1 Date, 11/17/2025

Process Integration and Intensification

CHEG6211

Aman Kassaye (PhD)

College of Engineering
Department of Chemical Engineering
2 Contents of this lecture

 Fundamentals of Process Intensification

 Benefits with respect to the issue of concern
3  The earth's very negative mass balance of fossil resources, world
population is expected to reach 9,000,000,000 by 2040. we will
essentially use up all the world’s oil resources 2050, gas 2070 and
coal 2500. The question is how to solve the resources problem?
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You can use different options
Option- Develop Innovative Methods and Technologies that would
drastically increase the efficiency of chemical process…
PI began in the industrial
laboratories of Imperial
Chemical Industries (ICI) in
the 1970s and 1980s. The
intial focus was on
developing novel equipment
and methods to improve
process efficiency and
reduce the size of chemical
plants.
The goal remains to
create more efficient,
sustainable, and safer
chemical processes.
Reference:
 Stankiewicz, Andrzej. "The principles and domains of process intensification." Chemical Engineering Progress 116.3 (2020): 23-28.
 Stankiewicz, Andrzej I., and Jacob A. Moulijn. "Process intensification: transforming chemical engineering." Chemical engineering progress 96.1 (2000): 22-34.
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Definition

 Process Intensification is a fascinating subject of chemical engineering that addresses

issues such as material efficiency, energy conservation, environmental effect, and
operational safety.

 Process Intensification (PI) is a design philosophy aimed at making chemical and process
engineering more efficient, sustainable, and cost-effective.

 It includes new methods and equipment design that result in significant savings in terms
of efficiency, capital, and operational expenses.

PI-Using much less to produce much more

LESS-Investment, Space, Time, Raw materials, Energy,…etc.

MORE-tens to thousands percent,,,

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 The Four Principles of process intensification
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 1st Maximize the effectiveness of Intra- and Intermolecular events.
It involves optimizing the interactions at the molecular level to improve reaction
rates, selectivity, and overall process efficiency.
• Kinetic Optimization: Adjusting conditions to favor desired reaction pathways
and minimize side reactions.
• Enhanced Mixing: Ensuring uniform distribution of reactants to avoid
concentration gradients and improve reaction rates.
Example: Microreactors-These devices have small channels that provide high
surface area-to-volume ratios, enhancing heat and mass transfer.

Van Gerven, Tom, and Andrzej Stankiewicz. "Structure, energy, synergy, time The fundamentals of process intensification." Industrial & engineering chemistry research
48.5 (2009): 2465-2474.
8  2ndUniform treatment for every single molecule in the process.
Process where every single molecules goes under the same conditions is
delivers ideally uniform product with minimum waste. Using microwaves
volumetric heating will give much closer to the ideal than a stirred-tank reactor
with Jacket heating.
Example: Intensive Mixing-Techniques such as high-shear mixing or the use of
static mixers can ensure that reactants are evenly distributed, preventing
concentration gradients and ensuring uniform treatment of all molecules
 3rd Optimize the driving forces at every scale and maximize the specific area to which
9
these forces apply.

 The principle relates to the transport rate across the interface. Enhance specific surface
areas through structuring of the process equipment, this will achive by maximization of
the interfacial area or surface to volume ratios. by making the channal diameter from
the milimeter to micrometer channal diameter. Example:- Specific surface area can
increased by reducing the characteristics dimension of the channels.

 Optimizing Driving Forces: Ensuring that the driving forces (e.g., Concentration,
Temperature, Pressure) are maximized at every scale can improve the rates of mass,
heat, and momentum transfer.

 Maximizing Interfacial Area: Increasing the surface area where reactions or transfers
occur can significantly enhance the efficiency of processes.
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 4th Maximize the synergetic effects from the partial process.

By integrating and optimizing these interactions, the combined effect can be

greater than the sum of individual effects. Combining one or more functions
into a single component (multifunctionality).

