Periodic Reporting for period 2 - SIMPLI-DEMO (Demonstration of Sonication and Microwave Processing of Essential Chemicals)
Periodo di rendicontazione: 2024-04-01 al 2025-09-30
SIMPLI-DEMO aims at strengthening the chemical process industry in its capacity to produce materials and chemicals in a sustainable and competitive way by moving from batch to continuous modular production with flexibility being ensured by the application of alternative energy forms.
Currently, the conventional technologies in the specialty and pharma sector tend to be batch-type, combined with mechanical mixing and conduction-based heat transfer, inherently leading to poor process control. SIMPLI-DEMO aims at intensified processes, where alternative energy sources enable continuous modular technologies to achieve localized actuation of multiphase, flow reactors for high-value product synthesis. SIMPLI-DEMO advances the TRL of modular flow technology for multiphase streams involving suspensions or viscous products from TRL5 (validation in relevant environment) to TRL7 (industrial system demonstration).
The projects ambition is to demonstrate the first pilot-scale system prototype for long-term uninterrupted modular flow operation of solids-laden and viscous-phase containing liquid process streams. We achieve this by combining continuous flow equipment (Reactive Extrusion-REX, Continuous Oscillatory Baffled Reactor-COBR) with the alternative energy forms of ultrasound and microwaves.
SIMPLI-DEMO has brought together a consortium of
4 end-user chemical companies
2 technology suppliers (ultrasound & microwave technology)
5 universities and research institutions (process control & automation, reactive extrusion, oscillatory flow, ultrasound, microwaves)
1 SME experienced in modular automation and
1 SME experienced in sustainability assessment and exploitation.
We have a 48-months work plan for the successful analysis, research, design, deployment, operation and evaluation of the SIMPLI-DEMO results. 7 WPs will be implemented in 5 parallel time blocks coordinated with one another.
The focus is on 3 technical-scientific work complexes:
1. Development of modular systems (WP1/2)
2. Parametric validation for flexible modular operation (WP3)
3. Demonstration of flexible modular production systems in industrial environment (WP4)
Currently, the conventional technologies in the specialty and pharma sector tend to be batch-type, combined with mechanical mixing and conduction-based heat transfer, inherently leading to poor process control. SIMPLI-DEMO aims at intensified processes, where alternative energy sources enable continuous modular technologies to achieve localized actuation of multiphase, flow reactors for high-value product synthesis. SIMPLI-DEMO advances the TRL of modular flow technology for multiphase streams involving suspensions or viscous products from TRL5 (validation in relevant environment) to TRL7 (industrial system demonstration).
The projects ambition is to demonstrate the first pilot-scale system prototype for long-term uninterrupted modular flow operation of solids-laden and viscous-phase containing liquid process streams. We achieve this by combining continuous flow equipment (Reactive Extrusion-REX, Continuous Oscillatory Baffled Reactor-COBR) with the alternative energy forms of ultrasound and microwaves.
SIMPLI-DEMO has brought together a consortium of
4 end-user chemical companies
2 technology suppliers (ultrasound & microwave technology)
5 universities and research institutions (process control & automation, reactive extrusion, oscillatory flow, ultrasound, microwaves)
1 SME experienced in modular automation and
1 SME experienced in sustainability assessment and exploitation.
We have a 48-months work plan for the successful analysis, research, design, deployment, operation and evaluation of the SIMPLI-DEMO results. 7 WPs will be implemented in 5 parallel time blocks coordinated with one another.
The focus is on 3 technical-scientific work complexes:
1. Development of modular systems (WP1/2)
2. Parametric validation for flexible modular operation (WP3)
3. Demonstration of flexible modular production systems in industrial environment (WP4)
During the first 36 months of SIMPLI-DEMO, activities progressed across all work packages as planned (WP4 starting in M36).
WP1 investigated HEUR, HMPE and NIPU chemistry at lab scale. New analytical and spectroscopic tools were developed to support reactive extrusion, particularly for HMPE. A pilot-extrusion guideline using ultrasound-assisted power transfer was created. In the second period, flexible REX systems for HEURs, HMPEs and PHUs were designed, integrating MW/US units, automation, modelling and continuous monitoring. HMPEs and PHUs were produced in an 18 mm pilot extruder, with optimisation and MW/US intensification ongoing.
WP2 focuses on a modular COBR system for zeolite and API synthesis. A high-temperature, high-pressure pilot unit with ultrasound, microwaves and PAT tools was revamped and validated, with first zeolite trials completed. Downstream development (filtration/washing) continues. For APIs, lab work progressed alongside the installation of two process systems, including a commissioned laboratory unit used for training in July 2023.
WP3 performed parametric studies on the effect of ultrasound and microwaves on HEUR/HMPE extrusion, NIPU synthesis and zeolite/API crystallisation. Key process parameters were identified, models developed and monitoring tools applied. Studies continued in batch and continuous modes in the second period, with further analysis of MW/US effects and monitoring techniques still in progress.
WP4, launched in September 2025, builds on WP1–WP3 to expand pilot plants and demonstrate modular reactive extrusion and crystallisation in industrial environments using MW/US as alternative energy sources. Efforts focus on process optimisation, scale-up and validation across all use cases.
WP5 delivered an initial assessment of economic feasibility and potential GHG reductions enabled by SIMPLI-DEMO technologies. Benchmark processes were compared with SIMPLI-DEMO alternatives using plant-wide simulations. Mass and energy balances informed equipment sizing and utility needs, and CAPEX/OPEX evaluations were carried out for both batch and continuous configurations using Aspen Plus and standard economic methods.
WP6 strengthened project visibility through communication, dissemination and exploitation activities, using coordinated tools (website, flyers, posters, social media, presentations) deployed across events and partner networks.
