The increased flexibility resulting from the modularization of process plants requires an advanced strategy to supervise the distributed control systems (DCSs). The connection and coordination of multiple process equipment assemblies (PEAs) into a modular plant (MP) is called orchestration and conducted in a so‐called process orchestration layer (POL). Standardized interfaces enable a seamless integration of PEAs into an MP. Current process control systems do not yet meet all required features regarding to interfaces and possibility of import/export of different data structures. Several aspects are presented which shall be taken into account when designing a POL. The POL's several layers are described in detail, resulting especially in flexibility and reusability of modular plants.

Scale-up predictions from a continuous flow micro-(lab) to milliscale (pilot or production) are important but not trivial. To overcome the necessity of time-consuming trials on the pilot or production scale, this work presents a modelbased approach that builds on prior lab experiments. However, it also improves the understanding of the involved chemical process. A complete process development for a highly exothermic organometallic reaction is conducted. Kinetic studies on a lab scale, using inline FT-IR measurements, constitute the basis for a systematic scale-up approach. Subsequently, the scale-up from microreactors (inner diameter of 0.5 mm) to milliscale pilot reactors (inner diameter of 2 mm) through increasing the channel diameter and flow rates is investigated. Model-based scale-up predictions are presented, including heat and mass balances.

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