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DOE OSTI2019

Systematic process intensification

Process intensification often requires innovative equipment and flowsheets to achieve significant improvement compared to traditional unit operations. Systematic methods are needed for automatic generation, screening, and discovery of promising intensification pathways at the conceptual design stage. In this contribution, we present a synopsis of the key elements of systematic process intensification (SPI), which include specification, representation, assessment, screening, and analysis. Here, we conclude with a brief overview of future challenges and research opportunities in each of these areas.

36 MATERIALS SCIENCE↗

DOE OSTI2019

The RAPID Manufacturing Institute – Reenergizing US efforts in process intensification and modular chemical processing

There has been a recent resurgence in both academic and industrial interest in process intensification as an approach to meet ever increasing challenges in the process industries. Process intensification provides the potential to reduce waste, improve energy efficiency, and potentially access new feedstocks – all areas that improve competiveness in industries such as chemical production, pulp & paper processing, fuels refining, and gas processing. In early 2017, the RAPID Manufacturing Institute was established as a partnership between the US Department of Energy and the American Institute of Chemical Engineers to drive the development and adoption of process intensification and the associated field of modular processing through energy intensive industries. Here, macroscopic drives that led to the establishment of RAPID are discussed as well as an overview of the technical structure of the institute. This is followed by a discussion of several representative technologies currently under development. Finally, the article concludes with a short discussion of future directions for modular and intensified processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Process intensification of solar thermal power using hybridization, flexible heat integration, and real-time optimization

Not provided.

Energy & Fuels↗

DOE OSTI2018

Dynamic Process Intensification of Binary Distillation via Periodic Operation

This paper applies the concept of dynamic intensification (defined as changes to the dynamics, operation strategy, and/or control of a process that lead to a substantially more efficient processing path) to binary distillation columns. The resulting strategy consists of manufacturing a target product as a blend of two auxiliary products, both having lower energy demands than a reference value, which corresponds to producing the target product(s) in a column operating at steady state. Here, a discussion of the appropriate control structures and switching strategies between the two auxiliary products is provided. An extensive case study concerning the separation of a methanol–1-propanol mixture was carried out, demonstrating that energy savings in the order of 1.4% are possible with no disruption in product quality or production rate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗

DOE OSTI2018

An overview of process systems engineering approaches for process intensification: State of the art

Process intensification offers the potential to drastically reduce the energy consumption and cost of producing chemicals from both bulk and distributed feedstocks. This review article aims to offer an extensive survey on state-of-the-art process systems engineering (PSE) approaches for process intensification. From both academic and industrial perspectives, this paper provides an overview of the development of various process intensification technologies, specifically those under the categories of separation, reaction, hybrid reaction/separation, and alternative energy sources. A current status analysis in the areas of modeling and simulation is then provided. An indicative list of PSE publications specialized on process intensification is presented to illustrate the progresses made so far towards the deployment of novel process intensification technologies. We also highlight some recent advances for the modeling, design, and synthesis of intensified systems, as well as for the assessment of their controllability/operability/safety performance. As a result, key open questions in these areas include: (i) how to systematically derive intensified designs, and (ii) how to ensure the operability and optimality of the derived intensified structures while delivering their expected functionality.

42 ENGINEERING↗

DOE OSTI2022

Computer-aided process intensification of natural gas to methanol process

The recent revolution in shale gas has presented opportunities for distributed manufacturing of key commodity chemicals, such as methanol, from methane. However, the conventional methane-to-methanol process is energy intensive which negatively affects the profitability and sustainability. Here an intensified process configuration that is both economically attractive and environmentally sustainable. This flowsheet is systematically discovered using the building block-based representation and optimization methodology. The new process configuration utilizes membrane-assisted reactive separations and can have as much as 190% higher total annual profit compared to a conventional configuration. Additionally, it has 57% less CO 2 -equivalent greenhouse gas emission. Such drastic improvement highlights the advantages of building block-based computer-aided process intensification method.

42 ENGINEERING↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

A parametric approach to identify synergistic domains of process intensification for reactive separation

Process intensification aims to combine multiple tasks within multi-functional units to drastically improve economic, energy or sustainability metrics of a chemical process. Limited work exists to systematically identify the synergistic domains where intensification outperforms its nonintensified counterpart. In this work, we computationally derive the synergistic domains of a reactive separation system. Specifically, we first postulate general models for both intensified and nonintensified systems. We use these models to generate data to train a ReLU-type artifical neural network (ANN). Further, the trained ReLU-NN model is formulated as a multi-parametric mixed-integer linear program (mp-MILP), and the critical regions of this mp-MILP define the synergistic feasible domains of intensification. We have derived these synergistic domains of vapor–liquid equilibrium (VLE)-based reactive separation for several industrial applications. These synergistic domains enable quick screening of properties that favor intensification.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Synthesis of operable process intensification systems: advances and challenges

Process intensification (PI) has been gaining increasing momentum in the chemical engineering research community and the chemical/energy industry. While many PI alternative technologies and their conventional counterparts exist, systematic approaches and tools to decide on the most promising intensified process solutions are currently rather lacking. Process Systems Engineering (PSE) can contribute uniquely to this challenge by leveraging process synthesis, design, analysis, and optimization tools. However, key open questions in this area still remain, including: (i) how to efficiently address the combinatorial design space and systematically deliver intensified designs, and (ii) how to ensure the operablility performances of the derived intensified structures at an early design stage. Here, this paper provides a brief review of recent progress towards the synthesis of operable process intensification systems, highlights major challenges, and discusses future research opportunities.

