Modular Plants and Process Intensification

Prof. Dr. Volker Hessel is a full professor for the chair of Micro Flow Chemistry and Process Technology at Eindhoven University of Technology. Having obtained his PhD degree in the field of organic chemistry from Mainz University in 1993, he started his professional career at the Institut für Mikrotechnik Mainz GmbH (IMM). He became group leader for microreaction technology in 1996. In 1999 he was appointed Head of the Microreaction Technology Department - now Chemical Process Technology. His fields of research span micro process engineering for mixing, fine chemistry, fuel processing and heterogeneous catalysis. In 2002 he was appointed Vice Director R&D and in 2007 as Director R&D at IMM. In, 2009 he was appointed as honorary professor to the Technical Chemistry Department at Technical University of Darmstadt. In 2012 he was appointed as Guest Professor at the Kunming University of Science and Technology in China. He is authority in the 35-man teamed Enquete Commission Future of the Chemistry of the parliament of Germany's state Nordrhein-Westfalia, giving advice, among others, for six large Chemparks including Bayer, Henkel, Lanxess, Evonik, and many more industries. Prof. Dr. Hessel is author or co-author of more than 270 peer-reviewed publications (with more than 30 extended reviews), 23 book chapters, and 5 books with regards to chemical micro process engineering and flow chemistry. He received the AIChE award "Excellence in Process Development Research" in 2007. He received the ERC Advanced Grant for his research topic "Novel Process Windows" in 2010. Iris Vural Gürsel is currently working on her PhD at Eindhoven University of Technology in the group of Prof. Dr. Volker Hessel on the subject of Process-Design Intensification. She received her BSc degree in Chemical Engineering from Bogazici University in Istanbul in 2008 with high honour. She obtained her MSc degree in Engineering and Technology Management from Industrial Engineering Department ranking first in class in 2010. She worked as a Process Engineer at Technical Services and R&D Department at Turkish Petroleum Refineries Cooperation in years 2008-2011. She is author or co-author of 9 journal papers including original research and review articles.

INTRODUCTION

Motivation

Industrial Process Development -

Transfer from Laboratory- to Production-Scale

50 % Idea

Contents of the Book

Plant Concepts in Chemical Industry



CURRENT PLANT CONCEPTS IN CHEMICAL INDUSTRY

Batch Multi-Product

Modular Plant Concept as a New Paradigm



MODULAR PLANT CONCEPT

Impact on Workflow

Impact on Process Design

Impact on Process Control

Impact on Construction

Impact on Operability

Impact on Control and Safety



MODULARIZATION IN THE CHEMICAL INDUSTRY

Design of Modules

Process Design with Modules



BENEFITS OF MODULAR PLANT CONCEPT IN CHEMICAL INDUSTRY

Flexibility

Lowered Risk

Lead Time Reduction /

Time-to-Market

Cost Reduction



SMART-SCALED PROCESS INTENSIFIED TECHNOLOGIES

Micro Process Technology

Novel Process Windows

High-Gravity High-Shear Equipment (Spinning Disk Reactors)

Alternative Energy Sources (Microwaves, Photochemistry)

Hybrid Separations

Multifunctional Reactors (Reaction Coupling, Integrated Reaction and Separation)



PROCESS SIMPLIFICATION AND PROCESS INTEGRATION

Use of Smart-Scaled Process Intensified Technologies in Modular Plants for Chemical Production

Synergistic Effects

Cost Analysis Case Studies

Step-Change, PI-Related Approaches in Systems Engineering



SMALL-SCALE DECENTRALIZED PROCESSING

Use of Modular Plant Concept for Decentralized Process

Application Fields



INDUSTRIAL IMPLEMENTATION -

APPLICATION CASES AND REAL-LIFE CONTAINERS DEVELOPED IN INDUSTRY

Modular Compact Container -

Modes of Hierarchical Assembly and Component Selection Tools

Process-Control Standardized Container -

From Monitoring, Safety Control Towards GMP

End-to-End Full-Chain Pharma Manufacturing -

From Feedstock to Tablet

Pragmatic `Half-End´ approaches - "Factory of Tomorrow"

Biopharmaceutical Manufacturing in Modular Plant

Heat Integration in Modular GTL Plant

Process Equipment Container -

For Water Soluble Specialty Polymers

Modularized Hydroformylation Process

Continuous Production of Active Pharmaceutical Intermediates in Container Unit

Modular, Continuous Production Unit for Solvent-Free High Viscous Polymer



CONCLUSIONS AND OUTLOOK