Abstract
This chapter gives an overview of the fundamentals of process intensification from a process systems engineering point of view. The concept of process intensification, including process integration, is explained together with the drivers for applying process intensification, which can be achieved at different scales of size, that is, the unit operation scale, the task scale, and the phenomena scale. The roles of process intensification with respect to process improvements and the generation of more sustainable process designs are discussed and questions related to when to apply process intensification and how to apply process intensification are answered through illustrative examples. The main issues and needs for generation of more sustainable process alternatives through process intensification are discussed in terms of the need for a systematic computer-aided framework and the methods and tools that should be employed through it. The process for the production of methyl-acetate is used as an example to highlight the generation of more sustainable process alternatives through this framework. Perspectives, conclusions, and future work are proposed in order to further develop the field of process intensification using a systems approach.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Gani R, Babi DK (2014) Systematic computer aided framework for process synthesis, design and intensification. In: Letcher T, Scott J, Darrell PA (eds) Chemical processes for a sustainable future. Royal Chemical Society, Cambridge, pp 698–752
Babi DK, Lutze P, Woodley JM, Gani R (2014) A process synthesis-intensification framework for the development of sustainable membrane-based operations. Chem Eng Process 86:173–195. doi:10.1016/j.cep.2014.07.001
Moulijn JA, Stankiewicz A, Grievink J, Górak A (2008) Process intensification and process systems engineering: a friendly symbiosis. Comput Chem Eng 32(1–2):3–11. doi:10.1016/j.compchemeng.2007.05.014
Stankiewicz A, Moulijn JA (2000) Process intensification: transforming chemical engineering. Chem Eng Prog 96(1):22–24
Reay D, Ramshaw C, Harvey A (2008). In: Reay D, Ramshaw C, Harvey A (eds) Process intensification. IChemE, Rugby.
Ponce-Ortega JM, Al-Thubaiti MM, El-Halwagi MM (2012) Process intensification: new understanding and systematic approach. Chem Eng Process 53:63–75. doi:10.1016/j.cep.2011.12.010
Bessling B, Schembecker G, Simmrock KH (1997) Design of processes with reactive distillation line diagrams. Ind Eng Chem Res 36(8):3032–3042. doi:10.1021/ie960727p
Agreda VH, Partin LR, Heise WH (1990) High-purity methyl acetate via reactive distillation. Chem Eng Prog 86(2):40–46
Freund H, Sundmacher K (2008) Towards a methodology for the systematic analysis and design of efficient chemical processes. Chem Eng Process 47(12):2051–2060. doi:10.1016/j.cep.2008.07.011
Lutze P, Babi DK, Woodley JM, Gani R (2013) Phenomena based methodology for process synthesis incorporating process intensification. Ind Eng Chem Res 52(22):7127–7144. doi:10.1021/ie302513y
Siirola JJ (1996) Strategic process synthesis: advances in the hierarchical approach. Comput Chem Eng 20:S1637–S1643. doi:10.1016/0098-1354(96)85982-5
Papalexandri KP, Pistikopoulos EN (1994) A multiperiod MINLP model for the synthesis of flexible heat and mass exchange networks. Comput Chem Eng 18(11–12):1125–1139. doi:10.1016/0098-1354(94)E0022-F
