Modular Process Systems
Designed for flexible just in time manufacturing, our modular process systems are the perfect tools for increasing size to product output ratios and decreasing waste production and energy costs.
From proven technology to fully customized designs, our modular process systems support many chemistries across diverse industries. Explore how our advanced technology, mechanical guarantees, and expert service can derisk your process implementation.
Benefits Of Pilot Plant Systems
Modular process systems come with a myriad of benefits that can significantly enhance the efficiency and success of your manufacturing operation.
Here are some key advantages:
Safety Risk Mitigation
Modular process systems enable the production of hazardous chemicals on a small scale which are then immediately consumed in downstream operations. This significantly reduces, or eliminates, the need for onsite storage of highly reactive chemical intermediates thus improving overall process safety.
Technical Risk Mitigation
Even with extensive engineering, plants are continuously upgraded throughout their lifetime to compete with new technology or comply with new regulations. Modular process systems are designed for plug and play operation where equipment or even entire unit operations can be replaced with relative ease. This minimizes the CAPEX for future plant upgrades and allows users to quickly restart production during turnaround events.
High Output to Size Ratios
New technology such as reactive distillation, membrane separation, and next generation catalysts enable modern modular process systems to reach high production rates with reduced footprint. By applying best practices these small plants may compete with larger installations and oftentimes have unique benefits such as near zero emissions.
Scalability
The output of a modular process operation can be increased by simply adding additional self contained modules. This feature eliminates implementation risk by simplifying the design thus lowering cost. Furthermore, it is easy to predict expansion costs because the equipment and implementation CAPEX estimates are based on prior projects.
Reactor & Separation Technology Combined
Modular process systems designed by ActiveSite are fully integrated to ensure seamless and efficient operations. Our technology incorporates reactor and advanced separation systems customized to the specific requirements of your process and product. ActiveSite has a 25 year history of catalyst development incorporated into our continuous and batch reactor designs. These units are then paired with an efficient separation to maximize product recovery and overall process yield.
Are You a Catalyst, Service or Systems Provider?
Why ActiveSite
for Pilot Plant Systems?
Choosing ActiveSite for your Pilot Plant Systems brings a wealth of benefits and value to your operation.
01
Delivery Flexibility
We understand that every operation has unique needs and requirements. We offer our modular process systems in various formats to best suit your needs. They can be delivered as fully modular production units designed for quick and efficient implementation and scalability.
Alternatively, we can provide technology packages for Engineering, Procurement, and Construction (EPC) companies. This gives you the freedom to construct and integrate the systems as per your specific operational and infrastructural requirements.
02
Mechanical Warranties
With ActiveSite, you're not just investing in a system; you're investing in peace of mind. We stand behind the quality and durability of our pilot plant systems.
To underscore our confidence and commitment, we have the ability to offer mechanical warrantees for our pilot plant systems. This ensures that you are covered against unforeseen mechanical failures, enhancing your operational continuity and reducing the risk of unexpected costs.
03
Expertise
With years of experience in the field, our team of skilled professionals possesses deep knowledge of catalysts and process development. Our expertise ensures that your system is designed, assembled, and operated to the highest standards, delivering optimal performance and results.
04
Customization
We understand that every process is unique. That's why we offer fully customized pilot plant systems that cater to your specific process needs. From the type of reactor to the separation system, every component is tailored to your process and product specifications, ensuring maximum efficiency and effectiveness.
05
Innovation
We are committed to incorporating the latest technology and innovation in our systems. From advanced reactors to cutting-edge separation systems, we provide you with the most modern and efficient solutions available.
06
Industry-Wide Application
Our Pilot Plant Systems cater to a wide range of industries including pharmaceuticals, specialty & fine chemicals, food & beverage, and biomolecular applications. This versatility allows us to serve a broad spectrum of clients and needs.
07
Support and Service
We don't just provide systems; we provide full support and service. From initial consultation to system delivery, installation, and maintenance, we stand by our clients every step of the way.
Discovery
Which chemistry do you want to run in the Modular Process Systems?
This will help us determine the type of equipment and materials needed for the reaction.
What are your volumes?
We’ll need to know the desired production volumes to determine the appropriate size and capacity of the Modular Process Systems.
What’s your timeline for implementation?
Understanding your timeline will ensure that the batch reactor system can be designed, manufactured, and delivered in a timely manner.
What utilities do you have available?
To ensure that the Modular Process Systems can be properly installed and operated, we’ll need to confirm available utilities, such as electrical power, water, and steam.
Share your current Modular Process Systems with us. We’ll ask for details about the current equipment and its performance to better understand your needs and requirements.
Identifying Milestones
Is the Modular Process technology already in-house?
We need to know if the client currently has a Modular Process System in place or if they will need to acquire a new one.
If not, we’ll run experiments.
