From world-scale to more modest proportions

Big is not necessarily the future in the engineering world, as will become apparent at ACHEMA 2006. The chemical industry needs engineering strategies which are able to cope with rapid changes in market demand. Modular technology and strict standardization will both have a role to play. Elements of microprocess technology will also be part of the equation.
What will the chemical plant of the future look like? The IMPULSE program has been working on this issue (Integrated Multiscale Process Units with Locally Structured Elements; www.impulse-project.net). This project, which was initiated by the EU in the 6th Framework Program, is looking primarily at the use of microtechnology. The companies and institutes which are involved in the project are convinced that this technology can lay the foundation for a new generation of production systems in the near future. In order to achieve its goals, IMPULSE intends to install locally structured components on production systems. These components will be integrated directly into the process equipment. The following list outlines some of the program goals:
-convert batch processes into continuous processes;
-modular, scalable processes;
-integration of a new generation of components into existing systems;
-subsystem miniaturization to facilitate distributed production.

Individual goals include minimization of the use of solvents or even deployment of solvent-free production systems, maximization of the space-time yield, increased selectivity, reduction in the cost of product separation and improved QC measurement technology.
One of the industrial partners in the IMPULSE program, Degussa, has demonstrated how this works in practice. In an effort to substantially increase process yield, the company is using the process intensification approach to significantly improve factors like the space-time yield by several orders of magnitude rather than by mere percentage points. The improvement could be based on highly-active catalysts or special micro-reactors which provide a more intensive exchange of heat and material according to Dr. Henrik Hahn, Process Intensification House Manager.
The concrete goals are to deploy new processes and systems which are based on new technology to take advantage of lower investment costs and shorter reaction timescales. The benefit of this approach is that capacity can be ramped up to meet increased demand. Not only that, the new technology will even make it possible to develop new types of products.
The chemical plant of tomorrow as envisaged by IMPULSE will probably not only be significantly smaller than today’s facilities, it will also be more efficient and have a lower impact on the environment. Plants can also be located closer to the customer, and this adds a new dimension to “demand driven production”. The strategy of distributing a larger number of smaller production facilities across Europe will reduce transportation costs, and it gives producers the opportunity to react quickly to changing market conditions.
Sometimes the engineering strategy simply has to change. If a plant operator wants to retain flexibility, make smaller product quantities and/or use the plant for more than one product, the tendency is to opt for a multi-product plant. Later, economic pressure can force the transition to mono production, because practical experience shows that cost performance will improve by at least 25%. The explanation is simple. Multi-product plants use a large number of small systems, which makes handling more cumbersome. Fewer tanks are needed in mono production, making it easier to automate the plant and reduce staffing levels. Larger tanks and systems automatically drive down specific energy consumption per ton. Intelligent process management and optimized kinetics increase selectivity throughout the process including preliminary stages by around 10%.
Construction of biofuel plants is booming
Interest in production facilities for biodiesel and bioethanol and in strategies for using biomass is not limited to the experts. The general public also shares this interest. The reason for this focused attention is simple. Fuels prices only seem to move in one direction (up), and we need to find alternative source of raw materials, at least in the medium term.
There is therefore no question that demand for biofuels will continue to increase, making this a very lucrative growth market for the plant construction industry. This market has international sponsors. Both the US and Europe offer tax incentives and define additive levels to promote biodiesel and bioethanol production. Experts predict that about 100 new facilities will be built in Europe by 2010 and around 60 in the US. The required investment will be in the neighbourhood of €6 billion.
Renewable raw materials will be turned into important chemical products. Basic chemicals will have to be converted into bio intermediates, for example ethanol, glycerin, hydromethylfurfural, lactic acid, propylene glycol, and other high-quality intermediates in order to be competitive with basic petrochemical products (olefines, aromatics, etc.). The production of glycerin from oil, ethanol from starch and isomaltose from saccharose is already a reality, but other products such as glycerin-based acrolein or sugar-based propylene glycol and lactic acid are still at the R&D stage.
White biotechnology continues to grow
To an increasing extend, biotechnology is able to offer alternatives to traditional chemical processing methods. In many cases, the conversion from a chemical process to a biotechnology process can significantly reduce resource consumption as well as the impact on the environment without the need for elaborate, costly investment. Experts believe that white biotechnology will become a more significant factor in the production of bulk chemicals and that we will see increasing use of bio catalysts. But, bioproduction places specific demands on process engineering. Special aspects of the treatment process, handling of large volumes, problems related to sterile equipment and strict safety regulations are the defining factors of a biotechnology production system, and they have to be included as an integral part of the overall process.
Trends that suppliers need to watch
The results of a survey conducted by the German Engineering Federation (VDMA) entitled “Trends in Process Technology 2004–2008” shed light on emerging engineering strategies. University faculty members and manufacturers were asked to give their views on process machinery and equipment. The survey revealed that the importance of automation technology will continue to increase. Manufacturers would be well advised to be prepared to supply more machines and devices that are automation ready. The diversity of fieldbus systems which manufacturers will have to cope with is expected to increase rather than decrease in the future. Suppliers will also have to keep a watchful eye on nanotechnology, membranes, sensors and instrumentation. Producers and university faculty members expect that the major advances in process engineering will be based on these technologies.
The product-related (“traditional”) services such as spare parts, repair, maintenance and field service will not become less important. On the contrary, teleservice appears to be a sensible way forward, and it could help producers to drive down costs. The study also showed that machine producers have identified a lack of sensors for moisture measurement and capture of various mechanical variables (e.g. pressure and vibration) in certain applications. There is room for improvement on existing sensors to improve self-monitoring, miniaturization, ruggedness and engineering design.