(180d) Use of Shortcut Methods in Process Development

Shortcut approaches can often be advantageously used in process development, where time or cost may preclude development of a traditional, fully integrated pilot plant. In some cases, they may represent the only viable method for elucidation of trace chemistry, via side-by-side comparison under carefully controlled conditions. This presentation describes a number of short cut approaches used in petrochemical process development. Examples include replacement of a $250,0000 pilot plant which would give the wrong answer, with a $5 syringe providing the correct answer; use of an NMR-tube as a continuous-flow fixed-bed catalytic reactor; batch simulation of various continuous unit operations (reaction, crystallization, stripping, extraction) in small vials. Commercialization case histories are examined to draw rules of thumb as to when shortcut methods may be successfully applied, vs. where they should be avoided in favor of more rigorous piloting and demonstration. Economic criteria for optimizing the scope and scale of pilot and development programs are discussed.