Pilot-plant layout

Figure 2. Locality plan, site plan, and pilot plant layout and profile.

Fig. 3 shows a pilot plant layout with restricted personnel access. This design would support the development and clinical manufacture of solid dosage forms, liquids, semisolids, aerosols, and sterile products. Multipurpose rooms are incorporated in each area to maximize the use of portable equipment, and scale factors similar to those shown in Table 1 are employed. Isolation suites are indicated in the manufacturing area their purpose and design are discussed in more detail later. The sterile area is isolated from the main corridor by the interior corridor design. At the far left, the main corridor provides access for future facility expansion, if necessary. 

The development section serves as an intermediary between laboratory and industrial scale and operates the pilot plant. A dkect transfer from the laboratory to industrial-scale processes is stiH practiced at some small fine chemicals manufacturers, but is not recommended because of the inherent safety, environmental, and economic risks. Both equipment and plant layout of the pilot plant mirror those of an industrial multipurpose plant, except for the size (typically 100 to 2500 L) of reaction vessels and the degree of process automation. 

These results led to the design of a pilot plant with a throughput of 10 kg/h whose overall layout is shown in Figure 3. The project was financed by the Association of the Plastic Producing Industry (Verband Kunststofferzeugende Industrie, VKE) and the Federal Ministry of Research and Technology (BMFT). 

Safe unit placement enhances the overall safety of a pilot plant. A containment cell or a separate building is not, however, a guarantee of safety. Other measures include Increased process monitoring of safety specific variables, limiting inventories of hazardous feedstocks and products, detailed hazard analysis and risk assessments, and good design practices. One essential element is to ensure that the pilot plant has adequate space to support its operation. This requires a careful evaluation of the required space before the unit is constructed. While a detailed layout and a careful... 

This chapter does not deal with the electronic soft- and hardware to document the data, to calculate the desired results, and to monitor failures. The hardware is available in different configurations and the software can be bought or developed to fit into the software used in production. The prerequisites discussed are those for the methods of measurements and the plant layout to permit automation. The general prerequisite is the use of the same freeze-drying methods from product development through pilot plant studies to production for example, the same principle of temperature and pressure measurements, identical definitions of tolerances, and similar criteria for statistical evaluations. If this prerequisite is not observed, the development steps may have to be repeated to permit later automation. 

Figure 6.18. Treatment layouts for the four scenarios studied in a pilot plant for removing radionuclides from drinking water. Sampling points are represented by numbers in brackets (Montana et al., 2013). Code ultrafiltration (UF), reverse osmosis (ROX electrodialysis reversal (EDR).

Figure I Basic layout of a pilot plant for production of oligo(ethylene terephthalate)s in a continuous process. 1 Polycondensation reactor 2 punched metal walk 3 condenser ...

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