(140a) Modular Scale Up Lab Design: Improving Batch-to-Continuous Speed to Market

Modular Chemical Process Intensification (MCPI) has its clear benefits, from improving process efficiency and productivity to enhancing process safety and sustainability. Unfortunately, many existing Lubrizol processes were designed before the onset of refined MCPI technologies. As such, Lubrizol is making concerted efforts to take their existing batch technologies and execute the development work which fosters the transition to continuous processing. However, for processes that have been well-established for decades, the transition from batch to continuous requires substantial development work.

The scale up of continuous, intensified unit operations can be challenging. To facilitate overcoming this challenge, Lubrizol has adopted a lab design strategy that will enable rapid scale up by leveraging multiple modular processing units. Previously, Lubrizol designed a flow chemistry lab that has evolved to now be complete with multiple modular systems, including a feeding/metering system, interchangeable reactor modules, post-reaction stripping and purification modules, and integrated use of in-line analytical technologies such as FTIR and FBRM. Recently, Lubrizol also committed to the design and construction of a high-pressure, high-temperature modularized lab space. The lab will feature a fully modular design consisting of multi-purpose feed vessels, a custom flow reactor skid, and an intensified evaporator/distillation skid. All aspects of this lab were designed with intentional flexibility and adaptability. The systems held within the lab will be able to safely accommodate myriad chemistries to enable the batch-to-continuous transitions for not just one Lubrizol process, but for numerous in future years. As added safety features, the lab also integrates into existing vent abatement systems allowing for integrated scrubbing, vacuum, fume incineration and emergency flaring required for scale ups which utilize highly hazardous chemicals.

This session will delve into the detail of the design and engineering of the lab, and how this modular space will cultivate safe, effective and timely batch-to-continuous processing transitions for the next generation of processing technologies.