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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/437,410 filed Dec. 21, 2016 by Martin Birch, et al. and entitled “Vaccine Facility” which is incorporated herein by reference as if reproduced in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

BACKGROUND

In general, processing facilities may comprise a number of different processing equipment needed to complete the desired process. Typical construction of a processing facility may comprise installation of the process equipment in a (at least semi) permanent location and configuration. Additionally, typical construction of processing facilities may include extensive testing of the equipment on site after at least a significant portion of the facility has been built on location.

SUMMARY

In an embodiment, 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.

In an embodiment, a reconfigurable modular processing facility may comprise 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.

In an embodiment, a method for operating a reconfigurable modular processing facility may comprise 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.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

FIG. 1 illustrates a perspective view of an exemplary reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 2 illustrates a cross-sectional view of such a reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 3 illustrates a top perspective view of such a reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 4 illustrates a detailed partial cross-sectional view of such a reconfigurable modular processing facility according to an embodiment of the disclosure.

FIGS. 5A-5C illustrate exemplary processes (e.g., process flows) that may be completed within the reconfigurable modular processing facility according to embodiments of the disclosure (e.g., showing exemplary flow between pods in various stations within the structure, related to a particular exemplary process).

FIGS. 6A-6C illustrate views of an exemplary pod that may be used within a reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 7 illustrates another view of such pods that may be used within a reconfigurable modular processing facility according to an embodiment of the disclosure, which might be configured to allow easy transport in standard shipping/trucking containers.

FIG. 8 illustrates a top view of a portion of an exemplary reconfigurable modular processing facility according to an embodiment of the disclosure, illustrating an exemplary lift in the shaft opening of an exemplary structure with rings (in various levels) of stations located thereabout.

FIG. 9 illustrates a view of an exemplary pod that may be used within a reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 10 illustrates an exemplary layout of one or more reconfigurable modular processing facility according to an embodiment of the disclosure.

FIG. 11 illustrates another exemplary layout of a reconfigurable modular processing facility according to an embodiment of the disclosure, demonstrating that other structure/facility shapes may also be included within the present disclosure for similar functional/operating facilities/structures.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.

The following brief definition of terms shall apply throughout the application:

The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;

The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);

If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example;

The terms “about” or “approximately” or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field (for example, +/−10%); and

If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.

Embodiments of the disclosure include systems and methods for a reconfigurable modular facility, where the facility may comprise a plurality of stations (e.g., within a structure for forming a facility) configured to receive (and allow interconnection between) a plurality of pods (which are typically mobile/readily-movable and may be configured for plug-and-play operation within the structure in conjunction with one or more other pods, in order to perform/form a modular process line). As used herein, a “pod” is a modular unit configured for use in the stations of a facility embodiment as described herein. The plurality of pods (or a portion of the plurality) may jointly contain equipment and/or materials needed to complete one or more processes, and the pods may be moved (e.g., repositioned, swapped out, and/or re-interconnected (in a different way) with other pods) within the facility (e.g., into or out of the stations) to configure and reconfigure one or more processes to be completed by the facility (e.g., the specific process(es) in the facility may easily be changed). As an example, the facility may be configured to produce pharmaceutical materials, such as vaccines, small scale biotech, oral solid doses, liquids, creams, ointments, and other similar products and materials. Because of the developing and changing nature of each of these end products, flexibility within the processes of the facility may be important to accommodate changes in the desired product. For example, a vaccine facility configured for a first vaccine production could quickly and easily be reconfigured (e.g. by moving or changing pods or their interconnections within the structure) for production of a second/different vaccine—for example, in a facility for making flu vaccine (which changes every year), certain pods could be moved/replaced/switched/swapped within the structure and/or certain interconnections between pods/stations could be changed to reconfigure the facility for next year's version of the flu vaccine.

The facility may comprise a pre-engineered structure forming the plurality of stations to hold (and typically interconnect) the plurality of pods. Many, most, or all of the stations and/or pods may comprise standard dimensions (which typically correspond to one another), such that any number of (similar) facilities can be built with such stations to house the pods, where each facility may use the pods to complete one or more processes. In some cases the facility may comprise one or more layers of stations (e.g., the structure of the facility may comprise stacked layers of stations resembling floors of a building), where the pods in such stations may be positioned adjacent to one or more pod in the horizontal direction and/or the vertical direction (e.g., horizontally adjacent to up to 2 pods and/or vertically adjacent to up to 2 pods). In some cases, a station may extend through two or more layers of the facility, in the vertical direction, and/or through two or more vertical walls, in the horizontal direction, creating an extended station (which may be sized to hold a corresponding extended pod), where the size of the station may be manipulated based on the size of the pod to be held by the station. Typically, each such layer would be generally circular or ring-shaped (which could include an octagon, hexagon, etc. or other shape with generally ring-like shape (e.g. radially symmetrical)). Typically, each layer would have a shaft opening in its center (which would extend vertically through the center of the entire structure—e.g., along the vertical centerline of the facility), and each layer would be essentially radially symmetrical about the vertical centerline (for example, such that the layer shape would be symmetrical (e.g. a mirror image) about any vertical plane passing through the vertical centerline of the facility, and typically all such layers would be the same shape and/or size). All of the stations together might be termed the “station structure” of the facility, for example formed of the vertical walls and levels.

