Re-engineering the chemical processing plant: process intensification

RE-ENGINEERING THE CHEMICAL PROCESSING PLANT......Page 1
PREFACE......Page 7
CONTENTS......Page 10
CONTRIBUTORS......Page 12
CONTENTS......Page 0
2. A BIT OF HISTORY......Page 14
3. THE PHILOSOPHY AND OPPORTUNITIES OF PROCESS INTENSIFICATION......Page 18
3.2. SAFETY......Page 20
3.3. TIME TO MARKET......Page 21
4. TECHNOLOGICAL BREAKTHROUGHS AND CREATION OF SHAREHOLDER VALUE......Page 23
5.1. PROCESS-INTENSIFYING EQUIPMENT......Page 25
5.2. PROCESS-INTENSIFYING METHODS......Page 33
REFERENCES......Page 40
2. HISTORICAL DEVELOPMENT......Page 46
3. PROCESS FUNDAMENTALS......Page 47
3.1. HYDRODYNAMICS......Page 48
3.2. FLOODING......Page 52
3.4. MASS TRANSFER......Page 53
3.5. PRESSURE DROP......Page 55
3.6. HEAT TRANSFER......Page 56
4. MECHANICAL DESIGN......Page 57
4.3. SEALS......Page 58
4.5. LIQUID DISTRIBUTION......Page 61
5. APPLICATIONS......Page 62
5.2. STRIPPING......Page 63
5.3. DISTILLATION......Page 66
5.5. ADSORPTION......Page 67
5.6. LIQUID–LIQUID EXTRACTION......Page 68
5.7. CRYSTALLIZATION......Page 69
5.8. REACTIONS......Page 70
5.9. OTHER APPLICATIONS......Page 71
6.1. SCALE-UP CRITERIA......Page 72
6.3. COMMERCIAL EXAMPLES......Page 74
7. FUTURE......Page 76
REFERENCES......Page 77
1. INTRODUCTION......Page 81
1.1. THE “DESKTOP” CONTINUOUS PROCESS......Page 82
1.2. EXPLOITATION OF CENTRIFUGAL FIELDS......Page 83
1.3. FREE MOTION OF A PARTICLE AROUND AN AXIS......Page 85
1.4. FLOW OVER A ROTATING SURFACE......Page 87
2. THE SPINNING DISC REACTOR......Page 88
2.1. THE NUSSELT-FLOW MODEL......Page 89
2.2. HEAT/MASS TRANSFER PERFORMANCE......Page 104
2.3. REACTOR APPLICATIONS......Page 112
2.4. COMPARATIVE SPINNING DISC REACTOR COSTS......Page 125
3. CONCLUSION......Page 129
1. INTRODUCTION......Page 132
2.1. CLASSIFICATION OF COMPACT HEAT EXCHANGERS......Page 134
2.2. PLATE HEAT EXCHANGERS......Page 135
2.3. SPIRAL HEAT EXCHANGERS......Page 137
2.5. PLATE–FIN HEAT EXCHANGERS......Page 138
2.6. FLAT TUBE-AND-FIN HEAT EXCHANGERS......Page 143
2.7. MICROCHANNEL HEAT EXCHANGERS......Page 144
2.8. MATRIX HEAT EXCHANGERS......Page 146
2.9. SELECTION OF HEAT EXCHANGER TECHNOLOGY......Page 147
3.1. FLOW PATTERN......Page 148
3.2. HEAT TRANSFER AND PRESSURE DROP......Page 149
3.3. FOULING......Page 151
4.2. VAPORIZATION......Page 154
4.3. CONDENSATION......Page 157
5.1. MACROMIXING......Page 158
5.2. MICROMIXING......Page 162
6.1. FEED/EFFLUENT HEAT EXCHANGERS......Page 164
6.2. PROCESS EVAPORATORS......Page 165
6.3. INTEGRATED HEAT EXCHANGERS IN SEPARATION PROCESSES......Page 167
6.4. REACTOR HEAT EXCHANGERS......Page 169
REFERENCES......Page 171
1. MICROTECHNOLOGY AS A KEY FOR THE ADVANCED DESIGN OF CHEMICAL PLANTS......Page 177
2.1. ENHANCEMENT OF HEAT TRANSFER AND MASS TRANSFER PROCESSES......Page 179
2.2. INHERENT PROCESS RESTRICTIONS IN MINIATURIZED DEVICES AND THEIR POTENTIAL SOLUTIONS......Page 180
2.3. CONSEQUENCES FOR THE SELECTION OF REACTION ROUTES AND PLANT DESIGN......Page 183
2.4. PROCESS CONTROL AND SAFETY......Page 184
