Upload
trandang
View
217
Download
1
Embed Size (px)
Citation preview
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Process IntensificationProcess Intensificationin Fine Chemicals and in Fine Chemicals and Advanced Materials:Advanced Materials:
methodology and achievementsmethodology and achievements
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1.Innovation, an answer to the challenges of Sustainable Development
2. Process Intensification, a new paradigm in Chemical Engineering
3. Process Intensification strategies
4. Process Intensification for Fine Chemicals and Advanced Materials: EXAMPLES and novelties
5. Perspective: Intensified Product Engineering
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
People
Planet Profit
The chemical industry identifies innovation and sustainable development as a chance.
The challenge for the process industries is not only to provide products and services to our consumer society, but to perform it with markedly lower reliance on raw materials, energy, labor and waste.
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
The chemical industry identifies innovation and sustainable development as a chance.
‘ Products and processes for a sustainable chemical industryProducts and processes for a sustainable chemical industry’
Green Green ChemChem 2004 (6), 5442004 (6), 544--556556
a tutorial paper from CEFIC with 158 referencesa tutorial paper from CEFIC with 158 references
…but
Through the application of ‘green’ chemistry and engineering, the industry has already implemented innovations in the field of renewable resources, eco-efficient products, energy efficiency, waste reduction and reuse, inherently safer processes:
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
The chemical industry identifies innovation...
but R&D intensity drops
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Courtesy A.Stankiewicz
but has a serious credibility problem…
The chemical industry identifies sustainable development…
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Many talk of green engineering(innovation ‘blah-blah’, reinvention of the wheel)
few apply basic principles.
ex: we need exergy analysis (environmental thermodynamics)))
Many claim to be sustainable…BUT very few prove it !
we need quantitative, robust, shared metrics.
A communication disaster: the fight against REACHwe need ethical managers, not ‘sharks’.
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1. Innovation, an answer to the challenges of Sustainable Development
2. Process Intensification, a new paradigm in Chemical Engineering
3. Process Intensification strategies
4. Process Intensification for Fine Chemicals and Advanced Materials: EXAMPLES and novelties
5. Perspective: Intensified Product Engineering
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
De Re MetallicaG.Agricola, 1556
Did we progress in 450 years?
Courtesy A.Stanjiewicz
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Early pharmaceutical chemistrydid we progress in 2000 years ?
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Yes, we progressed since 1556... we built large ‘cathedrals’.
Why then should we miniaturize our production tools ?
0.66sizecost ≈
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Dr. DeibelPdt Corporate
Engineeringat BASF
in CHE Manager(2006)
The classical world-scale plant is phased-out:• Paradigm change in plant engineering• Time-to-market• Modular plant techniques needed• Microprocess engineering will have a role on plant philosophy more than on absolute size
Same view: Dr. Aldo Belloni (Linde board of directors)in Process 13, 4 (2006) 64
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Courtesy DSM
reduce the plant size/cost
PI historical perspective:
late 1970s: Ramshaw developped Higee at ICI
Is our future a flexible mini-plant built on a table or bolted on a wall, from modular elements ?
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
PI, a new strategy:
Instead of adapting the physico-chemical transformation to existing, known, depreciated
but often inadapted equipment…
Process Intensification is a design strategy to adapt the process to the chemical reaction
“ Doing more with less ”adapting the size of equipment to the reaction replacing large, expensive, inefficient equipment by
smaller, more efficient and cheaperchoosing the technology best suiting each stepsometimes combining multiple operations in fewer
apparatuses.
