Chemical Engineering December 2022 - 40

integrated approach
can result
in a faster
implementation. The
engineering ideally is divided
into three phases,
as described in the
following sections.
Phase 1: Concept
study. Within the framework
of concept studies,
operating conditions,
such as pressure and
temperature, the type of
catalyst and the dosing
options are determined
from
the
FIGURE 4. This heuristic procedure can be applied for the scaleup of
hydrogenation reactors
for a specific impeller. At the same
time, while modeling the laboratory
reactor, a first design of the commercial
reactor
can be proposed
and compared to the model of the
laboratory-scale reactor.
During process development, it is
essential to find the critical mixing
task of the process (Step 3). This
mixing task can then be used as
the main scaleup criterion to commercial
scale. Due to the relationship
described in the Penney diagram,
other relevant mixing tasks will
change during scaleup. The commercial
reactor design is then finalized
by cross-checking all relevant
mixing tasks (Step 4). In a last step,
the scaleup can be verified using
computational fluid dynamics (CFD)
simulations (Step 5). This step is optional
- but can be especially useful
if complex requirements exist, such
as a certain homogeneity in temperature
or concentration distribution.
Process plant engineering
Having performed a successful
study followed by an appropriate
scaleup to the commercial scale, the
centerpiece of the process - the
hydrogenation reactor - is welldefined.
Now, the task at hand is
to design the industrial production
process and the corresponding systems
engineering. For the hydrogenation
of biomass-based materials,
single-source suppliers offer not only
the reactor design, engineering services
and construction of plants, but
also support for commissioning. This
40
laboratory
data. The upstream and
downstream process
steps, such as catalyst
preparation and separation,
are also considered
in the concept study. Special
attention is paid to the potential to
reuse the catalyst. Catalyst handling
is often underestimated and
needs to be addressed accordingly.
Depending on the concept, manual
operations, as well as partially
and fully automated systems, are
possible options.
Phase 2: Basic engineering. During
basic engineering, the dimensions of
the main equipment components
are determined. These are based on
the general requirements of the end
users, such as the desired production
volume and the available media
and energy sources. At the same
time, the piping and instrumentation
diagram (P&ID) is compiled during
this stage of development. Transfers
to storage tanks, devices for dosing
and safety devices are also defined
in the basic engineering. The P&ID is
an important planning document for
the further progress of the project.
A reduced number of interfaces in
this project phase leads to reduced
planning and investment costs. During
the basic engineering phase, it
is usually necessary to initiate the
procurement process for components
with long delivery times, in
order to be able to complete the
system in a timely manner. As a
result, this project phase is of the
utmost importance.
Phase 3. Detailed engineering. In
the subsequent detailed engineering,
the P&IDs, pipelines,
fittings,
measuring points and control circuits
are completed and finalized.
At the same time, the piping layout
and functional description of automation
are created. Based on these
documents, the procurement of
the components and the assembly
planning begins.
The combination of process development,
engineering and construction
and support for commissioning
strongly reduces project times,
which is essential in a growing field
like the hydrogenation of biomassbased
materials.
■
Edited by Mary Page Bailey
Authors
Konstantin Epp is a process specialist
at Ekato RMT's R&D department
(Hohe-Flum-Strasse
His
main
working area is gas-liquid
mixing and heterogeneous catalysis
with special focus on the piloting
and scaleup of hydrogenation
reactions and process optimization. Epp obtained his
Ph.D.
in inorganic chemistry from the Technical
University of Munich.
Wolfgang Keller is head of Ekato
RMT's R&D department (Hohe
Flum Strasse 37,
Schopfheim,
37,
D-79650 Schopfheim, Germany;
Phone + 49 7622 29349; Email:
konstantin.epp@ekato.com).
D-79650
Germany; Phone:
He
+49 7622 29468; Email:
wolfgang.keller@ekato.com).
has more than 20 years of professional
experience in process engineering
and development, especially
focused on polymer and
minerals processing applications. Keller holds an M.S.
degree in chemical process engineering from the University
of Karlsruhe.
Marc Labusch is head of Ekato
RMT´s reaction engineering R&D
group (Hohe Flum Strasse 37,
D-79650 Schopfheim, Germany;
Phone: + 49 7622 29742; Email:
marc.labusch@ekato.com).The
group is focused on the design of
stirred reactors for gas-liquid reactions
and for support during the
full lifetime of process plant projects,
from the laboratory to the industrial plant. Labusch
obtained his M.S.Ch.E. at the University of Applied Sciences
in Krefeld and received his Ph.D. at the University
of Duisburg-Essen.
Peter Rojan is the head of Ekato
RMT's Process Plant Solutions
Sales Group (Hohe Flum Strasse
37, D-79650 Schopfheim, Germany;
Phone: + 49 7622 29-529,
Email:
peter.rojan@ekato.com).
He has more than 20 years of experience
with the international
pharmaceutical and chemical industry
and the sales of process
plant equipment worldwide. Rojan previously worked for
major engineering companies in the fields of mechanical
and thermal separation processes. He holds a
M.S.Ch.E. from the University of Karlsruhe.
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