2.5. SUSTAINABLE DEVELOPMENT BY NUMBERING-UP AND DISTRIBUTED PRODUCTION......Page 185
3. FROM BASIC PROPERTIES TO TECHNICAL DESIGN RULES......Page 186
4.1. GENERAL REQUIREMENTS......Page 187
4.2. LIGA TECHNOLOGY......Page 188
4.3. WET AND DRY ETCHING PROCESSES......Page 189
4.5. MICROELECTRODISCHARGE MACHINING......Page 192
4.6. MICROMACHINING BY MEANS OF LASER RADIATION......Page 193
5. IMPLEMENTATION OF MICROREACTION TECHNOLOGY......Page 194
6. CONCLUSIONS......Page 197
REFERENCES......Page 198
1. INTRODUCTION......Page 201
2. OVERVIEW OF STRUCTURED REACTORS......Page 203
2.1. MONOLITHIC CATALYSTS AND REACTORS......Page 204
2.2. GAUZES......Page 206
2.3. STRUCTURED PACKINGS......Page 207
2.4. FOAMS......Page 208
2.5. ARRANGED CATALYSTS—THREE-LEVELS-OF-POROSITY (TLP) REACTORS......Page 210
2.6. MEMBRANE-ENCLOSED CATALYTIC REACTOR (MECR)......Page 212
2.6.1. PRODUCTION OF FATTY ACIDS BY FAT HYDROLYSIS IN A MEMBRANE REACTOR......Page 213
3.1. ENVIRONMENTAL CATALYSIS......Page 214
3.2. PRODUCTION OF SYNGAS......Page 215
3.3. SCALE-UP......Page 217
4. MULTIPHASE REACTIONS......Page 218
4.1.1. COCURRENT OPERATION......Page 220
4.1.2. MASS TRANSFER......Page 222
4.1.3. COUNTERCURRENT OPERATION IN MONOLITHS AND ARRANGED PACKINGS......Page 223
4.1.4. MONOLITH REACTORS......Page 225
5. CONCLUSIONS......Page 232
REFERENCES......Page 233
1.1. WHY IS MIXING IMPORTANT?......Page 237
1.2. PROCESS INTENSI.CATION......Page 239
1.3. MOTIONLESS (STATIC) MIXERS......Page 240
1.3.2. LIMITATIONS......Page 241
2.1. REYNOLDS NUMBER......Page 242
2.3.1. FRICTION FACTORS......Page 243
2.3.2. PRESSURE DROP AND ENERGY DISSIPATION: TURBULENT FLOW......Page 244
3.1. SLOW REACTIONS......Page 245
4.1. MACROMIXING (OR BLENDING) PERFORMANCE......Page 246
4.2.2. TURBULENT AND TRANSITIONAL FLOW MIXING IN MOTIONLESS MIXERS......Page 247
4.2.3. MIXER RANKINGS FOR TURBULENT-FLOW BLENDING APPLICATIONS......Page 248
4.2.5. BLENDING CORRELATIONS: LAMINAR FLOW......Page 249
4.3.1. MICROMIXING LIMITED......Page 250
4.4.1. MACROMIXING OR MESOMIXING LIMITATION......Page 251
5.2.1. MOTIONLESS MIXERS......Page 252
5.2.2. GAS–LIQUID EJECTORS......Page 253
5.4. GUIDE TO EQUIPMENT SELECTION......Page 254
5.5.2. REACTION REGIME......Page 255
5.6.1. FLOW PATTERNS......Page 256
5.6.2. PRESSURE DROP......Page 257
5.6.4. MASS TRANSFER COEF.CIENTS......Page 260
5.6.6. CHARACTERIZATION OF BUBBLE-SIZE DISTRIBUTION......Page 261
6.2. TURBULENT-FLOW CORRELATIONS......Page 262
6.2.2. SULZER (KOCH) MIXERS......Page 263
6.4. SCALE-UP/SCALE-DOWN......Page 264
7.2. HEX REACTOR TYPES......Page 265
SYMBOL EXPLANATION UNITS......Page 267
GREEK SYMBOLS......Page 268
REFERENCES......Page 269
1. INTRODUCTION......Page 271
2.1. REACTIVE DISTILLATION......Page 272
2.2. MEMBRANE-BASED REACTIVE SEPARATIONS......Page 274
2.3. REACTIVE ADSORPTION......Page 277
2.4. REACTIVE EXTRACTION......Page 279
2.5. REACTIVE CRYSTALLIZATION/PRECIPITATION......Page 283
2.6. REACTIVE ABSORPTION/STRIPPING......Page 285
3.1. EXTRACTIVE DISTILLATION......Page 286
3.2. ADSORPTIVE DISTILLATION......Page 287
