Case Study - Scale-up of an agricultural waste-to-furfural technology
A leading Indian agro-industrial company engaged Beacon Solutions for independent technical guidance on scaling an innovative process that converts agricultural waste into furfural. We assessed commercial feasibility and prepared the client for the Basic Engineering phase.
- Client
- Indian Agro-Industrial Company
- Year
- Service
- Process scale-up advisory
Client background
A leading Indian agro-industrial company engaged Beacon Solutions to provide independent technical guidance for scaling an innovative process for converting agricultural waste into furfural. Having successfully demonstrated the technology at pilot scale, the client sought expert support to assess commercial feasibility and prepare for the Basic Engineering phase.
The challenge
Transitioning from pilot plant operation to commercial production does not scale linearly, due to reaction kinetics, flow regimes, and several other factors. The client required an experienced process specialist to:
- Evaluate pilot plant performance and operating philosophy.
- Review process data and identify scale-up risks.
- Assess the readiness of the technology for commercial implementation.
- Identify critical data gaps requiring further validation.
- Develop a structured roadmap for Basic Engineering.
Our approach
Beacon Solutions conducted a comprehensive technical review of the pilot facility, including:
- Assessment of the complete process configuration and operating methodology.
- Review of hydrolysis, extraction, solvent recovery, purification, and solids handling systems.
- Evaluation of process operability, fouling, corrosion, phase separation, and utility integration.
- Analysis of pilot operating history and performance trends.
- Identification of technology risks, engineering challenges, and opportunities for process optimization.
Following the site assessment, Beacon Solutions prepared a technical review summarizing key observations, scale-up considerations, and recommendations to support the client's transition into the Basic Engineering stage.
Deliverables
- Independent assessment of technology readiness for commercial scale-up.
- Early identification of critical engineering and operational risks.
- Clear recommendations for additional pilot validation where required.
- A structured roadmap for progressing from pilot operations to commercial plant design.
- Technical guidance to support informed investment and engineering decisions.
What we did
- Process scale-up advisory
- Pilot plant technical review
- Technology readiness assessment
- Basic Engineering roadmap