Periodic Reporting for period 1 - SIMPLI-DEMO (Demonstration of Sonication and Microwave Processing of Essential Chemicals)
Okres sprawozdawczy: 2022-10-01 do 2024-03-31
SIMPLI-DEMO aims at strengthening the chemical process industry and in particular the specialty chemicals and pharmaceuticals industries in its capacity to produce materials and chemicals in a sustainable and competitive way by moving from batch to continuous and 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's vision is that of intensified processes, where alternative energy sources enable continuous and modular technologies to achieve localized actuation of multiphase, flow reactors for the purpose of high-value product synthesis. SIMPLI-DEMO focuses on the synthesis of specialty polymers and particles for use in a wide variety of every-day-use products, e.g. insulation, paints and coatings, plastics, catalysts, as well as health applications, which are important domains in the chemical industry today and into the future. Therefore, 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 present the first pilot-scale system prototype demonstration for the long-term uninterrupted modular flow operation of solids-laden and viscous-phase containing liquid process streams allowing for decentralized production. We want to achieve this by combining continuous flow equipment (Reactive Extrusion-REX, Continuous Oscillatory Baffled Reactor-COBR) with the alternative energy forms of ultrasound and microwaves as process enablers for the transition from batch to continuous.
The results of this project will revolutionize the way the chemical industry currently approaches the process intensification of complex multiphase processes, by overcoming the technical barriers hampering continuous flow processing. No scale-up of this extent and breadth in the field of ultrasound- and microwave-assisted continuous chemical processes has been validated and demonstrated so far.
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's vision is that of intensified processes, where alternative energy sources enable continuous and modular technologies to achieve localized actuation of multiphase, flow reactors for the purpose of high-value product synthesis. SIMPLI-DEMO focuses on the synthesis of specialty polymers and particles for use in a wide variety of every-day-use products, e.g. insulation, paints and coatings, plastics, catalysts, as well as health applications, which are important domains in the chemical industry today and into the future. Therefore, 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 present the first pilot-scale system prototype demonstration for the long-term uninterrupted modular flow operation of solids-laden and viscous-phase containing liquid process streams allowing for decentralized production. We want to achieve this by combining continuous flow equipment (Reactive Extrusion-REX, Continuous Oscillatory Baffled Reactor-COBR) with the alternative energy forms of ultrasound and microwaves as process enablers for the transition from batch to continuous.
The results of this project will revolutionize the way the chemical industry currently approaches the process intensification of complex multiphase processes, by overcoming the technical barriers hampering continuous flow processing. No scale-up of this extent and breadth in the field of ultrasound- and microwave-assisted continuous chemical processes has been validated and demonstrated so far.
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)
In M1-18, the activities focused on starting work in all work packages (except WP4) as described in the DoA.
In WP1, the chemistry of the different cases of polymerisation - Hydrophobically modified Ethylene oxide Urethane (HEUR), Hydrophobically Modified PolyEthers (HMPE) and Non-Isocyanate Polyurethanes (NIPU) - is currently being investigated at lab scale. In addition, analytical tools are developed and analysed that enable various analytical procedures in the set-up of the extrusion technology (reactive extruders) and are specifically geared to the unique chemistry behind HMPE synthesis. By leveraging spectroscopic techniques for modular implementation of probes, we aim to enhance our understanding of the process and ensure transfer to the reactive extrusion synthesis process and high-quality production. A guideline is established for pilot extrusion processing, assisted by ultrasound-induced power transfer, addressing varied material properties and insights were provided into the power transfer efficiency.
WP2 consists on the implementation of flow process equipment (COBR) for the synthesis of zeolites and particle synthesis. An automated modular system unit was revamped for the synthesis of zeolites at higher temperature and pressure including ultrasound, microwaves actuators and multiple particle size analyzers (PATs). The new pilot unit was validated with the first synthesis of zeolites. The study of downstream sections (filtration and washing) for manufacturing of high added value chemicals has started. For the Active Pharmaceutical Ingredients (APIs), lab experiments run in parallel with the design, purchase and installation of two process systems of different scales. A laboratory unit was successfully received and installed. Training of the lab unit was conducted in July 2023.
