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Roadmap Process Intensification
Prof.dr. Hans de Wit
Platform Ketenefficiency
Voorzitter action group PI
Projectleider Roadmap PI
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Process intensification
Process Intensification is a set of often radically innovative
principles ("paradigm shift") in process and equipment
design, which can bring significant (factor 2) benefits in terms
of process and chain efficiency, capital and operating
expenses, quality, wastes, process safety, etc."
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Achievable goal just in energy terms
20 % less energy-consumption
in 2050
just by PI
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The Action Group PI
• Taskforce Energy Transition was initiated by 6 ministries including the Ministries of
Economic Affairs and VROM, to drastically cut energy consumption by 2030
• Platform Chain Efficiency – (PKE) mandated to identify public/private collaborations
which could bring major energy savings in industry
• Process Intensification identified as possible “transition path”
• Action Group PI mandated by the Platform to accelerate the introduction of PI
technology in the following sectors:
• Large volume chemicals (PETCHEM)
• Specialty chemicals and pharmaceuticals (FINEPHARM)
• Ingredients based on Agro feedstock (INFOOD)
• Consumer products (CONFOOD)
Prof.dr.Hans de Wit
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Stakeholders
Action Group PI
Industry Technology providers Representative bodies Government
Process industry ECN MKB Ministry of
(AkzoNobel, DSM, Shell…) Economic Affairs
NIZO VNCI
Equipment suppliers
Regiegroep Chemie
(Stork, Zeton, …) TNO VNPI
Engineering consultants TU Delft (…) Taskforce Energy Transition
(Tebodin, Technip, …)
WUR
SenterNovem
(…)
(…)
Prof.dr.Hans de Wit
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Small/large industry, knowledge infrastructure,
representative bodies and government are all
represented in AGPI or Senior Advisory Board
Members Action Group PI
Dr. ir. A. de Groot ECN
Prof. dr. ir. A. Stankiewicz TU Delft
Ir. W.F. de Vries SenterNovem
Dr. H. Schoenmakers (Associate member) BASF, member of the Steering Board Fachsection
Prozessintensivierung (DECHEMA-VDI ProcessNet)
Prof. dr. J.H.W. de Wit (Chairman) Former CTO Corus, former member Board TNO
Prof.dr.Hans de Wit
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Senior Advisory Board
• Ir. J.G. Dopper Former member Board of Directors DSM, Chairman Platform Chain
efficiency, Member Taskforce Energy transition
• Dr. ir. G.A. van Harten President DOW Benelux
• Drs. L.M.L.H.A. Hermans President MKB
• Prof. dr. ir. J.T.F. Keurentjes Director Research & Technology, AkzoNobel Base
Chemicals
• Ir. G.J. van Luijk Chairman Board of Directors, TU Delft, 3 TU’s
• Prof. dr. E.M. Meijer Senior Vice President Global Unilever Foods R&D
Prof.dr.Hans de Wit
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Networking activities of Action Group PI
• Discussions with DSTI, microreactor technology initiative and DPI for
future coordination/execution of R&D activities
• Intensive contacts with Fachsektion Prozessintensivierung (DECHEMA-
VDI ProcessNet)
• Formal support from the Working Party on Process Intensification of the
European Federation of Chemical Engineering (EFCE)
• Collaborative project proposals in cooperation with European Technology
Platform on Sustainable Chemistry (SUSCHEM) for the 1st call of the FP7
program
Prof.dr.Hans de Wit
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Instruments of the Action Group PI
1. Facts and Figures: Collecting and evaluating data from
experts and vendors on what is happening, from businesses
on what is needed
2. Quick Scan: Helping industry identify PI possibilities in their
own process, with a focus on SME’s
3. PI Roadmap: Identifying potential and barriers for PI
technologies, ranking and designing development routes,
generating action plans and clustering long-term
developments
Prof.dr.Hans de Wit
1. FACTS AND FIGURES Plaats hier uw
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The technology input for the roadmap
• 73 technologies identified
• 47 technologies described
in "technology reports"
• Literature search about
complete
• Patent search about
complete
• Chinese texts being
translated
• Info equipment
manufacturers is being
worked on:meeting
planned first quarter 2008
Prof.dr.Hans de Wit
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CONTENT OF TECHNOLOGY REPORT
