Integrated process development

Heinzle, E. Hungerbiihler, K. (1997) Integrated Process Development The Key to Future Production of Chemicals. Chimia, 51, 176-183. 

Based upon laboratory and mini- or pilot-plant experiments process flow-sheets are prepared that also take environmental and safety aspects into consideration. Studies on these aspects are carried out in parallel with chemistry and engineering research in the form of so-called Integrated Process Development (see Heinzle and Hungerbiihler, 1997). 

With the introduction of advanced process simulation tools [25], the so-called integrated process development established. Here the most time-consuming pilot plant phase is bypassed by a combined approach of experimental miniplant testing and numerical process modeling. 

The principle of integral process development [26] covers much more than just the optimization of a process. This approach begins with computer-aided decision procedures in the conception phase. Tools are available in which the process structure is suggested, for example should the process be a batch or a continuous operation The software tool for process synthesis PROSYN uses databases which include knowledge of experts, material data and calculation models for unit operations. Interfaces to process simulation tools such as ASPENPLUS and material databases are also supplied. PROSYN also delivers an economic evaluation of the future production process. 

The above-mentioned integrated process development combines simulation tools with miniplant equipment to bypass the set-up of a pilot-scale plant Similar to this combined approach, a micro structured reactor plant can bridge laboratory-scale and micro-scale development. One could think of a future micro-integrated process... 

To emphasize the large variety of downstream processes and the importance of integrated process development between fermentation, recovery, and formulation, four bioprocesses are briefly discussed below. 

Implementing an inherent safety review process is one mechanism companies can use to institutionalize inherent safety. The review process should integrate well with company systems for process safety management, new product development, and project execution. Safety, health, and environmental considerations in the new product or process development effort can be strengthened via the introduction of the inherent safety review. Companies may also build inherently safer design concepts into their existing process safety management system and process hazard reviews. 

Rogers, R. L., D. P. Mansfield, Y. Malmen, R. D. Turney, and M. Verwoerd (1995). The INSIDE Project Integrating Inherent Safety in Chemical Process Development and Plant Design. International Symposium on Runaway Reactions and Pressure Relief Design, August 2-4, 1995, Boston, MA, ed. G. A. Melhem and H. G. Fisher, 668-689. New York American Institute of Chemical Engineers. 

After tlie system has been defined, a hazard evaluation technique can be used to identify different types of hazards within tlie system components and to propose possible solutions to eliminate the hazards. This topic is treated in more detail in the next t o chapters. These procedures are e.xtremely useful in identifying system modes and failures that can contribute to the occurrence of accidents diey should be an integral part of different phases of process development from conceptual design to installation, operation, and maintenance. The hazard evaluation tecliniques tliat are useful in tlie preliminary and detailed stages of tlie design process include ... 

In order to achieve this goal of a fully integrated process sequence, a concerted research and process development effort must take place. Present R D efforts are devoted to the development of cost-effective pyrochemical processes for the recycle of plutonium in residues. Future efforts will be aimed at the recycle of reagents in each individual process. The objectives of the recycle are to produce plutonium metal which can be further purified, and to generate small volumes of residues which can be discarded or recycled. 

The co-processing of coal with heavy crude oil or its heavier fractions is being developed to lower capital requirements for coal hquefaction and to integrate processing of the products of coal conversion into existing petroleum refineries. This development appears to represent the main route by which coal-based liquid fuels will supplement and perhaps someday displace petroleum-based fuels. 

Tobin, K. G., Capie, W. (1982). Relationships between formal reasoning ability, loeus of eon-trol, academic engagement, and integrated process skill development. Journal of Research in... 

The recycling of contaminated polyurethane waste is described with reference to a glycolysis process developed by Bayer and Daimler-Benz in which the wastes from three-layer composite instrument panels are treated. The reuse of contaminated PU is achieved by dispersely integrating the impurities in the secondary polyol during the glycolytic dissociation. The impurities are modified in such a way that they act as a filler in the secondary polyol. 3 refs. 

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