FEL Study with Experimental Validation

LOCATION: Canada

Integrated FEL-2 Study

Client Objective

AGEIAS’ client, who are developing a novel process for the production of a battery application specialty chemical, requested AGEIAS to conduct a Front-End Loading 2 (FEL-2) study to assess the technoeconomics of their novel process. A major knowledge gap for the process was the reaction residence time. An assumption provided by the client was a reaction time of approximately 24 hours based on lab testing.

The AGEIAS Approach

The team at AGEIAS realized that from a scale up perspective, a 24-hour residence time would have a significant negative impact on technoeconomics. AGEIAS calculated that the plant might need more than 30 tanks to achieve the desired throughput, for which they would incur major capital costs. Instead of moving forward with the process assumption provided, AGEIAS started asking questions, looking for ways to fill the knowledge gap to bring validity to the FEL-2 study findings.

AGEIAS investigated the client’s previous lab testing and found that mixing was deficient, resulting in poor interaction between acids and solids present in the reaction. Using in-house equipment, AGEIAS quickly set up a high shear mixing setup to run the reaction and demonstrated how reaction time could be significantly reduced with proper scaling. AGEIAS identified the underlying mechanism limiting the process — mass transfer/mixing — rather than simply completing the study with an unchallenged assumption to fill a knowledge gap. Customer Value AGEIAS’ insight and resolution of knowledge gaps through experimental work provided greater validity and confidence to the findings of the FEL study and identified a major developmental focus area to optimize process performance and economics for scale up.

Capabilities Demonstrated

Execution of FEL engineering studies and preparation of engineering deliverables
Experimental knowledge gap resolution
Capital-cost reduction through better process understanding
Mixing and mass-transfer expertise

How We Help You:

The business case for a novel process often starts with an FEL study. The outcomes of the study are only as good as the foundation they are built on. That foundation is weakened by the inevitable knowledge gaps of a novel process in early development. In addition to FEL engineering deliverables, AGEIAS also provides the insight to resolve knowledge gaps and identify R&D focus areas to bring greater confidence to process development and economic assessments.