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Centre of ExcellenceIntensification of Chemical and Bio Processes

University College of Technology (A)

Osmania University Hyderabad 07Osmania University, Hyderabad‐07

PROCESS INTENSIFICATION: What?

Process Intensification is the Development of NovelApparatus and Techniques that are expected to bringApparatus and Techniques that are expected to bring• dramatic improvements in Manufacturing and

Processing• substantially decreasing

Equipment ‐ Size / Production‐Capacity Ratio,iEnergy Consumption,

Waste Productionultimately resulting in cheaper, sustainableTechnologies

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• Process Intensification covers all types of ProcessIndustries and operations including Reactions, Heat andMass Transfer, Mixing, Blending, Separations,Distillation etc.

• Already several new concepts have been introducedand are being introduced.

• Alternate Energy sources have also been considered.

• Multidisciplinary R&D approach is essential .Collaboration between Chemical Engineering and otherdisciplines is of crucial importance.

Process Intensification: How?

Reactors•Static Mixer

Columns•Rotating Packed Bed

Separationsll

•Biochemical Processesl h l

Static Mixer•Micro Channel•Spinning Disc•Heat Exchange•Membrane

•Rotating Packed Bed•Rotating Fluidized Bed

•Reactive Distillation•Reactive Extraction•Divided Wall Column Distillation•Membrane Distillation

•Textile Technology•Food Technology

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INSTITUTIONAL INFORMATIONUG Level (B.Tech) Pre‐TEQIP Post‐TEQIP

(2010‐2011) (2012‐13)1. Chemical Engineering 60 602. Food Technology 20 203. Textile Technology 20 20PG Level (M.Tech)1.Chemical Engineering(a) Plant Design 05 18(b) Chemical Reaction Engineering 05 18(c) Process Dynamics and Control 05 18(d) Environmental Engineering ‐‐ 18(e) MS Ph.D PD/CRE/PDC (with IICT) 05 052. Chemical TechnologyTech of Pharmaceuticals and Fine Chemicals 05 123. Materials Science and Technology 05 184. Bio‐Chem. Engg and Bio‐Tech.(Self Finance) 18 18

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Basic InformationUGC Autonomous Status (2f and 12b) Obtained

NAAC Accreditation obtained 3 31/4 with A gradeNAAC Accreditation obtained 3.31/4 with A grade

NBA Accreditation obtained for Three UG Programs

92% of teaching faculty are with PhD qualification92% of teaching faculty are with PhD qualification

Total worth of the Sponsored Projects (other than TEQIP) : Rs. 63.35 Lakhs

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Specific Areas• Multi Phase Systems • Novel Reactors and Reaction Media• Reactive Separations• Application of Catalysis• Intensification of Heat and Mass Transfer Rates• Intensification of Heat and Mass Transfer Rates• Application to Nano Technologies• Substitution of Chemical with Bio transformations • Modelling and Simulation • Improved Process Control and Automation • Augmentation of Reaction Velocity with Microwave and Ultrasonics• Improvement of Process Safety and Industrial Waste Water

TreatmentTreatment• Intensification in Textile Finishing and Tie and Dye Process • Drying of Food Grains by Novel Methods • Intensification of Edible Oil Processing and Refining

MoUs ObtainedIICT, HyderabadIITH, HyderabadBITS Pilani, Hyderabad CampusBVRIT, NarsapurUniversity Malaysia Sabah, MalaysiaKansas State University, USABHEL, R&D, HyderabadRamkey Enviro Engineers Ltd., Hyderabad

ifi i l d b dProcess Intensification Consultants, HyderabadInventa Chemicals Limited, HyderabadClair Engineers LimitedAPPCB

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Research

70

80

90

30

40

50

60

70

2009‐10

2010‐11

2011‐12

2012‐13

2013‐14

0

10

20

PhDs M.Techs International National

Team of CoEPrincipal and Head of the Institution:

Prof. Chintha SailuCoE Coordinator

Prof. S. Ram Mohan Rao

Principal Investigatorsf k– Prof. V. Venkata Basava Rao

– Prof. A. Ravindranath– Prof. J. Hayavadana

and Other Teaching Faculty Researchers

Important Researchers from Private Sector– Mr.C. Satynarayana, M/S. Inventaa Chemicals Limited– Dr. K. Sainath, M/S Clair Engineering Limited– Mr. A. Bhasker Reddy, M/S. Enfab Industries– Mr M Narayana Reddy M/S Virchow LabsMr. M. Narayana Reddy, M/S Virchow Labs– Mr. B.Chakradhar, M/S Ramkey Enviro Engineers Limited

Other Institutional Faculty/ Researchers• Prof. D. P. Rao, Process Intensification Consultants• Dr. Ch. Venkateshwarlu, BVRIT• Dr. S. Sridharan, IICT• Dr. M. Narasimaha, IIT‐Hyderabad• Dr. B. Satyavathi, IICT• Dr. Raghunandhan, BHEL, R&D

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Plan of ActivitiesCollaboration between faculty members from the departments around acommon research programme in the campus.

