Historical Analysis of Chemical Plant Development

These disadvantages should be overcome by miniplants, generally defined similar as in [1, 60], strictly based on a modular design. In order to adapt to varying needs, several modules may be operated in parallel. Typical module capacities range from 100,000 to 1,000,000 lb/yr. Operation of the miniplants should be so reliable and simple that the majority of these plants can be operated by personnel not specially skilled in process technology. Start-up and shutdown have to be performed fast to allow just-in-time production. The entire plant should be transportable including footprint and containment volume. 

Another issue with the miniplant concept relies on standardization, rendering a different strategy for increasing throughput. Whilst current scale-up processes are based on an incremental progression of know-how, this should be achieved in miniplants in one stage. The small standardized modules should, at best, be fabricated using mass production techniques. 

Encapsulation in containment vessels allows near zero emission rates to be reached in miniplants, e.g. by purging the reactor with an inert gas sent to a scrubber. This embedding of the miniplant should also dramatically reduce the risk of explosion or environmental contamination in case of an accident Even if modules of the miniplant are damaged or break, the robust encasement will be mechanically and chemically stable enough to prevent pollution. 

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