Educating the Customer: PI - What

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Educating the Customer PI - Whats it all
about? Dr Mike Jones, Protensive PROCESS
INTENSIFICATION Meeting the Business and
Technical Challenges, Gaining Competitive
Advantage The Royal Institution of Great Britain,
London 19th November 2003
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What is PI?
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What is PI?
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What is PI?
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What is PI?
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What is PI?
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A Reason So 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
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What is PI?
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Typical Methods for Contacting Two Fluid Phases
Channel Scale 50?m - 500?m
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Scale-Up for Intensified Processes Future Vision
Low Volume Fine Chemicals Several single channel
devices with high flow velocity could produce 10s
of ?l/s or around 1kg per day.
Medium Volume Chemical Production Blocks with
1000s of channels running in parallel could
provide higher yield when accurate manifold
technology developed.
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A pair of adjacent channels in the catalytic
plate reactor showing the coupling of an
endothermic reaction (Methane Reforming) with an
exothermic reaction (Methane Combustion)
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Comparison of the Productivity of Different
Reactors
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Electrolytic flow cells
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Liquid Film
Solid Surface
Micro Mixers
Influence of Surface Waves
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Typical raman spectra taken from SDR.
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FTIR ATR bulk polymerization of styrene
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FT-NIR following a polymerization
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Polymerization evaluated by 1H NMR
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• Control
• size
• size distribution
• form
• coating

• Applications
• Pharmaceuticals
• Electronics
• Inkjets
• Semiconductors

Why?
Every molecule the same experience
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- 75 yield after 4 hrs - 25 unreacted starting
material ? recycle,
reprocess
Every molecule the same experience
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On-Disc Monitoring of CaCO3 Production

• Probes mounted on disc surface to monitor ion
  depletion.
• Results confirm particle production is mass
  transfer limited and takes place on the spinning
  disc.

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Real-Time Film Thickness Monitoring
Examples of film thickness measurements made
using this system. Film thickness typically is in
the 0.01m to 1mm range.
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Liquid-Solid Mass Transfer Results
Results for 6mm Electrodes at 9 Radial Locations
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Summary

• Rapid process screening
• Rapid process development
• Rapid scale-up
• Novel products and processes
• JIT

• Integrated processes
• common standards