All the collaborating departments are expected to share their physical andintellectual resources with each other.

Emphasis on emerging industry and societal needs in close collaboration withindustries and users, within India and abroad.

Inculcate an R&D culture in the institutions as evidenced by significantincreases in research outputs, collaborative and sponsoredresearch, publications, patents, innovations, commercialized products andPhD enrolments.

Enhancing postgraduate education through increased enrolments for Mastersand Doctoral programmes in topics closely linked to economic and societalneeds.

Increased collaboration with National and International research institutionsto improve quality of research and development, further tap into global poolsof knowledge and create a critical mass with potential for global research anddevelopment.

PRINCIPAL

COE COORDINATOR

PRINCIPAL INVESTIGATOR 1

Intensifying Equipment

PRINCIPAL INVESTIGATOR 1

Intensifying Methods

PRINCIPAL INVESTIGATOR 2 Intensifying Bio

Processes

PRINCIPAL INVESTIGATOR 3 Food and Textile

Processes

Rotating Packed BedRotating Fluidized Bed

Micro Reactors

Reactive DistillationReactive ExtractionNano technology

ApplicationsBio Processes

Food grains dryingMicro‐oven and fluidized

bed dryingIntensification of die

process in textileApplications process in textile Industries

Process Intensification ConsultantsM/s Ram Key

M/s Clair Engg.IICT

APPCBIITHBITS

Process Intensification consultantsDRDLBHELIICT

BARCIITHBITSNFC

Dr. Reddy LabsINVENTAVIRCHOW

IICTIITHBITS

NINLakshmi Kantham Spiining

IICTIITHBITSHU

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Rotating Packed Bed

Advantages• Very high volumetric mass Transfer coefficients• Size is smaller thus reducing in operating and fixed costs• High gas velocity and tendency to flood is reduced• Larger driving force of liquid flow due high rotational speed will allow high viscous liquids• Micro‐mixing and gas liquid contact at low liquid hold up

Equipment

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Equipment

• Literature survey clearly indicates theadvantages of mass transfer operation in splitpacking for gas phase controlled mass transferoperation

• Though absorption studies has been carried inthis RPB, there are no studies reported fordistillationdistillation

Objectives• This project aims to evaluate the performance

of the rotating packed bed with split packingfor distillation studies which is usually a gasphase controlled process at total reflux

• The systems selected for study are methanol‐water and acetic acid‐ water

Progress• Literature Survey is done by Two UG (B Tech) students• One PG (M.Tech) student is working for RPB• Quotations are being prepared to procure the RPB

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Rotating Fluidized Bed

Concept• Fluidization gas is injected tangentially via

multiple gas inlet slots at the outer cylindricalwall of the fluidization chamber.

• As a result of the tangential gas‐solid dragforce, the solid particles in the fluidizationchamber rotate as well and experience aradially outwards centrifugal forceradially outwards centrifugal force.

• A radially outwards centrifugal force exertedon the solids is balanced by a radially inwardsgas‐solid drag force.

• By the action of the centrifugal force, theparticles tend to form a rotating particle bedagainst the outer cylindrical wall of thefluidization chamber.

Advantages ApplicationsAdvantages• High Heat and Mass Transfer rates• Bubble free fluidization• More Gas Throughputs• Easy separation of gas and solid• More compact equipment• Fluidization of Cohesive Particles

ApplicationsFCC raiser: •More uniform temperature allows to use high cracking temperature• Use of more active catalystBioMass Combustion:•High Combustion Efficiency

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Rotating Fluidized Bed with Static Geometry

Tangential feed inlets

LR

Rotating solid particles bed

(a) (b)

DR

DE

DR

DE

IO

Schematic of the RFB‐SG reactor with tangential feed inlets, reactor diameter (DR), exhaust diameter (DE), axial length of the reactor (LR) and inlet opening thickness (IO). (a) Front view (b) Side view

Objectives• Hydrodynamic variables like the centrifugal force, the injection pressure, the radial and tangential

slip velocities, solids hold‐up are to be calculated for various particles of Geldart –A, Geldart ‐B toallow for a comparison among different fluidization chamber designs

• Unstable bed behavior, like slugging and channeling, is also to be predicted to alienate the desirableregimes

• Design of Internals like slots, chimney, solids input and output are to be studied

Progress of the Work• Two M.Tech Students are involved• Fabrication of RFB‐SG is in progress• The Photo graphs of the set‐up are shown here

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Divided Wall Column Distillation

• Energy used for continuous distillation processes comprises approximately 40% oftotal energy use in chemical process industry

• Dividing wall column (DWC) not only leads to energy saving but also to capital saving• A DWC, shown in Fig.3, is a single shell thermodynamic equivalent of a fullyA DWC, shown in Fig.3, is a single shell thermodynamic equivalent of a fully

thermally coupled column, which allows separation of three or more componentsinto high purity products within one shell.