1. Technology
1.1 Description of technology / working principle 4. Where can information be found?
1.2 Types and “versions” 4.1 Key publications
1.3 Potency for Process Intensification: possible 4.2 Relevant patents and patent holders
benefits 4.3 Institutes/companies working on the technology
1.4 Stage of development 5. Stakeholders
2. Applications 5.1 Suppliers/developers
2.1 Existing technology (currently used) 5.2 End-users
2.2 Known commercial applications 6. Expert’s brief final judgment on the technology
2.3 Known demonstration projects
2.4 Potential applications discussed in literature
3. What are the development and application issues?
3.1 Technology development issues
3.2 Challenges in developing processes based on
the technology
Prof.dr.Hans de Wit
2. QUICK SCANS Plaats hier uw
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Quick Scans help industry identify PI possibilities in their
own process
• End of September 10 new Quick Scan “available”
• Some are “available” from the past
• Approximately 25 will be carried out by February 2008
• Overview of QS by DSM in the past is being used
• Confidentiality issues are to be solved
• QS Summary format is available: may solve IP issues
• Responsible partnering is a must: www.responsible-partnering.org/index.php
• QS results will be used to update PI Roadmap in 2008
Prof.dr.Hans de Wit
3. PI ROADMAP
We are developing the PI Roadmap with input from the review
panel, the industry sectors representants and the sector
teams
Process to create PI Roadmap
REVIEW PANEL SECTOR TEAMS
• Review A - Benefits: energy B - Ripeness C - Potential of better • Select most
useful PI saving, CO2 of products promising PI
technologies emission, technology technologies
based on: competitiveness • Define required
actions and time
planning (incl.
"low hanging
fruits") to
INDUSTRY SECTOR REPRESENTANTS overcome barriers
for the selected PI
• List and rank • Develop vision on • Define "barriers to
technologies
industry needs: future overcome" for
• Agree on
energy savings, products and implementation of PI
consolidated
emission processes technologies
actions and time
decreases, etc. • Match industry needs • Prioritize useful PI
planning among
with available PI technologies based on the
sectors
technologies needs and barriers
Source: AGPI, Roland Berger
3. PI ROADMAP
Process technology specialists from both industry and
academia are contributing to the development of the PI
roadmap
Contributors to the PI Roadmap
Review Panel
Jacob Moulijn - ex TU Delft Fons Meijs - ex DSM Ben Stouthamer - ex
Shell
Sector Team PETCHEM Sector Team INFOOD
Hans Feenstra - Marco Giuseppin - Avebe
AkzoNobel
Jan Maarten de Bruin - COSUN
Peter Arnoldy - Shell
Gabrie Meesters - DSM
Michiel Schenk - Dow
Johan Sanders - WUR
Frits Hesselink - Lyondell
Jacob Moulijn - TU Delft
Peter Alderliesten - ECN
Hans Veenenbos - VNCI
Sector Team FINEPHARM Sector Team CONFOOD
Raf Reintjes - DSM Ardjan Krijgsman - Unilever
Frans Kaspersen - Organon Ruud Verdurmen - Numico
Gerard Lagerweij - Solvay Tom van Hengstum / Albert van der Padt -
FrieslandFoods
Ary van Berckel - TNO
Caroline van der Horst / Peter de Jong - NIZO
Joop Schouten / John van der Schaaf - Tue
3. PI ROADMAP
The Review Panel has reviewed the PI technology reports,
and has
summarized the main benefits and barriers EXAMPLE
Review Panel – example: Hydrodynamic cavitation reactors
Review Description
Potential for energy saving - medium "Similarly to ultrasound and microwave, the energy
of liquid flow can be used to purposefully create
Potential for CO2 emission reduction - low cavitation for intense reaction and other operations.
