Flow Chemistry Services
Transition from batch to flow
In theory, any batch process can be converted to flow, you just need the proper equipment.
Think of flow as building the equipment around the chemistry instead of force-fitting all chemistries to stirred tanks.
Step 1 Familiarization and proof-of-concept
Step 1 : Familiarization and proof-of-concept
The first step in the transition from batch to flow is the thorough familiarization with the components being processed: their phases, densities, rheology, heat capacities, etc. In other words, we must know how they flow so that we can select and size appropriate reactors. Once the reactor is selected, we can conduct a proof-of-concept trial in our state-of-the-art flow laboratory.
Know more about how to select the reactor
In our flow laboratory, we have a variety of flow reactors, suitable for a wide range of applications along with the pumps, back pressure regulators, safety systems, and analytical facilities to conduct a thorough trial; safely, effectively, and quickly..
Step 2 Lab scale Optimization
Step 2 : Lab scale Optimization
Once the proof-of-concept is done and technical feasibility of converting into flow is established, we can go ahead with optimization studies. For this, we combine statistical analysis through design of experiments, conduct these judiciously chosen experiments and analyze the results through methods like response surfaces. Our modelling and simulation experts could even make a mathematical model of the process being run in the reactor for deeper understanding of the system and to facilitate the scale-up.
Once the optimized parameters are in-hand we are in a position to predict the performance of the system at the commercial scale.
Step 2 First techno-commercial analysis
Step 3 : First techno-commercial analysis
We can now put costs to the commercial scale plant using which a thorough techno-commercial analysis of the flow process can be conducted. This gives a fair idea of the profitability of the flow process and thus forms the basis of a GO/NO-GO decision by the strategic arm of our clients.
Step 4 Piloting
Step 4 : Piloting
In case of a GO decision, we must still be doubly sure of our models and calculations. For this, we undertake a piloting exercise. In this exercise, the equipment used can still be incorporated in the final commercial plant, so its’ not a sunk cost. The piloting philosophy is to validate our models and hence, we use only a portion of the full plant to predict its performance and see if our experiments bear this out. If they don’t, we update our model with these new insights and make a more accurate model.
Step 5 Second techno-commercial analysis
Step 5 : Second techno-commercial analysis
With the updated model, we will offer an updated techno-commercial report for the decision makers to make a final GO/NO-GO decision, before initiating commercialization.
Step 6 Commercial Plant
Step 6 : Commercial Plant
Amar flow laboratory will offer complete support to the EPC contractor to incorporate Amar reactors in the commercial plant. We will provide detailed advice on sizing, costing, and participate in HAZOP studies, and advise on selection of pumps and ancillaries so as to build the contractors comfort with our systems.