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Scaling and piloting OF chemical technologies


Scaling and piloting OF chemical technologies
ECT Center possesses a unique set of competencies that allow bringing a laboratory development to a project and industrial production within a reasonable time.

We are able to create new chemical technologies based on scientific results, embodying them in a serial product that is in demand on the market.
Our competencies include:
  • Verification of laboratory technology, if necessary, its refinement.
    Basic layout
  • Development of the instrumentation scheme, its completion, purchase.
  • Development of a mathematical model of chemical-technological processes and devices.
  • Site preparation taking into account the specifics of the process (fire / explosion hazard, gases, pressure, raw materials, waste, the need for round-the-clock work). Equipping with a waste management system, if necessary - protected ventilation, etc.
  • Development of a pilot plant scheme, approval. Writing a plan for conducting experimental work.
  • Construction and installation works, commissioning.
  • Completion of the installation using existing equipment. Purchase of the necessary equipment. Manufacturing of non-standard equipment.
  • Operation of the installation in a given mode, production time, data collection.
In addition, we provide economic research support: marketing research, investments, terms and payback of the project, feasibility study.
Scaling
The commercialization of scientific research and its industrial implementation imply the scaling up of chemical process and its testing at a pilot plant.

This is a delicate controlled process of transition from the laboratory stage to the experimental industrial. That is not just a mechanistic increase in reaction volumes and reagent feed rates, but an accurate reproduction of the process in industrial conditions with the appropriate adjustments and changes in the work scheme.

At this stage, the subtleties of the process are being worked out, which cannot be identified on a laboratory scale, a refinement is being carried out for a number of parameters:
  • thermal effects;
  • mass transfer;
  • distribution of flows of liquids and/or gases;
  • methods of dosing and mixing reagents;
  • recycling of material flows;
  • clarification of material and heat balances;
  • determination of specific consumption rates of reagents and waste generation.
Scaling allows you to assess the commercial potential of the development, remove technological, team and consumer risks.

In the process of scaling the technology, it is possible to carry out production of pilot batches of products for testing. Our production facilities allow us to produce from tens of kilograms to tens of tons of various specific chemical products per year.

Tests of pilot batches allow to remove a significant part of the risks regarding the applicability of the obtained products to consumers.
MORE THAN 30 PILOT UNITS OF DIFFERENT SCALE HAVE BEEN BUILT
SEVERAL DOZENS OF SUCCESSFUL PROJECTS ON SCALING AND PILOTING CHEMICAL TECHNOLOGIES HAVE BEEN IMPLEMENTED
working with:
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30+
The mathematical model allows you to see the passage of material flows and chemical reactions in a wide range of system state parameters in "live mode".

Mathematical modeling of processes and devices saves time for the implementation of the process or modernization of the production line, reduces material costs and is available to our partners as part of complex projects or as a separate service.
Creation of a pilot unit
Piloting allows to work out and optimize the technology, brought to an larger scale:
  • find out the stability of the scalable process in time;
  • determine the loss of catalyst activity;
  • determine the parameters of equipment operation (corrosion) etc.
When piloting the process for a long time ("resource run"), an extensive array of data is collected about the operation of the pilot unit and the flow of the process under conditions as close as possible to industrial ones.
Initial data for design
At the next stage, it is possible to develop Initial Data for Design (Basic Design Data)- key information about the chemical process, on the basis of which it is possible directly design the production facility.

The Basic Design Data in the general case include:
  • Full and detailed description of the entire production process.
  • Feasibility study of the project.
  • Material, thermal, energy flows.
  • Technological maps with control points and control parameters.
  • Basic requirements for equipment and its placement.
  • Basic layout.
  • Equipment materials, selection criteria, sources.
  • Safety regulations.
  • Indicators for emissions, effluents, waste disposal.
  • Emergency Response Standards.
Competencies
The result is provided by our technical capabilities and a team of professionals.
  • Own test site. All the necessary basic infrastructure - gases, heat, cold, water, electricity, various capacitive and other equipment.
  • High speed of construction and installation works, purchases.
  • Technical staff on site. All with extensive experience in the chemical industry.
  • A staff of engineers with chemical engineering education, specialized software for calculating devices in particular and processes in general.
  • Technical competencies - locksmith and mechanical department. Proven reliable contractors and suppliers for metal structures and equipment, instrumentation, reagents.
How do
we work?
FIRST TOUCH WITH A CUSTOMER
SIGNING A NON-DISCLOSURE AGREEMENT
DETAILED ACQUAINTANCE WITH THE TASK.
JOB FEASIBILITY DETERMINATION
PRELIMINARY ESTIMATION OF THE COST AND TERMS OF IMPLEMENTATION
ANALYSIS OF THE RESULTS OF R&D
CLARIFICATION OF THE SCOPE OF WORK DETAILS OF TIME AND COST OF WORKS

PERFORMANCE OF WORK
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Our scaling and piloting services help to establish additional production of a chemical product, expand the range of products, replace chemical raw materials purchased abroad, resume lost production or technology in the optimal time.
We are looking forward to collaboration!
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