Process intensification novel

C. (1997) Synthesis of nano-particles of CaC03 in a novel reactor, in Process Intensification in Practice Applications and Opportunities (ed. J. Semel), Mechanical... 

For the sake of developing commercial reactors with high performance for direct synthesis of DME process, a novel circulating slurry bed reactor was developed. The reactor consists of a riser, down-comer, gas-liquid separator, gas distributor and specially designed internals for mass transfer and heat removal intensification [3], Due to density difference between the riser and down-comer, the slurry phase is eirculated in the reactor. A fairly good flow structure can be obtained and the heat and mass transfer can be intensified even at a relatively low superficial gas velocity. 

Therefore, in this definition process intensification encompasses both novel apparatus and techniques which are designed to bring dramatic improvements in production and processing (Figure 1.8) [25]. As a result, safe, cheaper, compact, sustainable (environmentally friendly), and energy-efficient technologies are obtained. 

Phillips, C. H., Development of a novel compact chemical reactor-heat exchanger, in Green, A. (Ed.), Proc. of 3rd Int. Conf on Process Intensification for the Chemical Industry, BHR Group Conference Series, Vol. 38, pp. 71-87, Professional Engineering Publishing (1999). 

Microreactor and microprocess technology has, in some fine-chemical cases, approached commercial applications and become competitive with existing technology. Two main developments are awaited. Firstly, optimizing the process protocol conditions such that the chemistry is set to the limit of the reactor s capabilities in terms of mass and heat transfer. This so-called novel chemistry approach achieves the highest process intensification and can improve the costing of microprocess... 

The toolbox for process intensification is schematically shown in Figure 7. It includes process-intensifying equipment (PI hardware) and process-intensifying methods (PI software). Obviously, in many cases overlap between these two domains can be observed as new methods may require novel types of equipment to be developed and, vice versa, novel apparatuses already developed sometimes make use of new, unconventional processing methods. In Figure 7, examples of both PI hardware and PI software are shown. Many of them will be discussed in detail in other chapters of this book. Here, we give only a brief overview of the more important PI items. 

Chen J, Wang Y, Jia Z, Zheng C. Synthesis of nanoparticles of CaC03 in a novel reactor. In Semel J, ed. 2nd International Conference on Process Intensification in Practice. London BHR Group, 1997 157-164. 

There is no doubt that the ultimate development of process intensification leads to the novel field of microreaction technology (Figure 1) (7-9). Because of the small characteristic dimensions of microreaction devices, mass and heat transfer processes can be strongly enhanced, and, consequently, initial and boundary conditions as well as residence times can be precisely adjusted for optimizing yield and selectivity. Microreaction devices are evidently superior, due to their short response time, which simplifies the control of operation. In connection with the extremely small material holdup, nearly inherently safe plant concepts can be realized. Moreover, microreaction technology offers access to advanced approaches in plant design, like the concept of numbering-up instead of scale-up and, in particular, the possibility to utilize novel process routes not accessible with macroscopic devices. 

Process intensification refers to a chemical process using significantly smaller equipment. Examples include novel reactors, intense mixing devices, heat and mass transfer devices that provide high surface area per unit of volume, devices... 

Process intensification consists of the development of novel apparatuses and techniques that, compared to those commonly used today, are expected to bring dramatic improvements in manufacturing and processing, substantially decreasing the ratio of equipment size to production capacity, energy consumption, or waste production and ultimately resulting in cheaper and more sustainable technologies (35). 

A wide variety of polymeric membranes with different barrier properties is already available, many of them in various formats and with various dedicated specifications. The ongoing development in the field is very dynamic and focused on further increasing barrier selectivities (if possible at maximum transmembrane fluxes) and/ or improving membrane stability in order to broaden the applicability. This tailoring of membrane performance is done via various routes controlled macro-molecular synthesis (with a focus on functional polymeric architectures), development of advanced polymer blends or mixed-matrix materials, preparation of novel composite membranes and selective surface modification are the most important trends. Advanced functional polymer membranes such as stimuli-responsive [54] or molecularly imprinted polymer (MIP) membranes [55] are examples of the development of another dimension in that field. On that basis, it is expected that polymeric membranes will play a major role in process intensification in many different fields. 

Finally, it is worth mentioning that a successful integration of catalytic reaction steps with product separation and catalyst recovery operations will also be dependent on innovative chemical reaction engineering. This will require the widespread application of sustainable engineering principles [48].In this context process intensification , which involves the design of novel reactors of increased volumetric productivity and selectivity with the aim of integrating different unit operations to reactor design, and miniaturization will play pivotal roles [49, 50]. 

The innovative character of Process Intensification is in nice harmony with the objectives of Process Systems Engineering (Moulijn J.A. et al., 2006). It is so fliat Process Intensification needs the very front-end creativity for the generation of the novel concepts and principles for the processing tasks. Such novel concepts and principles are also the key elements in process synthesis for the generation of the innovative and inventive designs in terms of systems synthesis and equipment design. 

The methodology of conceptual process synthesis for process intensification is focused on the generation of the novel concepts and techniques for the processing tasks. The methodology of conceptual process synthesis for process intensification is illustrated in Figure 1. 

However, the integration of PIM also creates synergy in the development of intensified processes, novel product forms, and size dependent phenomena, which in turn provides novel intensified processes. Process intensification-miniaturization is seen as an important element of sustainable development because it can deliver 1) at least a 10-fold decrease in process equipment volume 2) elimination of parasitic steps and unwanted by-products, thus eliminating some downstream processing operations 3) inherent safety because of reduced reactor volume 4) novel product forms 5) energy, capital, and operating cost reduction, and an environment friendly process 6) plant mobility, responsiveness, and security and 7) a platform for other technologies. 

The combination of process intensification and process miniaturization is an important element of sustainable technology and a platform for advancement in multidisciplinary science and engineering. There are now several examples of intensified processes being utilized in industry, as apparent from patent activity. Some of these intensified processes are confined to a single unit operation, while others integrate several intensified unit operations in the more efficient production of existing/improved/novel products. 

Thompson, L.T. Novel fuel processing catalysts and reactors. In Microreaction Technology and Process Intensification, Symposium at the 226th American Chemical Society National Meeting, New York, 7-11 September 2003 ACS, Abstract Number 35. 

On-demand (on-site) synthesis The use of novel equipment/technologies for process intensification avoids the storage/transport of hazardous chemicals. They could be generated on-site and immediately converted into final product. 

A large variety of books and review papers is thus available, but often they either do not employ a comprehensive approach or are not consistent with the approach of sustainable industrial chemistry that is the core of this book. In addition, for educational purposes, it is useful to overview the main methods and tools available to develop a novel and innovative sustainable industrial chemistry. This chapter is dedicated to catalysis as key tool for sustainability and process intensification. 

PI encompasses not only the development of novel, more compact equipment but also the development of intensified methods of processing, such as the use of alternative energy sources [4]. In addition, one of the objectives of process intensification is to move away from batch processing to small continuous reactors. The better control of the reaction conditions often allows us to improve not only the... 

A general review of continuous processing/process intensification in the pharmaceutical industry has been made by Rubin ef a. [22], while the use of PI novel technologies to reshape the petrochemical and biotechnology industries has been analyzed by Hahn [23] and Akay [24], respectively. Recent advances in biotechnology process intensification have also been reviewed by Choe ef al. [25] and Akay et al. [26]. The use of monoliths as biocatalytic reactors to achieve PI by smart gas-liquid contact has been reviewed by Kreutzer ef al. [27]. 

---