Process Integration (PI)

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1. DEFINITION & OBJECTIVE

In 1983 PI was described by Colin Ramshaw as “devising exceedingly compact plant which reduces both the main plant item and the installation costs”. Its basic principle says: Smaller is safer. It means the minimization of used technical equipment (“What you don´t have, can not break down!”) and the development of methods and techniques that increase efficiency of chemical and biochemical processes.


2. FIELD OF APPLICATION

Because of the increasing consumption of chemical products caused by new markets and new products developing new ways of PI is especially wanted in chemical industry. But also other industry sectors like the food industry sector can benefit of it.


3. DESCRIPTION OF TECHNIQUES AND METHODS

As it can be seen in the graphic below PI depends on two different parts: the technical equipment like pipes, reactors etc. and methods with increased efficiency. It is job of scientists and engineers to find a compromise.


General1.JPG

Figure 1: PI technologies


Fundamental benefits for a company using PI:

  • Energy savings (20-80%)
  • Selectivity & yield increase (up to >10 times)
  • Process safety increase (the reactor volume and inventory of chemicals decrease  better reaction control)


Also several types of costs can be lowered:

  • Land costs (much higher capacity per unit of manufacturing area)
  • Other investment costs (cheaper, compact equipment, lower piping…)
  • Costs of raw material (higher yield/selectivities)
  • Costs of utilities (energy savings)
  • Costs of waste-stream processing (less waste is generated)


General2.JPG

Figure 2: Cycle of benefits for PI

Reference: Stankiewicz, A: Introduction to process intensification; Presentation in M.Sc. Course on Process Intentisification, Nov, 2008


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