Cavitations are created either by passing liquid
Potential improvement through a throttling valve (or similar) or by liquid
cost competitiveness - medium whistle (in which liquid energy is used to create a
steel blade vibration). In both cases micro
Ripeness: application in X years - 10-15 cavitations are created in which, after implosion,
Ripeness of related technology fields - medium extreme high temperatures and pressures occur.
These conditions are applied for reaction (limited
Likeliness of overcoming barriers - medium demonstration) or homogenization/emulsification
and cell disruption (fair commercial demonstrations
Potential for innovative products - medium available). Main benefit is increased yield and
selectivity (substantial) with limited positive effect on
Character required R&D - energy savings and safety (mild operation
fundamental conditions). Laboratory scale studies have given
proof of concept, but major efforts are still required
to develop rules for intensification and optimization,
as well as modelling, scale up and design. A
concerted effort by Academia and equipment
manufacturers is needed to develop robust systems
in the next 15 years."
3. PI ROADMAP
Review Panel – inventory matrix of benefits and barriers
ILLUSTRATIVE
Material cost
Erosion
Fouling
Scaling
Energy
Quality
Cost
CO2
…
…
Barriers Benefits
Photochemical reactorsX
X Microreactors
Reactive distillation
…
PI technologies
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For each sector the most important needs have been
determined, these vary considerably between the sectors
PRELIMINARY
Importance
to sector PETCHEM FINEPHARM INFOOD CONFOOD
• Energy savings • Selectivity • Cost competitiveness • Cost competitiveness
• Cost competitiveness • Sustainability • Product differentiation • Yield
• Safety¹ • Cost competitiveness (within quality • Line availability
•High • Regulation • Lead time tolerances) • Product quality
• Food safety
• Product functionality
• Social impact • Safety • Selectivity on end- • Energy saving
• Reliability • Reliability product • Plant safety
• Reliability on tolerances • Flexibility
•Medium •Energy saving
• Energy savings • Selectivity on waste
streams
•Low Prof.dr.Hans de Wit
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Barriers for the implementation of PI
Technical / equipment •Economic •Culture / organization
• •
– Reliability (non proven – Insufficient pay-back on – Lack of PI knowledge
technology) new process technology – Lack of chain vision
– Retrofitting PI technologies – Long development path – IP issues for co-operation during
in current plants difficult
– Suppliers for industrial R&D/development
– Multipurpose reactor is applications are lacking – Insufficient valorization of
needed
(unit cost, manufacturing sustainability
– 80% of equipment on technology) – most – Paradigm shift, cultural change
market is not (yet?) suitable novel equipment is only necessary
for industrial production but suitable for product
only useful for product – Long learning curve
development
development – Commitment to development
programs insufficient
Prof.dr.Hans de Wit
Source: Sector working sessions, October / November 2007
3. PI ROADMAP – EXAMPLE 1: DISTILLATION PROCESS FOR PETCHEM SECTOR
For distillation processes in the PETCHEM sector, 4
technologies were identified that can increase energy
efficiency WORK IN PROGRESS
Drivers Need to improve cost competitiveness through energy efficiency
Targets 10-20% overall energy efficiency increase
5% energy efficiency 10-20 % energy
Process increase efficiency increase
objectives
Replace last
2.1.4. distillation step (for
2.2.8.1.
PI Heat- 95 to 99% purity)
Reactive Splitted wall
integrated by a filtration step
techno- distillation column¹
distillation 5%
logies 5% 5% 2.2.3. Reactive
5%
• Payback on adsorption
investment 2.2.3.
X%?
• Short life of • Maximum plant Pervaporation
Barriers • Tar
catalysator downtime for 5%
deposits • Barriers?
