Industrial Processes and Scale-Up
A.Y. 2025/2026
Learning objectives
The aim of the course is to provide students with the theoretical notions for the correct scale up of unit operations in the chemical industry. The course will analyze characteristics, usefulness and limits of laboratory scale equipment, bench scale, pilot plant and industrial plant. The mock up plants for the study of the transport phenomena involved will be discussed. The methodologies for defining the correct models for the scale up starting from the experimental data collected in the laboratory scale will be presented. The lectures will start from the basic theoretical concepts of chemical plants.
Expected learning outcomes
At the end of the course, the student is expected to be able to: 1) define the development status of a technology and its TRL; 2) apply the basic concepts of process design for the development of a new technology; 3) identify the possible critical aspects of a unit operation on industrial scale and identify possible solutions; 4) design laboratory-scale experiments to obtain the data at the basis of the scale up process; 5) select and define the kinetic and thermodynamic models necessary for scaling up; 6) use process simulation software for process design, scale up and plant optimization.
Lesson period: First semester
Assessment methods: Esame
Assessment result: voto verbalizzato in trentesimi
Single course
This course cannot be attended as a single course. Please check our list of single courses to find the ones available for enrolment.
Course syllabus and organization
Single session
Responsible
Lesson period
First semester
Course syllabus
The course will be devoted to a specific introduction of the scaling-up methodology for chemical processes from a chemical and an engineering point of view. Both chemical reactions and separation processes will be taken into account. More in detail, the following topics will be explained and discussed:
1) Scaling up theory
- Introduction to software simulation
- Scale up and numbering up
- 0.6 rule and TRL of a technology
- Scaling up methodology
- Chemical plant project basis considerations
- Process Flow Diagram (PFD) hierarchical approach
- The rules of thumb for industrial chemistry
- Mathematical, physical, chemical models
- Equipment and Operation in pilot plants
- Pilot plant and cold flow models (mock up): steam cracking industrial case study
- Experimental techniques in scale up
- Carbon Capture Utilization Storage: basic principles and analysis of the scale up and TRL of these new processes
- Hazop analysis for the evalutation of the risks connected with scale up
2) Scale up theory development for separation columns and reactors
2.1 Water-Acetic Acid distillation column:
- Phase equilibria discussion and interpretation
- Evaluation and optimization of the cost of the column
2.2 Acetic acid- methanol esterification reactor
- Equilibrium reactors (equilibrium, conversion, Gibbs reactor)
- Kinetic models for the reaction and parameters regression
- Simulation of Batch and PFR for this system
3) Simulation science
- Use of a commercial software for static simulation PRO II
- Introduction of a commercial software for dynamic simulation: DYNSIM
- Exercises on LVE, distillation columns and chemical reactors (for items 2.1 and 2.2)
- Virtual Crude Distillation Unit excercises
1) Scaling up theory
- Introduction to software simulation
- Scale up and numbering up
- 0.6 rule and TRL of a technology
- Scaling up methodology
- Chemical plant project basis considerations
- Process Flow Diagram (PFD) hierarchical approach
- The rules of thumb for industrial chemistry
- Mathematical, physical, chemical models
- Equipment and Operation in pilot plants
- Pilot plant and cold flow models (mock up): steam cracking industrial case study
- Experimental techniques in scale up
- Carbon Capture Utilization Storage: basic principles and analysis of the scale up and TRL of these new processes
- Hazop analysis for the evalutation of the risks connected with scale up
2) Scale up theory development for separation columns and reactors
2.1 Water-Acetic Acid distillation column:
- Phase equilibria discussion and interpretation
- Evaluation and optimization of the cost of the column
2.2 Acetic acid- methanol esterification reactor
- Equilibrium reactors (equilibrium, conversion, Gibbs reactor)
- Kinetic models for the reaction and parameters regression
- Simulation of Batch and PFR for this system
3) Simulation science
- Use of a commercial software for static simulation PRO II
- Introduction of a commercial software for dynamic simulation: DYNSIM
- Exercises on LVE, distillation columns and chemical reactors (for items 2.1 and 2.2)
- Virtual Crude Distillation Unit excercises
Prerequisites for admission
The indispensable prerequisites are a good knowledge of physical chemistry, in particular of chemical kinetics, of the laws of thermodynamic equilibrium and of the basic theory of distillation columns and liquid-vapor equilibria. It is also recommended to have basic notions on transport phenomena (turbulent flow, laminar flow, heat exchangers) and chemical reactors. These prerequisites are taught in the three-year degree courses in industrial chemistry, mainly Physical Chemistry I, Physical Chemistry II, Chemical Plants with Laboratory, Industrial Physical Chemistry, Industrial Chemistry, Complements of mathematics and numerical calculus.
Teaching methods
The course will be based on 48 h of lessons in room in which: 1) theory of scale up will be explained (60%); 2) simulation software of chemical plants will be introduced and used (20%); 3) industrial case studies and examples will be considered (20%). Moreover, during the course, a visit in a industrial plant will be probably proposed and organized.
Teaching Resources
- A. C. Dimian, C. S. Bildea, A. A. Kiss: Integrated Design and Simulation of Chemical Processes", 2nd Edition, Elsevier disponibile nella biblioteca di Chimica)
- V. Ragaini, C. Pirola, "Processi di Separazione nell'Industria Chimica", Hoepli
- The properties of Gases and Liquids Autori: B. Poling; J. 'O Connell; J. Prausnitz. McGraw-Hill 2004
- Scale-up Methodology for Chemical Process. Autori: J. B. Euzen, P. Trambouze, J. P. Wauquier, Edition Technip.
- Presentations of classroom lessons and other teaching material (scientific articles) always available on the MY ARIEL-UNIMI platform
- V. Ragaini, C. Pirola, "Processi di Separazione nell'Industria Chimica", Hoepli
- The properties of Gases and Liquids Autori: B. Poling; J. 'O Connell; J. Prausnitz. McGraw-Hill 2004
- Scale-up Methodology for Chemical Process. Autori: J. B. Euzen, P. Trambouze, J. P. Wauquier, Edition Technip.
- Presentations of classroom lessons and other teaching material (scientific articles) always available on the MY ARIEL-UNIMI platform
Assessment methods and Criteria
All the topics considered in the course will be discussed in a oral or written examination. Theoretical questions and/or practical exercises using the simulation software will be requested. The students should be able to discuss all the topics of the course, to explain the industrial examples considered in the lessons and to make exercises using the simulation software concerning optimization of columns or reactors.
Professor(s)
Reception:
Monday: 9:30-13:30 am
Pilot Plants Laboratory (Build # 7 of the Chemistry Departement)