Process Intensification (PI) is a topic receiving a lot of attention recently. While working in a pilot plant, I came across the philosophy of Process Intensification (PI). This is to improve a facility either by introducing new technology or optimising existing equipment to output more products and profit, (essentially). At least I like to tell myself that, we did the best we could with the tools we have, while balancing safety, production and cost.
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| Generic birds eye view of a ‘plant’ - but with the right set of eyes, there is always potential for to improve this ‘plant’ |
Plant improvement
can be taken under 2 approaches:
1.
Equipment driven approach
1)
Usually in testing new/novel application
2)
Investment in new
2.
Process intensification
1)
Time scales, flow patterns, & temperatures
2)
Inherent properties of material reaction &
physical properties
3)
Build on process knowledge – small improvements
with big performance changes
Questions to ask yourself:
Here we examine reaction kinetics, heat of reaction & physical properties of a process. The business drivers are of course, production, cost, project management, efficiency. To push the boundaries of process conditions. Some questions you should ask yourself….
1.
Why is the temperature limited?
2.
What happens when it is exceeded?
3.
Can you add reagents in different order?
4.
Aim to remove many rate limiting steps?
5.
And remove unwanted steps?
6.
Can you operate continuously rather than batch?
7.
Can you increase impeller speed of stir tank OR
use extra reagents?
8.
Can you use impinging jets – i.e. change to reacting
in a pipe rather than reactor? (more turbulence)
9.
Can you use inline mixer in pipe, to save energy
usage downstream (of course you would need too elevated pressures & temperatures)
10.
Can you speed up a reaction?
1)
Use a new catalyst
2)
Use Jet mixed tank
3)
Is heat transfer & mixing efficiency
important
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| Generic pipes with gate valves and flanges - Can this be optimised? heat loss, leakages are just some thoughts |
Process Intensification is a very interesting high level. I urge all people working in the industry to read upon it. This philosophy should be deeply ingrained into the lives and minds of all who work in industrial processes.
Regards,
Mr C
