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One Stop Shop for Continuous Manufacturing

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This is our “Arrow of Success”, our One Stop Shop for continuous manufacturing and process intensification. The interaction between our engineering and process development teams delivers a unique advantage to your process performance and your process efficiency. Let’s look at the different phases. 

 

 

Phase 1 Process Research: Our Process Research Phase is further divided into 2 Phases. The first is the Route Scouting Phase in which we work on finding the chemical route. The second phase is the Process Concept Phase in which we make use of the chemical route with as few unit operations and solvents as possible, and develop clever strategies for potential by-products. During the Process Research Phase, we conduct a literature survey, Batch/MW testing and solvent screening.

 

Phase 2 Process Design: This is the Process Design Phase. At this point we ask the question “What does the process need?”. From 6 perspectives, we identify critical parameters for a process on the basis of a methodology we call “MIC Fish”, in order to understand what the process needs from the chemistry, as well as from the chemical engineering perspective. First, a block flow diagram of the potential plant delivers an appropriate focus on the plant realization during development. This phase also contains risk assessment and a first plant cost estimation.  

 

Phase 3 Feasibility: The Feasibility Phase is divided into two or three sub-phases. First, the chemical feasibility is where a continuous process is developed and optimized. The technology selection responds to the identified critical parameters. The second step, the Technical Feasibility Phase, is when we do a process verification on scalable equipment and generate data for the basic engineering. The second stage is also when we work on updating the plant costs. 

 

Phase 3c Pilot Plant: Phase 3c is optional for large scaling factors and for technologies that are difficult to scale. It might be necessary to implement a classical pilot plant. 

 

Phase 4 Basic Engineering: During the Basic Engineering Phase we start with the user requirement specification (URS) of the plant, where we incorporate our generated process knowledge into the plant design and provide an offer for the plant. Automation and control strategy is potentially generated with advanced features like PAT, model predictive control and advanced protocols like MTP. Specification of the main equipment based on the technology selection takes place now as well. 

 

Phase 5 Turnkey Core Plant Skid: Phase 5 realized the plant realization and starts with a detailed engineering. After the design release (Design Qualification DQ) the plant will be assembled. The Factory Acceptance Test (FAT) proves the correct execution of the design. After shipment to and installation at the customer’s site the engineers of Microinnova execute Site Acceptance Tests (SAT) and hand over the plant to the customer. Installation Qualification IQ, Operation Qualification OQ and Process Qualification PQ can be executed by Microinnova on request.  

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