DSM Urea Plus
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Unit operations: A.D.Little 1907Transport phenomena: 1960 Bird, Steward, Lightfoot
Process Intensification, serving SD goals
EFCEWP PI
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
«« Reengineering the Chemical Processing PlantReengineering the Chemical Processing Plant »»R.Bakker, Marcel Dekker ed. 2003
Reach intrinsic kinetics of phenomena
maximize transfer rate
Fick law: flux = coefficient x interface x gradient
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Mass
Tra
nsf
er
Mass
Tra
nsf
er
Heat TransferHeat Transfer
Courtesy BRITEST
JacketedStirred Tank
Microreactor
Pulsed Column
LoopReactor
Rotating Packed Bed
Educter
Static Mixer
Static Mixer/Plate Exchanger
PlateExchanger
Spinning DiscReactor
Equipment already exist that can be characterized by their E & m
transfer performances
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1. Innovation, an answer to the challenges of Sustainable Development
2. Process Intensification, a new paradigm in Chemical Engineering
3.Process Intensification strategiesin Fine Chemicals, Spec Chemicals, Pharmaceuticals, Advanced Materials
4. Process Intensification for Fine Chemicals and Advanced Materials: EXAMPLES and novelties
5. Perspective: Intensified Product Engineering
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Process Intensification strategy
Tactics 1: multifunctionality (design methodology) unit operations have to be ‘compatibilized’
Tactics 2: thermodynamicsincrease potential of reactants, by activity or diffusivity
Tactics 3: miniaturization to increase force fields
Tactics 4: energeticscreate force fields at a mesoscopic level
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1- Multifunctionality in PIfor Fine & Spec Chemicals and Advanced Materials
reactive distillation:convincing demos in petrochemicals......narrow operating windows, mediocre flexibility
hybrid separations:membrane-reaction coupling: some applicationsin fine chem, bio... where mild media, low requirementsmembranes still show low performances
static mixers are commonplace, including reactive versions, but their performances are average
monolithic reactors (supporting catalysts, enzymes, cells) increasingly used in loop reactorsmany external loops (« intensive » engineering)
chromatographic reactors, SMB are industrial
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Loop reactors: Air Products retrofit of hydrogenators with a monolithic reactor: productivity x 10 to 50.
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Chromatographic reactors, Simulated Moving Beds:example of DSM 7-ADCA in Delft (NL)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
2- Thermodynamics (solvents) in PIfor Fine & Spec Chemicals and Advanced Materials
neoteric solvents:super-critical fluids (SCF) and ionic liquids (IL)
still a curiosity, despite recent announcements (and to the exception of SCF extractions):
applications are very specificSCF are not good solventscosts are not convincingIL toxicity is not assessed !
some investment in IL engineering by major companies
trend = solvent-free processes
REM : Water is not a “green” solvent ! but bio-based oxygenates are.
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Ionic liquids (IL) organic salts with low melting point (usually <100°C)- vapor pressure is extremely low, no solvent lost- large range of temperature (200 to 300 Kelvins)Is this all new ?? a fashion-driven rediscovery of early work in the 1970s on ‘molten organic salts’…
PCl
Cl N
N+ 2 EtOH + 2
POEt
OEt
N
NH+
Cl -
DEOPP
Biphasic Acid Scavenging utilizing Ionic Liquids
Example of the BASFBASIL solvent-free process
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
SC media: DuPont 275 M$ for a tetrafluoroethylene SC polymerization production unit. Fluorinated vinyl polymers are non-explosive when mixed with CO2 and can be continuously polymerized in SC medium.
Thomas Swan C° world’s first multi-reaction super-critical flow reactor, a commercial-scale continuous facility for running reactions in SC CO21000 tpa
M.Poliakoff (U.Nottingham)
CO2-expanded solvents:Continuous hydrogenation of sertralinein scCO2/THF: commercial route to Zoloft® (Pfizer)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
trend = solvent-free processes, mecano-chemistry
reactive extrusion, optionally under SC conditions
LIST
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
3- Miniaturization in PIfor Fine & Spec Chemicals and Advanced Materials
microreactors start boomingmicrochannels, microfilms, microcolumnsmono-, di- or tri-phasic mediadrivers:
switch from batch to continuousnew operating conditionscontrol of properties of final product/formularespect of regulations, incl. FDA.
World-class manufacturers and engineering:IMM, Siemens, Hitachi, Velocys, BTS,... ,...
MESO-technologies: structured at the millimetric scale
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
a quick visi
t in th
e “zoo”
of micr
odevices
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Degussa + Uhde, Demis Projekt:microstructured epoxidation reactor
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Miniaturization in PI for Fine Chemicals and Advanced Materials
MESO-technologies: structured at the millimetric scale, best compromise performance/operability,now widely developed
AlfaLaval
Compact reactive heat exchangers (Marbond, Heatric, Alfa-Laval)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
4- Alternative energy in PIfor Fine & Spec Chemicals and Advanced Materials
still very few industrial applications of microwaves, acoustic fields, electric fields, plasmas, etc...
in the other hand, gravitational fields find industrial applications:
Spinning Disks, Rotating Packed Beds and Tube Reactors are still under developmentNot yet widely adopted, the challenge of size reduction favors them.
at the R&D level (excl. rare cases): impinging jet reactors, supersonic, oscillating reactors, intensive rotor-stator, ...
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Energy sources such as UV light, microwaves, ultrasounds are used in a controlled way to heavily increase the efficiency of achemical reaction, thus making it more eco-friendly…
…but little is known on commercial applicationsChallenge = design rules
plasma reactor microwave generators electrosynthesis
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
PROPHIS solar photoreactor
C. Schiel et al, 2001
Solar energy: a curiosity...
