A+ R A-

Debottlenecking

Increase Your Capacity with Continuous Manufacturing!

 

Increase Capacity with Continuous Manufacturing

 

 

   Problems with Batch Production                   Batch to Conti Arrow              Solutions with Continuous Production

 

Batch Production Problems

Flow Chemistry Production Solutions

  

Pre-Product Preparation
More tanks needed → high space demand Install additional mobile mixing stations →
space savings >90%
Not mobile Mobile design mounted on a movable skid

 

 

Reaction
Fixed installation with high space demand Mobile installation with small space demand
Extensive process times due to large mass & heat transfer distances Short process times due to enhanced mass & heat transfer
Potential safety issues due to high reactor volume Increased safety due to reactor volume reduction
High manpower demand Reduced manpower due to easy automation

 

 

Storage
Batch release by sampling Product release by online/inline analytics
High storage demand due to buffering of the batch Low storage demand due to online/inline drumming
Quality fluctuations due to lower process capability Stable quality due to continuous manufacture

  

 

 

 

The 4 Steps of Debottlenecking

 

  

Batch Vessels

 

 

Step 1: Evaluation of the Current Status

 

 

  • Execution of an on-site workshop

 

  • Definition of debottlenecking opportunities

 

  • Suggestion for further procedures


   

Design of Debottlenecking Concept

 

 

 

Step 2: Design of a Debottlenecking Concept

 

 

  • Conceptual engineering

 

  • Process flow diagram

 

  • Automation concept

 

 

Engineering & Plant Construction

 

 

 Step 3: Engineering & Plant Construction

 

 

  • Basic engineering

 

  • Detailed engineering

 

  • Plant construction


 

Plant Delivery & Start-Up

 

 

 Step 4: Plant Delivery & Start-Up

 

 

  • Installation on-site

 

  • Plant start-up

 

  • Site acceptance test 

Enhanced

 

 

 

 

Capacity!

 

 

 

 

  

 

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