Scaleup system

Temperature. The reaction was normally carried out over the range from 25° to 39°C.—the reflux temperature of methylene chloride. Good results were obtained at 10° and at 100 °C. in dichlorobenzene, and there seems to be little reason to require any specific range. Since it was convenient to use solvent reflux as a secondary temperature control, the scaleup system was operated in the range 25°-39°C. 

Correlations of nucleation rates with crystallizer variables have been developed for a variety of systems. Although the correlations are empirical, a mechanistic hypothesis regarding nucleation can be helpful in selecting operating variables for inclusion in the model. Two examples are (/) the effect of slurry circulation rate on nucleation has been used to develop a correlation for nucleation rate based on the tip speed of the impeller (16) and (2) the scaleup of nucleation kinetics for sodium chloride crystalliza tion provided an analysis of the role of mixing and mixer characteristics in contact nucleation (17). Pubhshed kinetic correlations have been reviewed through about 1979 (18). In a later section on population balances, simple power-law expressions are used to correlate nucleation rate data and describe the effect of nucleation on crystal size distribution. 

The constant may depend on process variables such as temperature, rate of agitation or circulation, presence of impurities, and other variables. If sufficient data are available, such quantities may be separated from the constant by adding more terms ia a power-law correlation. The term is specific to the Operating equipment and generally is not transferrable from one equipment scale to another. The system-specific constants i and j are obtainable from experimental data and may be used ia scaleup, although j may vary considerably with mixing conditions. Illustration of the use of data from a commercial crystallizer to obtain the kinetic parameters i, andy is available (61). 

Murthy, A. K. S., Design and scaleup of slurry-hydrogenation systems, Chemical Engineering, pp. 94-107, September 1999. 

Also assume that the pilot- and full-scale vessels will operate at the same temperature. This means that A(o-out,bout, . )and/i/2 will be the same for the two vessels and that Equation (1.49) will have the same solution for provided that 7 is held constant during scaleup. Scaling with a constant value for the mean residence time is standard practice for reactors. If the scaleup succeeds in maintaining the CSTR-like environment, the large and small reactors will behave identically with respect to the reaction. Constant residence time means that the system inventory, pV, should also scale as S. The inventory scaleup factor is defined as... 

Section 1.5 described one basic problem of scaling batch reactors namely, it is impossible to maintain a constant mixing time if the scaleup ratio is large. However, this is a problem for fed-batch reactors and does not pose a limitation if the reactants are premixed. A single-phase, isothermal (or adiabatic) reaction in batch can be scaled indefinitely if the reactants are premixed and preheated before being charged. The restriction to single-phase systems avoids mass... 

If the pilot reactor is turbulent and closely approximates piston flow, the larger unit will as well. In isothermal piston flow, reactor performance is determined by the feed composition, feed temperature, and the mean residence time in the reactor. Even when piston flow is a poor approximation, these parameters are rarely, if ever, varied in the scaleup of a tubular reactor. The scaleup factor for throughput is S. To keep t constant, the inventory of mass in the system must also scale as S. When the fluid is incompressible, the volume scales with S. The general case allows the number of tubes, the tube radius, and the tube length to be changed upon scaleup ... 

The scaleup strategies that follow have been devised to satisfy Equation (3.31) for liquid systems and Equation (3.32) for gas systems. 

Series Scaleup of Laminar Gas Flows. The scaling equations are similar to those used for turbulent gas systems but the exponents are different. The different exponents come from the use of Equation (3.22) for rather than Equation (3.23). General results, valid for any form of scaleup that uses a single tube, are... 

Confounded reactors are likely to stay confounded. Data correlations can produce excellent fits and can be useful for predicting the response of the particular system on which the measurements were made to modest changes in operating conditions. They are unlikely to produce any fundamental information regarding the reaction rate, and have very limited utility in scaleup calculations. 

When two or more phases are present, it is rarely possible to design a reactor on a strictly first-principles basis. Rather than starting with the mass, energy, and momentum transport equations, as was done for the laminar flow systems in Chapter 8, we tend to use simplified flow models with empirical correlations for mass transfer coefficients and interfacial areas. The approach is conceptually similar to that used for friction factors and heat transfer coefficients in turbulent flow systems. It usually provides an adequate basis for design and scaleup, although extra care must be taken that the correlations are appropriate. 

Now our experiment has been designed We will use plastic pipe with an inside diameter of 1.6 in. and length of 50 ft and pump water through it at a rate of 27.5 gpm. Then we measure the pressure drop through this pipe and use our final equation to scaleup this value to find the field pressure drop. If the measured pressure drop with this system in the lab is, say, 1.2 psi, then the pressure drop in the field pipeline, from Eq. (2-13), would be... 

Small steady-state reactors are fiequently the next stage of scaleup of a process from batch scale to full commercial scale. Consequently, it is common to follow batch experiments in the laboratory with a laboratory-scale continuous-reactor process. This permits one both to improve on batch kinetic data and simultaneously to examine more properties of the reaction system that are involved in scaling it up to commercial size. Continuous processes almost by definition use much more reactants because they run continuously. One quickly goes from small bottles of reactants to barrels in switching to... 

The conversion of power systems and replacement of a fraction of them, can proceed vigorously, since production and scaleup of systems utilizing this process can be very rapid. Except for the cores, all fabrication, parts, techniques, tooling, and other procedures are simple and standard and very economical— and are already on hand and used by a great many manufacturing companies worldwide. 

The scaleup weight-per-kilowatt of systems using this system process will be sufficiently low to enable rapid development of electrically powered transport media such as automobiles. These will have weight about the same as now, carry a small battery as a backup jump-starter, and have very agile performance... 

The design procedure used by Kosters, of Shell Oil Co., who developed this equipment, requires pilot plant measurements on the particular system of HTU and slip velocity as functions of power input. The procedure for scaleup is summarized in Table 14.5, and results of a typical design worked out by Kosters (in Lo et al., 1983, pp. 391-405) are summarized in Example 14.11. Scaleup by this method is said to be reliable in going from 64 mm dia to 4-4.5 m dia. The data of Figure 14.18 are used in this study. 

Most of these types of equipment have at least several hundred installations. The sizing of full scale equipment still requires pilot planting of particular systems. The scaleup procedures require geometrical and hydrodynamic similarities between the pilot and full scale plants. Hydrodynamic similarity implies equalities of... 

For design of a large-scale commercial extractor, the pilot-scale extractor should be of Ihe same type as that to be used on the large scale Reliable scaleup for industrial-scale extractors still depends on correlations based on extensive performance data collected from both pilot-scale and large-scale extractors covering a wide range of liquid systems. Only limited data for a few types of large commercial extractors arc available in the literature,... 

The trickle bed reactors that operate in the downflow configuration and have a number of operational problems, including poor distribution of liquid and pulsing operation at high liquid and gas loading. Scaleup of these liquid-gas-solid reactors is much more difficult than a gas-solid or gas-liquid reactor. Nevertheless, the downflow system is convenient when the bed is filled with small catalyst particles. And, because the catalyst particles are small, these reactors are quite effective as filters of the incoming feed. Any suspended fine solids, such as fine clays from production operations, accumulate at the front end of the bed. Eventually, this will lead to high pressure differentials between the inlet and outlet end of the reactor. 

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