42 ENGINEERING↗

DOE OSTI2024

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗

DOE OSTI2021

Dynamic Process Intensification via Data-Driven Dynamic Optimization: Concept and Application to Ternary Distillation

Process intensification is a design philosophy aimed at making chemical processes safer and more efficient. Its implementation often results in significant modifications to the design and structure of the process, with several conventional unit operations occurring in the same physical device. Traditionally, process intensification has focused on steady-state operation. In our previous works, we introduced dynamic process intensification (DPI) as a new intensification paradigm based on operational changes for conventional or intensified units. DPI is predicated on switching operation between two auxiliary steady states selected via a steady-state optimization calculation that ensures that the system generates, on average and over time, the same products as in nominal steady-state operation, but with favorable economics. This paper extends the DPI concept and introduces a novel dynamic optimization-based DPI strategy (Do-DPI) that involves imposing a true cyclic operation rather than switching between two discrete states. We discuss its implementation using surrogate dynamic models learned via system identification. Here, an extensive case study concerning a ternary distillation column separating a canonical hydrocarbon mixture shows that Do-DPI can reduce energy use by more than 4% relative to steady-state operation, with no significant deviations in product quality and production rate.

42 ENGINEERING↗

DOE OSTI2024

Effects of process intensification on homogeneity of an IgG1:κ monoclonal antibody during perfusion culture

The pharmaceutical industry employs various strategies to improve cell productivity. These strategies include process intensification, culture media improvement, clonal selection, media supplementation and genetic engineering of cells. However, improved cell productivity has inherent risk of impacting product quality attributes (PQA). PQAs may affect the products’ efficacy via stability, bioavailability, or in vivo bioactivity. Variations in manufacturing process may introduce heterogeneity in the products by altering the type and extent of N-glycosylation, which is a PQA of therapeutic proteins. We investigated the effect of different cell densities representing increasing process intensification in a perfusion cell culture on the production of an IgG1-κ monoclonal antibody from a CHO-K1 cell line. This antibody is glycosylated both on light chain and heavy chain. Our results showed that the contents of glycosylation of IgG1-κ mAb increased in G0F and fucosylated type glycans as a group, whereas sialylated type glycans decreased, for the mAb whole protein. Overall, significant differences were observed in amounts of G0F, G1F, G0, G2FS1, and G2FS2 type glycans across all process intensification levels. G2FS2 and G2 type N-glycans were predominantly quantifiable from light chain rather than heavy chain. It may be concluded that there is a potential impact to product quality attributes of therapeutic proteins during process intensification via perfusion cell culture that needs to be assessed. Since during perfusion cell culture the product is collected throughout the duration of the process, lot allocation needs careful attention to process parameters, as PQAs are affected by the critical process parameters (CPPs).

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Process Intensification and Scale-Up of a Continuous Enzymatic Hydrolysis and Separation Process

Combining separate unit operations into one where the best of each part can be maximized is one of the benefits of process intensification. An example is the combination of lignocellulosic biomass enzymatic hydrolysis with the downstream solid-liquid separation step to produce clarified sugars ready for fermentation or catalytic upgrading. The productivity and endpoint yield of enzymatic hydrolysis both enjoy the benefits of reduced feedback inhibition through the continuous removal of sugars by incorporating separations into the reactor. Likewise, the efficiency of recovering clarified sugars from the enzymatic hydrolysis slurry can be enhanced by operating separations equipment at steady-state conditions simultaneously with the continuously fed hydrolysis process. A key parameter that enables greater processing capacity while also raising the risks of failure is the solids loading or concentration. Higher solids loading allows for smaller reactor vessels and results in clarified sugars of higher concentration; however, required pumping power increases, reactor agitation may become ineffective, and membrane flux suffers. Feedstock material attributes influenced by upstream pretreatment must also be scrutinized more carefully: dilute-acid pretreated and deacetylated-and-disc-refined feedstocks exhibit different characteristics that affect agitation and pumping. The authors invite you to further explore the process science enabling the scale-up of this technology from conceptual work at the bench to pilot-scale industrially-relevant equipment where the challenges and solutions of integration and process optimization are expounded upon.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2018

Dynamic process intensification of binary distillation based on output multiplicity

