This document discusses challenges in scaling up chemical processes from the laboratory to the industrial scale. It emphasizes the importance of a systematic approach using models informed by experiments at different scales. Dimensionless groups allow insights from small-scale experiments and models to be applied at larger scales by capturing key relationships unaffected by scale. Process design challenges include variability in feedstocks, utilizing waste streams, energy costs, regulations, and rapid time to market.

1. Scale-Up Challenges in Chemical Engineering: The Role of ChemicalEngineers in the 21st Century

2. Plan Our activities The challenges for chemicalengineers A systematicapproach Industrialexamples

3. At a glance Pilot & scale up

4. Whyischemical engineering becomingcritical in thiscentury

5. Accessibility of the feedstock

6. Complexity of the feedstock

7. Complexity of the feedstock

8. Process design iseasy…

9. The model approach Lab Pilot Model -Fluidizationvelocities -Mass transfer coefficients -Pressure drops -MIXING -Bubbling/spargers -Entrainment -Foaming -Controllability/stability -Nozzles locations -Diffusion -Tray locations -Separationefficiencies -Product samples Conservation equations Constitutives equations Set boundary conditions Set operating conditions -Reactionkinetics -Heat of reactions -Equilibriumcurves -Mass transfercoeff. -Solubilityisotherms -Activity coefficients -Heat of solutions -Diffusivity coefficients -Operating temp/press -Rheology 𝑃𝐷𝐸/𝑂𝐷𝐸

10. Heattransfer in pyrolisiskiln No mixing Heat conduction 𝑑𝑇𝑑𝑡−𝑘𝐶𝑝𝜌𝛻2𝑇=0 𝑇∞ Boundary conditions 𝑆1 𝑘𝛻𝑇=𝑅 on 𝑆1 𝑘𝛻𝑇=0 on 𝑆2 𝑆2 𝑅=𝜎𝑆1(𝑇∞4−𝑇𝑆14) 𝛿 𝑇∞ 𝑇0 𝑇 𝛿

11. Lowtemperature canola protein extraction –extracting value fromlow value streams Oil: 1$/kg Meal: 0,20$/kg Meal: 0,20$/kg Oil: 1$/kg Isolates: 8 $/kg

12. Model application in process design– Phosporusremoval The Biodome Existingprocess Fish farms Packedbedreactor Phosphorus + water Water

14. Adsorption rate (−𝑟𝑃)2) Reaction of phosphoruswith lime to formhydroxylapatite 6𝑃𝑂43−+10𝐶𝑎2++2𝑂𝐻−−𝑟𝑃𝐶𝑎10𝑃𝑂46∗6(𝑂𝐻)2 Development of the model for 1-dimensional transientisothermalpackedbedreactor (no volume change) 𝑑𝐶𝑝𝑑𝑡=𝐹𝑉(𝐶𝑝,0−𝐶𝑝)+𝑟𝑝 Resolution 𝑟𝑝=−𝑘𝐶𝑝𝛼𝐶𝐶𝑎𝑂𝛽 𝑘=𝑘0exp−𝐴𝑅𝑇

15. Conclusion – Process design challenges Variability of the feedstock Need to extract value fromwastestreams Cost and variability of energy sources Environmentalregulations Water, air Rapid time to market Requiresqualifiedchemicalengineers AND a systematicprocess design approach

16. Scale-Up Challenges in Chemical Engineering: The Role of ChemicalEngineers in the 21st Century

18. Model application in process design: New processfeasibility - bioreactors Wheyproteinconcentrate Candy waste Ethanol Enzymes Yeasts Wheyproteins

19. The mechanisminvestigated Β-Galactosidase Lactose Glucose Galactose Yeast EtOH -13% Distillation/ Molecularsieves EtOH -200 proof

20. The scale change impacts In Gulliver's travel the hero arrives in a world with very tiny people. Can a scaled down human being can survive? Then he arrives in a world with giants. Can a scaled up human being survive ?

21. The scale change impacts Ants can support 10 times their own weight Water strider can walk on water but not a man

22. The scale change relations Scalerelationships – withgeometricalsimilarities Several implications in fluidmechanics, heattransfer and mass transfer.

23. Common dimensionless groups – the chemicalengineer’sapproach

24. Common dimensionless groups