Advanced existing processes

Debottieneck and Optimize Existing Process through Advanced Design and Controi... 

Since zeolite catalysts are successfully introduced in the refining and petrochemical industries, it is not surprising that most of the recent advances concern incremental improvements of existing processes with the development of new generations of catalysts (e.g., dewaxing, ethylbenzene and cumene synthesis). The number of newer applications is much more limited, for example, direct synthesis of phenol from benzene and aromatization of short-chain alkanes, etc. However, both the improvement and development of processes contribute significantly to environmental advances. 

Low-cost saline water conversion is a problem which has not been satisfactorily solved to date. New ideas, new processes, innovations, and improvements on existing processes are needed and can be achieved only through continued research. The development of saline water conversion processes has advanced in a number of broad fields, each of which incorporates a number of different processes. These fields can be... 

Applications of biocatalysis in large-scale processes in industry advance only slowly against established chemical processes, even with stoichiometry-based chemistry. Introduction of biocatalysis into existing processes often requires process modifications that are not economical in view of the short life span of the product and/or the low fixed costs of the existing process owing to written-off plant. It should be emphasized that the desire to reduce chemical wastes, imposed by either company policy or governmental measures, needs to be matched by favorable process economics. Therefore, the introduction of biocatalytic options at the very beginning of product and process development is of the utmost importance. 

The application of whole cells and isolated enzymes in the chemical industry is advancing rapidly, andmany companies areinvesting in so-called white biotechnology. That said, most of the biocatalytic processes are aimed at new compounds which are difficult to synthesize by conventional chemical routes. Replacing an existing chemical process with a biocatalytic route is trickier, because the new process must deliver the same quality of product (or better), at a lower overall cost. The existing process has an advantage here, since its capital costs are already repaid. Thus, in order... 

R D (big R and Big D) is an integrated activity from initial research on a new product or process to full-scale development The type of work done in support of a technologically advanced, existing businesses. 

In 1985 the National Academy of Sciences of the United States published a landmark study Opportunities in Chemistry which mapped out some of the important discoveries in the field over the preceding 20 years. The very first point made in the Pimentel Report (named after the chairman of the study group) was that the successful competitiveness of the chemical industry depends critically on the constant improvements of existing processes and the introduction of new ones. Thus advances in chemical catalysis and synthesis hold the key to a successful chemical industry. Indeed they estimated that a large proportion ca. 20%) of the entire US Gross National Product is generated through the use of catalytic processes. 

Knowledge of the chemical structures of the major organic components in biomass is quite valuable in the development of processes for producing derived fuels and chemicals. Information on the chemical structures can often lead to methods of improving existing processes and to development of advanced conversion methods. Somewhat more detailed information on the chemical structures of the major components in biomass is presented here. 

Partly as a result of business constraints on research, many fine chemical processes are a long way from optimum, especially when compared to bulk chemical processes, in terms of yield, productivity and effluents. Important improvements in competitiveness could be achieved by development of new catalysts. Due to complexity, development of new catalysts generally requires time, and the industry generally prefers the use of old classical methods that are well known and require a short development time. The three technical requirements for a new catalytic process to be industrialised are the following 1) The chemistry must be already well advanced at the start of the project so as to fit with the timetable, 2) The chemistry must be easily adaptable to the existing industrial plant (with little modifications), 3) The chemistry must provide a breakthrough in terms of economics and effluents compared to existing processes. 

The available data from the services indicate that corrosion in weapons systems is the primary cost driver in life-cycle costs (46). Quantifying corrosion is difficult as neither the mechanisms nor the methodologies exist to quantify accurately. Analysis of field data reveals instances where questionable materials selection early in the acquisition process has led to enormous unanticipated increases in life-cycle costs because of corrosion (J Argento, US Army TACOM-ARDEC, Picatinny Arsenal, NJ, Personal Communication, 1999). In view of force reduction and a reduction in budgets, consideration must be given to the selection of advanced materials, processes, and designs that will require less manpower for corrosion inspection and maintenance. 

Comprehensive polymerization models may be used by scientists and engineers to reduce the time required to develop new polymer products and advanced production processes for their manufacture as well as to optimize existing processes. 

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