GEGELESO, OLUWATOSIN AYO

159041041
CHG 858 ASSIGNMENT

CLASSIFICATION OF PILOT PLANTS

1. Classification by processing material
a. Wet Pilot Plant
The Wet Pilot Plant is designed for processing fluid and wet materials,with an emphasis
on dairy products, fruits and vegetables for food industry pilot plants.
b. Dry Pilot Plant
The Dry Pilot Plant is designed for processing products in a low relative humidity
environment, with an emphasis on powders and confectionery products.

2. Classification by Size
Pilot plants can be classified many different ways. The most common way is by size.
a. Laboratory scale, bench top pilot plants or microunits
These are pilot plants that generally fit on a bench top or inside a small laboratory hood
(hence the name). In general they are in the range of 5-15 ft2 and use 1/16" to 1/4" tubing
for piping. Traditionally totally manual and continuously attended, many new versions
are heavily automated and designed to run continuously, unattended.
b. Integrated pilot plants or research scale pilot plants
This remains the workhorse of the industry and may vary in size from several frames or
pallets to a unit occupying a small building. In general they are in the range of 10-500 ft2
and use 1/8" to 1" tubing and/or 1/4" to 2" pipe. They are usually automated and may
frequently be designed for unattended operation.
c. Demonstration units, semi-works units or prototype units
These are units designed to operate at the lower end of plant scale. They are very large,
typically in the order of 500 ft2 or more, and utilize smaller commercial pipe sizes
typically in the range of 1"-8". Normally they are closely resemble the plant in
automation and operation.

While classification by size is useful in placing the pilot plant's costs, scale and
requirements in perspective, it is not very useful. The size of a pilot plant has little
intrinsic merit; it only indicates that a larger unit is generally more expensive to design,
construct and operate.

3. Classification by Research Purpose

Another classification is by research purpose or strategy. Generally pilot plants can be

broadly grouped into their research program purpose. In this case purpose refers to the
overall program approach rather than just the pilot plant design philosophy.
a. Process Simulation
This strategy involves making the pilot plant resemble the actual process as much as
possible. The pilot plant will typically includes all major process steps in the actual order
used in the plant, utilizing as much of the plant equipment and conditions as possible. As
much of the actual process is followed as closely as possible in the design and
construction of this type of pilot plant.

This type of pilot plant strategy lends itself to an established process which has a
relatively long projected life. While expensive, it is frequently the least risky approach;
with sufficient time and resources an answer to most operating problems can usually be
obtained.
b. Problem Solving
This strategy involves focusing the pilot plant on solving a specific problem or
addressing a specific concern. The pilot plant is designed to investigate a very specific
area or problem and only those components of the process affecting the area or problem
are included. Sometimes this type of pilot plant resembles a piece of the operating plant
while at other times it bears little relationship to any part of the commercial process.

This type of pilot plant strategy is probably the most common in wide use. In a large
organization, specialized pilot plants can sometimes be reused to support work on
different processes with little or no added investment. In a smaller organization,
specialized pilot plants can sometimes be constructed as required and mothballed or
decommissioned for later reuse.
c. Basic Research
This strategy focuses on studying the underlying principles behind a process or problem
with a view towards developing a new or improved understanding of the theoretical basis.
This could allow solving the problem more effectively or developing a major process
improvement. This type of pilot plant is designed to gather the required basic data or
investigate the basics of the process or operation; it has little if any resemblance to the
process plant. The design of the pilot plant is set by the data required and the type of
investigation desired. It is usually heavily influenced by available analytical tools,
techniques and limitations. The distinction between laboratory style research and a Basic
Research pilot plant is frequently obscured with size and complexity swaying the
classification into the pilot plant range.

It is important to realize that this type of pilot plant strategy uses the pilot plant as more
of a research tool than a research unit. It is usually only feasible for a larger organization
due to it's high cost, specialized nature and extended duration. On the other hand it is
frequently a major tool for new theoretical understanding of many processes.

4. Classification by Design Approach

A final commonly used classification of pilot plants is based on their design approach.
The type of pilot plant based on the design approach is different from the type of pilot
plant strategy in that it refers to the specifics of the design of the pilot plant rather than to
the general program purpose, strategy or philosophy. A process simulation pilot plant
strategy follows the process design closely. The pilot plant itself may be a general
purpose pilot plant in that it is designed to cover all or at least a broad range of the plant's
operating conditions or a problem solving pilot plant designed to focus on a narrower
process area.
a. General Purpose Pilot Plants
A general purpose pilot plant is constructed for a broad, relatively non specific purpose. It
typically is designed to operate over a wider range of feed rates, feedstocks and operating
conditions. General purpose pilot plants are frequently used by equipment vendors for
testing a proposed installation or by companies doing research on unit operations over
their entire process.
b. Single Purpose Pilot Plants
A single purpose pilot plant is constructed to allow a single part of a process to be
investigated in greater detail. It usually has a clearly defined purpose and little auxiliary
operations not required to achieve this end. The operating ranges are usually more
restrictive than in a general purpose pilot plant but they may be substantially broader if
that is the primary purpose of the pilot plant program.
c. Multi Purpose Pilot Plants
A multi purpose pilot plant is designed for two or more dissimilar purposes. Typically
these purposes usually require substantially different capabilities and designs. This type
of pilot plant should be approached with great caution particularly by a new or relatively
inexperienced organization. In many cases, the actual benefits incurred are few while the
relatively hidden liabilities and problems numerous.
d. Multiple Unit Pilot Plants
A multiple unit pilot plant is a single purpose pilot plant repeated two or more times in a
single unit. While sharing a common infrastructure including, usually, utilities, analytical,
instrumentation and control systems, area and operating personnel, separate unit
capabilities are provided. Typically, this allows simultaneous operation in any of the
following modes:
  data generation by testing a common feed or catalyst at separate operating
conditions
 data verification by running identical tests and comparing results
 multiple testing in support of different programs by testing different feed or
catalysts at different operating conditions

This type of pilot plant is gaining wide acceptance. A variation on the design is to include
trains or modules to allow expansion of one or all of a train's basic capabilities to other
areas, in effect making the unit somewhat of a multiple purpose multi-train pilot plant.

High Throughput Pilot Plants

These are typically lab scale microunits with numerous separate reactors or small process
trains with 10-50 per unit. Their intent is to allow a bank of similar experiments to be run
simultaneously to develop a range of data for evaluation. Very expensive, very complex
and very difficult to run they are certainly a new tool in the research world.
Summary
Note that all these classifications are subject to wide interpretation. Just as a valve may be
called a globe valve, a throttling valve, a multiple turn valve, a slow acting valve, and
similar different names to describe one of its functions so a pilot plant is, after all, what it
is – no matter what you call it. Every organization has different names, different
definitions, and a different logic.