REKAYASA PROSES

Aulia Ulfah Farahdiba

Email: auliaulfah.tl@upnjatim.ac.id

Jurusan Teknik Lingkungan

Fakultas Teknik
Universitas Pembangunan Nasional Veteran , Jawa Timur
 Executive summary
• In scale-up, product and processdevelopment
tend to move in smallsteps
– Lab scale to bench scale, then to pilot scale,finally
to production scale
– This reduces the risk with the largerinvestments
in the next step
• Scale-down is mainly for troubleshooting or
development of processes used in ongoing
production
“Definitions”
• Laboratory scale (OK at university)
– Done in test tubes etc., some grams of product
• Bench scale (OK at university)
– Device fits in a normal room, kilograms
• Pilot scale (almost never at university)
– A “small industrial machine” that requires several
men to operate it, possibly has its own building,
tens of kilgrams to tons ofproduct
• Industry scale, machinery may occupy the
area of a university campus
These are the steps to industrial production!
• Lab scale: prove that a product can be made from
raw materials (“Proof of conceptstudy”)
• Bench: make enough product to test its
properties, learn about fundamentals of
processing, improve formulation
• Pilot: Try small scale production before bigger
investment at high risk. Critical points?Problems?
Automation? Space and power requirements?
Help in designing a factory or plant!
Use of pilot plant
• Check alternatives before designing full scale
production
– For example: which types of pumps, separators,
heat exchangers, mixers, dryers, etc.
– Handling interruptions in production: emptying
reactors or tanks, cleaning, shut-down and start-
up procedures
• When full-scale production is ongoing
– Solve problems without interrupting production,
take the problems to the pilotmachine
 Further uses of pilot plant
• Check the product again! Demonstrations in lab
and bench scale are not enough.
– Food product: sensory, chemical, and microbiological
qualities; shelf-life; test marketing
– Improvements in formulation andprocessing
• Note that the pilotresults can discourage or
prevent going to full scale
– This is not a failure despite losses, this is part of the
reasons why pilot testing is done. The useful result is
that a risk is avoided and the production plant will not
be constructed, then failing with a largeinvestment.
You simply can NOT
• Design a full-scale plant based on test tube
experiments
– The designer will not know what todo, without
some testing of alternatives
– The risk of failure is too high, especially withthe
big investment required: you can not get the
money (by loaning or by sellingshares)
Many decisions needed
• Mixing
– Type of mixer, power or mixing speedused
• Heating or cooling
– What rate of heating (cooling) is goodor
desirable?
– How long should we “hold” a high temperature?
• Each unit operation requires several choices
– These can not be decided without pilot equipment
Full scale production decisions needed for design
• How much should be produced?
– What is the market demand, what is theforecast
for it?
– The demand depends on price, and production
costs depend on amount produced…
– What is availability of raw materials? Cost, supply,
price forecasts, …
• Do we expect to increase production capacity?
Which effects of such increase need
consideration in initial design?
What is down-scaling?
• The production process needs decisions
– Troubleshooting: Solve problems that are causing
losses (poor quality, interruptions in production,
…)
– Improve productivity or product quality
– Assess lower cost raw materials, additives,
consumables, unit operations
• Some of this is fit for the pilot plant
– Test new raw materials, test new mixer, heater,
sensor, or control system …
Down-scaling to bench scale
• Benefits
– Small material costs, while pilot would needtons
of raw materials
– Can test conditions that are not possible with
process equipment (higher temperatures,
pressures, …),or such that might damage the pilot
machine
– Pilot is designed to be similar to actual
production, just smaller. Bench scale should be
designed to enable experiments, observations and
measurements.
Bench-scale downsides
• Not similar to actual processoperation
– Often slower, smaller, batch instead of continuous
– Results may not be correct
– The decisions suggested by bench-scale need
checking in pilot scale, before going to production
plant
Making paper (lab scale)
• You can make single
sheets of paper in the
lab with a“handsheet
mold”
• It is just a standard
size and shape gravity
filtering device (small
vacuum from water
column)
Bench-scale papermaking

• Fiber suspension
is sprayed inside
a rotating drum
onto afilter
• The water is
centrifuged out
• Drum about
similar size as in
a washing
machine
A pilot paper machine
A “real” paper machine
 Goals for each
• Real machine
– Designed to produce as quickly as possible product of
sufficient quality, beat competitors on market
• Pilot
– Help sell the real machine by demonstrating it to buyers,
down
Scale-

help develop next real machine, troubleshoot production

problems. Imitate several real designs when possible.

up
Scale-
• Bench
– Inspect one unit operation at a low cost for some
decisions about raw materials, additives, process
parameters. Designed for experiments and observation.
Duplicate key phenomena of real process, not the
process itself.
• Lab
– Nothing to do with the actual process. Demonstrate a
reaction, or a composite material, etc. Characterizeraw
materials and their quality variations ordifferences.
Summary
• Scale-up
– Moving from lower cost and smaller scale, tohigher
cost and larger scale
• Scale-down, opposite of scale-up
– Most often about trouble-shooting or further
development of a large scale process that need
experiments in smaller scale
– Sometimes scale-down of a product, in theextreme
this is miniaturization
• More customers for lower cost smaller sizeproduct
• Drones vs. airplanes is one example