Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation


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Industrial Process Scale-up

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Write a review Rate this item: 1 2 3 4 5. Preview this item Preview this item. Industrial process scale-up : a practical innovation guide from idea to commercial implementation Author: Jan Harmsen Publisher: Kidlington : Elsevier, Allow this favorite library to be seen by others Keep this favorite library private.

Find a copy in the library Finding libraries that hold this item Reviews Editorial reviews. Publisher Synopsis " User-contributed reviews Add a review and share your thoughts with other readers. Finally, guidelines for process concept design in the research stage are provided to obtain radically novel solutions. Sustainable development is development that meets the needs of the present generation without compromising the ability of future generations to meet their own needs. Sustainable development is about three dimensions; social, ecological and economic. The social dimension means that developments fit in cultural institutions and people values are preserved.

Where there are threats of serious or irreversible damage, lack of full scientific certainty shall not be used as a reason for postponing cost-effective measures to prevent environmental degradation. The economic dimension means that developments are economical. These dimensions were made popular by Elkington [6] by introducing the triple P catch phrase: people, planet and profit. Many companies incorporated this triple P sustainable development into their strategic goals. The United Nations World Conference in Johannesburg in adopted the triple P phrase and made it suitable for government by transforming the profit term into prosperity [8].

It is therefore concluded that triple P sustainable development has reached sufficient consensus to be fruitful for co-operations between industrial, government and academic partners. In the book Sustainable development in the process industries: cases and impact [1], several successfully implemented sustainable industrial cases are described.

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The cases include the use of biomass for fuels [9], metal processing [10], metal scrap recycle in combination with cement and concrete production [11], food production in combination with oil refining, electricity production and cement production [11]. This illustrates that the triple P concept can also be implemented in industrial practice. For innovation between very different partners, including governments, industrial symbiosis is a very useful concept.

It is a practical way of embedding industrial processes in society, environment and business contexts. Several implemented industrial cases of industrial symbiosis, also called industrial by-product synergy, are available from Mangan [11], and Wu [12]. Wu in particular provides a spectacular case that proves the power of industrial symbiosis.

It is the Dow Chemicals plant symbiosis with the city of Terneuzen, the local water board and a technology provider. It is about transforming the city waste water into boiler feed water. This symbiosis resulted in the reuse of 2. This case won the European Responsible Care Award in [12]. The technologies applied in this industrial symbiosis case are all conventional. It is thereby a prime example of a social innovation; a new way of co-operation between industrial, governmental and institutional and technology partners where all social, ecological and economic parameters move in the desired direction.

In many cases, however, meeting triple P sustainable development goals and constraints requires radically novel technologies, which in turn require a considerable innovation effort.


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Open innovation with a partnership of companies and academic groups is a way of obtaining the desired result. In open innovation: Best knowledge of each partner is used. A typical open innovation consortium for a radically novel process innovation consists of an academic group, a contract research organization, a technology provider, an engineering contractor and an end-user of the technology; a manufacturer of a chemical or other product [2].

Open innovation can also occur between partners of a value chain; so a chain of suppliers and customers to optimize a part of the value chain. This can occur, in particular, when renewable feedstocks replace fossil feedstocks.

Green Processing and Synthesis

Then, novel supply chains have to be established [2]. Here is a short checklist for a manufacturer to decide whether to enter an open innovation consortium or not [3]: Do you have all capabilities in your own company to bring the innovation to commercial implementation? Do you foresee a potential conflict of interest now or later with a partner? Then do not pursue with that partner. TRL determination helps to judge a technology from outside the company, notably from universities or contract research institutes, on its readiness for commercialization.

It also facilitates a discussion between the open innovation partners about the present status of the technology and what needs to be done to bring the technology to commercial implementation. There are several descriptions of TRL.

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The Department of Energy of the US is the closest to the process industries [13]. The author has used this description to derive TRL level definitions that are applicable to the process industries in general and also added the stages belonging to the TRL levels.

The TRL definitions and stages are provided in Table 1. Innovation is the pathway from idea to commercial implementation. An effective and efficient method for process innovation is the 4-D stage-gate innovation funnel. The basic idea is that the most critical items for success are addressed in the early innovation stage. If the idea then fails, little money is lost. The 4-D innovation funnel contains the stages: discovery research , development, demonstration and deployment commercial implementation [2].

In the discovery research stage, it is important to generate novel breakthrough concepts which are much better in all three sustainable development dimensions. Green chemistry principles are of great use here [14], as well as process intensification techniques [15, 16] and functional concept design [3]. In the development stage, it is important to reduce the risks associated with direct implementation to acceptable levels at minimum cost.

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For process development, this means amongst others, having an integrated pilot plant down-scaled from the commercial scale design. Or in other words, first the commercial scale design is made and then the down-scaled pilot plant is designed and tested. Demonstration plants: in general, a factor 10 smaller in capacity than full commercial scale plants, are often applied for very large processes in the oil and steel industries, to reduce the investment risk [3]. For chemical processes, the demonstration plant is also the first commercial scale plant [3].

For successful commercial scale implementation, a reliable design as well as a well-prepared start-up is essential. A practical guide from idea to commercial scale implementation is available [3]. To meet sustainable development goals and constraints, novel technologies will be required.

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These novel technologies come about via radically new concept designs. For engineers, it is a challenge to make these novel concept designs of processes, products and systems. It means designs that provide for the need of people, while having a factor 4, 10 or even 20 lower environmental impacts, are economical and socially accepted [9].


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Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation
Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation Industrial Process Scale-up. A Practical Guide from Idea to Commercial Implementation

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