Part A $-$ Scale Up

You have developed a stable formulation that is ready to be upscaled to a pilot batch of $500L$

$(=500$ kg$).$ Your formulation recipe can be found here $($link$).$ Currently, you can make a $)$

batch in the lab using the following equipment:

One $200mL$ beaker $($internal diameter $($ID$)$ of $6cm)$ for mixing GelMaker Hydro and Glycerin.

One $1\mathrm{.}5L(ID=11cm)$ beaker for mixing the rest of Phase A and mixing in Phase $B$ and $C.$

One $)$ beaker for mixing Phase $B.$

One propeller $(N_p=0\mathrm{.}6,$ diameter $=4cm)$ operating at $2500rpm$ for mixing.

One sawblade impeller $,$ diameter $\{$:$=4(cm))$ operating at $4000rpm$ for homogenising.

Assume Phase A density is $1,100k\frac{g}{m^3},$ Phase B density is $800k\frac{g}{m^3},$ and combined moisturiser

density is $1,000k\frac{g}{m^3}.$ You may assume a constant viscosity value of $0\mathrm{.}05$ Pa$.$s for every phase

throughout the whole assignment.

Propose how you will scale the manufacturing up to $500L,$ calculate sizes for pilot$-$scale equipment

$($tanks and impellers$)$ and discuss necessary precautions or adjustments you might need to make to

your manufacturing procedure. Please include all your thoughts and full calculation procedures. You

will get extra marks for considering things like geometric parameters of vessels, baffles, etc.

Part B $-$ Costing

In addition to above information from Part A$,$ you have obtained some equipment information from

the manufacturers as shown in Table $1$ below.

Table $1$: Costing and sizing information on selected equipment. Note: tanks can be manufactured to the closest $10cm$

diameter at a given volume.

Using the table above, decide what size equipment you are going to buy and calculate how much it

will cost. Then, using Lang Factor method, approximate the required fixed capital investment and

working capital for your plant. Assume the tanks and mixers are the only needed pieces of major

process equipment. Show full working and discuss any other assumptions made.

Part C $-$ Mixing

What are the new impeller speeds at a pilot scale? Discuss any assumptions you made in

order to perform the calculations. Reflect on your calculated answers.

Discuss what would happen to the mixing times upon scaling up from laboratory to pilot

scale $($you will get extra marks for performing the calculations$).$ If you choose to calculate

mixing times, comment on those.

Calculate the power ratio for mixing of each Phase A $($by itself$),$ Phase B $($by itself$)$ and

combined Phase A&B at the lab and pilot scales.

If your industrial electricity price is $16$ cents per kWh$,$ then how much do you expect to pay

per batch for mixing these phases at a pilot scale? Assume Phase A gets mixed for $10$

minutes, Phase B for $15$ minutes, and combined final product $($all phases$)$ for $25$ minutes.

Which operation do you expect to be the most power intensive and why?