Unit Operations

In chemical and pharmaceutical development, unit operations form the foundation of process development.

AP-Miniplant designs and builds tailor-made laboratory plants, miniplants and pilot plants in which key unit operations such as distillation, extraction, filtration or crystallization are implemented in a reproducible manner – including appropriate measurement, control and automation technology. This results in practical experimental plants for process development, scale-up and technical feasibility studies.

Gain an overview of our expertise and feel free to contact us if you have any questions about the plants shown or would like to request a quotation.

Content

Absorption
Adsorption
Humidification & Evaporation
Distillation & Rectification
Extraction
Crystallisation & Precipitation
Filtration
Mixing
Reactive rectification
Drying
Evaporation
Q & A about pilot plants with unit operations

Whether batch or continuous: unit operations are the building blocks from which complete processes are formed. In an integrated laboratory or pilot plant, parameter windows, material properties, separation performance and energy input can be determined under realistic conditions, which is key for scale-up, safety and product quality in the chemical and pharmaceutical industries.

AP-Miniplant has many years of experience in implementing both batch processes and continuous processes, consisting of one or multiple unit operations, within fully automated laboratory plants. A selection of different unit operations that we have implemented can be found here.

Absorption

Absorption is used in pilot and research plants to selectively transfer components from gas or liquid phases into an absorption medium. Each system is engineered according to the specific material system, operating conditions and separation requirements. Automated control ensures stable operation and reproducible results.

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Adsorption

Adsorption processes are applied when components are selectively bound to solid materials, often under demanding temperature or process conditions. In addition, fixed-bed reactors filled with catalyst can also be used as test plants for catalysts or catalyzed reactions. Pilot plants are designed based on the chosen adsorbent, regeneration concept and operating parameters. This enables realistic process evaluation at pilot scale.

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Humidification & Evaporation

Humidification and evaporation processes are essential for controlling phase transitions and material conditions. Our systems enable controlled adjustment of moisture content and evaporation rate under defined operating conditions, whereby steam flows can be precisely regulated down to very low flow rates using our proprietary evaporation technology.

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Distillation & Rectification

Distillation is a key separation unit operation for complex mixtures. Our pilot plants are tailored to your material system, required separation efficiency and target throughput. Different column designs and operating modes can be implemented and automated as needed.

Distillation Plant made of Glass

This glass distillation plant can be used for research and educational purposes. It consists of…

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Extraction

Extraction pilot plants are used to selectively separate target components from liquid or solid phases. Different solvents, contacting principles and operating parameters can be evaluated at pilot scale. Modular system designs enable flexible adaptation to various process concepts.

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Crystallisation & Precipitation

Crystallisation is one of the one of the most unpredictable unit operations. It requires precise control of temperature, concentration and mixing. Our pilot plants support the investigation of crystal formation, growth behaviour and product quality. Both batch and continuous crystallisation processes can be realised.

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Filtration

Filtration is widely used for solid–liquid separation in chemical and pharmaceutical processes. Pilot plants are individually designed according to particle properties, product requirements and separation behaviour. Automated operation supports reproducibility and reliable scale-up.

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Mixing

Mixing processes are crucial for material homogeneity and reaction control. Our systems take rheological properties, mixing intensity, and residence times into account. Thanks to our extensive experience in the field of polymerization plants, we can also offer solutions for highly viscous material systems. Different agitator and mixing concepts can be investigated and optimized on a pilot scale.

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Reactive rectification

Reactive rectification integrates chemical reaction and separation in a single process step. Pilot plants enable the evaluation of reaction kinetics and separation efficiency under realistic conditions. Each system is tailored to the specific reaction system and operating strategy.

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Drying

Drying processes are used to remove solvents or moisture from solid materials. Pilot plants are designed according to thermal properties and product sensitivity. Controlled operation provides reliable data for scale-up decisions.

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Evaporation

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Are you planning a pilot plant for chemicals or pharmaceuticals?
Briefly describe your process (material system, pressure/temperature, desired basic operations, analytics/PAT, scope of automation). We provide support from design to commissioning – as a miniplant or pilot plant.

Q & A about pilot plants with unit operations

What is the difference between unit operations and an overall process?

In modern laboratory facilities, miniplants, and pilot plants, several unit operations can be combined in a modular or integrated manner. Typical combinations include, for example, reaction with downstream distillation, extraction with filtration, or crystallization with drying. The selection and arrangement of unit operations is process-specific and depends on the material system, throughput, operating mode (batch/continuous), and safety requirements.

Which unit operations can be combined in a pilot plant?

Unit operations have a decisive influence on separation performance, energy efficiency, product quality, and operational safety. In process development, they enable relevant parameter windows to be determined and risks to be identified at an early stage. Pilot plants with realistically designed basic operations provide reliable data for scaling up from laboratory to production plants – especially in the chemical and pharmaceutical industries.

Batch or continuous – which operating mode makes sense for a test plant?

Whether batch or continuous operation makes sense depends on the process objective and stage of development. Batch plants are particularly suitable for flexible trials, small quantities of material, and frequent recipe changes. Continuous basic operations, on the other hand, enable stable operating conditions, better scalability, and are often closer to later production processes. Pilot plants allow both concepts to be compared in a realistic manner. Continuous process control in an automated test plant is particularly suitable for investigating long-term stability, which allows, for example, the accumulation of by-products, control concepts, or process yields to be better evaluated.

What measurement, control, and automation technology is commonly used for unit operations?

Typical measured and controlled variables include flow rate, pressure, temperature, level, and composition. AP-Miniplant’s laboratory and pilot plants are equipped with PLC-based automation, data acquisition, and optional process-oriented analytics. Appropriate automation increases reproducibility, data depth, and operational reliability – especially in complex test facilities.

What safety requirements play a role in basic operations?

Safety requirements depend on factors such as pressure, temperature, material properties, and the solvents used. In the chemical and pharmaceutical industries, aspects such as explosion protection (ATEX), pressure equipment design, emergency shutdown, and safe media handling are particularly relevant. These requirements should be taken into account when designing basic operations in laboratory and pilot plants in order to minimize subsequent scaling risks.

How does a basic operation on a laboratory scale differ from a pilot plant?

On a laboratory scale, flexibility and rapid parameter studies are paramount, while pilot plants replicate basic operations closer to industrial conditions. Pilot plants take into account higher throughputs, longer running times, realistic apparatus geometries, and automation. Both scales complement each other in process development and together provide the basis for industrial scale-up. With a well-designed, continuous test plant on a miniplant scale and possibly supplementary simulation software, the costly and time-consuming construction of a pilot plant can be avoided.

How does the design and planning of a pilot plant?

Project planning begins with the definition of process objectives (material system, basic operations, operating mode). This is followed by concept design, safety assessment, mechanical and process engineering design, and automation. In close consultation with the customer, we create customized laboratory or pilot plants that are precisely tailored to development and scaling objectives.