Intensification process

Keywords Methodology, Conceptual process synthesis. Process intensification. Process phenomena, Microstructured devices... 

Figure 7.1 Relationship between process intensification fields, physical process intensification, process miniaturization, selectivity, process viiibility, and phenomenon-based...

Most of those not active in PI will have encountered applications of process intensification in their domestic environment, rather than in their work. The microwave oven uses electric fields to intensify the energy input to foodstuffs and liquids, to cook and/or raise their temperature. We may find it difficult to find other orders of magnitude intensification processes within our living space , but an examination of consumer electronics and the power devices needed to drive such systems can reveal existing and potential applications of PI. Even the heat pump/chiller, used to maintain comfort conditions, has benefited from the rotating intensification methods invented by Professor Ramshaw. 

Can higher pressure be used to increase either reaction rates or mass transfer Clearly the higher pressure must be paid for in terms of compression costs, but the overall system benefits may justify this - high pressure is briefly discussed as an intensification process in Chapter 3. 

From the point of view of catalytic activity and in terms of selectivity and waste production, zeolites are the most traditional microporous catalysts with clear advantages over the conventionally used homogeneous acid catalysts. Zeolites find applications in the petrochemical and fine chemical industries, and also in gas separation, purification, and ion exchange [13-15] in addition, zeolites are used in pharmaceutical industry, sensing microsystems, nanotechnology, the intensification process, and green chemistry. 

The intensification process is sensitive and should therefore be used to detect the less abundant antigen. Similarly, if one of the primary antibodies gives a high background or is widely expressed throughout the tissue, this signal should not be enhanced with NiCl. ... 

The best way to deal with a hazard in a flowsheet is to remove it completely. The provision of safety systems to control the hazard is much less satisfactory. One of the principal approaches to making a process inherently safe is to limit the inventory of hazardous material, called intensification of hazardous material. The inventories we wish to avoid most of all are flashing flammable liquids or flashing toxic liquids. 

Intensification of hazardous materials results in a safer process. In... 

It is particularly in the serial inspection of castings, that radioscopy constitutes state-of-the-art when applied in conjunction with systems for image intensification, digital image processing and automatic image evaluation. For the examination of welds, however, standardization is still non-existent, thus rendering more difficult the application of this inspection technique.As a consequence the approval procedures of the respective supervisory or certification boards are often complicated and of necessity set up for each individual case. 

USP-grade anhydrous magnesium carbonate is used as a flavor impression intensification vehicle in the processed food industry (see Flavors and spices). Basic magnesium carbonates are used as free flowing agents in the manufacture of table salt, as a hulking agent in powder and tablet pharmaceutical formulations, as an antacid, and in a variety of personal care products (see Pharmaceuticals). 

Methyl- and dimethylnaphthalenes are contained in coke-oven tar and in certain petroleum fractions in significant amounts. A typical high temperature coke-oven coal tar, for example, contains ca 3 wt % of combined methyl- and dimethylnaphthalenes (6). In the United States, separation of individual isomers is seldom attempted instead a methylnaphtha1 ene-rich fraction is produced for commercial purposes. Such mixtures are used for solvents for pesticides, sulfur, and various aromatic compounds. They also can be used as low freezing, stable heat-transfer fluids. Mixtures that are rich in monomethyinaphthalene content have been used as dye carriers (qv) for color intensification in the dyeing of synthetic fibers, eg, polyester. They also are used as the feedstock to make naphthalene in dealkylation processes. PhthaUc anhydride also can be made from m ethyl n aph th al en e mixtures by an oxidation process that is similar to that used for naphthalene. 

Substitution If intensification is not possible, then an alternative is to consider using a safer material in place of a hazardous one. Thus it may be possible to replace flammaole solvents, refrigerants, and heat-transfer media by nonflammable or less flammable (high-boiling) ones, hazardous products by safer ones, and processes which use hazardous raw materials or intermediates by processes which do not. As an example of the latter, the product manufactured at Bhopal (carbatyl) was made from three raw materials. Methyl isocyanate is formed as an intermediate. It is possible to react the same raw materials in a different order so that a different and less hazardous intermediate is formed. 

Deficiency of natural AO in the organism brings to intensification of oxidizing processes in lipids and to occurrence in them of oxidation products in quantities that ar e above normal. 

The term process intensification is used synonymously with minimization. Process intensification is also often used more specifically to describe new technologies which reduce the size of unit operations equipment, particularly reactors. Innovative process intensification techniques are receiving more and more attention. Interesting possibilities for a range of unit operations, including reaction, gas-liq-... 

Section 4.3 on Process Development includes additional examples of opportunities for process minimization or intensification, including ... 

Whiting, M. J. L. (1992). The Benefits of Process Intensification for Caro s Acid Production. Trans. IChemE 70 (March), 195-96. 

Ramshaw, C. The Chemical Engineer (London) No. 415 (1985) 30. Process intensification-a game for n players. 

An interesting way to retard catalyst deactivation is to expose the reaction mixture to ultrasound. Ultrasound treatment of the mixture creates local hot spots, which lead to the formation of cavitation bubbles. These cavitation bubbles bombard the solid, dirty surface leading to the removal of carbonaceous deposits [38]. The ultrasound source can be inside the reactor vessel (ultrasound stick) or ultrasound generators can be placed in contact with the wall of the reactor. Both designs work in practice, and the catalyst lifetime can be essentially prolonged, leading to process intensification. The effects of ultrasound are discussed in detail in a review article [39]. 

The reactions are still most often carried out in batch and semi-batch reactors, which implies that time-dependent, dynamic models are required to obtain a realistic description of the process. Diffusion and reaction in porous catalyst layers play a central role. The ultimate goal of the modehng based on the principles of chemical reaction engineering is the intensification of the process by maximizing the yields and selectivities of the desired products and optimizing the conditions for mass transfer. 

Integration of the separation and reaction step has several advantages, but an inherent downside of such a process intensification step is the loss of degrees of freedom for process design and process control (Figure 10.9). 

Jarosch, K., Tonkovich, A., Perry, S., Kuhlmann, D., and Wang, Y. (2005) Microreactor Technology and Process Intensification, in ACS Symposium Series, vol. 914, American Chemical Society, New York, pp. 258-273. 

Phillips, C.H., Lausche, G., and Peerhossaini, H. (1997) Intensification of batch chemical processes by using integrated chemical reactor... 

Stankiewicz, A. (2003) Re-Engineering the Chemical Processing Plant, Process Intensification, Marshal Dekker, New York. 

Jachuk, R.J. (2002) Process intensification for responsive processing. Trans. IChemE, 80 (A), 233-238. 

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