WP3 has focused on the parametric studies to investigate the effect of ultrasound and microwaves (mainly in batch operation mode) on the four case-studies of the project - HEUR/HMPE extrusion, NIPU synthesis, zeolite and API synthesis. First, the effect of critical process parameters including microwaves and ultrasound on these processes has partially been identified, but this work is still in progress. Second, process models for the processes have been developed. Third, online monitoring tools and techniques have been applied to the synthesis process units for the selected polymerization processes and zeolite/API syntheses.
The activities of WP5 are related to the plantwide process model development, techno-economic, environmental and sex, gender and intersectionality assessments of all case studies. The work presented herein delivers a comprehensive approach for the state-of-the-art processes of the four SIMPLI-DEMO cases. Hybrid models that combine Aspen Plus process simulation software and Python environment are currently under development. The main objective of developing such models is to overcome challenges associated with not well-studied systems that deal with polymer processes and components with missing properties.
In WP1, the chemistry of the different cases of polymerisation - Hydrophobically modified Ethylene oxide Urethane (HEUR), Hydrophobically Modified PolyEthers (HMPE) and Non-Isocyanate Polyurethanes (NIPU) - is currently being investigated at lab scale. In addition, analytical tools are developed and analysed that enable various analytical procedures in the set-up of the extrusion technology (reactive extruders) and are specifically geared to the unique chemistry behind HMPE synthesis. By leveraging spectroscopic techniques for modular implementation of probes, we aim to enhance our understanding of the process and ensure transfer to the reactive extrusion synthesis process and high-quality production. A guideline is established for pilot extrusion processing, assisted by ultrasound-induced power transfer, addressing varied material properties and insights were provided into the power transfer efficiency.
WP2 consists on the implementation of flow process equipment (COBR) for the synthesis of zeolites and particle synthesis. An automated modular system unit was revamped for the synthesis of zeolites at higher temperature and pressure including ultrasound, microwaves actuators and multiple particle size analyzers (PATs). The new pilot unit was validated with the first synthesis of zeolites. The study of downstream sections (filtration and washing) for manufacturing of high added value chemicals has started. For the Active Pharmaceutical Ingredients (APIs), lab experiments run in parallel with the design, purchase and installation of two process systems of different scales. A laboratory unit was successfully received and installed. Training of the lab unit was conducted in July 2023.
WP3 has focused on the parametric studies to investigate the effect of ultrasound and microwaves (mainly in batch operation mode) on the four case-studies of the project - HEUR/HMPE extrusion, NIPU synthesis, zeolite and API synthesis. First, the effect of critical process parameters including microwaves and ultrasound on these processes has partially been identified, but this work is still in progress. Second, process models for the processes have been developed. Third, online monitoring tools and techniques have been applied to the synthesis process units for the selected polymerization processes and zeolite/API syntheses.
The activities of WP5 are related to the plantwide process model development, techno-economic, environmental and sex, gender and intersectionality assessments of all case studies. The work presented herein delivers a comprehensive approach for the state-of-the-art processes of the four SIMPLI-DEMO cases. Hybrid models that combine Aspen Plus process simulation software and Python environment are currently under development. The main objective of developing such models is to overcome challenges associated with not well-studied systems that deal with polymer processes and components with missing properties.
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 will be performed in M18-24 in WP5, based on the mass & energy balances that were calculated during the first reporting period (i.e. M1-18). The polluting drivers will be also identified serving as decisionmaker for further technology optimization at the development stage.
Inventory data were also collected from the end-users and the academic partners
The expected benefits for SIMPLI-DEMO have not changed compared to the start of the project:
• 30-80 % energy savings
• 40-70% resource efficiency
• Up to 60% reduction in CO2 emission
• 20-45% savings in CAPEX
• 45-55% savings 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 will be performed in M18-24 in WP5, based on the mass & energy balances that were calculated during the first reporting period (i.e. M1-18). The polluting drivers will be also identified serving as decisionmaker for further technology optimization at the development stage.
Inventory data were also collected from the end-users and the academic partners
The expected benefits for SIMPLI-DEMO have not changed compared to the start of the project:
• 30-80 % energy savings
• 40-70% resource efficiency
• Up to 60% reduction in CO2 emission
• 20-45% savings in CAPEX
• 45-55% savings in OPEX