Industrial Processes and Scale-Up
A.Y. 2026/2027
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 can be attended as a single course.
Course syllabus and organization
Single session
Responsible
Lesson period
First semester
Course syllabus
The course provides a focused introduction to the methodology of chemical process scale-up from both chemical and engineering perspectives. Both chemical reactions and separation processes will be addressed. In particular, the course will cover the following topics:
**1) Scale-up Theory**
* Introduction to process simulation
* Scale-up and numbering-up approaches
* The 0.6 scaling rule and the Technology Readiness Level (TRL) framework for the development of new technologies
* Scale-up methodology and process development
* Basic principles of chemical plant design
* Hierarchical approach to Process Flow Diagram (PFD) development
* Empirical rules for industrial scale-up
* Mathematical, physical, and chemical models for process scale-up
* Design and operation of pilot plants
* Pilot plant models and cold-flow mock-ups: industrial steam cracking case study
* Experimental scale-up techniques for residence time distribution (RTD) analysis
* Carbon Capture, Utilization and Storage (CCUS): fundamental principles and analysis of scale-up strategies and Technology Readiness Levels
* Hazard and Operability (HAZOP) analysis for risk assessment during scale-up and methodologies for ensuring the safety of industrial chemical processes
**2) Development of Scale-up Theory for Separation Columns and Chemical Reactors**
**2.1 Water-Acetic Acid Distillation Column**
* Analysis and interpretation of fluid-phase equilibria
* Economic evaluation and cost optimization of an industrial distillation column
**2.2 Acetic Acid-Methanol Esterification Reactor**
* Equilibrium reactors (chemical equilibrium, conversion, and Gibbs reactor)
* Kinetic models for the esterification reaction and parameter regression
* Simulation of batch, plug flow (PFR), and continuous stirred-tank (CSTR) reactors
**3) Process Simulation**
* Use of commercial software for steady-state process simulation (PRO/II and APS)
* Introduction to commercial software for dynamic process simulation (DYNSIM)
* Practical exercises on distillation columns and chemical reactors (related to Sections 2.1 and 2.2)
**1) Scale-up Theory**
* Introduction to process simulation
* Scale-up and numbering-up approaches
* The 0.6 scaling rule and the Technology Readiness Level (TRL) framework for the development of new technologies
* Scale-up methodology and process development
* Basic principles of chemical plant design
* Hierarchical approach to Process Flow Diagram (PFD) development
* Empirical rules for industrial scale-up
* Mathematical, physical, and chemical models for process scale-up
* Design and operation of pilot plants
* Pilot plant models and cold-flow mock-ups: industrial steam cracking case study
* Experimental scale-up techniques for residence time distribution (RTD) analysis
* Carbon Capture, Utilization and Storage (CCUS): fundamental principles and analysis of scale-up strategies and Technology Readiness Levels
* Hazard and Operability (HAZOP) analysis for risk assessment during scale-up and methodologies for ensuring the safety of industrial chemical processes
**2) Development of Scale-up Theory for Separation Columns and Chemical Reactors**
**2.1 Water-Acetic Acid Distillation Column**
* Analysis and interpretation of fluid-phase equilibria
* Economic evaluation and cost optimization of an industrial distillation column
**2.2 Acetic Acid-Methanol Esterification Reactor**
* Equilibrium reactors (chemical equilibrium, conversion, and Gibbs reactor)
* Kinetic models for the esterification reaction and parameter regression
* Simulation of batch, plug flow (PFR), and continuous stirred-tank (CSTR) reactors
**3) Process Simulation**
* Use of commercial software for steady-state process simulation (PRO/II and APS)
* Introduction to commercial software for dynamic process simulation (DYNSIM)
* Practical exercises on distillation columns and chemical reactors (related to Sections 2.1 and 2.2)
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%).
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 course topics will be assessed through either an oral or a written examination. The assessment will include theoretical questions and/or practical exercises involving the use of process simulation software. Students are expected to demonstrate a thorough understanding of all course topics, discuss the industrial case studies presented during the lectures, and solve simulation-based exercises related to the optimization of separation columns and chemical reactors.
The assessment will be based on the following criteria:
* Ability to explain concepts using appropriate scientific and technical terminology.
* Ability to critically analyze examples and case studies, both those discussed during the course and independently developed.
* Ability to clearly describe the theoretical topics, exercises, and industrial examples covered in the course.
* Ability to critically discuss process scale-up and its industrial applications.
* Quality and clarity of the presentation.
* Appropriate use of specialized technical vocabulary.
The final grade will be awarded on a 30-point scale (out of 30). No midterm examinations or continuous assessment activities are scheduled during the course.
The assessment will be based on the following criteria:
* Ability to explain concepts using appropriate scientific and technical terminology.
* Ability to critically analyze examples and case studies, both those discussed during the course and independently developed.
* Ability to clearly describe the theoretical topics, exercises, and industrial examples covered in the course.
* Ability to critically discuss process scale-up and its industrial applications.
* Quality and clarity of the presentation.
* Appropriate use of specialized technical vocabulary.
The final grade will be awarded on a 30-point scale (out of 30). No midterm examinations or continuous assessment activities are scheduled during the course.
ICHI-02/A - Chemical Plants - University credits: 6
Lessons: 48 hours
Professor:
Pirola Carlo
Shifts:
Turno
Professor:
Pirola CarloProfessor(s)
Reception:
Monday: 9:30-13:30 am
Pilot Plants Laboratory (Build # 7 of the Chemistry Departement)