Integration of Processes: Combining multiple process steps into a single

unit can create synergies that improve efficiency. For example, combining
reaction and separation processes can enhance both steps by continuously
removing products and driving the reaction forward.

Van Gerven, Tom, and Andrzej Stankiewicz. "Structure, energy, synergy, time The fundamentals of process intensification." Industrial & engineering chemistry research
48.5 (2009): 2465-2474.
11 Domains of Process Intensification

The four domains of PI are Spatial, thermodynamic, functional, and

temporal. Intensification needs simultaneous addressing the four
domains.

 These domains are used to identify possible PI opportunities by

applying the fundamental principles of process intensification.

 The spatial domain refers to the use of structure to intensify a process

(Reducing the physical size of equipment while maintaining or
improving performance).
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 The Thermodynamic domain is concerned with different methods of giving
energy to the process (Enhancing energy efficiency and reducing energy
consumption).

This domain involves optimizing the energy input and output of the process. It
focuses on using alternative energy sources and improving energy efficiency.

Example: Heat Integration - Using waste heat from one part of the process to
provide energy for another part,
13 Domains of Process Intensification

 The Functional domain entails using unit integration to speed up a process

(Combining multiple functions into a single piece of equipment (Synergy)).

Example: Reactive Distillation - Combining reaction and distillation in a single unit

allows for continuous removal of products, driving the reaction forward and improving
both reaction and separation efficiencies

 Finally, The Temporal domain involves using dynamic operations to accelerate a

process (Optimizing the time aspects of processes, such as reaction times and cycle
times).

Example: Periodic Operation - Operating a reactor in a cyclic manner to take advantage

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Four principles of PI relate to the four domains (spatial, thermodynamic, functional, and
temporal)

 Maximize the Effectiveness of Intra- and Intermolecular Events

 Spatial Domain: Microreactors enhance molecular interactions by providing high

surface area-to-volume ratios, ensuring effective collisions and reactions.

 Thermodynamic Domain: Optimizing temperature and pressure conditions to favor

desired reaction pathways and improve reaction kinetics.

 Functional Domain: Using catalysts with specific active sites to enhance reaction
rates and selectivity.

 Temporal Domain: Implementing dynamic operation modes to maintain optimal

reaction conditions over time.
15 Uniform Treatment for Every Single Molecule in the Process

 Spatial Domain: Microreactors and static mixers ensure uniform distribution

of reactants, providing consistent conditions for all molecules.

 Thermodynamic Domain: Maintaining uniform temperature and pressure

conditions throughout the process to avoid hotspots or cold spots.

 Functional Domain: Designing catalysts with uniform active sites to ensure

consistent interaction with all molecules.

 Temporal Domain: Using continuous flow reactors to provide steady-state

conditions, ensuring uniform treatment over time.
16 Optimize the Driving Forces at Every Scale and Maximize the Specific Area to
Which These Forces Apply
 Spatial Domain: High-gravity (HiGee) technology and rotating packed beds
increase the interfacial area, enhancing mass transfer rates.
 Thermodynamic Domain: Heat integration techniques optimize energy use,
improving heat transfer efficiency.
 Functional Domain: Membrane reactors combine reaction and separation,
optimizing concentration gradients and enhancing driving forces.
 Temporal Domain: Periodic operation modes optimize the timing of energy
input and reactant addition to maximize driving forces.
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Maximize the Synergetic Effects from Partial Processes

 Spatial Domain: Integrating multiple process steps in a single unit, such as

in reactive distillation, enhances synergies between reaction and separation.

 Thermodynamic Domain: Using exothermic reactions to provide heat for

endothermic processes within the same unit.

 Functional Domain: Multifunctional equipment like membrane reactors

combines reaction and separation, leveraging synergies for improved
efficiency.

 Temporal Domain: Implementing cyclic operation modes to take advantage

of transient conditions, enhancing overall process performance.
18 Reactive distillation
Reactive distillation is a successful example of process intensification technology for
enhanced chemical manufacture.

