che_june-2024 - 29

be used to perform more accurate lifecycle
analysis (LCA), especially if the
technology is intended as a cleaner,
more environmentally friendly alternative
to an existing production process.
Full-size demonstration (7-9)
The next stage of technology maturation
is to design, build and operate
a full-scale demonstration system
under the expected range of operating
conditions. Given the larger size
of the full-scale demonstration plant,
development times and schedules
will be similar to conventional large
CPI projects (see Figure 1, for example),
and will require applying for
regular environmental and construction
permits approval.
Learnings from the design and
operation of the pilot plant will be
used as reference for the full-size
facility. The process flow diagrams,
heat and material balances, P&IDs,
equipment data sheets, specifications
for piping, instruments and
components can be used as basis,
considering all markups or recommendations
from the pilot-plant operations.
Redundancy requirements
(for example, pumps, compressors,
and other vital equipment) can be
higher for the demonstration plant,
since it will be expected to operate
continuously under commercial (or
service) conditions.
When determining the scaleup
strategy, a typical decision is to scale
up by increasing capacity of the
equipment, or by adding modules
of similar capacity. Scaling up by increasing
capacity usually comes with
the benefit of economies of scale, but
increases the risk that performance
and cost will deviate from those predicted
from the pilot-plant data. Also,
very large pieces of equipment may
require on-site assembly.
Scaling up by adding modules may
come at the initial cost of dis-economies
of scale, due to a higher number
of smaller pieces of equipment,
but may have several advantages
that could prove beneficial in the
long run: the smaller scaleup factor
reduces the risk of unpredictability in
cost and performance, the smaller
module size may allow serial manufacturing
at a factory (which benefits
quality assurance and control), and
the larger number of units may allow
for learning curve effects to improve
productivity (and reduce costs).
Often, a combination of both strategies
is desirable. The team may
select to design and build modules
from a minimum commercially competitive
capacity (as determined
through technoeconomic and business
case analysis) for the first-ofits-kind
full-scale plant, and increase
the module capacity over several
future iterations of the technology,
to access economies of scale while
maintaining quality control of manufacturing.
The initial modules can be
designed to fit into units transportable
by land or sea, and later modules
that exceed transportation size
limits could be separated into a series
of packages (or " kits " ) that can
be manufactured at the factory, then
transported and sequentially assembled
on site.
When evaluating the procurement
and construction strategy for the first
commercial plant, it is often recommended
to begin considering longterm
logistic solutions, including
potential partnerships with suppliers
of goods and services. At this point,
the team may decide which parts
of the supply chain to source from
third-party suppliers, and which to
source in-house.
Large engineering, procurement,
and construction (EPC) firms
that
have well-established supply chains
may elect to adhere to their existing
processes and perform several design
and assembly tasks in-house.
Smaller or startup companies may
opt for third-party engineering companies
for design and workshops for
module assembly tasks. When outsourcing
design or assembly tasks,
it is important to have adequate intellectual
property
agreements in
place, as discussed below.
Performance testing for the demonstration
plant should be similar to tests
performed in similar projects in the CPI
and should aim to validate fulfilment of
desired performance targets. Performance
curves, obtained from variation
of flowrates and conditions (for example,
start up, variation of load and so
on) should be another important output
of performance testing.
The cost and performance data
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