Fundamentals of Process Intensification

Andrzej Stankiewicz  is Full Professor and Chair of Process Intensification at Delft University of Technology, the Netherlands,  and Director of TU Delft Process Technology Institute.  With almost 40 years of industrial and academic research experience he is author of numerous scientific publications on process intensification, chemical reaction engineering and industrial catalysis. Prof. Stankiewicz is one of the pioneers of process intensification. He is also editor of Chemical Engineering and Processing: Process Intensification and Series Editor of the Green Chemistry Books Series and chairs currently the Board of the European Process Intensification Centre (EUROPIC). Current research interests of Prof. Stankiewicz focus on control of molecular interactions and intensification of chemical reactions using electricity-based energy fields (e.g. laser, microwave, UV). The research in that area has brought him prestigious Advanced Investigator Grant from the European Research Council and (with co-workers) another grant from the Bill and Melinda Gates Foundation.  Tom Van Gerven is Professor of Process Intensification at the University of Leuven, Belgium and head of the Process Engineering for Sustainable Systems section in that University. He is author of numerous publications on process intensification, solid waste treatment and sustainable processing. He focuses on the use of ultrasound and light for efficient chemical processing. Since 2013, he is chairman of the Working Party on Process Intensification at the European Federation of Chemical Engineering.Georgios Stefanidis is Professor at the Univeristy of Leuven, Belgium. His research interests are process intensification, chemical processing, chemical reactor engineering, biomass gasification, reforming of hydrocarbons and oxygenated fuels, CO2 utilization and crystallization.

• Preface xiAbout the Authors xiiiPart I Principles 11 Introduction 31.1 Short History of Process Intensification 31.2 Definitions and Interpretations of Process Intensification 51.3 Fundamentals of Process Intensification – Principles, Approaches, Domains, and Scales 8References 112 The Four Principles 152.1 Principle 1 – Toward Perfect Reactions 152.2 Principle 2 – What Experience Molecules? 192.3 Principle 3 – Driving Forces, Resistances, and Interfaces 212.4 Principle 4 – About the Synergies 21References 23Part II Domains 253 STRUCTURE – PI Approaches in Spatial Domain 273.1 Randomness and Order: Why Structure? 273.2 Structures Targeting Molecular Events 293.2.1 Molecular Imprints 293.2.2 Molecular Reactors 333.2.3 Shape-Selective Catalysts 343.2.4 Semirigid Structures: Liquid Crystals 383.3 Structures Targeting Heat Transfer 393.3.1 Microstructured Reactors 393.3.2 Structured Heat Exchangers 463.4 Structures Targeting Mass Transfer 493.4.1 Microstructured Separation Systems 493.4.2 Structured Internals for Reactions and Separations 553.5 Structures Targeting Mixing and Fluid Flow 633.5.1 Micromixers 633.5.2 Static Mixers 673.5.3 Fractal Systems 71References 734 ENERGY – PI Approaches in Thermodynamic Domain 834.1 Energy in Chemical Processes – A Broader Picture of the Present and the Future 834.2 Electric Fields 854.3 Magnetic Fields 904.4 Electromagnetic Fields 934.4.1 Microwaves 934.4.1.1 Liquid-Phase Organic Synthesis Reactions 974.4.1.2 Gas-Phase Catalytic Reactions 994.4.1.3 Solid–Liquid Extraction 994.4.1.4 Adsorbents Regeneration 1024.4.1.5 Crystallization 1034.4.1.6 Distillation 1034.4.1.7 Membrane Processes 1044.4.2 Plasmas 1044.4.2.1 Plasma-Assisted Methane Coupling to Acetylene (Huels Process) 1064.4.2.2 Plasma-Assisted Coal Gasification for Synthesis Gas Production 1084.4.2.3 Plasma-Assisted CO2 Dissociation 1094.4.3 Photochemical and Photocatalytic Reactors (Artificial Light) 1114.4.4 Solar Reactors 1184.4.5 Induction Heating 1264.5 Acoustic Fields 1294.6 Flow Fields 1424.6.1 Hydrodynamic Cavitation 1424.6.2 Ejector-based Liquid Jet Reactors 1444.6.3 Supersonic Flow 1474.6.4 Impinging-stream Reactors 1504.7 High-Gravity and High-Shear Fields 1524.7.1 Rotating Packed Beds 1544.7.2 Spinning Disc Reactors 1584.7.3 Rotor–Stator Devices 1604.7.4 Process Intensification by Solids Moving in Centrifugal Fields 1654.7.5 High Gravity Fields in Microprocessing Systems 167References 1695 SYNERGY – PI Approaches in Functional Domain 1975.1 Combining Functions 1975.2 Synergies at Molecular Scale 1995.2.1 Multifunctional Catalysts 1995.2.2 Synergistic Use of Alternative Energy Forms 2025.3 Synergies in Processing Units – Multifunctional Equipment and Integrated Operations 2055.3.1 Integrating Catalysis and Mixing –The Monolithic Stirrer Concept 2055.3.2 Integrating Mixing and Heat Exchange – Static Mixer Reactors and Heat Exchangers 2055.3.3 Heat Exchangers as Chemical Reactors 2085.3.4 Heat Pumping in Distillation Systems 2095.3.5 Integrating Reactions and Separation – Reactive Separations 2115.3.5.1 Reactive Distillation 2115.3.5.2 Membranes in Chemical Reactors 2135.3.5.3 Reactive Adsorption 2155.3.5.4 Reactive Extraction 2225.3.5.5 Reactive Crystallization 2235.3.5.6 Reactive Absorption 2265.3.6 Reactive Comminution 2275.3.7 Handling Chemical Reactions in Highly Viscous Media – Reactive Extrusion 2345.3.8 Integrating Separation Techniques – Hybrid Separations 2355.3.8.1 Extractive Distillation 2355.3.8.2 Adsorptive Distillation 2375.3.8.3 Membrane Distillation 2385.3.8.4 Membrane Crystallization 2405.3.8.5 Extractive Crystallization 2415.3.8.6 Membrane Absorption/Stripping 2425.3.8.7 Membrane Chromatography (Adsorptive Membranes) 2455.3.8.8 Membrane Extraction 246References 2476 TIME – PI Approaches in Temporal Domain 2576.1 Oscillatory Flow Reactors 2586.2 Reverse Flow Reactors 2626.3 Periodic Operation of Trickle Bed Reactors 2696.4 Cyclic Distillation 2716.5 Pulse Combustion 2756.6 Pressure Swing Adsorption 2846.7 Desorptive Cooling 2866.8 Variable Volume Operation of Stirred Tank Reactors 2886.9 Short Contact Time Reactors 2906.9.1 Catalytic Partial Oxidation of Alkanes 2916.9.2 Catalytic Partial Oxidation of Cellulose 293References 296Part III Fundamentals in Practice – Designing a Sustainable, Intensified Process 2997 Process Intensification and Sustainable Processing 3017.1 Introduction 3017.1.1 Sustainable Earth? 3017.1.2 Sustainable Processing and the Position of PI 3027.1.3 Sustainability Assessment Tools Applied to Process Intensification 3037.2 Ecological Assessment of Intensified Technologies 3127.2.1 Microreactor Engineering 3137.2.2 Other Intensified Processes 3167.3 Process Intensification and Inherent Safety 317References 3228 How to Design a Sustainable Intensified Process? 3318.1 Conceptual Process Intensification Design 3318.2 Case Study of Bhopal 332References 339Index 341