• Retrofit difficult retrofit of 35
• Limited • Retrofit difficult
days applicabilit
• Convince y
management
2007 2017 2037-47
Time
1) Already applied by BASF
Source: PETCHEM working session, 6 November 2007
3. PI ROADMAP – EXAMPLE 3: WATER SEPARATION FOR INFOOD SECTOR
For water separation processes in the INFOOD sector,
4 technologies were identified that can increase energy
efficiency WORK IN PROGRESS
Drivers Need to improve cost competitiveness through energy efficiency and water use
Targets higher energy efficiency, reduced water use
Increase energy efficiency in
water removal process
Process Increase energy Increase energy Increase energy
objective efficiency by 10- efficiency by 50% efficiency by 80-
20% 90%
Product
Membrane Use of Water extraction
PI technologies filtration zeolites1) displacement1
) with
ligands1)
• Fouling • High investments • High investments • Separation of
• Flux • Process • Limited know-how ligands from end
Barriers • Viscosity complexity (two- availability in NL product
(dust) step process)2) • Upscaling • Specificity of
• Robustness • Unknown • Solvent food ligands
technology grade • Upscaling
2007 2017 2037-47
Time
Source: INFOOD working session, 26 October 2007
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Actions for implementation
•The PI Roadmap will evolve further in the course of 2008:
• The roadmap will be further developed for the longer term (30-40 years)
• The potential of chain efficiencies will be further investigated
• The results of the Quick Scans will be incorporated in the PI Roadmap
Up till 1-1-2008 AGPI is pulling the PI carriage
From 1-1-2008 to 1-6-2008 AGPI will not pull but push!
The stakeholders will start off the necessary actions primarily.
AGPI will watch developments critically and make sure that no unwanted overlap will arise in the
programs in Nl, by using open communication lines with all concerned.
AGPI will communicate intensely with all stakeholders
A broad program needs to be developed for the acceleration
of the implementation of Process Intensification
Concept of a broad program for Process Intensification
PI PROGRAM
100
Explorative Long term Mid / short Piloting Consulting %
/ strategic term &
Industrial
fundamenta research applied knowledge
contributio
l research research dissemina-
n
tion
75% 85-100%
33-50%
25%
0-10% 0%
Public-Private Public-Private
Co-operation Enterprise
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Examples of consortia
• European programs and consortia: AGPI facilitates
• National PP coöperation, TTI like ?, precompetitive: AGPI facilitates
• Bu to Bu cooperation: special industrial programs for direct low
hanging fruit technology solutions and for common development
of R&D/Technology programs : no direct involvement AGPI
• Single Bu technology solutions: low hanging fruit: no direct
involvement AGPI
• Bu to Knowledge org.: single issue R&D contracts: AGPI may
facilitate initial phase
Prof.dr.Hans de Wit
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Sustainable energy is hot topic
for industry and R&D community
•KNAW report: ‘Duurzaamheid duurt het langst’
•ADEM : ECN en 3 TU’s
•NWO/FOM proposal
•EOS LT, SENTER/NOVEM, EAC committee etc
•Commissie duurzame energie (minister Plasterk en minister van der Hoeven)
•PI initiative PKE , supported ao by VNCI
•etc
Prof.dr.Hans de Wit
3. PI ROADMAP - PLANNING
The draft PI Roadmap will be presented during a concluding
meeting on December 19, 2007
Planning PI Roadmap development process
Oct Nov Dec
Activity 40 41 42 43 44 45 46 47 48 49 50 51 Responsible
Technology reports AGPI
Technical review Review Panel
Industry needs, PI technology prioritization,
technological barriers
PETCHEM: General 1st working session 2nd working session Industry representation
Cracker working session Cracker specialists
Ammonia working session Ammonia specialists
FINEPHARM working session Industry representation
INFOOD working session Industry representation
CONFOOD working session Industry representation
Finalization / aggregation PI Roadmap Sector Teams, Academics
Concluding meeting 19 december
Today
Source: AGPI, Roland Berger
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Conclusions
• PI roadmap will be ready before end 2007
• A roadmap is remains dynamic
• Implementation and first update process starts in
January 2008
• Implementation will probably be of diverse nature
and be Europe wide.
• Communication on implementation will be vital for
efficient use of resources