In some cases, a station may be large enough in the horizontal direction to hold one standard pod, two standard pods, and/or one extended pod (which may be larger than the size of one standard pod, and may be extended in size to accommodate particular equipment within the extended pod). In some cases, a station may be large enough in the vertical direction to hold one standard pod, two standard pods, and/or one extended pod (which may be larger than the size of one standard pod, and may be extended in size to accommodate particular equipment within the extended pod). Typically, most stations would be sized to correspond to a uniform/standard pod size and/or shape, and any extended pods might be configured to be (up to) twice the height and/or twice the length/depth and/or twice the width of such uniform/standard pod (with (extended) stations corresponding to such extended pods being sized to match). In some embodiments, portions of the station (e.g. the floor or roof of the level(s) and/or the vertical walls) might be configured to allow for removal or moving (e.g. sliding or folding) to allow two or more standard-sized stations to be combined to form an extended-sized station.

The pods may be moved into and out of the stations using a lift within the facility (e.g. with the pods and the lift being configured to allow for removable attachment of a pod to the lift, and the lift being configured to lift/raise/lower such attached pod and to (rotationally) orient and place such pod within the corresponding/target station (e.g. the lift can place such a pod into any station in the facility structure)—typically in automated fashion). The pods may be configured to automatically connect to one or more connectors within each station (e.g. typically each station in a facility has identical connectors—e.g. connectors of the same type(s) located in the same position(s)), thereby integrating the pod into a process to be completed within the facility. In some cases, the pods may be easily movable within the facility (i.e., moving a pod from one station to another and/or replacing one or more pods either with pods from other stations in the structure or with new pods transported in from outside the structure/facility) because of the automatic connection (or disconnection) with the stations, the standardized dimensions of the pods and the stations, and the capability of the lift to interface with and move the pods into and out of the stations (e.g. any and all stations in the structure).

The modular design of the facility, the control provided by the lift, and/or the station connectors may allow for removal of people from close proximity to the processes completed within the facility. For example, in some embodiments the entire facility could be automated (so it might operate without human workers/operators within the facility or with only a minimal crew of operators whose primary job would be to monitor the process and/or operate the process and/or reconfiguration remotely using the automated functionality of the facility). In other embodiments, the lift could interact with the stations (e.g. moving pods in and out) with minimal (or no) human physical interaction (e.g. the pod loading and unloading process could be entirely automated). This may remove a source of contamination within the process, and may prevent workers from exposure to hazardous substance and/or dangerous work environments.

Referring now to FIG. 1, an exemplary embodiment of a modular facility 100 is shown. The facility 100 may comprise an outer structure 102 (here shown in transparency) surrounding the interior structure elements (e.g. encasing the exterior of the facility, e.g. the station structure). If there is an outer structure, it typically comprises a door/opening/entry, allowing movement of pods from outside the facility to within the facility (and typically leading to the shaft opening, so pods can enter the facility and be loaded onto the lift). The facility 100 (for example, the station structure) may comprise a plurality of vertical walls 110, where the vertical walls 110 may extend through/between a plurality of levels 130 (i.e., floors, layers), thereby creating a plurality of stations 120 (i.e., silos) formed by the walls 110 and the levels 130 (e.g. the vertical walls form a series of stations on each horizontal level and the levels form vertical stacks of stations). In the embodiment shown in FIG. 1, the facility 100 may comprise a generally circular (i.e., cylindrical) shape (typically ring-like, with a shaft opening centrally located—and ring/circle here is intended to include an octagon, hexagon, etc. which might encircle the shaft opening and approximate a circle by functionally allowing a lift located in the shaft opening to rotate (e.g., about the vertical centerline of the shaft opening and/or station structure) to align with any station on a level), while in other embodiments, the facility 100 may comprise a rectangular or other building shape (as discussed with FIG. 11, for example).

FIG. 2 illustrates a vertical cross-section view of the facility 100 shown in FIG. 1. In some embodiments, adjacent vertical walls 110 (of adjacent stations) may comprise a “V” shape, for example intersecting to form a “V” shape, with the two sides of the V connecting toward the center of the (circular) modular facility 100 (as better seen in the embodiment of FIG. 3). In some embodiments, the stations 120 may be located between two adjacent V shaped walls 110 (e.g. the silo space/opening of the station (which would be configured to house a pod, for example with an insertion port/opening located towards the shaft opening 132 and typically aligned with the vertical centerline of the station structure and typically sized to allow for insertion and removal of a pod) may be formed when two adjacent “V” shaped walls provide parallel walls therebetween). In some embodiments, the vertices of the “V” shaped walls might not actually meet, but the “V” shaped walls would nevertheless maintain generally the “V” shape (e.g. angled) orientation (e.g. shaped generally like a pie wedge, in order to form the generally rectangular (box-like) silo space for the pods when located about the generally circular shape of the levels of the structure). In some embodiments, the stations 120 may be approximately rectangular (e.g., the silo space may be approximately box-like), while the overall facility 100 may be circular, and the V shaped walls 110 may create the rectangular shape of the stations 120 (e.g., the box-like silo spaces located between the V-shaped walls). In the embodiment shown in FIG. 2, each level 130 may comprise a plurality of stations 120 located in generally circular positions around the (outer portion) circumference of the level 130. Typically, the facility 100 would have a shaft opening 132 located centrally and extending through all levels 130 of the station support structure, with the stations located about the circumferential perimeter of the shaft opening 132 and with the shaft opening 132 being large enough so that the radius extends outward from the vertical centerline further than the lift when loaded with a pod (which might include an extended pod in some embodiments).

