The course introduces the fundamental concepts and principles of process intensification, focusing reviews on process intensification approaches across four key domains: spatial, thermodynamic, functional, and temporal. Advanced methods in energy integration, reaction engineering, and innovative separation techniques are explored to broaden students’ understanding. Case studies on the application of intensified processes in various industries, including chemical, biochemical, and energy sectors, provide practical insights.

• Demonstrate an understanding of key concepts in process intensification and their application in chemical reaction engineering and process design.
• Utilize innovative principles to enhance efficiency, sustainability, and flexibility in industrial processes.
• Critically analyze and propose improvements to existing processes by integrating methods such as shrinking the size of individual equipment, modularization, and process integration.
• Approach process intensification as a revolution, encouraging thinking beyond conventional methods to achieve transformative improvements.

• Introduction to Process Intensification

  • Overview of process intensification (PI) and its role in improving industrial processes
  • Key principles of PI: improving efficiency, reducing energy consumption, and enhancing sustainability

• Process Intensification Approaches

  • Spatial Intensification: Techniques for optimizing the use of space, such as compact reactors and equipment
  • Thermodynamic Intensification: Enhancing thermodynamic efficiency, reducing energy use, and maximizing energy recovery
  • Functional Intensification: Innovations that combine functions, such as multi-functional reactors and integrated systems
  • Temporal Intensification: Reducing reaction times and improving process throughput through faster processing

• Fundamentals of Intensified Equipment

  • Shape-Selective Catalysts: Catalysts designed to enhance reaction rates and selectivity by controlling the size and shape of reactant molecules
  • Microreactors: Small-scale reactors designed for efficient heat and mass transfer, faster reactions, and better process control
  • Static Mixers: Devices used to improve mixing efficiency and enhance reaction rates without moving parts
  • Reactive Distillation: Combining distillation and reaction in a single unit to intensify separation and reaction processes
  • Membrane Reactor: Using membranes to separate reactants and products within a reactor, improving selectivity and yield
  • Reverse Flow Reactor: A reactor design that alternates flow directions to optimize reaction conditions

• Transport Phenomena in Intensified Systems

  • Understanding the role of heat, mass, and momentum transfer in intensified systems
  • Analyzing how these phenomena impact the performance and efficiency of PI processes

• Economic and Environmental Evaluations

  • Techniques for evaluating the economic feasibility of intensified processes
  • Assessing environmental impacts: energy consumption, emissions, and sustainability metrics

• Advanced Methods in Energy Integration, Reaction Engineering, and Separation Techniques

  • Energy integration techniques to minimize energy use and improve overall system efficiency
  • Advanced reaction engineering approaches for optimizing catalytic processes
  • Innovative separation techniques that complement process intensification

• Case Studies on the Application of Intensified Processes

  • Examination of real-world applications of PI in various industries:
    • Chemical Industry: Case studies on intensified chemical reactions and separations
    • Biochemical Industry: Applications in fermentation, enzyme catalysis, and bioengineering
    • Energy Sector: Using PI to improve energy efficiency in power generation and renewable energy processes