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July 20021
8th MEETING OF THE PROCESS INTENSIFICATION NETWORK
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
2 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Presentation of the RHODIA Group
Process Intensification : principles and devices
Potential Benefits of PI for RHODIA main processes
3 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Presentation of the RHODIA Group
Process Intensification : principles and devices
Potential Benefits of PI for RHODIA main processes
4 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
North America
22% of total sales*3 200 Employees10 R&D Centers28 Production Facilities
Asia-Pacific
11% of total sales*2 000 Employees5 R&D Centers21 Production Facilities
Latin America
16% of total sales*5 100 Employees3 R&D Centers12 Production Facilities
Europe
51% of total sales*16 700 Employees18 R&D Centers64 Production Facilities
Sales of €7 279 millionand 27,000 employees
5 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
A Key Player in Specialty Chemicals2001 sales in € billions
12.0 10.8
10.0 9.1
8.0 7.36.5 6.3
5.56.04.9
4.0
2.0
0.0RhodiaDegussa AG* ICI* Clariant Rohm
& HaasDSM* Ciba SC
* Specialty chemicals part
6 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Sales
€7,279 million
Worldwide employees
27,000Marketing presence
150 countries
R&D budget
€215 million
Rhodia at a Glance
7 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Market-Driven Enterprises
FineOrganics
Life Science Systems Polyamide Intermediates
Technical Fibers
EngineeringPlastics
Silicones
Silica Systems
Performance Polymers, Paintsand Construction Materials
Rhodia ChiRex
PharmaceuticalIngredients
Intermediates
Rhodia Food
Home, Personal Care & IndustrialIngredients
Phosphorus & Performance Derivatives
Specialty Phosphates
Perfumery& Specialties
Textile Yarns(including the Nylstarjoint venture)
Consumer Specialties
Industrial Specialties Polyamide Services
& Specialties
Eco Services
Electronics and Catalysis
Acetow
8 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Presentation of the RHODIA Group
• Different processes by Rhodia
⌦ Synthesis of organic compounds
⌦ Synthesis of inorganic compounds
⌦ Polymerization
9 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Presentation of the RHODIA Group
Process Intensification : principles and devices
Potential Benefits of PI for RHODIA main processes
10 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Process Intensification : principles (R. Jachuck) and devices
• Significantly enhances the transport rates• Match mass transfer rate to rate of desired chemical reaction• Match heat transfer rate to exothermicity of reaction
• Gives every molecule the same processing experience• Match flow behaviour (eg plug flow, backmixed) to reaction scheme• Match residence time to desired reaction time
Rather than adapting the operating conditions and chemistry to available classical equipment,
the process structure, architecture and equipment can be adapted to the physico-chemical transformation
11 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
• Process Intensification : principles and devices
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Mas
s Tr
ansf
er P
erfo
rman
ceM
ass
Tran
sfer
Per
form
ance
Heat Transfer PerformanceHeat Transfer Performance
JacketedStirred Tank
Pulse Column
LoopReactor
Rotating Packed Bed
Educter
Static Mixer
Static Mixer/Plate Exchanger
PlateExchanger
Spinning DiscReactor
Microreactor
12 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
Presentation of the RHODIA Group
Process Intensification : principles and devices
Potential Benefits of PI for RHODIA main processes
13 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• Organic Synthesis
• Case of multiple reactions : influence of mixing (1/2)
• A + B " R Rapid reaction controled by mixing : k1 = 12000 m3/mol.s• B + R " S Slow reaction controled by kinetic : k2 = 2 m3/mol.s
• Selectivity of reactiondefined by X = 2CS/(CR+2CS)
X when mixing is improved
Re
Experiments of Mahajan & Kirwan
Impinging Jet mixer
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0 500 1000 1500 2000 2500 3000
X
14 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• Organic Synthesis
• Case of multiple reactions : influence of mixing (2/2)• similar schemes as the Bourne exemple exist for Rhodia organic
products, even more complicated but the principle is the same• PI can raise the selectivity of reaction, that is to say the yield of
the desired product and diminish secondary products=> higher yield of desired product=> easier or no separation required
•
• Case of exothermic reactions• introduction rates are limited by the speed of heat removal (risk of
degradation of product, risk of hot points)• PI can allow quicker introductions and better temperature
homogeneity=> improvement of productivity=> improvement of quality
15 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis
different steps
=> Improvement of productivityto improve significantly theproductivity of the process, allthe steps must be intensified
PRECIPITATION
SEPARATION / WASHING
DRYING
CALCINATION
PRESENTATION
16 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
PRECIPITATION
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis : precipitation step
- physico - chemistry of the system- temperature- local and mean concentrations =>MIXING- shearing => HYDRODYNAMIC
* crystal size distribution* agglomeration degree* agglomerate cohesion* pore distribution* pore structure
AggregationAgglomeration
Nucleation
Growth
. .. .. .
PRECIPITATION
17 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis
• Actual state• Agitated batch or semi-batch reactors, with big volumes and moderated
specific power input and complex hydrodynamic
Limitations and potential difficulties :- semi-batch and especially continuous case : all the particles don ’t have the
same history => large particle size distribution- scale up
. limitated specific power input : limited mass and heat transfer
. difficulty of determination of scale up criteria : empirical way
18 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis
• How will PI help?
Accelerated heat and mass transferBetter contact of reactantsBetter hydrodynamic control
If tmixing < t précipitation induction, no impact of hydrodynamiccontrol by physico-chemistry
=> NEW PRODUCTS MORE EASILY SCALABLE
PRECIPITATION kinetics = f (physico-chemistry, hydrodynamic)
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
19 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
pHFormation of an insolublesecondary product
FORBIDDEN ZONE
Reactant 2Reactant 1
Final product
Potentially accessible zone during mixing of reactants
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA• Potential Benefits of PI for RHODIA main processes
• Inorganic Synthesis• Example of PI application (RHODIA patent 1994)
ClOHAlOHAlNaClOHAl yxyx ''4 )()()( →+
PAC ALUMINATE AQ S x ’>x et y ’<y
20 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis
• Example of PI application
FIRST INDUSTRIALIZATION TRIALClassical semi-batch reactorScale : 14 m3
- Initial introduction : reactant 1- Introduction of reactant 2- Ripening
=> formation of undesired secondary productimpossible separation
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
21 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
• Potential Benefits of PI for RHODIA main processes• Inorganic Synthesis
• Example of PI application
Installation of a quick mixer for reactants 1 and 2 - no formation of undesired products anymore
- final composition all the time in the mixer- rapid homogeneization
Rapid scale-up
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
22 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
INDUSTRIALISATION
23 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• Polymerization
• A way of improving productivity• Conversion of batch or semi-batch process to continuous process
raise the productivity because of gain of time in feeding and discharge, but problems of intermediates products
• PI, in the case of reactions limited by mass or heat transfer, will decrease the size of equipement, so the quantity of intermediates=> raise of productivity=> decrease of undesired intermediates
•
• Example of devolatilization• an important step in producing polymers, limited by mass transfer
• PI can allow quicker exchanges of mass, especially for highly viscous products
=> acceleration of product devolatilization
24 8th Meeting of the Process Intensification NetworkCranfield University Library, 14 November 2002
POTENTIAL BENEFITSOF PROCESS INTENSIFICATION FOR RHODIA
• Potential Benefits of PI for RHODIA main processes• CONCLUSIONS
• RHODIA believes that PI is really an opportunity especially for
• improving productivity• diminishing investment cost• improving quality of products• accelerating speed of developpement
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