• This is achieved by using a vertical partition wall that divides mainly central part ofthe column into prefractionator and main column sections.

• In each section, two components with greatest difference in volatility areseparated, while others are allowed to distribute

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Advantages of DWC

Progress• Two UG (B.Tech) students done literature survey• One PG (M.Tech) student is currently doing simulation studies of divided

wall packed bed distillation for BTX system

Micro Reactors• Micro-structured reactor channel diameters: sub mm to

mm range• Surface/Volume area: 1,000-50,000 m2/m3

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AdvantagesHigh surface-to-volume area; enhanced mass and heat transfer

Laminar flow conditions

Uniform residence time, backmixing minimized (increased precision and accuracy)

High-throughput and use of very small amounts of materials

Low manufacturing, operating, and maintenance costs (if mass produced), and low power consumption

Minimal environmental hazards and increased safety

“Scaling-out” or “numbering-up” instead of scaling-up

Type of conventional reactor

Specific interface area[m2/m3]

Type of microreactor Specific interfacearea

[m2/m3]

Features: AdvantagesSpecific interfacial area (S/V)

Packed columnCountercurrent flowCo-current flow

10-35010-1700

Micro bubble column(1100µm x 170 µm)

5,100

Bubble columns 50-600 Micro bubble column(300 µm x 100 µm)

9,800

Spray columns 10-100 Micro bubble column(50 µm x 50 µm)

14,800

Mechanically stirred 100 2000 Falling film 27 000Mechanically stirred bubble columns

100-2000 Falling film microreactor

(300 µm x 100 µm)

27,000

Impinging jets 90-2050

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Features: AdvantagesMass and heat transfer

Source: J.C. Schouten, Symposium on Micro Process Engineering for Catalysis & Multiphases, Eindhoven University of Technology, February 2006

Features: AdvantagesG

L

10‐5

10‐4

atal

yst)

Cyclohexene Hydrogenation

Mass transfer

G

10‐8

10‐7

10‐6

0.001 0.01 0.1 1 10 100

Reac

tion

Rat

e (m

ol/s

/g c

a

Conventionalequipment

Microreactor Results

LG 0.001 0.01 0.1 1 10 100

Mass transfer coefficient, KLa (s‐1)

Cyclohexane hydrogenation was performed in micro packed bed reactor. The catalyst was standard platinum supported on alumina powder. It was determined that overall mass transfer coefficient (KLa) was 5-15 s-1 as opposed to 0.01-0.08 s-1 for laboratory trickle bed reactors

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Potential application for microreactors

• Synthesis of hazardous gases: chlorine, iso‐cyanates, hydrogen cyanide phosgenecyanide, phosgene…

• Hydrogen production via steam reforming, partial oxidation of methane, from higher alkanes and alcohol to syngas

• Synthesis of ethylene oxide, propylene to acrolein, oxidative dehydrogenation of alcohols to aldehydes

• Oxidation of ammonia

Micro Reactors • Promising technology:

enhanced mass and heat transferefficient process intensificationinherently safe operation uniform residence time

• Some issues still remain:integration with sensors, actuators, and other associated equipment, such as pumps;reactor monitoring and control; high activity stable catalysts needed.

Progress

O Ph D h b l t d i i t b f i t d t• One Ph D has been completed in micro reactors by foreign student from Nigeria

• Micro mixing studies are being done by Two PG (M.Tech) students and further kinetic studies are also in progress

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Reactive DistillationCatalyst

Reactor

MeOH

MeOAc

HOAc

AcOH

H2SO4

MeOH

H2OConventional

Process

H2O

Reactive Distillation

• High Purity of MeoAc

• Reduced capital cost to one fifth

• Consume only one-fifth energy

Work done

SEMIBATCH TYPE BATCH TYPE

Lactic Acid + Butanol = butyl lactate + Water

CH3CHOHCOOH + C2H5CH2CH2CHOH ↔ CH3CHOHCOOC4H+H20

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1:1 MOLE RATIO OF LACTIC ACID AND BUTANOL WITHOUT CATALYST

200

250

300O

LLEC

TED

,ml

20%

60%

450

500

550

600

650

700

88%

60%

0

50

100

150

0 100 200 300

VOLU

ME

OF

WAT

ER C

O

TIME,min

88%

0

50

100

150

200

250

300

350

400

450

0 50 100 150 200 250 300 350 400 450 500 550

VOLU

ME

OF

WAT

ER in

ml

TIME in min

60%

20%

BATCH TYPE

SEMIBATCH TYPE

Three M. Techs and Two Ph Ds are completed and one on continuous reactive distillation is on goingOne Project worth of Rs.7 lakhs got from AICTE under R&DThree Publications (one International + two in national Journals) have been made.

Thank You