The facility 100 may comprise a lift 140 (or other similar pod-moving element configured to load and unload pods from the stations, all included within the term “lift” as used herein) located within a center portion of the facility 100 (e.g. within the shaft opening 132, typically centered on the central vertical axis of the station structure/facility), wherein the stations 120 may be located about the lift 140, and wherein the lift 140 may be configured to access each of the stations 120 in the facility 100 (e.g. the lift may load and/or unload pods with respect to any station in the facility/station support structure). For example, the lift 140 may be configured to move one or more pods 150 within the facility (typically one pod at a time), wherein the pods 150 may be configured to fit within a station 120 of the facility 100. The lift 140 may be configured to removably attach (e.g., lock) to the pod 150, move the pod 150 in a vertical direction (up and down between levels), move the pod in a radial direction (to point/orient the pod at a specific/target station for that level), move the pod 150 in a linear horizontal direction (e.g., extending/retracting/telescoping into a station 120 and out of station 120, e.g., across the shaft opening 132), and/or detach/unlock from the pod 150. Typically, the lift 140 would be configured to support and move pods up to at least a standard weight and/or size (e.g. the maximum weight and/or dimensions for a standard pod).

In some embodiments, the facility may comprise one or more extended stations 122 configured to hold one or more extended pods 152. In the example shown in FIG. 2, the extended pod 152 may comprise a vertical pod that is sized to fill two standard-sized stations 120 in a vertical direction (i.e., a vertical extended station 122). In other embodiments, a horizontal extended pod might be sized to fill two standard-sized stations in a horizontal direction (e.g. a horizontal extended station). The extended pod(s) 152 may be larger than a standard pod 150 to accommodate one or more pieces of equipment that are larger than a standard pod 150. For example, the extended pod 152 may comprise a large vessel or tank. In some embodiments, the lift can accommodate an extended pod in size and weight (e.g. up to twice the size and/or weight of a standard pod).

Referring to FIG. 3, a top perspective view of the facility 100 is shown. A level 130 of the facility is shown, wherein the level 130 may be divided into stations 120 by a plurality of vertical walls 110 (e.g. “V” shaped). A plurality of pods 150 may be inserted into the stations 120, where the pods 150 may be removable (i.e., the pods 150 may be moved into the stations 120 and/or moved out of the stations 120, for example by the lift 140). The lift 140 (typically located in shaft opening 132 in FIG. 3) may comprise a main vertical shaft 141 (i.e., pole, guide) and a horizontal arm 142 configured to hold/support (e.g. removably locking) and direct (and/or convey/move/insert/retract) a pod 150 into or out of a station 120 (e.g. by linear horizontal movement/extension/retraction to span the shaft opening 132). Additionally, the lift 140 may comprise a collar 144 configured to fit around the vertical shaft 141 and attached to the horizontal arm 142. The collar 144 may be configured to rotate with respect to the vertical shaft 141 (e.g. between set rotational positions corresponding to the stations) and may be configured to move in a vertical direction along the vertical shaft 141. Thus, the collar 144 may direct/orient/point the horizontal arm 142 toward a desired/target station (for loading/unloading of a corresponding pod into the silo space of the station through its insertion port/opening). In some embodiments, the collar 144 may be configured to rotate to set positions about the vertical shaft 141, where the set positions of the collar 144 may correspond to the positions of the stations 120 located about the circumference of the facility 100 (and the circumference of the vertical shaft 141). The horizontal arm 142 may be configured to extend outward from the collar 144 toward the stations (e.g. forming a platform or fork on which to removably attach/place the pod), and may comprise a retractable (e.g. telescoping) mechanism configured to move toward and away from the collar 144 (e.g. so that the pod may be horizontally inserted into or removed from the station), conveying a pod 150 into and out of a station 120 (e.g. across the shaft opening 132). In some embodiments, the horizontal arm might be configured so that, when retracted, it projects radially just short of the shaft opening 132 (allowing for a shorter telescoping feature to load/unload pods from stations), while in other embodiments it may project radially a shorter distance but be configured to telescopically extend outward further to load/unload pods with respect to stations (since the telescoping aspect would have to cross more of the shaft opening 132).

As described above, the vertical walls 110 may comprise a V shape, where the stations 120 may be defined by the vertical walls 110. Additionally, each of the levels 130 may comprise a floor (and/or ceiling) of some kind configured to define the vertical boundaries of the stations 120 and/or to support the pods (although in other embodiments, the pods could be supported by features (such as rails) located on the sides of the V-shaped walls, and there might not be a need for pre-defined floors or ceiling for the stations—e.g. the levels might be formed by such support features which could hold pods in place via removable attachment to the vertical walls). In some embodiments, the facility 100 may comprise open spaces 112 between the stations 120 (i.e., within the V shape of the vertical walls 110), and these open spaces 112 may contain additional processing equipment, such as utilities, piping, etc. that may connect each of the stations 120 to one another and optionally to external sources. So in some embodiments, the connectors of the stations and linking means therebetween (such as piping allowing various pods in the stations to interconnect) could be located within the v-shaped walls (for example at least partially in the gaps/open spaces within the “V”). In some embodiments, a pod in one station might be interconnectable to another pod in any other station in the facility, but in other embodiments a pod might only be directly interconnected to other pods in adjacent stations (and interconnection of two non-adjacent pods would have to be indirect, through at least one other pod that is adjacent to both of the other non-adjacent pods).