 Reactive distillation is an example of a process intensification technology that can

be applied to the functional domain of process intensification

 Reactive distillation is a process that combines chemical reaction and distillation

in a single apparatus.

 It allows chemical reactions and separation to take place simultaneously inside the
column. This provides a valuable synergistic effect that overcomes the equilibrium
limitations of many reactions.
 The benefits of reactive distillation
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Process Simplification: Complex conventional processes can be reduced to a
reactive distillation column which is typically much easier and cheaper to operate and
maintain

Capital Savings: Reducing the equipment units used leads to a considerable

reduction of capital expenditure

Increased Conversion: The removal of products from the reactive liquid phase
causes chemical equilibrium to be re-established at a higher conversion rate, and full
conversion is attainable

Increased Selectivity: Undesired side reactions can be suppressed by removing the

target product from the reactive section of the reactive distillation column

Reduced Capital Investment and Significant Energy Savings

20  In the context of reactive distillation, the reaction and
distillation occur simultaneously in the same equipment, which
leads to increased efficiency and reduced equipment size
 In reactive distillation, the feed is mixed in the column and the
nature of the feed is such that they are reactive.
 Due to the chemical reaction, the products are formed and the
nature of the product is usually such that they are easily
separable from each other and the feed reactants
themselves. There are various trays installed in the column on
which the formed products get separated.
 How it works, The feed, which contains the reactants, is introduced into the column
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 The reactants react to form products due to the presence of a catalyst

 The nature of the product is usually such that they are easily separable from
each other and the feed reactants themselves

 There are various trays installed in the column on which the formed products get
separated

 The conditions in the reactive column are suboptimal both as a chemical reactor
and as a distillation column, since the reactive column combines these

 The introduction of an in situ separation process in the reaction zone or vice

versa leads to complex interactions between vapor–liquid equilibrium, mass
transfer rates, diffusion, and chemical kinetics
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23

Reactive Distillation is a type of process operation which is a

combination of a chemical reactor and a distillation column.
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The synthesis of methyl acetate was carried out in a packed Reactive Distillation
Column (RDC) by catalytic esterification using acetic acid and methanol as reactants
in a pilot-scale experimental. A strong acidic ion exchange catalyst, Amberlyst-15,
was used to enhance the rate of heterogeneous esterification reaction
  Rectifier: The rectifier is the section of a distillation column above the
25 feed tray where the rising vapor is stripped of the lighter components

It consists of a pot (or reboiler), rectifying column, a condenser, some means

of splitting off a portion of the condensed vapor (distillate) as reflux, and one
or more receivers.

 Stripper: The stripper is the section of the distillation column below the
feed tray where the descending liquid is stripped of the heavier
components. In a side stripper, the water from the bottom of the rectifier is
stripped out of any remaining product.

These two components work together to separate the components of a

mixture based on their different boiling points.
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Based on the four principles of process intensification, Reactive distillation can be
considered as an intensified process because:

• It reduces the number of process steps and equipment, leading to lower capital
and operating costs.

• It enhances the mass and heat transfer rates, resulting in higher conversion and
selectivity.

• It exploits the synergy between reaction and separation, allowing for

overcoming equilibrium limitations and simplifying complex processes.

• It improves the process safety and environmental performance, by reducing the

inventory of hazardous materials and the energy consumption.
  PI differs from traditional chemical processes
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Efficiency and Resource Utilization

o Traditional Processes: These often involve large-scale equipment, leading to high
energy consumption and resource inefficiencies.
o PI: Focuses on compact, multifunctional designs. It optimizes mixing, heat
transfer, and mass transfer, resulting in improved efficiency and reduced
resource usage.
Equipment Size
o Traditional Processes: Use bulky equipment, requiring substantial space.
o PI: Embraces smaller, more integrated designs. Monolithic reactors,
microchannel units, and static mixers.
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Process Integration:
o Traditional Processes: Often treat individual steps in isolation.

o PI: Considers the entire process, integrating various functions.

