Scale-up Of Process Research Articles

A new approach for scale-up of pulsed disc and doughnut columns based on the similarity principle

A detailed experimental study is performed to understand the effect of scaling up on the hydrodynamic behavior of Pulsed Disc and Doughnut Columns (PDDCs) using three different systems without mass transfer. The phase system used in the experiments consists of tap water as the dispersed phase and 10% P507/kerosene with different saponification rates as the continuous phase. Dispersed phase holdup and Sauter mean diameter (d32) were measured under different operating conditions. The operating parameters that have varied are the pulsation intensity and flow rate of both liquid phases. The geometrical parameters are plate spacing spacing and column diameter. Further, the empirical correlations based on the similarity principle have been proposed to predict the dispersed phased holdup and Sauter mean diameter for a better understanding of the scale-up process.

Enhancing L-asparagine Production Through In Vivo ATP Regeneration System Utilizing Glucose Metabolism of Escherichia coli.

L-asparaginase synthetase, an ATP-dependent enzyme, necessitates ATP for its catalytic activity. However, the integration of L-asparaginase synthetase into industrial processes is curtailed by the prohibitive cost of ATP. To address this limitation, this study explores the construction of an efficient ATP regeneration system using the glucose metabolism of Escherichia coli, synergistically coupled with L-asparaginase synthetase catalysis. The optimal conditions for L-asparagine yield were determined in shake flasks. A total of 2.7 g/L was the highest yield achieved under specific parameters, including 0.1 mol/L of substrate, 0.2 mol/L glucose, 0.01 mol/L MgCl2 at pH 7.5, a temperature of 37 °C, and agitation at 300 r/min over 12 h. The process was then scaled to a 3-L fermenter, optimizing the addition rates of the substrate and magnesium chloride, and employing a constant glucose feed of 10 g/L/h. The scale-up process led to a significant enhancement in the production of L-asparagine. The yield of L-asparagine was increased to 38.49 g/L after 20 h of conversion, and the molar conversion rate reached 29.16%. This strategy has proven to be effective in improving the efficiency of L-asparagine production. When compared to in vitro ATP regeneration methods, this in vivo approach showcased superior efficiency and reduced costs. These findings furnish pivotal insights that may propel the enzymatic synthesis of L-asparagine toward viable industrial application.

Applying Intelligent Control for the scale-up of advanced oxidation processes for treated wastewater.

Applying Intelligent Control for the scale-up of advanced oxidation processes for treated wastewater.

A solvent-free processed low-temperature tolerant adhesive

Ultra-low temperature resistant adhesive is highly desired yet scarce for material adhesion for the potential usage in Arctic/Antarctic or outer space exploration. Here we develop a solvent-free processed low-temperature tolerant adhesive with excellent adhesion strength and organic solvent stability, wide tolerable temperature range (i.e. −196 to 55 °C), long-lasting adhesion effect ( > 60 days, −196 °C) that exceeds the classic commercial hot melt adhesives. Furthermore, combine experimental results with theoretical calculations, the strong interaction energy between polyoxometalate and polymer is the main factor for the low-temperature tolerant adhesive, possessing enhanced cohesion strength, suppressed polymer crystallization and volumetric contraction. Notably, manufacturing at scale can be easily achieved by the facile scale-up solvent-free processing, showing much potential towards practical application in Arctic/Antarctic or planetary exploration.

Insights into the effect of operating parameters and hydrodynamics on hydrolysis reaction in Copper–Chlorine thermochemical water splitting cycle for hydrogen production: Modelling and experimental validation

Copper–Chlorine (Cu–Cl) thermochemical cycle is being explored as one of the promising technologies for large scale production of clean hydrogen from water using nuclear or renewable energy. In this method, water splitting is achieved through a series of reactions in a loop producing only hydrogen and oxygen with complete recycle of all the intermediate copper and chlorine compounds. The first step of the cycle is the hydrolysis reaction wherein steam reacts with solid CuCl2 to form solid Cu2OCl2 (copper oxychloride) and HCl gas. The products enter the subsequent steps of the cycle and are recycled back to complete the loop. Multiple side reactions in the hydrolysis step result in reduced yield and loss of chemicals from the cycle. Efficient reactor design and optimal operating conditions of hydrolysis reactor is imperative towards achieving sustained closed loop operation and reducing the energy demand of Cu–Cl cycle. This paper presents a mathematical model for the simulation of hydrolysis reaction in a bubbling fluidized bed reactor. The one-dimensional model is developed based on modified two-phase theory of fluidization and is coupled with kinetics of multiple side reactions to investigate the effect of operating parameters and hydrodynamics on the conversion and yield of Cu2OCl2. The model results are validated with experimental data in 50 mm and 100 mm semi-batch fluidized bed reactors. The developed model clearly brings out the effect of different process parameters for process optimization and scale-up of the hydrolysis reactor for efficient integration in the cycle.