Process intensification focuses largely on process and equipment design . Much less emphasis has been placed on operational changes to achieve cost savings and increased efficiency. Here, this article introduces the concept of dynamic intensification, defined as changes to the dynamics, operating strategy and/or control of a process that lead to a substantially more efficient processing path. This idea is illustrated in the context of binary distillation. Output multiplicity properties are exploited to establish a new periodic operating mode based on switching between two auxiliary products, which, on a time–average basis, is more energy efficient than steady–state operation. An extensive case study is presented concerning the distillation of a propanol–acetic acid mixture, confirming the theoretical developments. In contrast to previous research (e.g., on cyclic distillation), the present concept has significant advantages as it relies on existing hardware and exploiting system nonlinearity, rather than using specialized equipment operated in a discontinuous fashion.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Recent advances in the chemical process industry have allowed for the intensification of reactors and unit operations, by enhancing heat and mass transfer or combining multiple unit operations. Process intensification can enable chemical plants to be constructed in a more compact, modular fashion, offering improvements over conventional on-site approaches to capital construction, operations and maintenance. This modular chemical process intensification (MCPI) offers several benefits over conventional stick-built (CSB) plant construction in terms of reduced footprint, reduced energy consumption, lower cost, less waste and improved safety and quality control. However, acceptance of MCPI over CSB construction practices within the chemical industry can be impeded by the uncertain risks associated with investing in new technology. Furthermore, the work here documents a case study during the development of a modular chemical plant for capturing distributed energy resources within chemical production. This MCPI approach to plant construction is contrasted with a CSB approach for producing the same chemical product. Data collection tools were developed, based on a literature review, and data was collected from the technology developer to understand the process technology. Sensitivity analysis was then conducted to analyze the business rationale for the application of MCPI over CSB across several market scenarios. It was found that MCPI would be better suited for capacities up to 150 000 metric tons per year, but that improvement in payback period was needed. Additionally, for MCPI approach to achieve acceptable payback periods, efforts are needed to reduce the cost of capital equipment and compress the schedule for ramping up modular production.

42 ENGINEERING↗

DOE OSTI2021

Specialty chemicals production case study: Economic analysis of modular chemical process intensification versus conventional stick‐built approaches

Abstract The beneficial synergies of chemical process intensification and plant modularization present a unique step‐wise advancement opportunity for many chemical manufacturers, but economic case studies are needed to raise awareness of such opportunities. The primary objective of this case study is to better understand the business case economics of a specialty chemical plant using modular chemical process intensification (MCPI), by comparing it with that of a conventional stick‐built (CSB) plant that produces the same product at the same production capacity. When comparing MCPI against CSB approaches for a plant project strategy decision, analysts should thoroughly understand and model the differences and similarities in scope bases. The MCPI approach for this case study benefitted from dramatic reductions in capital expenditures (CAPEX). A sizeable reduction in plant spatial volume likely explains some of these reductions. Sizeable operational expenditure (OPEX) reductions with the MCPI plant appear to be associated with the reduced operator staffing required from converting a labor‐intensive batch process into an automated, continuous flow process. Traditional project investment economic measures strongly favored the MCPI case for the design, construction, and operation of the specialty chemical plant. The net present value for the MCPI case was nearly twice that for the CSB case over a ten‐year period, and the payback period for the CSB case was nearly five times longer than that of the MCPI case. The opinion‐based perspective of the study participant identified significant contributors to superior MCPI economic performance for this case study. With the two conditions of low MCPI CAPEX and high product profit margin, economic analysis indicates that incorporation of a backup MCPI train, for operational redundancy when downtime occurs, is a very beneficial strategy.

O'Connor, James T.↗

DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer: Radio frequency (RF) assisted drying of paper and board

Conventional multi-cylinder drying of paper and board typically relies on both conductive drying from steam-heated cylinders and convective drying, where heated air flows over the paper web surface. Conduction primarily contributes to heat transfer, while convection is the main driver of mass transfer. However, conventional drying systems are heavily dependent on steam, usually powered by fossil fuels, and are often energy-inefficient with high levels of waste. Additionally, these surface-driven processes result in a lower percentage of energy absorption compared to the energy supplied, leading to significant energy losses. To improve this long-standing process, an experimental system was developed to investigate a process intensification approach involving the integration of Radio Frequency (RF) heating, a volumetric electromagnetic technology, alongside traditional conduction and convection drying methods. This study also emphasizes the use of sensors to continuously monitor key parameters such as moisture content, supply system temperatures, sample temperatures, air flows, and drying rates in real-time. The effect of RF as an auxiliary energy source in localized environments at varying moisture levels was explored to optimize industrial drying systems, quantify potential improvements, and provide insights for future studies. Experimental results from trials combining RF with convection and with the base case alternating conduction-convection drying processes are presented. It is shown that RF is a viable process intensification approach for paper drying improving the drying rate and energy intensity at higher moisture contents. These findings offer valuable insights for process intensification and contribute to the process development, modeling, and simulation of advanced paper drying techniques.

42 ENGINEERING↗