Page 456 - Design of Simple and Robust Process Plants
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11.4 Process Simplification and Intensification 443
11.4
Process Simplification and Intensification
The technique for simplification and intensification cannot be generalized because
each operation has its own solutions. However, it can be classified into categories to
enable the thought process for development and application of simple designs. The
simple design solutions for different units are ranked in sequential order of increas-
ing complexity to support a designer in the design process.
11.4.1
Avoiding or Eliminating Functions
No storage ± what you do not have cannot leak, and does not cost anything.
Transport of fluids can benefit from gravity forces and pressure differences.
Opportunities are process situations with repetitive actions called, do±undo±redo,
like heating±cooling±re-heating, separation±mixing±separation, and pressurizing±
depressurizing±pressurizing.
11.4.2
Combination of Functions
Reaction and reaction; Reaction and separation; Separation and separation.
Integration of equipment. Most equipment has the possibility to integrate adja-
cent equipment. This reduces not only equipment costs but also installation and
piping costs.
11.4.3
Intensification of Functions
High surface area per volume, as for heat and mass exchangers.
Increase mass and heat transfer (kA and UA).
Benefit from centrifugal forces for phase separation, eventually combined with
mass transfer or reaction, as in rotating packed beds.
11.4.4
Overall Process Simplification
Key elements are:
. Operation at 100% conversion.
. Adiabatic operations.
. Prevention of waste.
. Single train design and single component design.
. Selection of optimal pressure levels.
. Logistic strategy.
