(164c) Process Intensification of Multiple Separations in a Pilot Plant Process Via the Implementation of a Nutsche Filter

A new process in the research and development phase rarely makes it through scale up from laboratory to pilot scale and beyond without a significant technology change. In some cases, it results from the infeasibility of the process at a larger scale using the laboratory technology, but often times, the changes are the result of process intensification and optimization in preparation for the construction of a commercial scale unit.

In this particular case, a pilot plant was being constructed in part to provide scale-up information on the reaction system, but the primary goal was to deliver market development samples for a startup company in a timely and inexpensive fashion. This presented opportunities to investigate ways to reduce capital and operating expenses for the pilot plant, even if there is a possibility that the process implemented in the pilot plant will not be the ultimate commercial solution.

This presentation is a case study based on a pilot plant facility operating in South Charleston, West Virginia. A solids-handling process was scaled-up from a laboratory facility and was originally designed to utilize a three-step separations process to precipitate, wash, and dry the final product. We will explore the evolution of the project, the project goals, and other deciding factors that led to the implementation of the three-step process inside of a single Nutsche filter-dryer despite the possibility that the commercial process will be different. The presentation will also discuss the benefits and disadvantages of the Nutsche filter in a pilot plant setting.