Purpose
Translate experimental performance into an engineering basis for the next scale.
Scale-up is not a geometric exercise. Mixing, heat transfer, mass transfer, residence-time distribution, pressure drop, solids behavior, controls, and equipment constraints can change as the system grows.
ONB Engineering combines modeling, engineering calculations, data review, and stage-appropriate design work to define the next-scale basis and reduce the risk of committing to equipment before the critical uncertainties are understood.
When this service is useful
Assess whether the evidence supports pilot, demonstration, or commercial design assumptions.
Identify transport, hydrodynamic, thermal, mechanical, and operability effects that may not appear in the laboratory.
Convert process requirements into preliminary sizing, equipment lists, specifications, and vendor questions.
Prioritize development work that materially reduces design or scale-up uncertainty.
Scope and capabilities
Scale-up basis
Design basis, performance targets, governing phenomena, scale criteria, uncertainty, and required validation.
Reactor sizing and performance
Kinetics, residence time, heat and mass transfer, hydrodynamics, pressure drop, and operating-window analysis.
FEL-1 and FEL-2 studies
Stage-appropriate engineering definition for feasibility, option selection, cost basis, risk reduction, and next-stage planning.
Process engineering package
Process flow diagrams, mass and energy balances, equipment list, utility basis, operating philosophy, and preliminary specifications.
Equipment design support
Preliminary sizing, equipment datasheets, layouts, materials considerations, and technical interfaces with vendors or fabricators.
Vendor and fabrication support
Technical bid questions, vendor-data review, clarification of design intent, and engineering support through equipment definition.
Typical deliverables
- Process and scale-up design basis
- Mass and energy balances
- Process flow diagrams
- Reactor or equipment sizing calculations
- Equipment list and preliminary datasheets
- Utility requirements and interfaces
- Scale-up risk register and data gaps
- Prioritized testing and engineering plan
A stage-gated approach prevents false precision.
Early engineering should be detailed enough to support the decision, but not so detailed that unvalidated assumptions become embedded in the design. ONB Engineering aligns the level of definition with the project stage and explicitly separates knowns, estimates, and open questions.
Representative applications
Frequently asked questions
What is the difference between a scale-up study and an FEL study?
A scale-up study focuses on whether performance and governing phenomena translate to a larger system. An FEL study adds broader process definition, options, equipment, cost basis, risks, and execution planning. They often overlap and can be combined.
Can ONB Engineering support a fabricator or equipment vendor?
Yes. ONB Engineering can prepare or review the process basis, sizing calculations, datasheets, technical questions, and vendor information needed to maintain design intent.
How much data is needed before beginning?
The data requirement depends on the decision. An early readiness assessment can begin with limited data, while final equipment definition requires stronger validation. ONB Engineering can first identify the minimum information needed.
Does ONB Engineering provide detailed mechanical design?
ONB Engineering’s core scope is process and reactor engineering, preliminary equipment definition, modeling, and engineering-package support. Detailed mechanical, structural, electrical, or stamped fabrication design can be coordinated with appropriate discipline specialists when required.