcass compared with the 20 C water spray treatment. However, all of the 50 ppm chlorine spray treatments at three different temperatures were not significantly different. The skin color of chicken carcasses did not change significantly after the spray treatments at temperatures less than 60 C. The chilling process with 50 ppm chlorinated ice water at 4 C further reduced more C. jejuni (approximately 1 log cfu/carcass) among the water spray treatments but did not result in greater reduction of C. jejuni among the chlorine spray treatments.

Gas holdup in slurry bubble column reactors of a 150 t/d coal liquefaction pilot plant process

Gas holdup in slurry bubble column reactors of a 150 t/d coal liquefaction pilot plant process

CONCENTRATION OF LOW- AND MEDIUM-LEVEL RADIOACTIVE WASTES WITH THREE-STAGE REVERSE OSMOSIS PILOT PLANT

A study of the application of different membrane processes to nuclear technology has been conducted at the Institute of Nuclear Chemistry and Technology (INCT) for many years. One application of membrane methods involves the purification and concentration of liquid low- and medium-level radioactive wastes (LLLRWs and LMLRWs). The separation of radioactive model solutions as well as LLLRW and LMLRW samples has been examined with various reverse osmotic modules equipped with thin-composite polymeric membranes. On the basis of these investigations, membrane modules were selected for the pilot plant processing of liquid wastes from nuclear centers. A three-stage JP3RO reverse osmosis unit was constructed. The installation is described in this paper, and the results of preliminary pilot plant experiments are presented.

Selective Synthesis of a New Ascomycin Rearrangement Product (SDZ ASD732) on a Pilot Plant Scale

The process for a pilot plant synthesis and the purification of a semisynthetic ascomycin derivative (1, SDZ ASD732) showing interesting biological activities is described. Conditions for the key transformation, a base-induced cascade of rearrangement and epimerization reactions of ascomycin leading to the selective formation of the new ascomycin derivative 1, were developed and successfully upscaled. Rapid screening of important reaction parameters was achieved by using automated parallel synthesis. In addition, a highly efficient purification process was found and implemented in the pilot plant process, resulting in an efficient separation of the semisynthetic ascomycin derivative from its by-products. The purification protocol consisted of preparative silica gel chromatography followed by a crystallisation step. Starting from crystalline ascomycin with a purity of ≥95%, an overall yield of 53% was achieved with a final purity of >98%.

Gas holdup in slurry bubble column reactors of a 150 t/d coal liquefaction pilot plant process

Gas holdup data were obtained for three different kinds of coals in three coal liquefaction pilot plant reactors connected in series of the 150 ton-coal/day NEDOL process. The gas holdup measured was correlated with the superficial gas velocity calculated by taking into account the vapor–liquid equilibrium in the liquid or slurry phase at operating temperatures and pressures. The results showed that the gas holdup increases almost linearly with the superficial gas velocity in a range of 0.07–0.08 m/s and levels off with a further increase of the velocity. Little influence on the gas holdup was observed for the coal rank, the reactor temperatures ranges from 322 to 731 K and the pressures ranges from 16.8 to 18.7 MPa. Also, a comparison of the present data with those reported for other liquefaction reactors having diameters greater than 0.175 m indicated little effect of the diameter on the gas holdup. From the analysis of the data on the basis of the drift flux model, the flow in the reactors appears to fall in a homogeneous bubble flow regime within the range of the superficial gas velocity employed in the present experiment. Further, an empirical correlation between the gas holdup and the superficial gas velocity was obtained on the basis of the slip velocity concept for a homogeneous bubble flow.

Single stage biological nitrogen removal by nitritation and anaerobic ammonium oxidation in biofilm systems

In full scale wastewater treatment plants with at times considerable deficits in the nitrogen balances, it could hitherto not be sufficiently explained which reactions are the cause of the nitrogen losses and which micro-organisms participate in the process. The single stage conversion of ammonium into gaseous end-products--which is henceforth referred to as deammonification--occurs particularly frequently in biofilm systems. In the meantime, one has succeeded to establish the deammonification processes in a continuous flow moving-bed pilot plant. In batch tests with the biofilm covered carriers, it was possible for the first time to examine the nitrogen conversion at the intact biofilm. Depending on the dissolved oxygen (DO) concentration, two autotrophic nitrogen converting reactions in the biofilm could be proven: one nitritation process under aerobic conditions and one anaerobic ammonium oxidation. With the anaerobic ammonium oxidation, ammonium as electron donor was converted with nitrite as electron acceptor. The end-product of this reaction was N2. Ammonium and nitrite did react in a stoichiometrical ratio of 1:1.37, a ratio which has in the very same dimension been described for the ANAMMOX-process (1:1.31 +/- 0.06). Via the oxygen concentration in the surrounding medium, it was possible to control the ratio of nitritation and anaerobic ammonium oxidation in the nitrogen conversion of the biofilm. Both processes were evenly balanced at a DO concentration of 0.7 mg/l, so that it was possible to achieve a direct, almost complete elimination of ammonium without addition of nitrite. One part of the provided ammonium did participate in the nitritation, the other in the anaerobic ammonium oxidation. Through the aerobic ammonium oxidation into nitrite within the outer oxygen supplied layers of the biofilm, the reaction partner was produced for the anaerobic ammonium oxidation within the inner layers of the biofilm.