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Shengli Oil
Dow Chemicals
Protensive Higee
Gravitational fieldsindustrial applications from petrochemicals to ingredients:
Stripping of solvents
ultra-fast cooking
(2 s @ 130°C)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Cambridge Reactor Design
Baffle geometry coupled with intensity of oscillation produced by pistons control mixing
Small energy input, large effects:
NiTech
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1. Innovation, an answer to the challenges of Sustainable Development
2. Process Intensification, a new paradigm in ChEng
3. Process Intensification strategies
4.Process Intensification for Fine Chemicals
5. Perspective: Intensified Product Engineering
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
PI to reduce the plant size:why is ‘smaller beautiful’ ?
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
UCC, Bhopal 3 Dec 1984:cloud of 41 tons MIC
>2 500 killed
An inventory of 10 kg MICwould have been sufficient
(D.Hendershot, CEP 2000)
In Fine Chemicals and Advanced Materials:‘smaller is beautiful’ because
smaller is safer !
1 ppm COCl2
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Courtesy TU Delft
Accidents are due to large inventories !
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
ref: Merck
Batch 5m3
-20°C 5h Yield 72%
5 MINI-reactors0°C < 1 mn
continuousyield >92%
In Fine Chemicals and Advanced Materials:‘smaller is beautiful’ because
continuous mode performs better
Many cryo batchcryo batch processes are now replaced by meso-techs for continuous (quasi) room T processes
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Delocalized productions, close to customer, with much lower inventories… but also delocalized risk !
- Interox: 1 ton/day peroxysulfuric acid (1s in a 20 cm3 tubular reactor)
- Kvaerner: phosgene COCl2 modular generator, point-of-use, skid-mounted
- hydrogen cyanide, chlorine dioxide, ethylene oxide, …
In Fine Chemicals and Advanced Materials:‘smaller is beautiful’ because
smaller is more flexiblegood for on-site on-demand production
ref: A.Green BHRG
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
In Fine Chemicals and Advanced Materials:‘smaller is beautiful’ because
‘dream reactions’ are now possible
High T and P processing:T not limited by solvent boiling point
operation in liquid phase at elevated pressure (100 bar is easy)
Use of dangerous reagents:ex: fluorination by F2 takes a few milli-
seconds in a miniature falling film
Explosive regimes:ex: even in detonating mode, ie. with
mixtures of pure hydrogen and oxygen
ref: IMM
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Selected examples of Process Intensification for Fine Chemicals
ex 1-4 Microprocessing chemical pilot plants
(FZK-DSM, MCPT-Idemitsu, IMM-X’ian Chem, CPC)
ex 5- SiProcess (Siemens)
ex 6- RAPTOR (AET Group)
ex 7- Spinning Tube-in-tube (Kreido)
for Advanced Materialsex 8- Micromembrane emulsifier (Velocys)
ex 9- Micromixer emulsifier (IMM)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Forschungszentrum Karlsruhe (www.fzk.de):65 cm, 290 kg, throughput 1700 kg of liquid chemicals per hour. “Micro” in its interior: micromixers and several ten thousands of microchannels.Reaction heat of several 100 kW is removed.
Process Intensification for Fine Chemicals: example 1fine chemicals plant in a ‘shoe-box’ FZK + DSM
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Other announcements:Clariant (2005): 1000 tpa pigment plant (?)Degussa (2006): several production plants (?)
FZK
Chemical production with FZK microstructured reactor at
DSM Fine Chemicals in Linz, Austria
• Within 10 weeks:300 tons of high-value product.
• Product yield increased compared to conventional processing
• Less raw material use and less waste generation, more process safety
• Now permanently in operation(announced at Achema May 2006)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
10 t/a 3.5m × 0.9m
“Pilot plant” at Kyoto UDr. T.Iwasaki
Plant running at industrial site of Idemitsu Kosan ?
heating shell
cooling shell )inlet
outletID = 500µm L=60 cm 94 pieces
Process Intensification for Fine Chemicals: example 2radical polymerization Idemitsu Kosan+Kyoto U
www.mcpt.jp
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
IMM developed in MainzXian invested ~5 M €
• Nitroglycerin production on a pilot plant level (15 kg/h NG, >100 l/h)• NG used as medicine for acute cardiac infarction• Product quality on highest grade• Plant to operate safely and fully automated• Environment protection by advanced waste water treatment & closed cycle
C&EN cover story 30May05
OHOH OH
OO O
O2N
O2N
NO2HNO3 / H2SO4
Process Intensification for Fine Chemicals: example 3nitroglycerin pilot-plant Xian Chemicals + IMM
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Sigma-Aldrich installed a standard Cytos in Buchs. Many catalog products are produced under lab conditions in flasks of up to 20 L.Of the 2000 compounds in this portfolio, about 800 could be produced in microreactors with little or no process modification.
