Industrial processes and scale-up

A.Y. 2019/2020
Lesson for
Overall hours
Learning objectives
The main objective of the course is to emphasize the importance of scale-up methodology for the unit operations in chemical plants (reaction and separation processes), to give the theoretical basis for a correct approach to a scaling-up and to introduce the simulation science and the process simulation. The correct theoretical and experimental approaches of this kind of study will be presented and discussed; different industrial examples will be considered. Moreover, devoted software (PRO II) available to industrial chemists and engineers for the scaling-up operations will be presented and used in the course. Virtual plants, crude distillation unit in particular, based on a graphical interface with a dynamic simulation software will presented and proposed to the students using the ITS (Immersive Training System).
At the end of the course the students will acquire the knowledge for: 1) to use simulation plant software for the project and optimization of a chemical plant; 2) to analyze a chemical process (reaction or separation) from a laboratory scale experiment to a possible industrial process layout; 3) to apply kinetic and thermodynamic models for scale up development of new technologies.

Course structure and Syllabus

Active edition
CHIM/04 - INDUSTRIAL CHEMISTRY - University credits: 6
Lessons: 48 hours
Professor: Pirola Carlo
Course content
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:

- Scaling-up of a chemical operation: meaning and importance
- Laboratories and pilot-plant studies
- Models for the interpretation of experimental data and simulation of a chemical unit operations: steady-state and dynamic models
- Physical and chemicals models
- Pilot plants: raw materials, mock-ups, degree of freedom, constructive materials, test program and use of results
- Experimental techniques in scaling-up methodology
- Applications to industrial process development: industrial examples and case-histories
- Control technology in chemical processes
- Environmental and regulatory issues
- Use of simulation softwares in the scaling-up: PRO II. Tutorial of these programs and their use for several aspects involved in the topics of the course.
- Immersive Training system for a virtual visit in a Crude Distillation Unit plant.

Suggested prerequisites
The basic prerequisites are a good knowledge of physical chemistry and a basic knowledge of transport phenomena, chemical reactors, distillation and absorption columns, fluid phase equilibria.

Reference material [required]
- A. C. Dimian, C. S. Bildea, A. A. Kiss: Integrated Design and Simulation of Chemical Processes", 2nd Edition, Elsevier (available in our 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.
- The slides discussed in the lessons, available for the students

Assessment method
All the topics considered in the course will be discussed in a oral 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.

Language of instruction

Attendance Policy
Strongly suggested

Mode of teaching
The course will be based on 48 h of lessons in room in which:
1) theory of scale up will be explained (40%);
2) simulation software will be introduced and used (40%);
3) industrial case studies will be considered (20%).
Moreover, during the course, a visit in the Radici plant in Novara will be proposed and organized.

Lesson period
First semester
Assessment methods
Assessment result
voto verbalizzato in trentesimi
Educational website(s)
Monday: 9:30-13:30 am
Pilot Plants Laboratory (Build # 7 of the Chemistry Departement)