Developments in scale-up procedures for industrial dryers

The aim of dryer scale-up is to increase batch size, or throughput of a continuous process, while maintaining final moisture content, product quality, end-use properties, safety and reliability. This article reviews and updates previously published material on scale-up processes of dryers in general and individual dryer types, particularly material from a Drying Technology special issue on scale-up in 1994. This is adapted to give a basic generic theory for scale-up, applying this to various dryers and noting specific exceptions. It is demonstrated that simplifying assumptions can often be reliably made for scale-up which reduce the level of complexity for modeling compared to equipment design and performance calculations. For example, prediction of drying rate and drying time in spray and flash dryers needs a kinetic model, but for scale-up a heat balance and scaling calculation usually suffices. Approximations such as a one-third power law for drying time are often effective. It is shown that there is some theoretical basis for empirical scale-up rules that have been used by dryer manufacturers. Scale-down is also important, selecting the most appropriate conditions for small-scale tests that will correspond to the desired performance at commercial scale. The individual concepts are not new, but they have not previously been unified into a simply stated general basis for scale-up.

Tailoring polishing steps for effective removal of polysorbate-degrading host cell proteins in antibody purification.

Ensuring the quality and safety of biopharmaceutical products requires the effective separation of monoclonal antibodies (mAbs) from host cell proteins (HCPs). A major challenge in this field is the enzymatic hydrolysis of polysorbates (PS) in drug products. This study addresses this issue by investigating the removal of polysorbate-degrading HCPs during the polishing steps of downstream purification, an area where knowledge about individual HCP behavior is still limited. We investigated the separation of different mAb formats from four individual polysorbate degrading hydrolases (CES1F, CES2C, LPLA2, and PAF-AH) using cation exchange (CEX) and mixed-mode chromatography (MMC) polishing steps. Our research identified a key challenge: The similar elution behavior of mAbs and HCPs during chromatographic separation. To investigate this phenomenon, we performed high-throughput binding screenings for recombinant polysorbate degrading hydrolases and representative mAb candidates on CEX and MMC chromatography resins. We then employed a three-step strategy that also served as a scale-up process, optimizing separation conditions and leading to the successful removal of specific HCPs while maintaining high mAb recovery rates (>96%). This strategy involved the use of surface response models and miniature columns for screening, followed by validation on larger columns using a chromatography system. Our results highlight the critical role of the inherent properties of mAbs for successful separation from HCPs. These results underscore the need to tailor the purification process to leverage the slight differences in binding behavior and elution profiles between mAbs and specific HCPs. This approach lays the foundation for developing more effective strategies for overcoming the challenge of enzymatic polysorbate degradation, paving the way for improved quality and safety in biopharmaceutical products.

The pathway to process scale-up

The pathway to process scale-up

Scale-up of a sorption process working with molecularly imprinted adsorbents for enrichment of winemaking residues and improvement of bioactivity

This work presents the scale-up of a sorption process for the fractionation and enrichment of bioactive compounds in winemaking residues using molecularly imprinted adsorbents. The process works with hydroalcoholic solvents and the improvement of the bioactivity of the produced fractions, comparatively to the raw extracts, is demonstrated. The proposed approach was experimentally validated through the designing and running of a pilot size sorption prototype for the automation of the fractionation method. The synthesis of the molecularly imprinted adsorbents was made at the gram-scale and spent diatomaceous earth, used for wine filtration, was considered as a possible source of bioactive compounds in winemaking residues.The different fractions produced were evaluated for their antioxidant activity through three different assays, namely radical scavenging activity, reducing power and inhibition of lipid peroxidation. The results obtained show the improvement of the bioactivity of most of the fractions comparatively to the original diatomaceous earth extract. The most enriched fraction is estimated to have a total phenolic content c.a. 3.8 times higher than the original extract. The radical scavenging activity, the reducing power and the inhibition of lipid peroxidation for this fraction were measured to be 6.4, 4.2 and 4.5 times higher, respectively, than the initial diatomaceous earth extract.This work provides new insights on biomass valorisation and circular bioeconomy by combining in the same research materials development, process design and application to real extracts with proved improvement of the bioactivity of purified products.

