R&D and laboratory research
Feedstock characterization, process testing and selection of operating conditions to support scale-up and design
Technology testing before industrial deployment
Before developing an industrial plant, it is necessary to determine the composition of the starting material, its processing behavior and the possibility of obtaining the required process streams. Laboratory research allows you to check individual stages of the process and reduce uncertainty when choosing equipment.
The scope of work is determined by the specific task and may include the study of samples, laboratory experiments, comparative tests, selection of operating conditions, pilot testing and preparation of recommendations for further engineering.
Materials under study
Main research objectives
Feedstock characterization
Generating the data needed to select a treatment method
Testing a process concept
Assessing the applicability of the selected process to a specific material
Comparison of processing options
Comparison of process options using test results
Selection of operating conditions
Determination of permissible temperature, time and other process parameters
Phase separation study
Assessment of the feasibility of obtaining separate liquid, solid and gas streams
Evaluation of treated products
Analysis of samples after the selected treatment
Preparing scale-up data
Generating design inputs for pilot or industrial equipment
Reducing process uncertainty
Verification of critical stages before deciding on plant design
Benefits of preliminary testing
Decisions based on representative samples
Tests are performed on samples representative of the customer's material
Checking individual stages
Critical processes can be investigated before a full production line is formed
Comparison of options
Operating conditions and process sequences are compared before selecting a baseline solution
Selection of equipment based on test results
Equipment functions are determined taking into account the behavior of the real product
Clarification of automation requirements
Defines the parameters that need to be measured and controlled in an industrial installation
Preparation for the pilot stage
Laboratory data are used to develop the scale-up test program
Reducing equipment-selection risk
Preliminary testing allows technology limitations to be identified before equipment is manufactured
Documenting results
Test steps, operating conditions and observations are documented within the agreed scope
Research approaches
The scope of the research is determined by the type of material, the required treatment outcome, the available sample volume and the stage of development of the project.
Research stages
- Receiving a task description
- Clarification of the required result
- Collecting available material data
- Preliminary assessment of research feasibility
- Coordination of sample volume and condition
- Test program development
- Sample preparation
- Performing preliminary measurements within the agreed scope
- Laboratory processing
- Changing and comparing operating conditions
- Collection of intermediate and final samples
- Evaluation of resulting process streams
- Recording results
- Analysis and conclusions
- Preparation of recommendations
- Determining the need for a pilot phase
- Data transfer for engineering
The sequence and scope of the stages depends on the material being studied and the task at hand. Not all tests require the same sequence and scope of work.
Sampling and sample preparation
Test results depend on how representative the sample is of the actual process stream. Before starting work, it is necessary to determine the origin of the material, the sampling, storage and transport conditions.
If the composition is heterogeneous, multiple samples or a composite sample may be required. The required mass or volume is determined by the test program and available laboratory equipment.
Initial material characterization
Before process testing, material characteristics that may influence the selected process are determined. The list of indicators is formed individually and depends on the type of raw material and the required result.
Some measurements can be performed in-house, and specialized analyses can, if necessary, be transferred to specialized laboratories.
Laboratory process simulation
Laboratory modeling reproduces a single process step or sequence of steps on a reduced scale. The goal is to verify the fundamental feasibility of the process and determine the factors influencing the result.
Tests can be performed in series with changes in temperature, time, mixing intensity, number of stages and other parameters. The set of variable factors is determined by the work program.
Phase separation study
For multicomponent materials, the possibility of obtaining separate oil, water, solid or gas streams is being explored. The stability of the separation and the need for additional processing steps are assessed.
The results are used to select settling, filtration, separation, heating, reagent treatment or other validated processes.
Thermal treatment tests
Thermal tests determine the behavior of a product when heated, the ability to remove water and volatile components, and changes in the physical properties of the material.
Test temperatures are selected for the sample composition and safety requirements. If necessary, the study is carried out in several stages with gradual changes in conditions.
Filtration and purification study
Filtration tests are used to evaluate the ability to remove mechanical and suspended impurities from liquid streams. The type of filter material and the number of stages are selected based on the results of experiments.
If necessary, additional sorption or combined post-treatment can be explored. The materials used and operating conditions are determined separately for each task.
Drying tests on solid residues
For solid and paste-like materials, the possibility of removing moisture and residual volatile components is being investigated. The permissible heating modes, changes in the physical state and characteristics of the resulting residue are determined.
Tests evaluate the need for mixing, the method of feeding the material, the possibility of condensation of the removed components and the requirements for the future drying module.
Pilot tests
Pilot testing is used when laboratory results alone are insufficient for industrial design. It uses a larger material volume and equipment that operates on the same principles as the proposed plant.
The tests assess process stability, stage throughput, control conditions and auxiliary-equipment requirements.
Scale-up of test results
The transition from a laboratory experiment to an industrial installation requires consideration of heat and mass transfer, residence time, mixing method, feed continuity and other factors that change with scale-up.
Laboratory results inform the engineering design, but industrial performance requires scale-up calculations and further verification.
Research results
Description of source material
Summary of the sample's physical state and properties relevant to the process objective
Test program
List of processes under study, modes and sequence of work
Results of laboratory experiments
Recorded conditions, observations and data obtained during the agreed program
Comparison of options
Comparison of tested operating conditions and process sequences
Product samples obtained
Feed, intermediate and treated samples as specified in the test program
Process conclusions
Assessment of the possibility of applying the studied process to a specific material
Recommended operating conditions
Preliminary parameters for further pilot or engineering development
Design input data
Requirements for main apparatus, auxiliary equipment, control and automation
Options and configurations
Preliminary research assessment
Analysis of the task and available data to determine the feasibility of laboratory work
Feedstock characterization
Sample preparation and determination of characteristics relevant to the selected process
Laboratory process testing
Carrying out a series of experiments with changing operating conditions and processing sequence
Comparative study
Comparison of several processing methods or process flow options
Pilot tests
Checking the selected process on an increased volume of material and clarifying equipment parameters
R&D with preparation for implementation
A coordinated program of testing, process recommendations and engineering input data
How the research program is developed
- Description of the process challenge
- Determining the required result
- Collection of available material data
- Determining sample volume
- Selection of process stages to be studied
- Selection of test variables
- Defining control points
- Determination of the composition of intermediate samples
- Selecting comparison criteria
- Defining safety requirements
- Determining the need for external laboratory analyses
- Agreement on the form of presentation of results
- Determining the need for a pilot phase
- Coordination of timing and sequence of work
Each test program is tailored to the material and process objective.
Research services and technical support
Research and development
Related Solutions
Engineering and design
Using research results to develop a process flow diagram and select equipment
Distillation and separation modules
Development of laboratory, pilot and industrial heating, separation and condensation modules
Distillation, regeneration and clarification of petroleum products
Testing operating conditions for the separation, dehydration and recovery of petroleum products
Processing of oil sludge and contaminated soils
Feedstock analysis and selection of conditions for preparation, separation and treatment
We will test the technology on your material before industrial implementation
A preliminary assessment requires a description of the task, information about the origin and composition of the material, the available sample volume, the required result and information about the intended industrial process.