Referring to FIG. 4, a detailed partial cross-sectional view of the facility 100 (from the lift 140 to the exterior of the structure) is shown. In FIG. 4, a pod 150 may be inserted into a station 120 by the lift 140 via the horizontal arm 142 of the lift 140. Additionally, the lift 140 may comprise a movable collar 144 attached to the horizontal arm 142, wherein the collar 144 is configured to move in a vertical direction about the lift 140, thereby moving the horizontal arm 142 in a vertical direction. In some embodiments, the collar 144 may be configured to rotate with respect to the vertical shaft 141, thereby rotating the horizontal arm 142 between different stations 120 on the same level. In some embodiments, the horizontal arm 142 may comprise a telescoping function configured to allow the horizontal arm 142 to extend toward the station 120 and to retract away from the station 120. This may allow the horizontal arm 142 to install (insert) a pod 150 into a station 120 and/or to remove a pod 150 from a station 120. In some embodiments, the station 120 may comprise one or more guides within the station (shown in more detail in FIG. 8) configured to interface with the pod 150 to align the pod 150 within the station 120 (e.g., to help with insertion and removal of the pod within the station) and/or aid in retaining the pod within the station.

In the example shown in FIG. 4, the station 120 may comprise one or more connectors 124 configured to interface with one or more corresponding connectors (e.g. connector attachment points) 154 of the pod 150 (for example, with one of connectors 124 and 154 being a male connector, and the other being the corresponding female connector). These connectors 124 and 154 may interface to connect the pod 150 to the overall process within the facility 100 (e.g. linking various pods to form a process line). For example, the connector 124 may comprise connections for utilities (such as water and electricity), and/or may comprise connections to process flow lines 128 located between the stations 120. Typically, the connectors for each station would have a standard configuration for placement of connectors (e.g. location and/or type) to allow use with standard configured pods (with each standard pod also having a corresponding/matching standard configuration for connectors—e.g. to allow plug-and-play of any standard pod within any station in the facility and/or even between facilities). In some embodiments, the connectors 124 may be configured to retract into the walls and/or floor of the station 120, and then when the pod 150 is inserted into the station, the connectors 124 may extend into the connectors 154 of the pod 150. In some embodiments, this may be accomplished by a spring mechanism. In some embodiments, the connector 124 may be configured to detect the presence of the pod 150 and may comprise a mechanical movement element (e.g. motorized actuator) configured to move the connector 124 into the connector 154 of the pod 150 (or vice versa).

The pod 150 may comprise an outer frame 151 configured to contain and/or support the other elements of the pod 150. The pod 150 may comprise one or more pieces of equipment 156 and/or materials located within the frame 151 of the pod 150. In some embodiments, the equipment 156 may connect to and interact with the connectors 154 of the pod 150 to move material (which could be pre-loaded within the pod or could be introduced into the pod from other pods in the process line and/or from input lines in the station structure) to and/or from the equipment 156. The equipment 156 may comprise vessels, reactors, mixers, piping, valves, exchangers, and any other process equipment needed to complete a process within the facility 100. In some embodiments, the equipment 156 may include one or more sensors for monitoring the condition and status of the pod 150 and the equipment 156 within the pod 150. These sensors may be configured to communicate with a control panel and or monitoring center. In some embodiments, the equipment within a pod may be interconnected (e.g. forming a portion of a process line within the pod).

In some embodiments, the process flow lines 128 may comprise flow lines between the equipment 156 of the adjacent pods 150. In some embodiments, the process flow lines 128 may comprise utility lines, such as electricity and water, which may be available for each pod 150 to facilitate operation of the pod 150. In some embodiments, the process flow lines 128 may comprise one more input line to the process from a source outside the facility 100. In some embodiments, the process flow lines 128 may comprise one or more waste lines configured to convey waste outside the facility 100. In other embodiments, all (or some) inputs to the processes of the facility 100 may come from pods 150 installed in the facility (e.g. without any external input lines). Similarly, in some embodiments, all (or some) waste from the processes within the facility may be collected in a pod 150 and optionally removed from the facility 100 in the pod 150 (e.g. without any external waste lines).

In some embodiments, one or more of the pods 150 may comprise a “clean” environment, wherein the assembly and operation of the pods 150 may be isolated from any contaminants that could affect the process to be completed within the facility. In some embodiments, the pods 150 may be completely sealed from the external environment (e.g. with a sealed shell encompassing the pod, typically with air-tight panels attached externally to the frame of the pod, and with sealant between any such panels), and thereby isolated from contaminants. In some embodiments, the pods 150 may be “self-contained” and may not require interaction from a person within the pod 150 to complete the process(es). In some embodiments, the pods 150 may be pressurized to a higher pressure than the external environment, further preventing contamination of the equipment and/or material within the pod 150. In some embodiments, the pods 150 may be pressurized with nitrogen. In some embodiments, clean pods might comprise sensors configured to detect and/or denote/alert with regard to a leak and/or contamination. The clean pod connectors may be configured to minimize or prevent contamination as well.

Referring to FIGS. 5A-5C, examples of processes that may be completed within the facility 100 (described above) are shown. The processes may be completed by a plurality of pods 150 and/or extended pods 152 in a particular layout within the facility 100.

