DAN F SMITH DEAPARTMENT OF CHEMICAL ENGINEERING

ADVANCED THERMODYNAMICS SPRING 2016 PROJECT PRENSENTATION ON PROCESS INTENSIFICATION BY SAINATH REDDY GUNDREDDI (L20400923) ROHIT SHINDE (L20355026) SONG WANG (L20359977)

LAMAR UNIVERSITY

INTRODUCTION PROCESS INTENSIFICATION METHODOLOGY AND ITS COMPONENTS

PROCESS INTENSIFICATION AND ITS COMPONENTS

PROCESS INTENSIFYING EQUIPMENT PROCESS INTENSIFYING METHODS BACKGROUND

HISTORY

PROCESS IN DECADES ALGORITHM FOR PROCESS INTENSIFICATION CASE STUDIES AND EXAMPLES CATALYST ASSISTED PRODUCTION OF OLEFINS FROM NATURAL GAS RESIN WATER ELECTRODE IONIZATION POWER GENERATION FROM MUNICIPAL SOLID WASTES(MSW) SIMULATION FOR POWER GENERATION FROM MSW SIMULATION BUILD UP PROCESS FLOW SHEET COMPONENTS LIST THERMODYNAMIC PACKAGE CONCLUSION REFERENCES

CONTENTS

Process intensification is commonly seen as one of the most promising development paths for the chemical process industry.

One of the most important progress areas for modern chemical engineering.

Process intensification concerns only engineering methods and equipment.  

Process Intensification has gained a momentum as a revolutionary approach to chemical process, in around last two decades.

PI has been described as “the key to survival of the fittest in international competition”.

Various scientists are interested in Process intensification due to its enormous advantages.

INTRODUCTION

“A strategy for making dramatic reductions in the size of a Chemical Plant so as to reach a given production objective” - C. Ramshaw, 1995

In other words, Process Intensification is a Modern approach that aims to shrink the size of a chemical plant but at the same time increases their efficiency.

Process - Route to manufacture Liquid processing Gas processing Solid processing Multiphase processing Intensification Reduce footprint Reduce cost Reduce environmental impact Increase output Increase value and or quality of product Increase safety, reduce risk

WHAT EXACTLY PROCESS INTENSIFICATION

PROCESS INTENSIFICATION AND ITS COMPONENTSAs shown in Figure , the whole field generally can be divided into two areas: process-intensifying equipment, such as novel reactors, and intensive mixing, heat-transfer and mass-transfer devices; process intensifying methods, such as new or hybrid separations, integration of reaction and separation, heat exchange, or phase transition (in so-called multifunctional reactors), techniques using alternate energy sources (light, ultrasound, etc.), and new process-control methods (like intentional unsteady-state operations).

METHODOLOGY AND ITS COMPONENTS

SMR Static-Mixer Reactor Monolithic Catalyst Micro-Reactors Rotating Devices

PROCESS INTENSIFYING EQUIPMENT

As highlighted in Figure , most process-intensifying methods fall into three well-defined areas: integration of reaction and one or more unit operations into so-called multifunctional reactors, development of new hybrid separations, and use of alternative forms and sources of energy for processing.

Multifunctional Reactors Membrane Reactors Hybrid Separations Use of alternate forms and sources of energy.

PROCESS INTENSIFYING METHODS

HISTORY Today, we are witnessing important new developments that go beyond “traditional”

chemical engineering. Engineers at many universities and industrial research centers are working on novel equipment and techniques that potentially could transform our concept of chemical plants and lead to compact, safe, energy-efficient, and environment-friendly sustainable processes.

These developments share a common focus on “process intensification” — an approach that has been around for quite some time but has truly emerged only in the past few years as a special and interesting discipline of chemical engineering.

In 1995, while opening the 1st International Conference on Process Intensification in the Chemical Industry, Ramshaw, one of the pioneers in the field, defined process intensification as a strategy for making dramatic reductions in the size of a chemical plant so as to reach a given production objective.

These reductions can come from shrinking the size of individual pieces of equipment and also from cutting the number of unit operations or apparatuses involved.

In any case, the degree of reduction must be significant; how significant remains a matter of discussion.

BACKGROUND

    Global

 Process Intensification

  1970s

 Major Chemical CompaniesResearch LaboratoriesICL, Shell, Bp, Courtaulds, Exxon 

 “Product Invention”Polymers, PEEK, Pruteen,PHB, Carbon Fibers.Processes; Fluidized beds.

1980s

 “Market forces” Mergers, sales and acquisitions.Pharma

Heat Exchange Networks (HENS). Colin Ramshaw. “Process Intensification” Spinning Disc reactor. 

  1990s

Emergence of Asia and Middle East as major players. Emergence of Biotechnology, Nanotechnology.

Batch to Continuous.Membranes.

  2000s

 Co2, Energy, Biofuels, Displays, TelecomsNanotechnology

 MicrofluidicsPharma, Batch to continuousCar catalyst exhaust  

  2010s

“Economic pause”TelecomsElectric carsAlternative energy sources 

Pharma; continuous tablet.Batteries.Ink Jet Technologies

PROCESS IN DECADES

ALGORITHM FOR PROCESS INTENSIFICATION

CATALYST ASSISTED PRODUCTION OF OLEFINS FROM NATURAL GAS

Introduction: Liquid Ethylene, an important olefin, is a key building block in the production of numerous chemicals and polymers and the largest volume organic chemical produced in the United States and the world todayProblem Statement: • In this process, hydrocarbons (either a natural gas liquids (NGLs) or naphtha feedstock) are

pyrolyzed at temperatures of 800°C–900°C and then cooled.• Coke forms and deposits on internal surfaces of the coils. These coke deposits cause

undesirable side effects, including constricting the flow of ethylene through the furnace, forcing higher furnace temperatures to maintain performance, and eventually halting ethylene production to remove coke from the furnace walls.

