CoRIAC Demonstration of Continuous Reactors with In-line Analytics for Fine Chemicals Production L. Geers, TNO
Process Intensification (PI) PI: Radically innovative principles in process and equipment design 2010 2020 Efficiency Efficiency Planet F Profit SMALLER PLANTS LOWER COSTS LESS ENERGY, RAW MATERIALS LESS EMISSION COMPANY WASTE SHORTER TIME TO THE MARKET SAFER PROCESSES People bringing significant benefits in terms of process and chain efficiency, capital and operating expenses, quality, wastes, process safety. source: European Roadmap for Process Intensification, Creative Energy, 2007
The goal of PI for the process industry source: European Roadmap for Process Intensification, Creative Energy, 2007 Source; European Roadmap for process intensification
Innovation risks: valley of death R&D investment Chance of failure Lab/bench-scale (1-3) Bench/Pilot scale (4-5) Demo (6-7) Commercial (8-9) Technological Maturity (TRL)
Challenges for implementation of PI process robustness: (in)sensitivity to process disturbances monitoring / control: robust control based on in-line analysis tools flexibility: multipurpose equipment for multiphase processes integration: combining unit operations and integrating analytical tools in unit operations (interfacing) scale-up: limits for scaling-up / numbering up Introduction of Process Intensification requires demonstration for relevant industrial processes under industrial conditions
Specific challenges for instrumentation main question: what kind of instrumentation is necessary for optimal monitoring & control of processes? equipment robustness: chemical & mechanical resistivity of instruments, low maintenance (especially for novel process windows) adequate interfacing: how to incorporate instrumentation in a process while preventing measurement interference (e.g. clogging, phase changes) novel process equipment: what are the characteristics of novel reactors, separators, etc., where to place what sensors
The CoRIAC project Goal: Demonstration of existing PI equipment for highly exothermal and solid-liquid processes in relevant industrial conditions Benchmarking of continuous reactors for specific processes determined by the end-users in the project Adapting existing analytical tools for continuous analysis Preparation of results for model-based process control Demonstration in pilot installation on end-user s site Total Budget: 6 Million Euro Duration: 4 years
CoRIAC: integral approach Industrial case providers Proces control Equipment & PAT providers Product Feedstock Pilot plant Analytical tools Waste Process modeling & control System integration Project coordination Programme organization Sponsor
CoRIAC project partners & lines Integration & on-site testing Develop + benchmark DSM Janssen P&G 1 2 3 1 2 1 2 Reactors ESK Chemtrix TNO Analysis Bronkhorst Mettler-Toledo TNO Pilot Zeton / K&H Modeling TU Eindhoven Support for design & development of pilot
Current project status 5 industrial processes identified by chemical partners (processes containing solids or fast highly exothermal processes) All processes were tested on lab scale (few ml) for characterization & determination of process parameters Bench scale experiments (1-10 L/hr) in continuous flow rig done for 2 processes in 2 types of reactors (benchmarking) Bench scale design done for next 2 processes Planning & gathering information for pilot plant design
New programme: Framework: Top Sector Chemicals Expansion of CoRIAC project Broader approach: also separation technology New chemical and also biochemical cases New equipment, analytics, sensors Also covering process control technology Programme is defined, now searching for new partners (Bio)chemical industry Process equipment producers (e.g. reactors, separators, piping, pumps) Measurement equipment producers (e.g. spectrometers, flow/chemical sensors) Process control technology providers
Benefits for partners Insight in the entire value chain. Learning from the do s and don ts of partners. Aligning with internal agenda/roadmap gives extra boost/leverage. Involvement in developments gives direction to internal R&D. Show the benefits of technologies to potential customers. Get better insight in the capabilities of multiple technologies. Shared risks/costs means lower initial R&D investments.
Any questions? Please contact: Martijn de Graaff Business development / Primary contact Phone: +31 (0)88 866 6437 Mobile: +31 (0)6 222 608 71 E-mail: martijn.degraaff@tno.nl Murk van Rooijen Project management Murk.vanrooijen@tno.nl TNO Industrial Innovation Leeghwaterstraat 46 2628 CA Delft Leon Geers Research Scientist Process Intensification Leon.geers@tno.nl