SDE3 was retained by GR International to develop a scale-up of their mineral nano-fiber production process from pilot to commercial scale. The process involves the production of two different families of nano-fiber products, with each product requiring precise control of temperature, pressure and ingredients in a batch reactor.
With this project, SDE3 developed a detailed mass and energy simulation of the process to produce each nano-fiber product. The simulation was used to test various production processes and post-treatment methods for each product. Extensive laboratory and pilot plant testing was conducted to determine scalability of the process, and to provide data to calibrate the simulation. Simulation modeling was conducted to determine profile, mixing, and heat transfer characteristics for the full-size reactor. Design of the full-scale plant was conducted using 3D CAD process modeling software.