If the client does not have an existing Modular Process System, we’ll recommend running experiments to determine the reaction conditions and establish a design basis for the new system.
Project proposal.
Once we have a design basis for the new system, we can produce a proposal. Based on the results of the experiments and the client’s requirements, Applied Catalysts will develop a design basis for the new Modular Process System and produce a proposal outlining the equipment, materials, and costs involved in the project.
What's in the Project Proposal?
Our proposal outlines the scope, details, and costs involved in designing, manufacturing, and installing a Modular Process System.
The proposal includes an opportunity summary that provides a brief overview of the project, a process schematic that outlines the process flow and equipment configuration, the required utilities needed to operate the system, the required footprint area, and the required timeline for the project’s completion.
Additionally, the proposal includes a budgetary price, which can be either for the sale or rent of the equipment, that provides a cost estimate for the system’s design, manufacturing, delivery, installation, and ongoing support. All of these items are critical to ensuring that the client understands the scope and costs of the project and can make an informed decision about whether to move forward with the Modular Process System proposal.
Our Process For Modular Process Systems
Reach out to our sales team and we will contact you with a rapid response. Our process involves consultation with both sales and technical to understand how ActiveSite can help solve your process development challenges. We enjoy helping clients at all levels of the development stage and have the equipment and expertise to supplement customer R&D to move your chemical technology from lab to production. See our white paper library for examples of how this process has been successful.
Process Catalysts
Metal Oxide Catalysts (MOC)
MOC products offer advantages as it can be used in both reductive and oxidative environments. Other advantages include high strength, attrition resistance, and tunable surface properties for various applications.
Custom Catalysts
Delivering on a foundation of catalyst development of over 30 years, we offer monolith-based, particulate catalysts, PGM, and base-metal catalysts.
Activated Carbon Monolith Catalysts (ACMC)
At ActiveSite, we strive to meet the unique needs of every customer. Whether you have a particular catalyst type in mind or need some additional guidance, we can help find the best solutions through all stages, from development to commercialization.
Granular Activated Carbon Catalysts (GACC)
GACC products have a high surface area and inert support for numerous catalyst applications. We can help you develop, test, and deliver the right catalyst.
Systems
Modular Process Systems
ActiveSite offers catalyst development services based on heterogeneous catalysts. Combining our testing services with our catalyst development services accelerates project success and maximizes value creation for the customer.
CATALYST DEVELOPMENT SERVICES
Catalyst Development
Active Site offers catalyst development services based on heterogeneous catalysts. Combining our testing services with our catalyst development services accelerates project success and maximizes value creation for the customer.
Catalyst Sourcing
There will be times when alternate suppliers are needed. As a supplier of catalyst and process technology ourselves, we can help customers source catalysts and chemicals in many areas.
Catalyst Testing
We offer lab-scale and show-tube scale testing of hydrogenation and other chemical processes under reductive or inert conditions. Other chemistries can also be run by request.
CATALYST SYSTEMS
Batch Reactor Systems
Batch reactor systems offer a reliable and flexible way to manufacture a wide range of chemical products and allow for better control over each reaction step, making them an ideal choice for many chemical manufacturers.
Continuous Reactors
Our continuous reactor systems offer productivity, reliability, and cost advantages for chemical manufacturing. Turn-key systems can be delivered.
Modular Process Systems
Designed for flexible just in time manufacturing, our modular process systems are the perfect tools for increasing productivity and driving profitability.
Separation Systems
Separation Systems are integral to a variety of industries that involve the processing of complex chemical mixtures that require safe, efficient, and reliable process equipment.
APPLICATIONS + INDUSTRIES SERVED
Biorenewables
Pioneering catalyst solutions for converting renewable resources into sustainable and eco-friendly bio-based products.
Learn moreCO2 Capture
CO2 capture is the absorption of CO2 from ambient air (direct capture) or from more concentrated streams from industrial and other combustion processes. We can provide supports that are ready for absorbants to be applied, or monoliths with absorbants applied to your specifications.
Learn moreFine Chemicals
Specialized catalysts designed for precision and efficiency in the synthesis of high-value fine chemicals.
Learn moreOleochemicals
Tailored catalysts facilitating the conversion of natural oils and fats into diverse industrial chemicals and products.
Learn morePharmaceuticals
High-purity catalysts designed to meet stringent regulatory standards for synthesizing complex pharmaceutical compounds.
Learn morePolymers
Innovative catalysts used in polymerization processes, crucial for creating a variety of synthetic polymers with desired properties.
Learn moreSpecialty chemicals
Customized catalyst solutions catering to the unique requirements of specialty chemical production, ensuring quality and performance.
Learn moreProcess - Performance Guaranteed Separation Systems
We give our clients the peace of mind that they need to invest in our equipment, knowing that it will perform as intended and meet their production goals.
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Rapid changeover from one chemistry to another
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Just-in-time manufacturing
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Seamless process scaleup