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Chemical innovation involves the development of new and improved chemical products, processes, and materials. Creative Engineers play a crucial role in driving chemical innovation, as we are responsible for designing and implementing the technologies and systems necessary to produce these new chemical solutions.

Pilot Scale

A small-scale preliminary study conducted to evaluate feasibility, time, cost, scaling factors, unpredicted results, further develop a process, etc. in order to properly design and implement a full-scale commercial process.

Commercial Scale

The permanent upsizing of a pilot scale or bench scale process into a batch or continuous production system.

Bench Scale

 The testing of materials, methods, or chemical processes on a small scale such as on a laboratory worktable or inside a lab hood or glovebox.

Connected Golden Spheres

Chemical Innovation

Characteristics

Bench Scale

  • One or more experiment stations

  • Bench or glove-box size

  • One or two experimenters

  • Investment up to $100K

  • Focus on confirming technology or process

Pilot Scale

  • Includes build, operate, revise

  • Owned, leased, or host space

  • Small team of technology specialists

  • Investment $100K to $2M

  • Focus on safe + economical scale up

Commercial Scale

  • Includes build and early production

  • Permanent space or long term lease

  • Full staffing plan

  • Investment of $1M and up

  • Focus on construction and production

Prerequisites

Bench Scale

  • Project Charter and success criteria

  • Prelim. R&D done and shared with team

  • Investment plan for all Stages

  • Identify IP protection needs

  • Resources are aligned

Pilot Scale

  • Bench Scale success proven

  • Bench Scale issues addressed

  • Investment Plan has continued support

  • Goals and success criteria defined

  • Resources ready for extended operations

Commercial Scale

  • Pilot or Bench Scale success achieved

  • Complete data package ready

  • Investment plan supported

  • Commercial Scale reporting plan done

  • All material logistics in place

Activities and Goals

Bench Scale

  • PDCA methodology of experiments

  • Stakeholder Communication Plan

  • Focus activities to support Project Charter

  • Gather evidence of success

  • Complete Lessons Learned

Pilot Scale

  • Design, build, operate new pilot system

  • Nurture new and existing stakeholders

  • ID early adopters for Commercial Scale

  • Begin Product Marketing Plan

  • Complete Lessons Learned

Commercial Scale

  • Design, build, operate production system

  • Production plan closely monitored

  • Cater to early adopters to gather feedback

  • Gather production and Q/C feedback

  • Monitor and report on production costs

Resources

Bench Scale

  • Main innovator very involved

  • “All Hands on Deck” attitude

  • Identify/Secure 3rd party resources

  • Bench Scale facility requirements

Pilot Scale

  • Funding for operating, decommissioning, and disposition of waste

  • Resources for extended operations/activities

  • Confirm 3rdparty resources and raw materials

  • Pilot Scale facility requirements

Commercial Scale

  • Secure competent resources

  • ID org. resources including production and maintenance

  • Secure funding for all facets of this stage

  • Commercial Scale facility requirements

Risks

Bench Scale

  • Establish and use Risk Register

  • Monitor expenses vs. budget

  • Evaluate safety risks for novel processing

  • Stick to Stakeholder Communication Plan

  • Have reserves for cleanup or deviations

Pilot Scale

  • Use proper Hazard Assessment Techniques

  • Secure good documentation in all areas

  • Use Change Management Process

  • Protect IP with procedures and documents

  • Agree on production limits of this scale

Commercial Scale

  • Use proven methods for Project Approach

  • Risk identification expands to supply chain, competition, early adopters

  • Start maintenance and sustaining plans

  • Invest in sales, marketing, and early adopters

Stakeholder Needs

Bench Scale

  • Well-documented success criteria

  • Convey risks and mitigation plans

  • Utilize Project Charter for alignment

  • Report frequently on expenses and results

  • Educate on CEI/Implementation Framework for Chemical Innovation (IFCI) process

Pilot Scale

  • Well-documented success criteria

  • Continue risk awareness activities

  • Report frequently on schedule, expenses, results both positive and negative

Commercial Scale

  • Well-documented success criteria

  • Utilize the expanded Stakeholder Communication Plan

  • Report according to Commercial Scale Reporting Plan

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