In the example of FIG. 5A, the process 500 may be an example of a large scale bioreactor process. The process 500 may comprise a pod 150 containing a first equipment 511. The first equipment 511 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. The process 500 may comprise a pod 150 containing a second equipment 512. The second equipment 512 may be located adjacent to the first equipment 511. In some embodiments, the second equipment 512 may receive process flow from the first equipment 511. The second equipment 512 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. The process 500 may comprise an extended pod 152 containing a third equipment 513 (i.e., the third equipment 513 may be large enough to occupy an extended station within the facility). The third equipment 513 may be located adjacent to (and below) the second equipment 512. In some embodiments, the third equipment 513 may receive process flow from the second equipment 512. The third equipment 513 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. In some embodiments, the third equipment 513 may comprise a 10,000 liter bioreactor.

The process 500 may comprise a pod 150 containing a fourth equipment 514. The fourth equipment 514 may be located adjacent to (and below) the third equipment 513. In some embodiments, the fourth equipment 514 may receive process flow from the third equipment 513. The fourth equipment 514 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. The process 500 may comprise a pod 150 containing a fifth equipment 515. The fifth equipment 515 may be located adjacent to (and below) the first equipment 511 and optionally adjacent to a portion of the third equipment 513. In some embodiments, the fifth equipment 515 may send and/or receive process flow to and/or from the first equipment 511 and/or the third equipment 513. The fifth equipment 515 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. The process 500 may comprise a pod 150 containing a sixth equipment 516. The sixth equipment 516 may be located adjacent to (and below) the fifth equipment 515 and optionally adjacent to a portion of the third equipment 513. In some embodiments, the sixth equipment 516 may send and/or receive process flow to and from the fifth equipment 515 and/or the third equipment 513. The sixth equipment 516 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500. The process 500 may comprise a pod 150 containing a seventh equipment 517. The seventh equipment 517 may be located adjacent to (and below) the sixth equipment 516 and optionally adjacent to the fourth equipment 514. In some embodiments, the seventh equipment 517 may send and/or receive process flow to and/or from the sixth equipment 516 and/or the fourth equipment 514. The seventh equipment 517 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 500.

In the example of FIG. 5B, the process 502 may be an example of a filling line process. The process 502 may comprise a pod 150 containing a first equipment 521. The first equipment 521 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 502. The process 502 may comprise an extended pod 153 (extended in a horizontal direction) containing a second equipment 522 (i.e., the second equipment 522 may be large enough to occupy an extended station within the facility). The second equipment 522 may be located adjacent to (and below) the first equipment 521. In some embodiments, the second equipment 522 may receive process flow from the first equipment 521. The second equipment 522 may comprise a portion of a filling line process, wherein a product may be moved horizontally within the second equipment 522. The process 502 may comprise an extended pod 153 containing a third equipment 523 (i.e., the third equipment 523 may be large enough to occupy an extended station within the facility). The third equipment 523 may be located adjacent to (and below) the second equipment 522. In some embodiments, the third equipment 523 may receive process flow from the second equipment 522. The third equipment 523 may comprise a portion of a filling line process, wherein a product may be moved horizontally within the third equipment 523.

The process 502 may comprise an extended pod 153 containing a fourth equipment 524 (i.e., the fourth equipment 524 may be large enough to occupy an extended station within the facility). The fourth equipment 524 may be located adjacent to (and below) the third equipment 523. In some embodiments, the fourth equipment 524 may receive process flow from the third equipment 523. The fourth equipment 524 may comprise a portion of a filling line process, wherein a product may be moved horizontally within the fourth equipment 524. The process 502 may comprise a pod 150 containing a fifth equipment 525. The fifth equipment 521 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 502. The fifth equipment 525 may be located adjacent to (and below) the fourth equipment 524. In some embodiments, the fifth equipment may receive process flow from the fourth equipment 524.

In the example of FIG. 5C, the process 504 may be an example of a small scale bioreactor process, where one of the pods 150 of the process 504 may contain a 2000 liter bioreactor, for example. The process 504 may comprise a pod 150 containing a first equipment 531. The first equipment 531 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 504. The process 504 may comprise a pod 150 containing a second equipment 532. The second equipment 532 may be located adjacent to the first equipment 531. In some embodiments, the second equipment 532 may receive process flow from the first equipment 531. The second equipment 532 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 504. The process 504 may comprise an extended pod 153 containing a third equipment 533 (i.e., the third equipment 533 may be large enough to occupy an extended station within the facility). The third equipment 533 may be located adjacent to (and below) the first equipment 531 and/or the second equipment 532. In some embodiments, the third equipment 533 may receive process flow from the first equipment 531 and/or second equipment 532. The third equipment 533 may comprise a portion of a filling line process, wherein a product may be moved horizontally within the third equipment 533.

The process 504 may comprise an extended pod 153 containing a fourth equipment 534 (i.e., the fourth equipment 534 may be large enough to occupy an extended station within the facility). The fourth equipment 534 may be located adjacent to (and below) the third equipment 533. In some embodiments, the fourth equipment 534 may receive process flow from the third equipment 533. The fourth equipment 534 may comprise a portion of a filling line process, wherein a product may be moved horizontally within the third equipment 533. The process 504 may comprise a pod 150 containing a fifth equipment 535. The fifth equipment 535 may be located adjacent to (and below) the fourth equipment 534. In some embodiments, the fifth equipment 535 may receive process flow from the fourth equipment 534. The fifth equipment 535 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 504. The process 504 may comprise a pod 150 containing a sixth equipment 536. The sixth equipment 536 may be located adjacent to the fifth equipment 535 and optionally adjacent to a portion of the fourth equipment 534. In some embodiments, the sixth equipment 536 may send and/or receive process flow to and/or from the fifth equipment 535 and/or the fourth equipment 534. The sixth equipment 536 may comprise a vessel, a reactor, and/or a mixer, and may be connected to one or more other pods 150 within the process 504.