A Review of the Production of Hyaluronic Acid in the Context of Its Integration into GBAER-Type Biorefineries

Biorefineries (BRFs) that process the organic fraction of municipal solid waste and generate bioproducts and bioenergies have attracted attention because they can simultaneously address energy and environmental problems/needs. The objective of this article was to critically review the microbial production of hyaluronic acid (MPHA) and its production profile for its integration into a GBAER-type BRF (a type of BRF based on organic wastes) and to identify the environmental and economic sustainability aspects of the modified BRF that would confirm it as a sustainable option. It was found that the MPHA by selected strains of pathogenic Streptococci was moderate to high, although the trend to work with genetically transformed (GT) (innocuous) bacteria is gaining momentum. For instance, A GT strain of Corynebacterium glutamicum reached a maximum HA production of 71.4 g L−1. MPHA reports that use organic wastes as sources of carbon (C) and nitrogen (N) are scarce. When alternative sources of C and N were used simultaneously, HA production by S. zooepidemicus was lower than that with conventional sources. We identified several knowledge gaps that must be addressed regarding aspects of process scale-up, HA industrial production, economic feasibility and sustainability, and environmental sustainability of the MPHA.

Optimising parameters for pilot scale steam explosion and continuous pressurised disc refining of Miscanthus and sugarcane bagasse for xylose and xylo-oligosaccharide release

The first comparative pre-treatment study of Miscanthus (Mxg) and sugarcane bagasse (SCB) using steam explosion (SE) and pressurised disc refining (PDR) pretreatment to optimise xylose and xylo-oligosaccharide release is described. The current investigation aimed to 1) Develop optimised batch-wise steam explosion parameters for Mxg and SCB, 2) Scale from static batch steam explosion to dynamic continuous pressurised disc refining, 3) Identify, understand, and circumvent scale-up production hurdles.Optimised SE parameters released 82% (Mxg) and 100% (SCB) of the available xylan. Scaling to PDR, Miscanthus yielded 85% xylan, highlighting how robust scouting assessments for boundary process parameters can result in successful technical transfer. In contrast, SCB technical transfer was not straightforward, with significant differences observed between the two processes, 100% (SE) and 58% (PDR).This report underlines the importance of feedstock-specific pretreatment strategies to underpin process development, scale-up, and optimisation of carbohydrate release from biomass.

Continuous chiral separation process for high-speed countercurrent chromatography established and scaled up: A case of Voriconazole enantioseparation.

An efficient method for the continuous separation of Voriconazole enantiomers was developed using sulfobutyl ether-β-cyclodextrin (SBE-β-CD) as a chiral selector in high-speed countercurrent chromatography (HSCCC) with different types. The separation was performed using a two-phase solvent system consisting of n-hexane/ethyl acetate/100mmol/L phosphate buffer solution (pH=3.0, containing 50mmol/L SBE-β-CD) (1.5:0.5:2, v/v/v). A fast and predictable scale-up process was achieved using an analytical DE HSCCC instrument. The optimized parameters were subsequently applied to a preparative Tauto HSCCC instrument, resulting in consistent separation time and enantiomeric purity, with throughput boosted by a remarkable 11-fold. Preparative HSCCC successfully separated 506mg of the racemate, delivering enantiomers exceeding 99% purity as confirmed by high-performance liquid chromatography analysis. This investigation presents an effective methodology for forecasting the HSCCC scale-up process and attaining continuous separation of chiral drugs.

Green Separation by Using Nanofiltration of Tristerix tetrandus Fruits and Identification of Its Bioactive Molecules through MS/MS Spectrometry.

