Pilot Plants
At PROCESSOL, we provide – Scalable solutions for Pilot Plants across a range of industries, trying to switch from Batch Process to Continuous Process. We customize each pilot plant as batch, semi-continuous, or continuous processes with specific equipment, control, and instrumentation solutions to deliver the objectives you desire.
Continuous Process Applications
- Continuous / Semi-continuous Process Pilot Plant Design
- Continuous process – Operability study
- Continuous Process – Lab Scaleup support
- Continuous Reactor - Fixed Bed Reactor / Loop Reactor / plug-flow reactor systems
- Continuous Liquid-Liquid / Solid-Liquid Separation / Filtration
- Continuous Distillation Column / Scrubber / Dryer
- Continuous Process Equipment Integration / Vendor Selection support
TYPES OF CUSTOMIZED PILOT PLANT
1. Continuous Process Pilot Plants:
Continuous Process is the preferred method over batch process. Continuous processing require less space, make better use of raw materials and produce a much higher volume of consistent products. Continuous process systems are cost-effective and becoming increasingly popular in the manufacture of pharmaceuticals / fine chemicals , creating faster reactions with better yields.
There is more complexity in setting up a continuous process system as compared to batch process but once that work is done, the payback is substantial.
Generally, bench scale testing is conducted on a batch basis in the laboratory. However, semicontinuous processes can be simulated at the bench scale. To test the boundary conditions and feasibility of any commercial process, pilot plant testing is required. It is at the pilot plant stage that continuous processes are truly tested.
At PROCESSOL, we provide – Scalable solutions for Pilot Plants across a range of industries, trying to switch from Batch Process to Continuous Process. We customize each pilot plant as batch, semi-continuous, or continuous processes with specific equipment, control and instrumentation solutions to deliver the objectives you desire.
2. Pilot Photo Reactors
In recent years, the feasibility of applying “light” has made the photo-reaction process an economical and competitive method for range of industries.
An engineering approach towards the Detailing, Designing, Integrating and Supplying of an innovative compact photo-reactor for Catalytic Reaction / Chlorination / Antibiotic removal / photo-Fenton reaction / at the pilot-plant scale. The Detailing include light characterization (photon count and spectral irradiation) and reactor characterization (material of construction, chemical compatibility, pressure rating, mixing, residence time distribution, heat transfer, scaling factor, etc.). The Photo reactor can be made to comply with the Hazardous area classification and GMP requirements.
PROCESSOL – Pilot Photo-Reactor offers efficient light penetration. The photo reactor also features a tuneable LED irradiation source with different wavelengths, Agitator with variable RPM and Pressure / Temperature monitoring and control.
PROCESSOL Pilot Photo-reactors represent important intermediate steps in the upscaling and optimizing production system in commercial scale in order to minimize technical and economical uncertainties. They can be used for the production of small amounts of chemical compounds in the development of APIs / Intermediates / Fine Chemicals.