Scaling process intensification technologies: what does it take to deploy?

• Key enablers for scaling up process-intensification (PI) technologies are identified • PI technologies rely less on the electricity grid vs. traditional ones • Interdisciplinary collaborations and lab-to-market partnerships are crucial • Business development experts should be involved at early TRL (3, 4) • Techno-economic analysis and LCA de-risk business development at TRL 3, 4 Process intensification (PI) has emerged as a transformative approach to enhancing efficiency, sustainability, and economics across chemical and manufacturing industries. However, within its dedicated communities, there is recognition of a persistent gap in transitioning these innovations from laboratory-scale success to widespread industrial adoption. Scaling up PI technologies is far more complex than simply replicating laboratory conditions on a larger scale. Challenges such as the integration with existing units and processes, proving economic viability, and navigating regulatory requirements often impede the practical implementation of PI innovations. This paper aims to identify the key enablers for scaling up PI technologies by presenting a roadmap to bridge the gap between concept and commercialization. While robust engineering design frameworks and advanced modeling tools are crucial, interdisciplinary collaborations and lab-to-market partnerships (or integrated scaling collaborations) are equally critical to drive the successful adoption of PI at the industrial scale.