Process: • Apply a novel catalytic coating on internal surfaces of the coils where ethane is converted at

extremely high temperatures to ethylene.• The coating catalyzes the oxidation of the carbon on the surface, greatly reducing coke

formation and its associated problems.Conclusion :Less coke formation within the coils contributes to longer run times and lower decoking frequency, leading to savings in energy and corresponding greenhouse emissions

CASE STUDIES AND EXAMPLES

RESIN WATER ELECTRODE IONIZATIONIntroduction:• Electrode ionization (EDI) is a modified version of electro dialysis (ED) that

contains conductive ion exchange (IX) resin beads within the dilute compartmentProblem Statement: • In Electro Dialysis, dilute solutions are used where due to the limited ion

concentration, ionic conductivity decreases and electrical energy is wasted in water splitting.

Process:• EDI combines the advantages of ED and IX chromatography. It utilizes in-site

regeneration of the IX resin beads by a phenomenon known as “water splitting”. Water splitting on the surface of the IX resin beads regenerates the beads and ensures higher ionic conductivity within the dilute compartment.

• The conductive IX resin beads in EDI provide sufficient ionic conductivity, even with a dilute solution, and provide an efficient ion transport pathway through the IX resin beads.

Conclusion:• This technology offers enhanced fluid and flow distribution, higher conductivity,

superior pH control, ease of materials handling and system assembly, and a porous solid support for incorporation of catalysts, biocatalysts, and other adjuvants.

POWER GENERATION FROM MUNICIPAL SOLID WASTES(MSW)Introduction:• Incinerator Plant Power generation from municipal solid wastes (MSW) is an

attractive technology in the areas of renewable energy utilization. MSW can be converted into energy both by the direct burning of MSW to produce electricity and by indirect burning by converting MSW into refuse derived fuel.

Problem Statement:• In RDF Plant, incineration involves a complex chemical process in which

many harmful products are generated (SOx, NOx, HCl, CO, HF, dioxin, furans, Hg, etc.)

• The plant contains five main parts. RDF combustion, post-combustion, + NOx reduction, making heat recovery in order to generate the steam and Solid separation.

• Process:• Conclusion:

SIMULATION BUILD UP

•Heat recovery section: the steam generator has three vertical radiant passes and a horizontal convection pass with surfaces of the evaporators, super heaters and economizers;

• Flue-gas treatment section: it consists of a SNCR system, a spray absorber system and a baghouse filter;

•Power generation section: it consists of a condensing turbine unit, coupled directly with the generator.

 

PROCESS FLOW SHEET

Flue-gas treatment section

COMPONENT LIST

For the components C, CaSO3, CaSO4 and CaCl2, it’s choosy to change the type from conventional to the solid, but in the flue-gas treatment section we have to specify it to solid type. 

There are couples of dynamic package which can be used to set up the simulation, following gives the property methods selection.

IEDAL gas property methods is for the RDF combustion section including post-combustion and NOx reduction parts. When the reactions happened in the stoichiometric reactor, the reactor generate the products including CaSO3, CaSO4 and CaCl2. Because of the electrolyte mixture, we choose ELECNRTL method to get accurate parameters.

THEROMDYNAMIC PACKAGE

Process Intensification has gained a momentum as a revolutionary approach to chemical process, in around last two decades. PI has been described as “the key to survival of the fittest in international competition”. With much emphasis on sustainable development nowadays, PI can come handy and make chemical and pharmaceutical processes much greener. Chemical Process and industry fraternity is looking towards PI as new paradigm in to lead chemical process industries. It took over transport phenomena.

The potential for PI remains largely untapped, but the economic rewards for those companies that to introduce PI are likely to be substantial and this will have environmental benefits for a more sustainable future for generations to come.

Future work will focus on the laboratory protocols section of the methodology. This involves further development of experimental equipment and procedures to demonstrate intensified, continuous operation. This is a vital part in proving the success of a PI concept and will allow determination of the benefits achievable, without the need for building a continuous pilot plant

Awareness of PI still has to be raised in some sectors of the chemical industry, though there are signs that many firms are looking towards innovation as a means of gaining a competitive edge and meeting legislation. A change in the way process development is traditionally done will be required for innovation to be properly adopted. This PI methodology provides a mechanism to promote such a change by encouraging PI to be considered where it may normally be overlooked.

CONCLUSION

http://www.rvo.nl/sites/default/files/2013/10/Process%20Intensification%20Transforming%20Chemical%20Engineering.pdf

http://www.slideshare.net/malcolmmackley/process-intensification-korea2012

http://www.slideshare.net/TareqHassan/process-intensification http://energy.gov/sites/prod/files/2015/02/f19/QTR%20Ch8%20-

%20Process%20Intensification%20TA%20Feb-13-2015.pdf http://

www.basf-qtech.com/p02/USWeb-Internet/basf-qtech/en/content/microsites/basf-qtech/prods

http://books.google.com/books?hl=en&lr=&id=JQKjAgAAQBAJ&oi=fnd&pg=PA112&ots=GQkE628PmBt4s&sig=qcBZ0PflQRDcTutmNQrW0LRYwM#v=onepage&q&f=false

REFERENCES

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