Advantage Pilot Plant to Ensure a Smooth Commercial Process

Why is a pilot plant important for research and development? Most processes are scale dependent, making a pilot plant an integral part of the commercial process. The transition from a small-scale operations to a large scale production plant can be a challenging process. In such cases, the transition needs to smooth, but the initial set-up can be difficult. 

A large scale production plant is usually built on information which has been gathered by smaller units. 
There could be variations in kinetics, with reactions not as per expectation.

A pilot plant can help minimize the risk of human error, making performing experiments easier. A pilot plant allows you to make authentic comparisons as well as aiding in producing products in small quantities. When produced in small quantities, studying the reaction process is easier. Samples can also be handed over to consumers. In fact, for a pharma glass company, testing glass before manufacturing in a pilot plant is always a good option. 

A pilot plant is useful as far as coming with estimates of mass balance. Companies will be able to yield proper estimates. Lab experiments usually yield erroneous mass balances because quantities are smaller. When it comes to large scale production, values are way higher. The plant allows for the production of specialty chemicals that could go down well with markets.

Pilot plant | Pharma Glaass

A pilot plant can help an industrial unit proceed from lab testing to a full fledged operation without too much of a risk associated.The economics of setting up a large scale production is taken care of as corrosion resistant products, which may be the case with pharma glass,  may not really sell well. 

The Benefit of a Pilot Plant in Speeding the Commercial Process

Have you ever asked yourself why you needs a pilot plant for research and development? In fact, a number of processes are scale dependent. It can be quite a challenging experience to transition from small-scale operations to a large scale production plant. The transition needs to be smooth but the initial setting up can be a big scare.

A huge production plant is sometimes built based on information which is gathered at the small unit. However, the kinetics may differ considerably and the reactions may not be up to par. However, sometimes the best laid plans may not go according to plan. The worst case scenario could be that uncontrolled heat build-up could lead to abnormal reactions and possible explosions even if some materials are corrosion-resistant.

This cannot be attributed to human error, rather it could be a process that went wrong. The process takes a different turn when there is a change. It is also not possible at times to forecast these problems as they may be too complex to comprehend. A pilot plant can be very helpful as far as minimising error is concerned. Therefore, experiments can be studied more thoroughly without posing a major risk. The pilot plant does not only provide data before increasing scale of production, it serves other function. This include:

Corrosion resistant

1. It helps in making an authentic comparison with commercial grade raw material against the grade counterpart in the laboratory. During a lab study, the use of raw material and catalyst is not very big. Therefore, a highly pure grade can be used for the experiment. However, when it comes to a production plant, using pure materials would be feasible. Commercial grade material is best used.

2. The plant can be used for the production of small product quantities which can be used as raw material for market testing. The plant can be used to produce quantities which can be used to study the reaction process which might follow. It is one of the best ways to test a product in the real market. Samples can be handed out to customers to gauge their reactions

3. The quality of waste and by-products can be studied, in addition to assessing their saleability.

4. Waste generated can also be studied to determine if waste treatment is necessary. This will help understand the economics associated with the process.

5. A pilot plant will help come up with a more detailed mass balance. It will allow companies to give yield estimates. Lab experiments normally generate a sizeable number of erroneous mass balances due to the fact that quantities are much smaller. When it gets down to a full-blown production, the values are much higher.

6. A pilot plant will give you the liberty of producing specialty chemicals that may be appreciated by a more niche market. Therefore, it can safely be said that a pilot plant can help a business go from lab testing to high production plant faster without posing much of a risk. It also aids in keeping in focus the economics involved in setting up a large scale production because corrosion-resistant products may not translate to saleability.