Reconfigurable modular processing facility

Abstract

Embodiments relate generally to reconfigurable modular processing facilities and methods for constructing and operating such. For example, a method for constructing a reconfigurable modular processing facility may comprise assembling a plurality of vertical walls, wherein the spaces between the walls define a plurality of stations; assembling a plurality of horizontal levels, wherein the spaces between the levels and the walls define the plurality of stations; constructing a lift within a center portion of the facility, wherein the lift is configured to access each of the plurality of stations; assembling one or more pods sized to fit within the stations, wherein the pods contain process equipment; configuring a process within the facility by moving one or more pods into one or more stations; and connecting the one or more pods to one another to complete the configuration of the process.

What is claimed is: 
     
         1 . A method for constructing a reconfigurable modular processing facility, the method comprising:
 assembling a plurality of vertical walls, wherein the spaces between the walls define a plurality of stations;   assembling a plurality of horizontal levels, wherein the spaces between the levels and the walls define the plurality of stations;   constructing a lift within a center portion of the facility, wherein the lift is configured to access each of the plurality of stations;   assembling one or more pods sized to fit within the stations, wherein the pods contain process equipment;   configuring a process within the facility by moving one or more pods into one or more stations; and   connecting the one or more pods to one another to complete the configuration of the process.   
     
     
         2 . The method of  claim 1 , wherein moving one or more pods into one or more stations comprises moving the one or more pods using a lift within the facility, and wherein the lift comprises at least one vertical shaft; a collar configured to fit around the vertical shaft, configured to move in a vertical direction along the vertical shaft, and configured to rotate about the vertical shaft; and a horizontal arm connected to the collar configured to extend away from the vertical shaft toward a station within the facility. 
     
     
         3 . The method of  claim 2 , wherein moving the one or more pods comprises:
 moving the pod onto the horizontal arm;   moving the collar in a vertical direction along the vertical shaft, thereby moving the horizontal arm and pod;   rotating the collar about the vertical shaft, thereby rotating the horizontal arm and pod about the vertical shaft;   aligning the collar, and therefore the horizontal arm and the pod, with a station configured to receive the pod; and   extending the horizontal arm toward the station, thereby moving the pod into the station.   
     
     
         4 . The method of  claim 3 , further comprising removably locking the pod onto the horizontal arm. 
     
     
         5 . The method of  claim 1 , further comprising constructing a plurality of process flow lines between the plurality of stations, wherein the process flow lines extend through and between the vertical walls and horizontal levels. 
     
     
         6 . The method of  claim 5 , wherein connecting comprises connecting one or more process flow lines to the pods. 
     
     
         7 . The method of  claim 1 , wherein the process flow lines comprise utility lines. 
     
     
         8 . The method of  claim 1 , further comprising reconfiguring the process by moving at least one pod into or out of the process, wherein moving the at least one pod comprises moving the pod into or out of a station of the facility. 
     
     
         9 . The method of  claim 1 , wherein the station comprises one or more tracks configured to interface with one or more tracks on the bottom surface of the pod. 
     
     
         10 . The method of  claim 1 , wherein the collar is configured to rotate between a set number of positions about the vertical shaft, and wherein the positions correspond to the stations located about the vertical shaft. 
     
     
         11 . A reconfigurable modular processing facility comprising:
 a plurality of stations defined by vertical walls and horizontal levels within the facility;   one or more process flow lines located between the plurality of stations, connecting the stations to one another;   one or more connectors located within the stations comprising connections to the one or more process flow lines;   a plurality of pods configured to fit within the plurality of stations, comprising one or more connectors configured to interface with the connectors of the stations, and comprising process equipment configured to complete a process within the facility; and   a lift configured to move the plurality of pods within the facility.   
     
     
         12 . The facility of  claim 11 , wherein the lift comprises:
 at least one vertical shaft;   a collar configured to fit around the vertical shaft, configured to move in a vertical direction along the vertical shaft, and configured to rotate about the vertical shaft; and   a horizontal arm connected to the collar configured to extend away from the vertical shaft toward a station within the facility.   
     
     
         13 . The facility of  claim 11 , wherein the facility comprises a circular or cylindrical shape, and wherein the vertical walls comprise a “V” shape. 
     
     
         14 . The facility of  claim 11 , further comprising one or more extended stations configured to hold an extended pod, wherein the extended pod is larger than the original pod. 
     
     
         15 . The facility of  claim 11 , wherein the stations comprise one or more tracks configured to interface with the pod to align the pod with the station. 
     
     
         16 . A method for operating a reconfigurable modular processing facility, the method comprising:
 installing a plurality of pods into stations within the facility, wherein the pods contain process equipment;   connecting two or more pods via connectors within the stations in a specific configuration for completing a process;   directing process flow from one pod to another pod to complete the process within the facility; and   collecting a final product within at least one pod of the facility.   
     
     
         17 . The method of  claim 16 , wherein installing a plurality of pods comprises moving the pods using a lift within the facility, and extending a horizontal arm of the lift to install the pod within the station. 
     
     
         18 . The method of  claim 16 , further comprising moving a pod during the completion of the process. 
     
     
         19 . The method of  claim 18 , further comprising moving a pod from a first station to a second station, and directing process flow from the moved pod to an adjacent pod. 
     
     
         20 . The method of  claim 16 , further comprising moving the pod containing the final product out of the facility.