Energy-Efficient Practices in Pilot Plant Operations

Industrial success is increasingly dependent on energy efficiency in today’s rapidly evolving world. Pilot plant facilities, which are small-scale versions of large industrial plants, play a significant role in research and development, process optimization, and scaling up of novel technologies. 

These facilities provide invaluable insights into the feasibility and efficiency of upcoming processes before they are implemented on a larger scale. Pilot plant operations have become increasingly energy efficient as sustainability and cost-effectiveness have gained importance.

A. Lab Evaporator set-up in the Pilot Plant Facility

One of the primary processes in pilot plant operations is evaporation. Evaporators remove liquid content from solutions, leaving behind concentrated product streams. Energy-efficient lab evaporator setups can greatly enhance productivity and sustainability.

Indirect heating and drying in inert conditions: Lab evaporators can employ indirect heating methods, such as hot oil or steam, to minimize energy losses through convection. 

Additionally, performing evaporation in inert conditions, such as under a nitrogen atmosphere, reduces the risk of oxidation and enhances the energy efficiency of the process.

High throughput under vacuum: By operating the lab evaporator under vacuum, the boiling point of the liquid in the solution decreases, allowing for efficient evaporation at lower temperatures. As a result, both energy consumption and product degradation are reduced.

Scrapping of dry solids for efficient heat transfer: Lab evaporators can be equipped with scraping systems that constantly remove dry solids from the heat transfer surface. This prevents fouling and ensures efficient heat transfer, optimizing energy usage and reducing cleaning downtime.

B. Agitated Thin Film Dryer (ATFD) in Pilot Plant Facility

One of the most energy-efficient dryers available on the market is an agitated thin film dryer (ATFD). Their unique design and operating principles make them ideal for pilot plant operations where heat-sensitive products require gentle and efficient drying.

Thermal efficiency exceeding 90%: ATFDs achieve remarkable thermal efficiencies due to their indirect heating mechanism. The product is spread as a thin film on the heated surface while being agitated. This allows efficient heat transfer without direct contact with hot air. This minimizes heat losses and maximizes energy utilization.

Short processing time: ATFDs offer rapid drying capabilities, with processing times ranging from a few seconds to a few minutes. This is particularly advantageous for heat-sensitive products that require quick drying to prevent thermal degradation. The short processing time saves energy and ensures high product quality.

C. Agitated Thin Film Evaporator (ATFE) in Pilot Plant Facility

Agitated Thin Film Evaporators (ATFEs) are widely used in the chemical, pharmaceutical, and food industries for concentration purposes. Their energy-efficient design and efficient heat transfer mechanism make them a preferred choice for pilot plant operations.

Efficiency compared to shell-and-tube heat exchangers: ATFEs outperform traditional shell-and-tube heat exchangers in energy efficiency. The thin film formed on the heated surface in an ATFE allows for efficient heat transfer, resulting in higher energy utilization and reduced energy consumption.

Enhanced scalability: ATFEs are highly scalable, making them suitable for pilot plant operations where processes need to be tested and optimized before large-scale implementation. A reliable and efficient process depends on the ability to accurately reproduce the heat transfer characteristics of large-scale evaporators.

D.Single Stage Short Path Distillation Unit Pilot Plant Facility

One example of an energy-efficient practice in pilot plant operations is the use of a single stage short path distillation unit. Distillation is a process used to separate components in a mixture based on their boiling points. In a pilot plant facility, where small-scale testing of processes is conducted, the use of a single stage short path distillation unit can offer significant energy savings.

A single stage short path distillation unit operates under high vacuum conditions, which allows for efficient separation of components. By reducing the pressure, the boiling point of the components is lowered, resulting in reduced energy consumption. The use of a short path distillation unit also eliminates the need for multiple stages of distillation, further reducing energy requirements.

E. Rising Film & Falling Film Evaporator Pilot Plant

Evaporators are commonly used in the chemical industry to remove solvent or water from a liquid mixture. In pilot plant operations, the use of rising film and falling film evaporators can offer several energy-efficient advantages.

Rising film and falling film evaporators are compact, versatile, thermally efficient, and cost-effective. Unlike traditional shell-and-tube evaporators, which require a large amount of space and have limited thermal efficiency, rising film and falling film evaporators are designed to maximize heat transfer and minimize energy consumption.

In a rising film evaporator, the liquid mixture flows upwards as a thin film over the heating surface, while in a falling film evaporator, the liquid flows downward under gravity. Both types of evaporators have a high surface area-to-volume ratio, which allows for efficient heat transfer and reduced energy requirements.

F. Liquid-Liquid Extractor (LLE) Pilot Plant

Liquid-liquid extraction is a process used to separate liquid mixtures based on their solubility in different solvents. In pilot plant operations, the use of a liquid-liquid extractor (LLE) can offer energy-efficient separation of liquid-liquid mixtures.

The energy efficiency of a liquid-liquid extractor is closely tied to the boiling point of the solvents used. By selecting solvents with low boiling points, the energy requirements for separation can be significantly reduced. The LLE process involves the mixing of the liquid mixture with a solvent, followed by the separation of the two phases. 

By utilizing solvents with low boiling points, the energy required for phase separation is minimized.

Cost Savings

Implementing energy-efficient practices in pilot plant operations can result in significant cost savings. By reducing energy consumption, operational expenses can be lowered, leading to increased profitability. Here are a few examples of cost savings that can be achieved through energy-efficient practices:

1. Reduced utility bills: Energy-efficient equipment and processes consume less electricity and other utilities, resulting in lower monthly bills.

1. Maintenance savings: Energy-efficient equipment often requires less maintenance due to reduced wear and tear, resulting in lower maintenance costs.

1. Waste reduction: Energy-efficient practices often result in less waste generation, leading to lower waste disposal costs.

1. Regulatory compliance: Many countries and regions have regulations in place to encourage energy efficiency. By complying with these regulations, pilot plant facilities can avoid penalties and fines. It is important to note that achieving cost savings through energy efficiency requires a long-term commitment. 

Energy-efficient practices should not be seen as a one-time fix, but rather as an ongoing effort to continuously improve energy performance and reduce operational costs.

As miniature models for large-scale industries, pilot plants set precedence for more extensive processes. This blog underscores the importance of adopting energy-efficient techniques, from lab evaporators to liquid-liquid extractors. 

These practices not only minimize costs but also bolster global sustainability efforts. As we move forward, it’s essential to make these methods the standard for future industrial endeavors.