Referring to FIGS. 6A-6C, an exemplary embodiment of a pod 600 is shown (where the pod 600 may be similar to the pods 150 described above). The pod 600 may comprise an outer frame 601 (which may comprise a metal structure or frame surrounded by walls/panels—e.g. encasing/enclosing the pod/frame to protect and/or seal the equipment within and/or to ensure the equipment fits within the standard pod sizing and does not project outward in a way that might cause interference during insertion of the pod into the corresponding station). In some embodiments, the outer frame 601 may comprise glass panels/walls. In some embodiments, the outer frame 601 may comprise plastic panels/walls (which could be transparent or opaque). In other embodiments, the pod might just have a base/support frame (e.g. a bottom), and the equipment would be mounted thereon and would be sized to ensure that the pod is able to fit within stations without interference. In some embodiments, the pod 600 may comprise a plurality of wheels 602 (or other transport elements) configured to assist in moving the pod 600 (e.g., along a floor, within a facility, within a station of a facility, onto a lift, and/or off of a lift). The pod 600 may comprise a removable locking/retaining mechanism (for example slots for interfacing with forks of the lift, perhaps with an interference locking mechanism (on either the pod or the lift/station) to securely fix the pod thereto), allowing the pod to removably attach to the lift and/or station. The pod 600 may comprise one or more pieces of equipment 606 housed within the pod 600, wherein the equipment 606 may be configured to complete at least a portion of a process once the pod 600 has been installed into a facility (as described above). In some embodiments, the pod 600 may comprise a control panel 603, which may comprise a plurality of control elements for the pod 600. The control elements may be configured to control the operation of the equipment 606 within the pod. The control elements may be configured to control the connection of the pod 600 into a facility (as described above). The control elements may comprise communication elements configured to allow for wired and/or wireless communication between the pod 600 and a control center (i.e., monitoring center, monitoring display, and/or automated controller) which may be monitored by an operator of the facility and/or operated autonomously in automated fashion (e.g. using a computer processor configured via software to operate the automated features of the facility). In some embodiments, the control panel 603 of the pod 600 may comprise a display 604 configured to communicate information from the pod 600 (e.g., from the equipment 606 of the pod 600). This information may include status information, maintenance information, operating conditions (e.g., temperature, pressure, etc.) for the entire pod 600 and/or the individual equipment 606, among other things.

Referring to FIG. 7, three pods 600 are shown, where a number (e.g. three pods, as shown in FIG. 7) of the pods 600 may optionally be sized to fit within a standard shipping container 700. This may allow for easy transport of the pods 600 to and from a facility (as described above). In some cases, a standard for dimensions of the pod 600 (and therefore the stations within the facility) may be determined based on the ability to transport the pods 600 (e.g., within a shipping container 700), wherein the pods 600 may be built (and optionally tested) at a location different from the facility, and then may be transported to the facility and installed within the facility (as described above).

FIG. 8 illustrates another view of a pod 600 being installed within a facility 100. The lift 140 may move the pod 600 into or out of a station 120 within the facility. The lift 140 may comprise a collar 144 configured to move vertically along a vertical shaft 141 (as described above), where the collar 144 may attach to a horizontal arm 142 configured to interface with the pod 600. In some embodiments, the stations 120 may comprise one or more tracks 121 configured to guide the pod 600 into the station 120. In some embodiments, the pod 600 may comprise coordinating tracks/slots/grooves/wheels on the bottom surface of the pod 600. Also, the horizontal arm 142 may comprise similar tracks (similar to forks of a fork lift) configured to interface with the pod 600 (e.g. via corresponding slots on its bottom) to hold the pod 600 in place on the horizontal arm 142. In some embodiments, the pods may have wheels configured to interact/interface with rails in the stations and slots configured to interact/interface with the forks of the horizontal arm of the lift. The shaft opening 132 and (radially symmetrical) generally circular placement of stations (e.g. shape of the levels) can be seen here.

FIG. 9 illustrates a detailed view of the pod 600 shown sitting on the horizontal arm 142. The collar 144 and horizontal arm 142 may move to align the pod 600 with the station 120 (and optionally align the pod 600 (slots or wheels) with the tracks 121 (or other retaining and/or guiding feature) of the station 120). In some embodiments, the horizontal arm 142 may extend (e.g. telescope) into the station 120, thereby moving the pod 600 into the station 120. In some embodiments, the horizontal arm 142 and/or lift may comprise an element configured to push the pod 600 off of the horizontal arm 142 (e.g. the support element of the horizontal arm) into the station (e.g. onto the tracks 121 of the station 120).

FIG. 10 illustrates an exemplary embodiment of the facility 100 as described above, where the facility 100 may be built near a plurality of (similar) facilities in the same area. The facilities 100 shown in FIG. 10 may each comprise a generally circular (or cylindrical) shape, as described above. In some embodiments, a plurality of such (cylindrical) reconfigurable modular processing facilities might be located in proximity to one another (e.g. on a common plat of land, which might form a master facility) and/or in some embodiments a pod from one such facility might be moved to another such facility within the master facility. In some embodiments, a transport mechanism (typically automated) might be configured to move pods from outside the structure (e.g. from truck unloading zone or rail unloading zone) into the structure (e.g. via a door/opening/entry) and to load the pod onto the lift.