Peschel A, Jörke A, Freund H, Sundmacher K (2012) Model-based development of optimal reaction concepts for plant wide process intensification. Comput Aided Chem Eng 31:150–154. doi:10.1016/B978-0-444-59507-2.50022-6
Lutze P, Román-Martinez A, Woodley JM, Gani R (2012) A systematic synthesis and design methodology to achieve process intensification in (bio) chemical processes. Comput Chem Eng 36:189–207. doi:10.1016/j.compchemeng.2011.08.005
El-Halwagi MM (1997) Pollution prevention through process integration: systematic design tools. Academic, San Diego
El-Halwagi MM (2006) Process systems engineering- process integration. Elsevier
Smith R (2005) Chemical process: design and integration. WILEY-VCH Verlag GmbH, Weinheim
Klemeš JJ, Varbanov PS, Kravanja Z (2013) Recent developments in process integration. Chem Eng Res Des 91(10):2037–2053. doi:10.1016/j.cherd.2013.08.019
Harmsen J (2010) Process intensification in the petrochemicals industry: drivers and hurdles for commercial implementation. Chem Eng Process 49(1):70–73. doi:10.1016/j.cep.2009.11.009
Linnhoff B, Townsend DW, Boland D, Hewitt GF, Thomas BEA, Guy AR, Marsland RH (1982) A user guide on process integration for the efficient use of energy. IChemE, Rugby
Papoulias SA, Grossmann IE (1983) A structural optimization approach in process synthesis—II. Comput Chem Eng 7(6):707–721. doi:10.1016/0098-1354(83)85023-6
Singhvi A, Madhavan KP, Shenoy UV (2004) Pinch analysis for aggregate production planning in supply chains. Comput Chem Eng 28(6–7):993–999. doi:10.1016/j.compchemeng.2003.09.006
Kazantzi V, El-Halwagi MM (2005) Targeting material reuse via property integration. Chemical Engineering Progress 101(8), 28–37. http://www.scopus.com/inward/record.url?eid=2-s2.0-27844440901&partnerID=tZOtx3y1
Babi DK, Holtbruegge J, Lutze P, Gorak A, Woodley JM, Gani R (2015) Sustainable process synthesis–intensification. Comput Chem Eng 81:218–244. doi:10.1016/j.compchemeng.2015.04.030
Oxley P, Brechtelsbauer C, Ricard F, Lewis N, Ramshaw C (2000) Evaluation of spinning disk reactor technology for the manufacture of pharmaceuticals. Ind Eng Chem Res 39(7):2175–2182. doi:10.1021/ie990869u
Lutze P, Gorak A (2013) Reactive and membrane-assisted distillation: recent developments and perspective. Chem Eng Res Des 91(10):1978–1997. doi:10.1016/j.cherd.2013.07.011
Asprion N, Kaibel G (2010) Dividing wall columns: fundamentals and recent advances. Chem Eng Process 49(2):139–146. doi:10.1016/j.cep.2010.01.013
Alfa Laval (2015) A new degree of deodorization control. http://local.alfalaval.com/de-de/wichtige-industrien/lebensmittel-molkerei-getraenke/oele/Documents/Desodorierung_Alfa%20Laval%20SoftFlex%E2%84%A2%20semi-continuous.pdf
Alfa L (2015) Gasketed plate-and-frame heat exchangers. Heat Exchangers. http://www.alfalaval.com/products/heat-transfer/plate-heat-exchangers/Gasketed-plate-and-frame-heat-exchangers/
Ramshaw C (1993) The opportunities for exploiting centrifugal fields. Heat Recovery Syst CHP 13(6):493–513. doi:10.1016/0890-4332(93)90003-E
Al Taweel AM, Yan J, Azizi F, Odedra D, Gomaa HG (2005) Using in-line static mixers to intensify gas–liquid mass transfer processes. Chem Eng Sci 60(22):6378–6390. doi:10.1016/j.ces.2005.03.011
Babi DK, Gani R (2014) Hybrid distillation schemes: design, analysis, and application. In: Gorak A, Sorensen E (eds) Distillation. Elsevier, London, pp 357–381. doi:10.1016/B978-0-12-386547-2.00009-0
Linnhoff B, Flower JR (1978) Synthesis of heat exchanger networks: I. Systematic generation of energy optimal networks. AIChE J 24(4):633–642. doi:10.1002/aic.690240411
