che_june-2024 - 27

SMS equipment for
(for example, solid waste, effluents,
fluegas), can be simulated by utilizing
synthetic samples created in the laboratory
by mixing commercially available
standard compounds. These
synthetic samples allow testing the
system performance against variations
in source materials quality to
identify any correlation between system
output variables and said inputs.
Initial laboratory tests can utilize
batch processing, where individual
subsystems or unit operations are
tested, and their outputs are fed
to the following unit operations in
the process, but bench-scale tests
should progressively aim to integrate
the subsystems until they
are able to replicate a continuous
or semicontinuous process. At this
point, the R&D team should seek to
run the bench-scale plant at conditions,
and with materials, that more
closely resemble those expected
in a real-life environment (or under
conditions that are close enough to
be considered relevant).
Once the laboratory and benchscale
testing has concluded, all gaps
of information about the physical,
chemical, thermodynamic and kinetic
behavior of the process should
have been addressed. At this point,
the initial computer-simulation models
should be revisited and adjusted.
The technical and economic performance
of the process should be
reassessed, with a lower level of
uncertainty, and a concept of both
a pilot-scale and a full-scale facility
should be developed on paper. The
concept for the pilot-scale facility will
be part of the work plan for the next
level of technology maturation.
Pilot process (TRL 6)
The next step in technology maturation
consists of designing, building
and operating a pilot plant. To design
the pilot plant, an adequate scale
should be selected (DOE recommends
a typical of 1/10th the capacity
of a commercial full-scale facility,
though the scale could be adjusted
depending on the system on evaluation
[1]). The capacity of the pilot
facility could also be defined in terms
of the smallest available commercial
component, when defining the process
around a critical technology, or
by the capacity of a module, if the
project design team is thinking on a
modular scaleup strategy.
The pilot-plant facility design
should follow the regular engineering
design process utilized for designing
a conventional plant, with some caveats,
as stated here:
* If possible, it is recommended to
design the pilot plant in a manner
similar to a skid-mounted packaged
unit. This would enable temporary
installation at different test sites to
widen the range of relevant conditions
where the full-scale unit is expected
to operate, while also allowing
convenient removal of the pilot
unit from the test site after the tests
have been completed.
* The design should consider adequate
flexibility in operating flowrates,
temperatures and pressures, and
adequate controls to adjust these to
cover a wide range of conditions, as
expected in results.
* The design should ideally consider
strategically located removable
spools, isolation valves, spectacle
blinds, and other facilities to enable
quick maintenance access, replacement
of parts, or on-the-go modifications
if required (this is particularly
important when the process handles
solids, sludge, precipitates or similar
substances that may present material
handling, plugging, freezing or transport
problems as operations begin).
* If the plant is expected to be tested
under varying weather conditions (or
transported to different locations), the
design of the facilities should consider
the range of expected extreme
conditions and include measures for
winterization, tropicalization or other.
Electric heat tracing or steam jackets
could be considered if the plant will
not typically be expected to operate
under extreme winter but could
be installed temporarily at a location
with very cold temperatures.
* In some cases, the pilot-plant design
can exclude utilities (unless the
utilities form an integral part of the
technology, such as in waste-energy
recovery from the process). In this
case, the utilities balance should
consider the quantities and specifications
of utilities (such as steam,
compressed air, nitrogen, natural gas,
electricity) that the plant will require to
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