FIG. 11 illustrates another exemplary embodiment of a facility 1100 which may be similar to the facility 100 described above, but may comprise a rectangular shape with rectangular aligned stations 1120. Persons of skill should appreciate that the disclosed reconfigurable modular facility embodiments may include a structure/facility of different shapes (e.g. non-circular). While the circular/cylindrical facility shown in FIG. 1 benefits from the radial symmetry about the shaft opening 132 (allowing for a single lift in a central shaft opening to access all stations, as described above), other shaped facilities are also contemplated and included within this disclosure. The lift 1140 for such other embodiments may be configured somewhat differently to accomplish the station loading and unloading (of pods) characteristic. For example, the facility 1100 may comprise one or more lift 1140 configured to move a plurality of pods 1150 within the facility 1100 (as described above). In some embodiments, the lift 1140 may comprise a series of vertical lift elements (e.g. one for each vertical column of stations within the facility) and/or a horizontal movement mechanism (such as a conveyor belt(s)) operable to move pods horizontally between stations on a level, or a single lift element (for movement in the z-direction) in conjunction with a horizontal movement mechanism(s) operable to move pods horizontally (e.g. on each level) in two directions (e.g. x and y directions). For example, in some embodiments, the horizontal movement mechanism might include such elements on each level of the facility (so the vertical lift element would lift and place the pod on a target level, and the horizontal movement element on that level would move the pod to the target station. In some embodiments, the lift element could be located internally within the station structure of the facility, or externally (e.g. attached to an external face/side of the station structure). In some embodiments, the lift element might be repositional about the outside of the station structure. For example, the lift 1140 may be located on the exterior of the facility 1100, and the facility 1100 may not comprise a vertical shaft opening, as is described above.

Some embodiments of the disclosure may comprise one or more methods of constructing a reconfigurable modular processing facility. In some embodiments, a plurality of vertical walls may be built, wherein the (rectangular/box-like) spaces between the vertical walls (which might be V-shaped) define a plurality of stations (e.g. silo spaces). Additionally, a plurality of levels (i.e., horizontal floors and/or horizontal locations for supporting pods on the structure such as rails) may be built or stacked (e.g. intersecting the plurality of vertical walls), wherein the stations may be defined by the spaces (e.g. silo spaces) between the levels and the spaces between the vertical walls. The stations within the facility may be sized to removably hold one or more pods.

In some embodiments, one or more portions of the levels may be built to be adjustable. As an example, a portion of a level (e.g. a portion of the floor of a station) may be removed or moved (e.g. by sliding) to form a vertical extended station (i.e., an extended station that encompasses two or more stations vertically). In some embodiments, one or more portions of the vertical walls may be built to be adjustable. As an example, a portion of a vertical wall (e.g. a wall portion between two horizontally adjacent stations) may be removed or moved (e.g. by sliding) to form a horizontal extended station (i.e., an extended station that encompasses two or more stations). In some embodiments, the extended station could be enlarged both vertically and horizontally, so the extended pod could be up to four standard pod/stations in size. In some embodiments, an outer structure may be built around the vertical walls and levels.

In some embodiments, process flow lines and/or utility lines may be built into and/or between the levels and vertical walls. These lines may connect the plurality of stations to one another. The lines may comprise valves so that the flow may be directed and reconfigured as needed.

In some embodiments, a lift may be constructed/placed/positioned within a center portion (e.g. a shaft opening) of the facility, where the lift may comprise a vertical shaft, a collar 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 (e.g. telescope) from the vertical shaft toward the plurality of stations. The lift may be positioned within the facility such that the horizontal arm of a single lift may be able to access all of the stations within the facility (e.g. loading and unloading pods into any stations in the facility).

In some embodiments, the lift may be configured to move a plurality of pods into the plurality of stations of the facility. The pods may contain equipment necessary for completing one or more processes within the facility. The pod may be moved onto the horizontal arm, and may optionally be removably locked onto the horizontal arm. The collar may move vertically along the vertical shaft, thereby moving the horizontal arm and pod. The collar may rotate about the vertical shaft, thereby rotating the horizontal arm and pod about the vertical shaft. The collar may be controlled to align the horizontal arm (and therefore the pod) with a target station (configured to receive the pod). The horizontal arm may extend (e.g. telescope) toward the station, thereby moving the pod into the station. In some embodiments, the horizontal arm may comprise a portion configured to unlock with the pod and optionally to push the pod into the station. Then, the horizontal arm may retract, leaving the pod located within the target station.

In some embodiments, the method of assembling the facility may comprise building and assembling the pods at a remote location, and may comprise testing and/or configuring the pods before they are transported to and installed within the facility. The pods may be positioned (e.g. automatically, using the lift to load and/or move pods within stations in the structure of the facility) in a particular configuration (within stations) to assemble the different steps of a process to be completed within the facility. In some embodiments, the facility may contain more than one process. In some embodiments, the processes within the facility may interact with one another. In some embodiments, one or more connectors may be built into a station, where the connectors of the station may be configured to interface with one or more connectors of the pods. The connectors may comprise access to the one or more process flow lines of the facility and/or utility lines. The connectors may be incorporated into the surfaces of the stations.