Zhao CY, Lu W, Tassou SA (2006) Thermal analysis on metal-foam filled heat exchangers. Part II: tube heat exchangers. Int J Heat Mass Transf 49(15–16):2762–2770. doi:10.1016/j.ijheatmasstransfer.2005.12.014
Osakada K, Shiomi M (2006) Flexible manufacturing of metallic products by selective laser melting of powder. Int J Mach Tool Manuf 46(11):1188–1193. doi:10.1016/j.ijmachtools.2006.01.024
El-Halwagi MM, Manousiouthakis V (1989) Synthesis of mass exchange networks. AIChE J 35:1233–1244. doi:10.1002/aic.690350802
Stankiewicz A, Moulijn JA (2004) Re-engineering the chemical processing plant. Marcel-Dekker, New York
Peschel A, Karst F, Freund H, Sundmacher K (2011) Analysis and optimal design of an ethylene oxide reactor. Chem Eng Sci 66(24):6453–6469. doi:10.1016/j.ces.2011.08.054
Calvar N, González B, Dominguez A (2007) Esterification of acetic acid with ethanol: reaction kinetics and operation in a packed bed reactive distillation column. Chem Eng Process 46(12):1317–1323. doi:10.1016/j.cep.2006.10.007
Liu G, Gan L, Liu S, Zhou H, Wei W, Jin W (2014) PDMS/ceramic composite membrane for pervaporation separation of acetone–butanol–ethanol (ABE) aqueous solutions and its application in intensification of ABE fermentation process. Chem Eng Process 86:162–172. doi:10.1016/j.cep.2014.06.013
Leyva-Díaz JC, López-López C, Martín-Pascual J, Muñío MM, Poyatos JM (2015) Kinetic study of the combined processes of a membrane bioreactor and a hybrid moving bed biofilm reactor-membrane bioreactor with advanced oxidation processes as a post-treatment stage for wastewater treatment. Chem Eng Process 91:57–66. doi:10.1016/j.cep.2015.03.017
Jordens J, Gielen B, Braeken L, Van Gerven T (2014) Determination of the effect of the ultrasonic frequency on the cooling crystallization of paracetamol. Chem Eng Process 84:38–44. doi:10.1016/j.cep.2014.01.006
Werth K, Lutze P, Kiss AA, Stankiewicz AI, Stefanidis GD, Górak A (2015) A systematic investigation of microwave-assisted reactive distillation: influence of microwaves on separation and reaction. Chem Eng Process 93:87–97. doi:10.1016/j.cep.2015.05.002
Douglas JM (1985) A hierarchical decision procedure for process synthesis. AIChE J 31(3):353–362. doi:10.1002/aic.690310302
Bayer B, Schneider R, Marquardt W (2000) Integration of data models for process design—first steps and experiences. Comput Chem Eng 24(2–7):599–605. doi:10.1016/S0098-1354(00)80002-2
Gernaey KV, Gani R (2010) A model-based systems approach to pharmaceutical product-process design and analysis. Chem Eng Sci 65(21):5757–5769. doi:10.1016/j.ces.2010.05.003
Hostrup M, Gani R, Kravanja Z, Sorsak A, Grossmann I (2001) Integration of thermodynamic insights and MINLP optimization for the synthesis, design and analysis of process flowsheets. Comput Chem Eng 25(1):73–83. doi:10.1016/S0098-1354(00)00634-7
Grossmann IE (2012) Advances in mathematical programming models for enterprise-wide optimization. Comput Chem Eng 47:2–18. doi:10.1016/j.compchemeng.2012.06.038
Siirola JJ, Powers GJ, Rudd DF (1971) Synthesis of system designs: III. Toward a process concept generator. AIChE J 17(3):677–682. doi:10.1002/aic.690170334
Kobus A, Kuppinger F-F, Meier R, Düssel R, Tuchlenski A, Nordhoff S (2001) Improvement of conventional unit operations by hybrid separation technologies—a review of industrial applications. Chem Ing Tech 73(6):714. doi:10.1002/1522-2640(200106)73:6<714::AID-CITE7142222>3.0.CO;2-S
