(109b) Scaling Up Particulate Process - Lessons from Industry

In the 1980’s, the Rand Corporation identified challenges in the commercialization of processes involving particles. Particulate process plants took longer to start up and achieved lower production rates than expected. Not enough has changed in more than 30 years. Processes involving particles are inherently more difficult than those for liquids and gases. A consistent lack of fundamental understanding dooms industry to empirical approaches, and the sensitivity of experiments to scale and equipment configuration leads to high costs and long development periods. Modeling by the discrete element method (DEM) has not yet fulfilled its promise, especially for small particles. This presentation will provide examples of the challenges involved in some of the unit operations of particle technology, and discuss strategies for scale-up, including the use of equipment suppliers, toll processors, modeling and pilot plants to bridge the knowledge gaps. Even with such strategies, education of both the engineer and the business leader is necessary to manage expectations and appropriately allocate resources.