Membrane technology allows the separation of active compounds, providing an alternative to conventional methods such as column chromatography, liquid-liquid extraction, and solid-liquid extraction. The nanofiltration of a Muérdago (Tristerix tetrandus Mart.) fruit juice was realized to recover valuable metabolites using three different membranes (DL, NFW, and NDX (molecular weight cut-offs (MWCOs): 150~300, 300~500, and 500~700 Da, respectively)). The metabolites were identified by ESI-MS/MS. The results showed that the target compounds were effectively fractionated according to their different molecular weights (MWs). The tested membranes showed retention percentages (RPs) of up to 100% for several phenolics. However, lower RPs appeared in the case of coumaric acid (84.51 ± 6.43% (DL), 2.64 ± 2.21% (NFW), 51.95 ± 1.23% (NDX)) and some other phenolics. The RPs observed for the phenolics cryptochlorogenic acid and chlorogenic acid were 99.74 ± 0.21 and 99.91 ± 0.01% (DL membrane), 96.85 ± 0.83 and 99.20 ± 0.05% (NFW membrane), and 92.98 ± 2.34 and 98.65 ± 0.00% (NDX membrane), respectively. The phenolic quantification was realized by UHPLC-ESI-MS/MS. The DL membrane allowed the permeation of amino acids with the MW range of about 300~100 Da (aspartic acid, proline, tryptophan). This membrane allowed the highest permeate flux (22.10-27.73 L/m2h), followed by the membranes NDX (16.44-20.82 L/m2h) and NFW (12.40-14.45 L/m2h). Moreover, the DL membrane allowed the highest recovery of total compounds in the permeate during the concentration process (19.33%), followed by the membranes NFW (16.28%) and NDX (14.02%). Permeate fractions containing phenolics and amino acids were identified in the membrane permeates DL (10 metabolites identified), NFW (13 metabolites identified), and NDX (10 metabolites identified). Particularly, tryptophan was identified only in the DL permeate fractions obtained. Leucine and isoleucine were identified only in the NFW permeate fractions, whereas methionine and arginine were identified only in the NDX ones. Liquid permeates of great interest to the food and pharmaceutical industries were obtained from plant resources and are suitable for future process optimization and scale-up.

Effects of operating parameters on single-stage ultrasonic separation of ethanol from its aqueous solutions

The effects of operating parameters on separation of ethanol from its aqueous solutions using ultrasonic atomization were investigated in a single-stage process. With an experimental setup similar to those used in previous work, we measured the degree of enrichment and the combined molar collection rate of ethanol and water for a single combination of the ultrasound power and frequency at 126 combinations of bulk liquid depth, composition, and temperature; carrier-gas inlet/outlet elevation and flow rate; and collection temperature. Enrichment depends strongly on bulk liquid composition, reaching a maximum at an ethanol mole fraction below 0.1, with the maximum enrichment depending on bulk liquid depth and inlet/outlet elevation. The collection rate depends strongly on inlet/outlet elevation and bulk liquid pool depth, and for high ethanol mole fractions is nearly independent of bulk liquid composition. Enrichment and collection rate increase with increasing bulk liquid temperature and decreasing collection temperature. The fact that increasing the carrier-gas flow rate increases the collection rate and decreases enrichment is interpreted in terms of size-selective transport of drops from the ultrasonically-generated fountain where they are atomized, to the cold trap where they are collected. The results are discussed in terms of operating parameters, transport phenomena (including evaporation and gravitational settling of atomized drops), the ultrasonically-induced fountain, and previously reported drop-size distributions. The duration of the experiments, conducted in batch, was such that the results should be relevant to both batch and continuous-flow operation. The work provides guidance and critical data for process scale-up.

Thermal-hydraulics performance evaluation of bubble swarms sweeping tube bundles in a direct contact gas-liquid-solid reactor

Direct contact gas-liquid-solid reactor pertains to an extremely high efficiency heat-exchange facility in industrial application. Nevertheless, the scarcity of quantitative analysis data hinders the optimal design of this type of reactor. In the present study, a novel variable bubbles size modeling approach which considers the bubble swarms breakup and coalescence rates, is proposed to evaluate the complex thermal-hydraulics performance of bubble swarms sweeping tube bundles. On the basis of verifying the responsibility of the numerical modelling with published experimental data, the intrinsic link of hydrodynamics and thermodynamics parameters on reactor features, including field characteristics, gas holdup, bubble swarms diameter distribution, gas–liquid interfacial area, temperature difference and heat flux inside different tube bundles regions, are deeply revealed. Results demonstrate that the temperature difference between bubble swarms and tube bundles walls is approximately equal to 2 K. Interestingly, different positions of heat exchanging tubes affect the peak value of circumferential heat transfer coefficient. For typical Tube 1–2, the maximum value of 3146.28 W/m2·K appears around 162°. The presence of tube bundles gives rise to the well-distributed iso-surfaces of bubble swarms which contributes to enhance heat transfer. When superficial gas velocities are respectively 0.09 m/s, 0.12 m/s and 0.14 m/s, the average bubble warms diameters are 13.47 mm, 16.22 mm and 17.24 mm. When initial liquid phase height increases from 342 mm to 378 mm, the corresponding gas–liquid interfacial area decreases by 16.2 % in total. Finally, two new modified dimensionless correlations were developed for the prediction of gas holdup and Nusselt number. The prediction errors are respectively 10 % and 6 %. The findings can improve the awareness for promising applications in design and scale-up processes of direct contact gas-liquid-solid reactor.