Structural Similarity and Its Surprises: Endothelin Receptor Antagonists - Process Research and Development Report

Process research and pilot plant processes are described for three endothelin (ET) receptor antagonists. The efficient synthesis of the parent compound Darusentan proceeds via a Darzens reaction from chloroacetate with benzophenone, addition of methanol to the resulting epoxide, saponification of the alkyl propionate and optical resolution of the racemic acid by crystallisation with a chiral amine. The final stage of the synthetic sequence involves the introduction of a pyrimidine moiety. Intermediates formed during this process can be used as starting materials for the synthesis of the two other ET receptor antagonists BSF 420627 and BSF 302146. An ether exchange reaction, which replaces the methoxy with a phenethyloxy substituent, enabled BSF 420627 to be prepared. The synthetic route to BSF 302146 employs trimethylaluminum to methylate the epoxide produced by the Darzens reaction.

Development of a Catalytic Tributyltin Hydride Cyclisation Process

The development of a pilot plant process to prepare the spirocyclic piperidine (2) from the tetrahydropyridine (4) via a radical cyclisation reaction is described. The pilot plant process involves the use of a catalytic amount of tributyltin hydride (0.14 equiv) generated in situ by the reaction of tributyltin chloride with sodium borohydride (1.1 equiv) in 2-propanol/ethanol containing azo-bis(isobutyronitrile) (AIBN). Initial laboratory conditions are described as well as the changes made on transfer to the pilot plant. Measurement of the levels of residual amounts of tin in the batches of (2) produced are reported.

Choice of Explanatory Variables: A Multiobjective Optimization Approach

In process control applications it is often necessary to derive a suitable process model from input/output data using multivariable regression analysis. However, problems frequently arise in selecting an appropriate set of independent (explanatory) variables and/or in handling problems caused by correlation between the measurements. The multiobjective function based approach presented in this paper addresses both problems and is shown to produce excellent results in practical applications. The proposed method minimizes a user-specified combination of the following three criteria:1)the data matrix related residue2)the observation or measurement related residue3)the condition number of the new data matrix of the selected explanatory variables.Four different algorithms for solving the resulting multiobjective optimization are compared. The model structure determined by applying the proposed method to a simulated process identification problem was identical to the actual model structure. A second successful application involved model structure determination for a 2 * 2 pilot plant process based on experimental input/output data.

１５０ｔ／ｄ規模石炭液化パイロットプラントによる開発研究 （ＩＩ） 鉄系石炭液化触媒の開発

The catalyst production system has been developed for a 150t/d NEDOL process pilot plant (PP). The following results were obtained through the PP operation;(1) Catalytic activity of pulverized pyrite in an inert atmosphere of 0.7μm of median diameter compares favorably with that of the synthetic pyrite.(2) From a viewpoint of economical and operable efficiency, two stage pyrite pulverization system (wet-type ball mill-wet-type agitated mill) is the optimum catalyst production system.(3) Catalyst slurry of pulverized pyrite characterizes high viscous and pseudo-plastic.(4) It was confirmed through the PP operation that the catalyst production system designed from above test data operated stably and produced highly active catalyst.

Energy saving in the aeration process by fuzzy logic control

An aeration fuzzy logic based control system has been developed and tested in the main aerobic reactor of a BARDENPHO process pilot plant. This system has been compared with two ordinary aeration process controllers: one- and two-aeration-level on/off controllers. Energy savings of about 40% over the one-level on/off controller and a more stable closed-loop response have been obtained. Thus, an improvement of about 60% in average deviation can be accomplished by the use of an AFLBC.

Use of Antimicrobial Spray Applied with an Inside–Outside Birdwasher To Reduce Bacterial Contamination on Prechilled Chicken Carcasses

Antimicrobial sprays applied using a modified inside–outside birdwasher to reduce Salmonella typhimurium and total aerobic bacteria on prechilled chicken carcasses were evaluated in a poultry processing pilot plant. Four Chemicals, including trisodium phosphate (TSP, 10%), lactic acid (LAC, 2%), cetylpyridinium chloride (CPC, 0.5%), and sodium bisulfate (SBS, 5%) were selected to be tested as antimicrobial agents. Each chicken carcass was inoculated by spraying the outside and inside of each carcass with S. typhimurium at 105 CFU per carcass. The inoculated carcasses then were passed through the birdwasher and sprayed with selected Chemicals at 35°C at a pressure of 413 kPa for 17 s. After a 60-s setting time on a shackle line, the carcasses were sprayed with tap water to rinse off Chemical residue. All the Chemical treatments reduced Salmonella on the chicken carcasses by approximately 2 log10 CFU per carcass. Total aerobes on the chicken carcasses, however, were reduced by 2.16, 1.66, 1.03, and 0.74 log10 CFU per carcass after spraying with 0.5% CPC, 5% SBS, 2% LAC, or 10% TSP, respectively. Spray treatments of both SBS and LAC caused slight discoloration in part of the chicken skin. The most effective antimicrobial spray treatment for reducing both Salmonella and total aerobes on prechilled chicken carcasses was 0.5% CPC.

