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How can you use process modeling to optimize pilot testing?

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Pilot testing is a crucial step in chemical engineering to validate and improve the design of a process before scaling it up to commercial or industrial level. However, pilot testing can also be costly, time-consuming, and risky, especially if the process involves complex reactions, separations, or interactions. That's why process modeling can be a powerful tool to optimize pilot testing and reduce uncertainty, waste, and errors. In this article, you will learn how to use process modeling to plan, execute, and analyze pilot testing for different types of chemical processes.

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1 What is process modeling?

Process modeling is the use of mathematical equations, algorithms, and software to simulate the behavior and performance of a chemical process under various conditions and scenarios. Process modeling can help you understand the physical, chemical, and thermodynamic properties of the process components, the mass and energy balances, the kinetics and dynamics of the reactions, the transport phenomena, and the control and optimization strategies. Process modeling can also help you visualize the process flow, design the equipment and instrumentation, and estimate the costs and benefits.

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Dr. Thomas Murphy, Ph.D., JD, MBA, Chemical Engineer

Top 1% Chemical Process Engineering and Top 1% Financial Economics
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Process modeling, including mathematical equations, chemical kinetics, heat & mass transfer, equipment design, sustainability, and economics are important at all stages. Chemical process engineers connect these total requirements together into unit operations to meet the objectives. For example, in the polymer products area, recycling occurs at both the manufacturing and post consumer levels. Continuously Stirred Tank Reactors (CSTR) and Plug Flow Reactors (PFR) are utilized and these need to be designed to match flow rates and product quality specifications using partial differential equations on the CSTR and reaction kinetics (eg Arrhenius EQ). Being at a chemical plant that has both a semi-works and research facility is the ideal.

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2 How to use process modeling for pilot testing planning?

Before you start pilot testing, you need to have a clear objective, scope, and methodology for your experiment. Process modeling can help you define these elements by allowing you to explore different options, test hypotheses, and identify potential issues. For instance, it can be used to select the most suitable operating conditions for achieving product quality and yield, determine the optimal size and configuration of the pilot plant based on scale-up criteria and resources, evaluate safety and environmental impacts of the process and design mitigation measures, as well as estimate material and energy requirements, waste generation, and economic feasibility.

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3 How to use process modeling for pilot testing execution?

During pilot testing, process modeling can be used to monitor and control your process to ensure it runs smoothly and reliably. It can provide real-time data, feedback, and guidance to compare the actual performance of your process with the expected or desired outcomes, as well as adjust operating parameters to optimize efficiency and stability. Process modeling can also detect and diagnose any faults, malfunctions, or disturbances in your process, such as leaks or blockages, and take corrective actions. Additionally, it can record and store data from your process, such as the input and output streams, the equipment status, and the product specifications.

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Rishabh Vishwanatha

Project Engineer- AkzoNobel
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Process simulation when done right, can give extremely accurate H&MB which will lead to precise scenario setting (Nominal, High, Low) for process data sheet and RFQs. This will give you some degree confidence in how your pilot plant will function even before it is constructed. Detailed PDS and RFQs will also give you an edge when it comes to getting competitive prices from vendors for process equipment. But, in order to get confident process simulation results, one must always validate the H&MB and chemistry results with either previously done experimental data or one must conduct the same in lab scale before moving to the pilot scale.

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4 How to use process modeling for pilot testing analysis?

After pilot testing, you need to analyze and interpret your results to draw conclusions and recommendations for your process improvement or scale-up. Process modeling can help you do this by enabling various calculations, validations, and evaluations. For instance, you can use it to calculate key performance indicators (KPIs) such as yield, purity, and profitability; validate the accuracy and reliability of the process model; evaluate its sensitivity and robustness; and identify opportunities and challenges for scale-up. This is done by analyzing the effects of scaling factors like geometry, residence time, or heat and mass transfer coefficients on process performance.

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HARIHARAN V

Graduate Engineering Trainee at ISRO Propulsion complex (IPRC) | Chemical Engineer | passionate about design and innovation | Defence Aspirant
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Process modeling serves as a critical bridge between pilot-scale experiments and full-scale operation. By simulating real-world conditions, it allows engineers to predict how processes will behave at larger scales. This predictive capability is invaluable for identifying potential bottlenecks and ensuring that scale-up efforts are grounded in data-driven insights. Moreover, the ability to tweak process parameters virtually helps in optimizing the process before committing to expensive, time-consuming changes in the actual setup.

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5 What are the benefits of process modeling for pilot testing?

Process modeling for pilot testing can be incredibly beneficial, as it can save both time and money, while also improving quality and safety. Furthermore, it increases knowledge and confidence, by providing insight into process behavior and performance. Process modeling also facilitates communication and collaboration between stakeholders, such as engineers, researchers, managers, and customers. Ultimately, it can reduce the number of trials, the amount of materials and energy used, and the duration of testing.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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HARIHARAN V

Graduate Engineering Trainee at ISRO Propulsion complex (IPRC) | Chemical Engineer | passionate about design and innovation | Defence Aspirant
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Process modeling serves as a virtual sandbox, allowing engineers to test various scenarios and optimize conditions before physical trials. It's crucial to consider that models are simplifications of reality, so while they can predict trends and identify potential issues, they cannot capture all the complexities of a real-world system. Therefore, it's essential to iteratively refine models with pilot testing data to improve their accuracy and reliability, ultimately saving time and resources in process development.

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How can you use process modeling to optimize pilot testing?

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1 What is process modeling?

2 How to use process modeling for pilot testing planning?

3 How to use process modeling for pilot testing execution?

4 How to use process modeling for pilot testing analysis?

5 What are the benefits of process modeling for pilot testing?

6 Here’s what else to consider

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