Embodiments of the disclosure may include methods for operating a reconfigurable modular processing facility. In some embodiments, a plurality of pods may be installed within the facility, where the pods may contain process equipment. The plurality of pods may be moved into a plurality of stations using a lift within the facility (often in automated fashion). A process may be completed by one or more pods that are connected to one another. The process may comprise directing process flow from (the equipment of) one pod to (the equipment of) another pod. In some embodiments, the process may comprise moving a pod from a first station to a second station, and directing process flow from the moved pod to an adjacent pod (which may be adjacent to the second station) and/or receiving process flow from an adjacent pod. In some embodiments, the process may comprise providing a pod with process input material(s) and moving/loading such pod into the facility and/or a specific station (e.g. via the lift in automated fashion). In some embodiments, the process may comprise collecting a final product within a pod, and moving the pod containing the final product out of the facility.

In some embodiments, the facility may be reconfigured from a first process to a second process. Reconfiguring the facility may comprise moving at least one pod within the facility (e.g., from one station to another). Moving the pod may comprise moving out of the existing process, moving into (adding to) the existing process, moving to another position within the existing process, moving a (often differently configured) replacement pod into the existing process (e.g. subbing/swapping out one pod for another), and/or modifying/altering/reconfiguring process flow between pods in a process line. In some embodiments, one or more pods will not be changed/moved (and the process flow might also be unaltered), such that the process can be modified with minimum amount of work/alteration/disruption. So, the facility might be configured into a first configuration for a first process (with pods in specific stations/arrangement and interconnected in a first specific way) and operated in the first configuration for a time period, and then the facility could be reconfigured into a second configuration for a second process (typically different from the first process, for example by moving and/or swapping/replacing/subbing, etc. pods within the stations and/or interconnecting the pods/stations in a second specific way) for operation in the second configuration. This reconfiguration approach could continue (e.g. periodically or as needed) (for example, to allow the process to adapt over time and/or to re-purpose the facility for a different process) (e.g. allowing for a third configuration, a fourth configuration, a fifth configuration, etc.).

In some embodiments, operation of the facility may comprise completing maintenance (or updating) on one or more of the pods, which may comprise moving the pod out of the corresponding station, completing maintenance and/or testing on the pod (e.g. remotely from the station and/or facility), and moving the pod back into the corresponding station after maintenance and/or updating. In some embodiments, the process of which the pod is a part may be temporarily paused during the maintenance. In some embodiments, the pod may be temporarily replaced by another pod during the maintenance (e.g. a substitute pod essentially identical to the pod undergoing maintenance might be inserted into the station corresponding to that pod, until maintenance is complete or going forward until maintenance is needed again (when the first pod could be re-inserted while the second pod now undergoes maintenance). Such an approach may allow for maintenance with little to no downtime for the facility. In some embodiments, pods would be routinely/periodically subbed out for maintenance (so that after a full maintenance substitution cycle, all pods in a process line would have undergone maintenance).

For additional information on modular construction which may be pertinent for some disclosed embodiments, applicant hereby incorporates by reference U.S. patent application Ser. No. 15/440,812 filed Feb. 23, 2017 by Haney, et. al., and entitled “Modular Processing Facility” to the extent that it does not contradict any specific disclosure set forth herein (e.g. the specific disclosure of this application trumps in discrepancies or conflicts with material incorporated by reference).

Having described various devices and methods herein, exemplary embodiments or aspects can include, but are not limited to:

In a first embodiment, 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.

A second embodiment can include the method of the first embodiment, 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.

A third embodiment can include the method of the second embodiment, 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.

A fourth embodiment can include the method of the third embodiment, further comprising removably locking the pod onto the horizontal arm.

A fifth embodiment can include the method of any of the first to fourth embodiments, 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.

A sixth embodiment can include the method of the fifth embodiment, wherein connecting comprises connecting one or more process flow lines to the pods.

A seventh embodiment can include the method of any of the first through sixth embodiments, wherein the process flow lines comprise utility lines.

An eighth embodiment can include the method of any of the first through seventh embodiments, 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.

A ninth embodiment can include the method of any of the first through eighth embodiments, wherein the station comprises one or more tracks configured to interface with one or more tracks on the bottom surface of the pod.

A tenth embodiment can include the method of any of the first through ninth embodiments, 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.

In an eleventh embodiment, a reconfigurable modular processing facility may comprise 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.

A twelfth embodiment can include the facility of the eleventh embodiment, 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.

A thirteenth embodiment can include the facility of the eleventh or twelfth embodiments, wherein the facility comprises a circular or cylindrical shape, and wherein the vertical walls comprise a “V” shape.

A fourteenth embodiment can include the facility of any of the eleventh through thirteenth embodiments, further comprising one or more extended stations configured to hold an extended pod, wherein the extended pod is larger than the original pod.

A fifteenth embodiment can include the facility of any of the eleventh through fourteenth embodiments, wherein the stations comprise one or more tracks configured to interface with the pod to align the pod with the station.

In a sixteenth embodiment, a method for operating a reconfigurable modular processing facility may comprise 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.

A seventeenth embodiment can include the method of the sixteenth embodiment, 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.

An eighteenth embodiment can include the method of the sixteenth or seventeenth embodiments, further comprising moving a pod during the completion of the process.

A nineteenth embodiment can include the method of the eighteenth embodiment, 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.

A twentieth embodiment can include the method of any of the sixteenth through nineteenth embodiments, further comprising moving the pod containing the final product out of the facility.

While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.

Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

Use of broader terms such as “comprises,” “includes,” and “having” should be understood to provide support for narrower terms such as “consisting of,” “consisting essentially of,” and “comprised substantially of.” Use of the terms “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.

Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

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.