Process intensification through the combined use of process simulation and miniplant technology

Various approaches to process intensification can be taken at various levels. At the lowest level, it may be possible to optimise basic physical, thermodynamic and chemical processes, for example, by changing geometries and surface structures, or using catalysts, etc. At the next level, possibilities include the use of cleverly designed plant items such as spiral heat exchangers or centrifugal reactors. Finally, at the highest or process level, improvements may involve carrying out several unit operations simultaneously in a single piece of equipment or making specific process modifications. This paper uses three examples (extractive distillation, reactive distillation column, steam injection) to demonstrate the breadth of possibilities for intensifying chemical processes. The processes were all developed with the help of process simulation and verified experimentally in laboratory-based miniplants. The information gained was essential to the successful design and operation of production-scale plant.