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The overall costs of production can be optimised. Figure 2, showing the “3P rule” also referred to as the triple bottom line[3] visualises the concept. From Figure 2 it can be seen that taking care of our planet, its people and generating a profit are not necessarily contrary targets. A somewhat different appreciation of PI, whereby a classical large chemical plant is transferred to a very small apparatus, is shown in Figure 3. Figure 3. A Vision of the Process Intensification[4] The Ideal Reactor The classical stirred tank reactor (STR) which still dominates the widespread picture of chemical production plants occupies the most unfavourable position on a graph of Mass transfer as a function of heat transfer as shown in Figure 4. The preeminent position of the SDR in Figure 4 is endorsed by numerous data in the literature. While the SDR with the very thin film reaction volume has been shown[5] to have heat transfer coefficients up to 30 000 W m-2 K-1. “Hex-reactors” exhibit values of 3500-7500 W m-2 K-1 and batch STR has typical coefficients of about 750 W m-2 K-1.[2,6,7] The volumetric mass transfer coefficients kLa (kL= mass transfer coefficient, a = area of transfer), determined from extraction experiments in the different equipments, also demonstrate that the SDR is outstanding. Thus, for the SDR a value for kLa = 0,4 s-1 has been determined [8] while for packed columns the value is 0,011 s-1[9,10] , that for the batch reactor is 0,0017 s-1[11] and for spray towers 0,007 s-1[10]. To summarize, all those values which have been reported lie orders of magnitude below those for the SDR. It is worth emphasising that since kL is proportional to D/Δx the speed of rotation of the disk is a key parameter for controlling kLa. 3PDF Image | Spinning Disk Reactor for Polymers and Nanoparticles
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