T. Schafer, Koch Modular, Paramus, New Jersey
Escalating environmental concerns and the imperative to mitigate climate change are driving an urgent need for innovative and sustainable energy solutions. Modular pilot and demonstration-scale plants have emerged as crucial tools in accelerating this transition as the global community grapples with reducing carbon footprints and transitioning to cleaner energy sources.1 These plants are instrumental in effectively transitioning between laboratory research and full-scale commercial deployment, offering a pragmatic approach to testing, optimizing and improving new technologies in a controlled, scalable manner.
The role of modular pilot and demonstration-scale plants. A modular pilot or demonstration-scale plant is a specialized facility used in the chemical and process industries to close the gap between laboratory research and full-scale industrial production. These plants are designed to test and validate processes on a smaller scale before a commitment is made to the high costs and risks associated with full-scale production.
Modular pilot and demonstration-scale plants are critical in researching and developing novel energy technologies. These plants facilitate a more efficient path from concept to commercialization by allowing for iterative data testing and process refinement. This not only reduces project timelines but also helps manage the inherent risks associated with developing new energy solutions.
Moreover, these plants enable comprehensive experimentation with sustainable feedstocks. They allow researchers to test various raw materials and processing techniques vital for developing scalable, sustainable energy processes. Through such experimentation, modular pilot and demonstration-scale plants contribute significantly to the validation and scaling of clean energy processes.
Benefits of pilot and demonstration-scale systems. One of the primary benefits of modular pilot and demonstration-scale plants is their role in process validation. Validating clean energy processes is crucial to ensure they are technically feasible and economically viable. Pilot and demonstration-scale plants provide a controlled environment where processes can be rigorously tested and refined. This step is essential in confirming that the processes work as intended and can be scaled up with minimal unforeseen issues (TABLE 1).
Process optimization. These plants are also instrumental in optimizing the efficiency and performance of clean energy systems. By conducting detailed experiments and trials, researchers can identify and implement improvements that enhance the overall performance of the energy systems.2 Examples of process optimization include improving energy conversion efficiencies, reducing waste and emissions, and enhancing the overall sustainability of the energy production process. This optimization is critical for developing competitive and effective clean energy technologies. TABLE 1 showcases the author’s company’s extensive testing on solvent extraction and distillation processes, including variable stages, mass throughputs, solvent-to-feed ratios and agitation speeds for efficient recovery of acetic and formic acids.
CAPEX and OPEX optimization. Modular pilot and demonstration-scale plants offer significant cost-reduction benefits. By validating and optimizing processes on a smaller scale, these plants help reduce capital expenditures (CAPEX) and operational expenditures (OPEX) associated with full-scale deployment. The insights gained from pilot and demonstration-scale testing can lead to more cost-effective design and operation strategies, resulting in long-term economic benefits. Additionally, these plants help shorten project schedules by enabling quicker optimizations and refinements, accelerating the timeline from development to commercialization.
Modular pilot and demonstration-scale plants in action. Modular pilot and demonstration-scale plants are crucial intermediaries in transitioning from laboratory research to full-scale commercial operations (FIG. 1). Notable examples include a bio-based plastic commercial-scale system, which showcases sustainable plastic production, and a carbon capture demonstration-scale system, aimed at reducing industrial carbon dioxide (CO2) emissions. The carbon capture pilot-scale system also provides early-stage testing for innovative capture technologies. Concurrently, the extraction and desolventization demonstration-scale system exemplifies efficient separation processes essential for various chemical and pharmaceutical applications. Each case study highlights the critical role of modular plants in advancing industrial innovation and sustainability.
Bio-based plastics. ORIGIN Materials is a prime example of a company within the industry that is developing and scaling up the production of bio-based chloromethylfurfural (CMF) from lignocellulose and cornstarch (FIG. 2). From the early stages of process development (FEL1), critical guidance was provided on scaling up the complex process of converting biomass into chlorinated hydrocarbon through reaction, distillation and filtration. This collaborative effort tackled significant challenges, such as compensating for varying byproduct compositions, selecting corrosion-resistant construction materials and designing slurry pipelines to ensure consistent yield. The project culminated in the construction of a demonstration-scale plant featuring 17 process modules, two stair modules and a large stand-alone vessel. ORIGIN Materials' downstream process then successfully converted the chlorinated hydrocarbon into bio-based plastics, showcasing the potential of sustainable materials in commercial applications.