3.3. MEMBRANE DISTILLATION......Page 290
3.4. MEMBRANE ABSORPTION/STRIPPING......Page 296
3.5. MEMBRANE CHROMATOGRAPHY (ADSORPTIVE MEMBRANES)......Page 297
3.6. MEMBRANE EXTRACTION......Page 300
3.7. OTHER HYBRID SEPARATIONS......Page 301
4. BARRIERS AND FUTURE PROSPECTS......Page 303
REFERENCES......Page 309
1. INTRODUCTION: AN OVERVIEW OF REACTIVE SEPARATIONS......Page 319
1.1. REACTIVE ABSORPTION......Page 321
1.2. REACTIVE DISTILLATION......Page 323
1.3. REACTIVE EXTRACTION......Page 325
2.1. GENERAL......Page 334
2.2. EQUILIBRIUM-STAGE MODEL......Page 335
2.3. RATE-BASED APPROACH......Page 336
2.4. COMPUTATIONAL FLUID DYNAMICS......Page 337
3.1.1. CHEMICAL SYSTEM......Page 339
3.1.2. PROCESS SETUP......Page 340
3.1.3. RESULTS AND DISCUSSION......Page 341
3.2.1. CHEMICAL SYSTEM......Page 342
3.2.3. RESULTS AND DISCUSSION......Page 344
3.2.4. DYNAMIC MODELING......Page 348
3.3.2. PROCESS SETUP AND OPERATION......Page 350
3.3.3. RESULTS AND DISCUSSION......Page 352
3.4.1. CHEMICAL SYSTEM......Page 353
3.4.3. RESULTS AND DISCUSSION......Page 354
3.5.2. PROCESS SETUP......Page 355
3.5.3. RESULTS AND DISCUSSION......Page 356
3.6.1. CHEMICAL SYSTEM......Page 357
3.6.3. RESULTS AND DISCUSSION......Page 359
4. SUMMARY AND OUTLOOK......Page 360
ACKNOWLEDGMENTS......Page 362
NOMENCLATURE......Page 363
ABBREVIATIONS......Page 364
REFERENCES......Page 365
A.1. BALANCE EQUATIONS......Page 375
A.2. MASS TRANSFER AND REACTION COUPLING IN FLUID FILMS......Page 376
A.3. NONIDEAL FLOW BEHAVIOR IN CATALYTIC COLUMN INTERNALS......Page 378
B.1. ABSORPTION OF NOX......Page 380
B.2. COKE GAS PURI.CATION......Page 382
B.3. METHYL ACETATE SYSTEM, BATCH DISTILLATION......Page 383
B.4. METHYL ACETATE SYSTEM, STEADY-STATE DISTILLATION......Page 384
B.5. SYNTHESIS OF METHYL TERTIARY BUTYL ETHER......Page 385
B.6. REACTIVE EXTRACTION OF ZINC......Page 386
1. INTRODUCTION......Page 388
3. RECUPERATIVE HEAT TRANSFER......Page 390
3.1. CATALYST DILUTION......Page 392
3.3. FLUIDIZED BEDS......Page 393
3.4. CATALYTIC MICROREACTORS......Page 394
3.4.1. CATALYTIC MILLIREACTORS......Page 397
3.4.2. CERAMIC CATALYTIC MILLIREACTORS......Page 398
3.4.3. CERAMIC CATALYTIC-PLATE HEAT EXCHANGER......Page 400
4. REACTIVE-RECUPERATIVE HEAT TRANSFER......Page 401
5. REGENERATIVE HEAT TRANSFER......Page 402
5.1. COMPARISON OF REGENERATIVE WITH CONVECTIVE, RECUPERATIVE, AND REACTIVE HEAT TRANSFER......Page 403
5.2. REGENERATIVE HEAT TRANSFER PROCESS FOR HYDROGEN CYANIDE MANUFACTURE......Page 406
5.3. DESORPTIVE COOLING FOR ENHANCED REGENERATIVE HEAT TRANSFER......Page 407
5.4. REGENERATIVE HEAT TRANSFER IN ADSORPTIVE REACTORS......Page 410
6. ELECTROMAGNETIC HEAT TRANSFER......Page 411
6.2. DIELECTRIC HEATING......Page 412
6.3. ELECTRIC ARC PROCESSES......Page 413
7. CATALYST MODIFICATION FOR ENHANCED HEAT TRANSFER......Page 414
8. SUMMARY......Page 415
REFERENCES......Page 416
1. INTRODUCTION......Page 418
2. CONVENTIONAL CONCEPTUAL DESIGN PRACTICES......Page 419
2.1. ELEMENTS OF CONCEPTUAL PROCESS DESIGN......Page 420
2.2. STEP-BY-STEP CONCEPTUAL PROCESS DESIGN......Page 422