d’Anterroches L, Gani R (2005) Group contribution based process flowsheet synthesis, design and modelling. Fluid Phase Equilib 228–229:141–146. doi:10.1016/j.fluid.2004.08.018
Kiss A, Pragt H, van Strien C (2007) Computer aided chemical engineering. In: 17th European Symposium on Computer Aided Process Engineering, vol 24, Elsevier, Amsterdam, pp 467–472. doi:10.1016/S1570-7946(07)80101-5
Caballero JA, Grossmann IE (2004) Design of distillation sequences: from conventional to fully thermally coupled distillation systems. Comput Chem Eng 28(11):2307–2329. doi:10.1016/j.compchemeng.2004.04.010
Madenoor Ramapriya G, Tawarmalani M, Agrawal R (2014) Thermal coupling links to liquid-only transfer streams: a path for new dividing wall columns. AIChE J 60(8):2949–2961. doi:10.1002/aic.14468
Urselmann M, Barkmann S, Sand G, Engell S (2011) Optimization-based design of reactive distillation columns using a memetic algorithm. Comput Chem Eng 35(5):787–805. doi:10.1016/j.compchemeng.2011.01.038
Amte V (2011) Computer aided chemical engineering, vol 29. doi:10.1016/B978-0-444-53711-9.50144-9
Seifert T, Sievers S, Bramsiepe C, Schembecker G (2012) Small scale, modular and continuous: a new approach in plant design. Chem Eng Process 52:140–150. doi:10.1016/j.cep.2011.10.007
Jaksland C, Gani R, Lien K (1995) Separation process design and synthesis based on thermodynamic insights. Chem Eng Sci 50:511–530. doi:10.1016/0009-2509(94)00216-E
Harper PM, Gani R (2000) A multi-step and multi-level approach for computer aided molecular design. Comput Chem Eng 24(2–7):677–683. doi:10.1016/S0098-1354(00)00410-5
Gani R, Hytoft G, Jaksland C, Jensen AK (1997) An integrated computer aided system for integrated design of chemical processes. Comput Chem Eng 21(10):1135–1146. doi:10.1016/S0098-1354(96)00324-9
Peters MS, Timmerhaus KD, West RE (2003) Sign and economics for chemical engineers. In: Peters MS, Timmerhaus KD, West RE (eds) 5th edn. Mc Graw Hill, New York. http://catalogs.mhhe.com/mhhe/viewProductDetails.do?isbn=0072392665
Carvalho A, Matos HA, Gani R (2013) SustainPro—a tool for systematic process analysis, generation and evaluation of sustainable design alternatives. Comput Chem Eng 50:8–27. doi:10.1016/j.compchemeng.2012.11.007
Kalakul S, Malakul P, Siemanond K, Gani R (2014) Integrated of life cycle assessment software with tools for economic and sustainability analyses and process simulation for sustainable process design. J Clean Prod 71:98–109. doi:10.1016/j.jclepro.2014.01.022
Marrero J, Gani R (2001) Group contribution based estimation of pure component properties. Fluid Phase Equilib 183–184:183–208. doi:10.1016/S0378-3812(01)00431-9
Huss RS, Chen F, Malone MF, Doherty MF (2003) Reactive distillation for methyl acetate production. Comput Chem Eng 27(12):1855–1866. doi:10.1016/S0098-1354(03)00156-X
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2016 Springer International Publishing Switzerland
About this chapter
Cite this chapter
Babi, D.K., Cruz, M.S., Gani, R. (2016). Fundamentals of Process Intensification: A Process Systems Engineering View. In: Segovia-Hernández, J., Bonilla-Petriciolet, A. (eds) Process Intensification in Chemical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-319-28392-0_2
Download citation
DOI: https://doi.org/10.1007/978-3-319-28392-0_2
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-28390-6
Online ISBN: 978-3-319-28392-0
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)