Energy saving in the aeration process by fuzzy logic control

An aeration fuzzy logic based control system has been developed and tested in the main aerobic reactor of a BARDENPHO process pilot plant This system has been compared with two ordinary aeration process controllers: one- and two-aeration-level on/off controllers. Energy savings of about 40% over the one-level on/off controller and a more stable closed-loop response have been obtained. Thus, an improvement of about 60% in average deviation can be accomplished by the use of an AFLBC.

Iron ore processing -- in-situ monitoring

Mossbauer spectroscopy has been used to provide detailed quantitative insight into the reaction products present at different stages of the processing/reduction of iron ores. Typical phases include: α-Fe2O3; Fe3O4; Fe1-xO; Fe3C and Fe, which are in agreeement with the results obtained using standard wet chemistry methods. As an extension of this post reaction examination of products, we have used Mossbauer spectroscopy for in-situ measurements during the week long operation of an iron ore processing pilot plant. Such in-situ measurements allow optimal control of the plant to be obtained with, depending on the strength of the source, a time constant of ~ 1 h.

Influence of soybean meal variety and processing temperature on the growth performance of pigs from 25 to 45 lb (1998)

Three hundred ninety high-lean growth pigs were used in a 17 d growth assay from 25 to 45 lb. Treatments consisted of soybean meal (SBM) from either high-oleic or check-line soybean varieties processed under pilot-plant processing conditions at four temperature ranges (80-85, 85-90, 90-95, 100-105 °C). Positive and negative controls were made using commercially obtained SBM (46.50%CP). Total dietary lysine was maintained at .95% except for the positive control (1.30%). Pigs fed commercial SBM with 1.30% dietary lysine had increased ADG and better F/G than pigs fed any other treatment. A SBM variety x processing temperature interaction was observed for ADG and F/G for each growth period. The interaction likely resulted from improvement in ADG and F/G with high-oleic SBM, but not the check-line SBM, as processing temperature increased. Pigs fed high-oleic SBM had improved ADG and F/G throughout all growth periods as processing temperature increased, so pigs fed high-oleic SBM processed at 80-85 °C had poorer growth performance than pigs fed any other treatment. These results indicate that pigs fed high-oleic SBM processed above 80-85 °C have similar performance to pigs fed SBM from other varieties.; Swine Day, Manhattan, KS, November 19, 1998

Pilot plant processing of ammoniacal nickel leach liquor for the recovery of nickel using LIX 64N

A process for the recovery of nickel from ammoniacal leach liquor through an integrated solvent extraction-electrowinning (SX-EW) flowsheet was tested on a pilot-plant scale. The objectives of the test run were to assess the reproducibility of laboratory-scale data in a large-scale continuous operation and to study the build up of impurities in the system. The pilot-plant test was conducted under operating conditions that were established from the laboratory-scale experiments. Efficiencies of nickel extraction, nickel stripping and ammonia scrubbing were comparable to the laboratory-scale values, whereas the current efficiency during nickel electrolysis was observed to be less than the laboratory-scale values. The electrodeposited nickel contained some cobalt and iron impurities.

Recovery of attached bacteria from GAC fines and implications for disinfection efficacy

A physical/chemical desorption technique was used to assess the impact of colonized granular activated carbon (GAC) fines released from biologically active carbon (BAC) contractors on disinfection performance. The procedure was found to be effective for the recovery of attached heterotrophic plate count (HPC) bacteria at GAC fines concentrations as low as 10 μg/l in experiments using fines colonized in the laboratory. Application of the desorption procedure to disinfected pilot plant process waters did not result in increased HPC recoveries. It was therefore concluded that after disinfection, attached bacteria in biologically treated waters have little impact on public health, either due to a low number of released fines or a low number of organisms attached to these fines.

Simulated Scale‐up and Cost Estimate of a Process for Alkaline Isomerization of Lactose to Lactulose Using Boric Acid as Complexation Agent

A continuous pilot plant process for converting lactose to lactulose, using boric acid as a complexation agent was previously developed. To appraise the commercial feasibility of the process, a scale-up to a commercial plant using the ERRC Food Process Simulator, a process simulator developed at the Eastern Regional Research Center was projected and a cost estimate made. The cost to produce a 55% lactulose syrup at a rate of 93 kilograms per hour (563359 kg year−1) was $5.20 per kilogram ($2.36 per pound). These costs, which do not include packaging or distribution expenses, do include a 25% return on the plant investment. © 1997 SCI.