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IbD PU Deliverable 3.1 1.3 The benefits of process intensification The principal advantages of PI relate to safety, environment, energy, and business, as highlighted in Figure 3 below. Business • Miniaturised plant • Reduced capital cost • Reduced operating costs • Distributed manufacturing • Faster introduction of new product to market Responsive processing Benefits of PI Process • Higher selectivity/product purity • Higher reaction rates • Improved product properties • Improved process safety • Wider processing conditions Faster, safer, greener processing • • • • Environment Reduced energy usage Reduced waste Reduced solvent use Smaller plants less obtrusive on landscape Sustainable processing Figure 3. Business, process and environmental benefits of PI (Boodhoo and Harvey, Ch. 1 in Process Intensification for Green Chemistry: Engineering Solutions for Sustainable Chemical Processing, 1st Edition. (K. Boodhoo & A. Harvey Eds.). John Wiley & Sons, Ltd. (2013)). Safety The reduction of plant size results in a smaller volume of toxic and flammable inventories within processes. An intrinsically safer plant can be attained with these approaches during the design process: minimization, substitution, moderation, and simplification. PI minimizes the volume of hazardous chemicals and employs moderate conditions, thereby reducing the possibility of explosion. In addition, the lower number of unit operations can simplify the process. PI is also capable of mitigating the risk of thermal runaways in highly exothermic chemical reactions by carrying out the process in reactors offering greatly enhanced surface areas to volume ratios for rapid removal of the liberated heat e.g. in microreactors and spinning disk reactors (Boodhoo and Jachuck, 2000; Boodhoo and Harvey, 2013; Reay et al., 2013; Westermann and Mleczko, 2016). 3PDF Image | Solids handling for intensified process technology
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