Carbon capture demonstration-scale system. An example of a carbon capture demonstration-scale system can be seen with ION Clean Energy, leading to the development of a modular CO2 capture system at Calpines’ Pittsburgh, California (U.S.), natural gas-fired power plant (FIG. 3). The project, completed over 14 mos from process design to module delivery, featured a sophisticated setup comprising three process modules and one stair module. This demo-scale system aimed to capture up to 95% of the CO2 emissions from a flue gas slipstream, effectively sequestering approximately 12 tons per day (tpd) of CO2 over a 13-mos to 18-mos period during a 1-megawatt (MW) test. The primary focus was to evaluate the performance of three different solvents (two were proprietary solvents developed by ION Clean Energy), specifically assessing their CO2 absorption capacity and long-term stability. This initiative demonstrated the feasibility of large-scale carbon capture and provided invaluable data to refine and enhance solvent technologies for future applications.
Carbon capture pilot-scale system. The University of Kentucky developed a modular pilot plant to verify and demonstrate advanced carbon capture technology at a coal-fired power plant (FIG. 4). The project, completed over 60 weeks, involved designing and modularizing six key modules, including five process modules and one stair module. The system was engineered to treat 1,660 actual cubic feet per minute (ft3/min) of raw flue gas, employing a heat integration method with various amine solvents for efficient CO2 capture.
The process begins with raw flue gas entering an absorber, where a regenerable solvent extracts CO2 from the gas. The cleaned flue gas exits the absorber, while the CO2-rich solvent is directed to a reboiled regenerator. CO2 is stripped from the solvent in the regenerator, resulting in a lean solvent and a CO2 product stream. The lean solvent is cycled back to the absorber to repeat the process, ensuring continuous CO2 capture.
The design incorporated a stripper for effective solvent regeneration and a heat-integrated cooling tower system, optimizing the overall energy efficiency of the process. This innovative approach demonstrates the feasibility of carbon capture at a pilot scale and provides a scalable solution to reduce CO2 emissions from coal-fired power plants.
Extraction and desolventization demonstration-scale system. The Food & Ag Tech Co. sought to develop a modular demonstration-scale system to refine tree-derived oils by extracting undesirable flavor components to yield two target products with varying flavonoid concentrations (FIG. 5). This year-long project involved the integration of four process modules and one stair module. Initial pilot testing with the columna, chosen due to potential emulsification concerns, did not yield the expected results, as emulsification was absent and extraction specifications were unmet. A successful pilot test followed using the author’s company’s columnb, confirming the process design basis and operational parameters. Taste tests ensured the final products met the client's flavor requirements, revealing the critical importance of proper oil degumming and necessitating adjustments to desolventization pressures due to inaccurate initial vapor pressure predictions of the flavonoids. The trees used for oil production thrive in harsh conditions and poor soils, offering sustainable food ingredients while promoting reforestation and community revitalization.
Takeaways. Modular pilot and demonstration-scale plants are pivotal in accelerating the transition to clean energy solutions. These plants provide a robust framework for developing and scaling up innovative energy technologies by enabling thorough process validation, optimization and cost reduction. The success stories of bio-based plastics, carbon capture systems and biofuels indicate the importance of these plants in driving the energy transition. As the global community seeks sustainable energy solutions, modular pilot and demonstration-scale plants will remain at the forefront of innovation, ensuring a cleaner and more sustainable future. HP
NOTES
KARR® Column
SCHEIBEL® Column
LITERATURE CITED
Mauricio, V., T. Schafer, et al., “Truckable modules paving the road for advantageous construction solutions,” Processing Magazine, August 2021, online: https://www.processingmagazine.com/home/article/21233990/truckable-modules-paving-the-road-for-advantageous-construction-solutions
Glatz, D. J., B. Cross, et al., "Optimal mixing for agitated extraction columns," AIChE, December 2022, online: https://www.aiche.org/resources/publications/cep/2022/december/optimal-mixing-agitated-extraction-columns
“Koch Modular announces its fabricated process modules have been installed at Origin Materials,” Hydrocarbon Processing, December 2021, online: http://www.hydrocarbonprocessing.com/news/2021/12/koch-modular-announces-its-fabricated-process-modules-have-been-installed-at-origin-materials
TOM SCHAFER is a chemical engineer with 48 yr of experience in process design, operations management, cost estimating, plant layout, and sales and marketing. His specific expertise in equipment design includes distillation, heat transfer, fluid flow and process control. Schafer earned BS and MS degrees in chemical engineering from Manhattan College.