Pilot scale-up production of poly(3-hydroxybutyrate) (PHB) from starch-based wastewater: A halogen-free process optimization for polymer recovery

The intracellular nature of microbial polyhydroxyalkanoates (PHAs) requires two main steps in their production: bioconversion and extraction. The most widely used method for recovering poly(3-hydroxybutyrate) (PHB) is solvent extraction. Traditional approaches involve the use of halogenated solvents, whose environmental and health hazards are well known. New alternatives advocate the use of sustainable agents, which can be an effective and economical choice. In this work, the bioconversion process of starch-based water into PHB by Cupriavidus necator DSM 545 was first scaled-up using previously optimized conditions. A statistical model was then developed to optimize the best conditions for polymer extraction using NaOH by response surface methodology with a central composite design. The optimized and validated conditions were: 0.05 M NaOH at 29.6 °C for 1 h, resulting in 87.31 ± 0.33 % polymer yield, 104.13 ± 2.22 % polymer purity and 104.76 ± 2.41 % polymer recovery. These conditions were validated for operation at three different biomass-to-NaOH concentrations: 5.7 g/L, 20 g/L and 79.5 g/L, and scaled-up without sacrificing polymer yield, with high levels of PHB purity and recovery. In addition, this work proposed an approach for the scale-up of a halogen-free process for PHB extraction using NaOH, considering parameters that can be easily integrated into the common ranges used in the industry.

Investigation of epoxy grouts incorporating date palm waste: Mechanical performance analysis

Epoxy grouts, consisting of epoxy resins, hardeners, and fillers, are extensively used in under-grouting due to their excellent mechanical attributes. Waste material incorporation into grout composites is becoming more popular because of growing environmental consciousness and a greater focus on sustainability. Recent research focuses on integrating date palm waste into epoxy grout composites for compression-based applications, such as under-grouting. Additionally, there is a notable gap in the literature regarding the scaling-up process from laboratory experimentation to industrial-scale manufacturing of such grout composites. The present study aims to investigate the feasibility of using date palm midrib wastes for under-grouting heavy machinery and equipment in local industries within Saudi Arabia. Three kinds of epoxy grouts of the exact composition of resin and hardener but with different substitutions of silica sand with date palm midrib waste were made. The microstructure and mechanical properties of the synthesized epoxy grout composites containing varying percentages (2%, 5%, and 10%) of date palm waste, specifically comprising midribs and midrib fibres, are critically assessed. The results show that using midrib fibers resulted in lower mechanical performance of the grout composite than when date palm midribs were used. Moreover, as the amount of date palm waste increases, the mechanical performance of grout specimens decreases. At a 28-day curing time, adding up to 10% date palm waste led to a loss in compressive strength of up to 5% and 66% for the composite containing midribs and midrib fibers, respectively. Correspondingly, adding up to 10% date palm waste reduced flexural strength by 32% and 68% for composite containing midribs and midrib fibers, respectively. Scanning electron microscopy shows that the decline in the mechanical properties of the epoxy composite containing the midrib fibers is attributed to the presence of augmented voids within the microstructure of the specimens. Optical microscopy of epoxy date palm (EDP) specimens shows that the presence of date palm content results in crack propagation along midrib boundaries and through midribs during compressive loading. Except for the grout composite containing 10% midrib fiber, the synthesized epoxy grout composites incorporating date palm midrib waste are more durable and sustainable than the benchmark grout material specified for foundation and heavy machinery applications. The absence of chemical treatments and specialized facilities simplifies the scalability of grout specimen preparation from laboratory to industrial scale.