Operational Strategies:
o Traditional Processes: Typically batch-based or semi-continuous.

o PI: Promotes continuous processing, reducing downtime and

enhancing productivity.
 Reaction Pathways:
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o Traditional Processes: Follow established reaction pathways.

o PI: Explores novel pathways, such as microwave-assisted reactions or

ultrasonic reactors. These alternatives can lead to faster and more
selective processes.

In traditional reactions, the heat is transferred from an external source to the

reaction mixture by convection and conduction, resulting in a temperature
gradient and inefficient heating.

In microwave-assisted reactions, the microwaves directly interact with the

molecules in the reaction mixture, resulting in homogeneous and rapid
heating, increased reaction rates, improved yields, and modified selectivity.
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Sustainability and Safety:
o Traditional Processes: May generate waste and pose safety risks.
o PI: Strives for cleaner, safer operations. It minimizes waste and
environmental impact.
Time Efficiency:
o Traditional Processes: May be time-consuming due to large volumes
and slow reactions.
o PI: Accelerates processes through intensified mixing, shorter residence
times, and innovative designs
31 non-reactive devices (Static mixer)
 Static mixer a classic example of PI equipment
Mixing is a central issue in process engineering and many industrial
fields.
 A static mixer can be a hollow tube or channel with a specific
geometrical construction that influences the flow structure in a
manner to promote secondary transverse flows that enhance
mass and heat transfer in the cross-section.
 Offering several advantages compared to batch processing and
mechanically stirred vessels.
The small space requirement, low equipment operation and
maintenance costs, sharp residence time distribution, improved
selectivity through intensified mixing and isothermal operation,
byproduct reduction, and enhanced safety are the main features
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According to collision
theory, the factors
responsible for the
effectivness of a reaction
event include:
number/frequency of
collosions, geometry of
approach, mutual orentation
of molocules in the moment
of collisions and their energy.

Van Gerven, Tom, and Andrzej Stankiewicz. "Structure, energy, synergy, time The fundamentals of process intensification." Industrial & engineering chemistry research
48.5 (2009): 2465-2474.
 PI-mainly deals with engineering methods and equipment.
33
34 The working principles of reactive distillation

 Maximizing the effectiveness of molecular events: Ensuring

that all molecules undergo the same processing experience.

 Optimizing driving forces and resistances over the greatest

specific surface area: This helps in maximizing synergistic
effects.
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 Insert-type configuration in which the typical design is a series of identical,
stationary inserts, called elements, and that can be installed in pipes,
channels, or ducts. The purpose of the elements is to redistribute the fluid in
the directions transverse to the main flow, these are the radial and tangential
directions. Static mixers divide and redistribute streamlines in a sequential
fashion using only the pumping energy of the flowing fluid.

 Motionless mixers typically exhibit lower energy consumption and reduced

maintenance requirements because they do not include moving parts. They
require smaller space, lower equipment cost, and no power except pumping
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Summary
 PI represents a paradigm change toward more efficient, sustainable,
and flexible chemical processes.
 To satisfy the needs of modern industry, it utilizes advances in
engineering, chemistry, and process design.
 process intensification is about thinking creatively, optimizing, and
pushing the boundaries of what’s possible in chemical engineering
[Link] ([Link])
37 Static mixer
 A static mixer consists of two main parts
1. Tube Element: This is the housing or pipe that contains the mixer It can be made of
various materials, including stainless steel, polypropylene, Teflon, PVDF, PVC,
CPVC, polyacetal, and even glass-lined steel.
2. Mixing Elements: These are the internal components designed to disrupt the flow
of liquids and promote mixing. They are typically in the form of baffles, blades, or
channels arranged in a specific pattern within the mixer. The mixing elements can
be made of metal or a variety of plastics
The working principle of a static mixer
The static mixer uses the energy from the flow of the fluid (provided by an external
component like a pump) to accomplish the mixing.
The mixing elements inside the tube element disturb the flow profile in such a way that
everything is mixed into one homogeneous mixture.
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