3. REACTION ENGINEERING......Page 424
3.1. SINGLE-PHASE SYSTEMS......Page 425
3.2. MULTIPHASE SYSTEMS......Page 428
4. COMPLEX DISTILLATION......Page 433
5. REACTION–SEPARATION AND REACTIVE–SEPARATION SYSTEM SYNTHESIS......Page 438
5.1. UNIT REPRESENTATION......Page 440
5.2. PROCESS REPRESENTATION......Page 442
5.3. OPTIMIZATION......Page 444
5.3.2. DESIGN STAGE......Page 445
6.1. REACTOR DESIGN: AMMOXIDATION OF PROPYLENE TO ACRYLONITRILE......Page 447
6.2. COMPLEX DISTILLATION......Page 448
6.3. COMBINED REACTION AND SEPARATION SYSTEMS: THE ACTIVATED SLUDGE PROCESS......Page 449
REFERENCES......Page 451
1. INTRODUCTION......Page 456
3. WHY WORK ON THE INTENSIFICATION OF CHEMICAL PROCESSES?......Page 457
4. KEY FEATURES OF PROCESS INTENSIFICATION TECHNOLOGIES......Page 462
5. INTRODUCING PROCESS INTENSIFICATION IN A CHEMICAL PROCESS......Page 464
6.1. S-IBUPROFEN......Page 471
6.2. UREA......Page 474
8.1. APPENDIX 1: EXCERPT FROM U.S. VISION 2020......Page 476
8.2. APPENDIX 2: EUROPEAN UNION RESEARCH PROGRAM......Page 477
8.3. APPENDIX 3. EXCERPT FROM THE CEFIC TECHNOLOGY PROGRAM SUSTECH......Page 478
REFERENCES......Page 479
2. INHERENT SAFETY......Page 480
3. HISTORY OF INHERENTLY SAFER DESIGN......Page 481
4. CONCEPT OF LAYER OF PROTECTION FOR PROCESS SAFETY......Page 482
6.1. SMALLER IS SAFER......Page 486
6.2.1. STORAGE......Page 487
6.2.2. PIPING......Page 489
6.3. PROCESS INTENSI.CATION......Page 491
6.3.1. NITRATION......Page 493
6.3.3. TUBULAR OR JET REACTORS......Page 494
6.3.7. COMBINED UNIT OPERATIONS......Page 495
7. METRICS FOR INHERENT SAFETY......Page 496
7.2. RISK INDICES......Page 497
7.3. OVERALL INHERENT SAFETY INDEX......Page 498
8. PROCESS INTENSIFICATION BENEFITS FOR PASSIVE AND ACTIVE LAYERS OF PROTECTION......Page 499
9. SUMMARY......Page 500
REFERENCES......Page 501
1.1. ENVIRONMENTAL PROBLEMS......Page 503
1.3. PRESENT TECHNOLOGY IS PART OF THE PROBLEM......Page 504
1.3.4. MTBE IN GASOLINE AS A REPLACEMENT FOR LEAD COMPONENTS......Page 505
2.1. GENERAL CONCEPT OF SUSTAINABLE DEVELOPMENT......Page 506
2.1.2.1 ECOLOGICAL PART (PLANET).......Page 508
2.2.2.3 ECONOMIC ISSUES (PROFIT).......Page 509
2.2. SUSTAINABLE TECHNOLOGY POSITIONING......Page 510
2.2.1. SOCIAL, ECONOMIC, AND ECOLOGICAL INTERACTIONS WITH SUSTAINABLE TECHNOLOGY......Page 511
2.2.2. ECOLOGICAL IMPACTS AS A FUNCTION OF CULTURAL, ECONOMIC, AND TECHNOLOGICAL ACTIVITIES......Page 512
2.2.3. TRANSITION TO SUSTAINABLE TECHNOLOGY SYSTEM LEVELS......Page 513
2.3. SUSTAINABLE TECHNOLOGY SCORECARD......Page 514
2.3.1. SOCIAL/PEOPLE......Page 515
2.3.2. ECOLOGICAL ASSESSMENT......Page 516
2.3.3. ECONOMY/PRO.T......Page 519
3. THE POTENTIAL FOR PROCESS INTENSIFICATION TO CONTRIBUTE TO SUSTAINABLE DEVELOPMENT......Page 520
3.2.1.1. CASE E: EASTMAN CHEMICAL METHYL ACETATE PROCESS......Page 521
3.2.2. CONCLUSION ON THE INDUSTRIAL PI CASES......Page 523
3.3.2.2. GLOBAL-WARMING IMPACT REDUCTION.......Page 524
3.3.3.1. SCARCE RESOURCE DEPLETION.......Page 526
4. EPILOGUE......Page 527
REFERENCES......Page 528