Synthacon on a contract basis:• a commercial multiproduct plant near Leipzig, by mid-2006, producing ~20 tpa• high added value chemicals (niche applications) with a range from 1 kg to 100 kg for pharmaceuticals
Process Intensification for Fine Chemicals: example 4Pharmaceutical chemistry, CPC
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
www.siemens.com/siprocess
Process Intensification for Fine Chemicals: example 5chemical microprocessor SIEMENS
SIPROCESS
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
www.siemens.com/siprocess
Combination of modularity with integrated automation. Each module has its own electronics and sensors to control the internal module functions.The electronics are connected to the higher-level automation system based on SIMATIC PCS 7 via a bus system, to which they are linked by plugging the module into a rack.
Process Intensification for Fine Chemicals: example 5chemical microprocessor SIEMENS
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Réacteur Agité Polyvalent à Transfert
Optimisé RectiligneReaction chamber
Injection gas, reagents
Motor
inlet
outlet
Jacket heatingand cooling
Operating pressure: 250 barOperating temperature: -100 to +300°CHeat exchange: > 150 m²/m3
(vs. batch reactor: <5 m²/m3)Stirrer rotating speed: 0 to 1500 rpmFeed flowrate: 0 - 150 l/hMaterial: HastelloyLength: 2 m
Process Intensification for Fine Chemicals: example 6RAPTOR continuous hydrogenator AET Group
www.aetgroup.com
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
C00001-01 Copyright AETGROUP SAS 2005
RAPTOR 1: diameter 8mm, 200 bar, 200°C
0
200
400
600
800
1000
1200
1400
0 20 40 60 80 100
Production tpa
Residence time (s)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Process Intensification for Fine Chemicals: example 7Spinning Tube in Tube reactor Kreido Labs
Couette Flow in a narrow annular gap between a stationary stator and a rapidly rotating, concentric, internal rotor, producing a coherent thin film in a high shear field
triglyceride + 3 MeOH glycerol + 3 fatty acid methyl ester
mass transfer limited !
biodiesel at a residence time of 0.5 secondcomplete pipe-to-pipe biodiesel production unit (STT 30G)
STT
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
1. Innovation, an answer to the challenges of Sustainable Development
2. Process Intensification, a new paradigm in Chemical Engineering
3. Process Intensification strategies
4. Process Intensification for Fine Chemicals and Advanced Materials
5. Perspective: Intensified Product Engineering
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Opportunities for microprocessingand process intensification
Intensified product engineering:
“precision engineering”
sharpening property distributionMW, particle diameter, size, etc.
challenge: high Peclet #(lowest possible axial dispersion)
potential for liquids and solids
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Inte
nsifi
ed fo
rmul
atio
n
liqui
ds A
ND s
olid
s
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Mono-disperse silica nanoparticles(segmented flow microreactor)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Transmembrane pressure drop: one phase is dispersed thru pores(principle known since early 1990s).Fine droplets directly generated by build-up and detachment at the surface of the membrane.
Process Intensification for Advanced Materials: example 8micro-membrane emulsifier Velocys
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
0.2-5 mm
not micro:milli !
• High shear at wall, lower shear in bulk• Small droplet sizes, uniform distribution• Rapid, in-line heating & cooling• Overcome scale-up challenges• Small, compact units
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
www.velocys.com
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Process Intensification for Advanced Materials: example 9micro-mixers emulsifier (Institute Mikrotechnik Mainz)
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
Process Intensification in Fine Chemicals and Advanced MaterialsProcess Intensification in Fine Chemicals and Advanced Materials ENKI Innovation www.enki2.com Jan 2007ENKI Innovation www.enki2.com Jan 2007
CONCLUDING REMARKS
• to implement PI, a reasonable set of basic data (kinetics, transfer rates) is necessary
• in miniaturization, the micron level is unnecessary : a millimeter scale is often sufficient and corresponds to an optimal ratio performance-to-operability
• the flexibility and the versatility of tools are still a challenge, as well as the process control (Engg methodologies required !)
• in the context of sustainable development, technologies able to confine reagents in a fully controlled process is a major strategic advantage
• companies in developing countries have identified PI as a catch-up issue
• strong differentiation on products can be obtained by process intensification of formulation (emulsions, suspensions, micro/nano particles)
• A good example of the ‘rush-to-be-second’ syndrom ???