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Transcript of Educating the Customer: PI - What’s it all about? Dr Mike Jones, Protensive PROCESS...
Educating the Customer: PI - What’s it all about?
Dr Mike Jones, Protensive
PROCESS INTENSIFICATION: Meeting the Business and Technical Challenges, Gaining Competitive Advantage
The Royal Institution of Great Britain, London: 19th November 2003
What is PI?
E q u ip m e nt P ro du c ts P ro ce sses E ffe c ts
P I
What is PI?
S m a lle rL ig h te r
C h ea p er
E q u ip m e nt P ro du c ts P ro ce sses E ffe c ts
P I
What is PI?
S m a lle rL ig h te r
C h ea p er
E q u ip m e nt
Im p ro vedN o ve l
P ro du c ts P ro ce sses E ffe c ts
P I
What is PI?
S m a lle rL ig h te r
C h ea p er
E q u ip m e nt
Im p ro vedN o ve l
L o w er co st
P ro du c ts
R e s ide n ce t im e
H e at tra ns fe rM a ss tra n s fe r
S e pa ra tionF lo w b e h av io ur
P ro ce sses E ffe c ts
P I
What is PI?
S m a lle rL ig h te r
C h ea p er
E q u ip m e nt
Im p ro vedN o ve l
L o w er co st
P ro du c ts
R e s ide n ce t im e
H e at tra ns fe rM a ss tra n s fe r
S e pa ra tionF lo w b e h av io ur
P ro ce sses
D e live ry sys te m sS u rfa ce e ffe c ts
F e e l
E ffe c ts
P I
Process Intensification - a definition
•Significantly enhances the transport rates
•Gives every molecule the same processing experience
CONCEPTS
- Match mixing/mass transfer rate to rate ofdesired chemical reaction
- Match heat transfer rate to exothermicity ofreaction (remove heat as it is produced)
- Match flow behaviour (eg plug flow, backmixed)to reaction scheme
- Match residence time to desired reaction time
A Reason
So rather than adapting the operating conditions and chemistry
to available classical equipment,
the process structure, architecture and equipment can be adapted to the physico-chemical transformation
What is PI?
E q u ip m e nt P ro du c ts P ro ce sses E ffe c ts
P I
SLUG FLOW
DROPLETEMULSION
PARALLEL FLOW
Diffusion between streams Diffusion in/out of droplets
Diffusion across the interface
Internal convective transportTypical Methods Typical Methods
for Contacting for Contacting Two Fluid PhasesTwo Fluid Phases
Channel Scale Channel Scale 5050m - 500m - 500mm
Scale-Up for Intensified ProcessesScale-Up for Intensified ProcessesFuture VisionFuture Vision
Low Volume Fine ChemicalsLow Volume Fine Chemicals
Several single channel devices with high flow velocity could Several single channel devices with high flow velocity could produce produce 10s of 10s of l/sl/s or around or around 1kg per day.1kg per day.
Medium Volume Chemical Medium Volume Chemical ProductionProduction
Blocks with Blocks with 1000s1000s of channels of channels running in parallel could provide running in parallel could provide higher yield higher yield whenwhen accurate accurate manifold technology developed.manifold technology developed.
COMBUSTION
CATALYST
PROCESS
CATALYST
COMBUSTION GAS
(CH4 + AIR)
PROCESS GAS
(CH4 + H2O)
A pair of adjacent channels in the catalytic plate reactor showing the coupling of an endothermic reaction (Methane Reforming)
with an exothermic reaction (Methane Combustion)
Comparison of the Productivity of Different Reactors
Reactor ReactorVolume
Yield of C5+kg/m3/hr
Sasol 432 .1 29.98
Exxon 23.8 43.84
Plate Reactor 1.0 163.12
Electrolytic flow cells
CEM
Na2SO4
Na+
H+
SO4-2
Na2SO4H2S04 NaOH
NaOH
OH-
Liquid Film
Solid Surface
Micro Mixers
Influence of Surface WavesInfluence of Surface Waves
Typical raman spectra taken from SDR.
8000
6000
4000
2000
0
540 560 580 600 620
FTIR ATR bulk polymerization of styrene FTIR ATR bulk polymerization of styrene
0.00
0.02
0.04
0.06
0.08
0.10
Log
100
200
300
400
500
min
2800 3000 3200
cm-1
FT-NIR following a polymerizationFT-NIR following a polymerization
0.0
20.0
40.0
60.0
80.0
100.0
120.0
0 100 200 300 400 500
Time (min)
Co
nve
rsio
n (
%)
(ppm)1.01.52.02.53.03.54.04.55.05.56.06.57.07.5
Styrene proton signals all but gone
Polymerization evaluated by 1H NMRPolymerization evaluated by 1H NMR
OH
trans-Pinocarveol
trans-Sobrerol
OH
OH
OH
trans-Carveol
p-Cymene
O
Pinol
O
-pinene oxide
O
campholenic aldehyde(2,2,3-trimethyl-3-cyclopentenacetaldehyde)
H +H2O/H +
- H2O- 2 H2O
N(Et)2
via cis-Sobrerol
Main products from the rearrangement of -pinene oxide
ACatalyst
B
Rearrangement reaction; A – -pinene oxide, B – campholenic aldehyde
ACat.
B
F
E
D
C
D
K
J
I
H
Simplified reaction paths, where B is the wanted product (campholenic aldehyde)
Control•size•size distribution•form•coating
Applications•Pharmaceuticals•Electronics•Inkjets•Semiconductors
Why?
Performance of SDR Process
0
10
20
30
40
50
60
70
80
90
100
0 20 40 60 80 100 120 140 160 180 200 220
Time (mins)
Co
nv
ers
ion
(%
)
VISCOUS LIQUIDS e.g. POLYMERISATION
- 75% yield after 4 hrs- 25% unreacted starting material
recycle, reprocess
On-Disc Monitoring of CaCOOn-Disc Monitoring of CaCO33 Production Production
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
800rpm, 5ml/s
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
800rpm, 5ml/s
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
400rpm, 5ml/s
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
400rpm, 5ml/s
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
400rpm, 10ml/s
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
0 2 4 6 8 10 12 14
Radius (cm)
Ca(
OH
) 2 C
on
cen
trat
ion
(g
/lit
re)
400rpm, 10ml/s
• Probes mounted on disc surface to monitor ion depletion.
• Results confirm particle production is mass transfer limited and takes place on the spinning disc.
Examples of film thickness measurements made using this system.
Film thickness typically is in the 0.01m to 1mm range.
Real-Time Film Thickness Monitoring
Liquid-Solid Mass Transfer Results
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 5000 10000 15000 20000
Shear Rate (1/s)
Ma
ss
Tra
ns
fer
Co
eff
icie
nt
(mm
/s) 38ml/s
21ml/s
10ml/s
6mm Electrode - 200 to 900rpm
Diffusion Theory Prediction
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 5000 10000 15000 20000
Shear Rate (1/s)
Ma
ss
Tra
ns
fer
Co
eff
icie
nt
(mm
/s) 38ml/s
21ml/s
10ml/s
6mm Electrode - 200 to 900rpm
Diffusion Theory Prediction
Results for 6mm Electrodes at 9 Radial Locations
Summary
• Rapid process screening
• Rapid process development
• Rapid scale-up• Novel products and
processes• JIT
• Integrated processes• common standards