Optimizing fouling mitigation in membrane distillation by controlled microbubble size and concentration

Fouling control strategies play a crucial role in membrane distillation (MD) process, primarily due to the significant limitation of fouling during the scaling-up process. The utilization of microbubbles (MBs) aeration has exhibited promising potential in mitigating membrane fouling when treating high salinity wastewater. Aeration can introduce gas-liquid two-phase flow on the membrane surface, thereby increasing the membrane surface shear force. The mechanism of aeration technology for controlling fouling includes the following points: introduction of gas-liquid two-phase flow; physical substitution of concentration polarization layer; pressure pulses caused by bubbles flowing through the membrane surface and increasement of the cross flow velocity. This research aims to optimizing the effect of air MBs with different concentrations and sizes introduced in the feed side on membrane fouling control, we creatively used the method of releasing pressure gradiently to achieve size regulation of MBs within a certain range for the first time, firstly regulated the generation of MBs by manipulating gas flow rate and release pressure. Under the optimal condition of 40 mL/min and 0.6 MPa, it will yield concentration of 1.58 × 104/mL and D50 Sauter size of 64.69 μm MBs with pure water permeance flux of 12.32 kg/(m2·h). It was observed that higher gas flow rates primarily increased MBs concentration, while lower pressures predominantly reduced MBs size through the method of inline imaging. Experimental results indicated that introduction of MBs can slightly improve the temperature polarization coefficient and mass transfer coefficient under different operating modes. Consequently, further investigations focused on the influence of MBs characteristics on different fouling control. All conditions reach 99 % rejection for inorganic salt and HA. This study provided empirical evidence that higher concentration and larger size of MBs intensify the gas-liquid two-phase flow disruption and exhibit a better shear effect on scaling phenomena, which yield advantageous outcomes in terms of augmenting permeance flux and water vapor production, with permeance flux increased from 40.12 % to 55.42 % for inorganic fouling and increased from 68.35 % to 80.15 % for inorganic and HA fouling. These results were confirmed via membrane surface using scanning electron microscopy and energy dispersive spectroscopy. In summary, this research aided in identifying appropriate operating conditions for mitigating inorganic and composite scaling by implementing air-infused MBs in direct contact membrane distillation (DCMD), which provides scientific and technical guidance for controlling fouling in MD in practical applications.

Modified Roller Compaction Model to Account for Roll Speed Effect on Powder Compaction in Dry Granulation Process

This study introduces a modification to the roller compaction model proposed by Sousa et al.1 to account for the effect of roll speed on powder compaction in the dry granulation process. The proposed model enhances the prediction accuracy, particularly at higher roll speeds, which are often overlooked in existing models. The modified model is validated using literature data, demonstrating improved performance compared to the original model. Additionally, the model is applied to a pharmaceutical formulation, showing its applicability in an industrial context. The integration of the model into gPROMS allows for global sensitivity analysis and design space exploration, providing valuable insights for process optimization and scale-up. The study contributes to the understanding of roller compaction dynamics and offers a practical tool for decision-making in pharmaceutical manufacturing.

Techno-Economic Modelling of Bioclarified Water Recovery from Petroleum Wastewater Using ASPEN Software and Box-Behnken Design

Application and efficiency of bio-coagulants for petroleum wastewater biocoagulation, flocculation, and sedimentation (bioclarification) are still confined to laboratory proof-of-concept practice. The scale-up process design of bio-clarified water recovery from petroleum wastewater has been a major research lacuna. This paper presents ASPEN Base Case Scale-Up Simulation (BCSUS) using optimum laboratory experimental data and techno-economic predictive models for bioclarified water production from petroleum wastewater. The BCSUS, process design, and economics were performed in the ASPEN Batch Process Developer V10 environment. Predictive models for predicting and optimizing techno-economic parameters such as return on investment (ROI), payback time (PBT), and production rate (PR) were achieved in RSM via the Box-Behnken Design (BBD) technique of Design Expert V13. The base case techno-economic model gave batch size, annual production cost, Total Capital Investment (TCI), PBT, and ROI of 406kg, $9195, $631484, 5.18 years, and 17%, respectively, at the selling price of 2 $0.225. The regression models gave R values of 0.9984 for ROI and 0.9920 for PBT, while the production rate was 0.8867. This study shows that a petroleum wastewater bioclarification scale-up design is feasible.