WP7 ensured effective coordination and management by TUDO, supporting smooth implementation and collaboration among partners.
WP1 investigated HEUR, HMPE and NIPU chemistry at lab scale. New analytical and spectroscopic tools were developed to support reactive extrusion, particularly for HMPE. A pilot-extrusion guideline using ultrasound-assisted power transfer was created. In the second period, flexible REX systems for HEURs, HMPEs and PHUs were designed, integrating MW/US units, automation, modelling and continuous monitoring. HMPEs and PHUs were produced in an 18 mm pilot extruder, with optimisation and MW/US intensification ongoing.
WP2 focuses on a modular COBR system for zeolite and API synthesis. A high-temperature, high-pressure pilot unit with ultrasound, microwaves and PAT tools was revamped and validated, with first zeolite trials completed. Downstream development (filtration/washing) continues. For APIs, lab work progressed alongside the installation of two process systems, including a commissioned laboratory unit used for training in July 2023.
WP3 performed parametric studies on the effect of ultrasound and microwaves on HEUR/HMPE extrusion, NIPU synthesis and zeolite/API crystallisation. Key process parameters were identified, models developed and monitoring tools applied. Studies continued in batch and continuous modes in the second period, with further analysis of MW/US effects and monitoring techniques still in progress.
WP4, launched in September 2025, builds on WP1–WP3 to expand pilot plants and demonstrate modular reactive extrusion and crystallisation in industrial environments using MW/US as alternative energy sources. Efforts focus on process optimisation, scale-up and validation across all use cases.
WP5 delivered an initial assessment of economic feasibility and potential GHG reductions enabled by SIMPLI-DEMO technologies. Benchmark processes were compared with SIMPLI-DEMO alternatives using plant-wide simulations. Mass and energy balances informed equipment sizing and utility needs, and CAPEX/OPEX evaluations were carried out for both batch and continuous configurations using Aspen Plus and standard economic methods.
WP6 strengthened project visibility through communication, dissemination and exploitation activities, using coordinated tools (website, flyers, posters, social media, presentations) deployed across events and partner networks.
WP7 ensured effective coordination and management by TUDO, supporting smooth implementation and collaboration among partners.
The construction of flow process equipment units (REX and COBR), both at laboratory and pilot scale, is in progress. Lab-scale investigations on the process chemistry is ongoing, as well as the research into the effects of ultrasound and microwaves. Together with the use of ultrasound and/or microwaves, synthesis time can be reduced and the quality of products can be enhanced.
The general public should be aware of the environmental impacts (i.e. resource efficiency and CO2-eq emissions) of the SIMPLI-DEMO technologies before the end of the project. Therefore, the calculation of preliminary environmental impacts (mainly but not limited to CO2-eq emissions) estimation was performed from M18 to M24 in WP5, based on the mass & energy balances that were calculated during the first reporting period. The polluting drivers will be also identified serving as decisionmaker for further technology optimization at the development stage.
During the second reporting periode, a technical comparison between benchmark (state-of-the-art) processes and the SIMPLI-DEMO cases, considering all the benefits introduced by sonication and microwaves technologies in the production process is initially performed. This provides a comprehensive engineering analysis, enabling the evaluation of improvements in economic performance. The analysis is supported by the development of plant-wide process models that simulate both the current state-of-the-art and the SIMPLI-DEMO processes. The initial improvements are reflected on mass and energy balances from which equipment sizing parameters and utility requirements are derived. Subsequently, an economic evaluation covering both operating and capital expenditures is performed for both benchmark and SIMPLI-DEMO cases. Process simulation is performed using Aspen Plus software coupled with custom-made coding approaches, while economic evaluation employed standard methodologies from literature to evaluate and compare the economic performance of the two different configurations (state-of-the-art batch processes versus continuous SIMPLI-DEMO cases).
The expected benefits for SIMPLI-DEMO’s have not changed compared to the start of the project, and are listed here again:
• 30 to 80 % energy savings
• 40 to 70% resource efficiency
• Up to 60% reduction in CO2 emission
• 20 to 45% savings in CAPEX
• 45 to 55% savinfs in OPEX
The general public should be aware of the environmental impacts (i.e. resource efficiency and CO2-eq emissions) of the SIMPLI-DEMO technologies before the end of the project. Therefore, the calculation of preliminary environmental impacts (mainly but not limited to CO2-eq emissions) estimation was performed from M18 to M24 in WP5, based on the mass & energy balances that were calculated during the first reporting period. The polluting drivers will be also identified serving as decisionmaker for further technology optimization at the development stage.
During the second reporting periode, a technical comparison between benchmark (state-of-the-art) processes and the SIMPLI-DEMO cases, considering all the benefits introduced by sonication and microwaves technologies in the production process is initially performed. This provides a comprehensive engineering analysis, enabling the evaluation of improvements in economic performance. The analysis is supported by the development of plant-wide process models that simulate both the current state-of-the-art and the SIMPLI-DEMO processes. The initial improvements are reflected on mass and energy balances from which equipment sizing parameters and utility requirements are derived. Subsequently, an economic evaluation covering both operating and capital expenditures is performed for both benchmark and SIMPLI-DEMO cases. Process simulation is performed using Aspen Plus software coupled with custom-made coding approaches, while economic evaluation employed standard methodologies from literature to evaluate and compare the economic performance of the two different configurations (state-of-the-art batch processes versus continuous SIMPLI-DEMO cases).
The expected benefits for SIMPLI-DEMO’s have not changed compared to the start of the project, and are listed here again:
• 30 to 80 % energy savings
• 40 to 70% resource efficiency
• Up to 60% reduction in CO2 emission
• 20 to 45% savings in CAPEX
• 45 to 55% savinfs in OPEX