Process Intensification For Green Chemistry: Engineering Solutions for Sustainable Chemical Processing -- Contents -- List of Contributors -- Preface -- 1 Process Intensification: An Overview of Principles and Practice -- 1.1 Introduction -- 1.2 Process Intensification: Definition and Concept -- 1.3 Fundamentals of Chemical Engineering Operations -- 1.3.1 Reaction Engineering -- 1.3.2 Mixing Principles -- 1.3.3 Transport Processes -- 1.4 Intensification Techniques -- 1.4.1 Enhanced Transport Processes -- 1.4.2 Integrating Process Steps -- 1.4.3 Moving from Batch to Continuous Processing -- 1.5 Merits of PI Technologies -- 1.5.1 Business -- 1.5.2 Process -- 1.5.3 Environment -- 1.6 Challenges to Implementation of PI -- 1.7 Conclusion -- Nomenclature -- Greek Letters -- References -- 2 Green Chemistry Principles -- 2.1 Introduction -- 2.1.1 Sustainable Development and Green Chemistry -- 2.2 The Twelve Principles of Green Chemistry -- 2.2.1 Ideals of Green Chemistry -- 2.3 Metrics for Chemistry -- 2.3.1 Effective Mass Yield -- 2.3.2 Carbon Efficiency -- 2.3.3 Atom Economy -- 2.3.4 Reaction Mass Efficiency -- 2.3.5 Environmental (E) Factor -- 2.3.6 Comparison of Metrics -- 2.4 Catalysis and Green Chemistry -- 2.4.1 Case Study: Silica as a Catalyst for Amide Formation -- 2.4.2 Case Study: Mesoporous Carbonaceous Material as a Catalyst Support -- 2.5 Renewable Feedstocks and Biocatalysis -- 2.5.1 Case Study: Wheat Straw Biorefinery -- 2.6 An Overview of Green Chemical Processing Technologies -- 2.6.1 Alternative Reaction Solvents for Green Processing -- 2.6.2 Alternative Energy Reactors for Green Chemistry -- 2.7 Conclusion -- References -- 3 Spinning Disc Reactor for Green Processing and Synthesis -- 3.1 Introduction -- 3.2 Design and Operating Features of SDRs -- 3.2.1 Hydrodynamics -- 3.2.2 SDR Scale-up Strategies -- 3.3 Characteristics of SDRs.

3.3.1 Thin-film Flow and Surface Waves -- 3.3.2 Heat and Mass Transfer -- 3.3.3 Mixing Characteristics -- 3.3.4 Residence Time and Residence Time Distribution -- 3.3.5 SDR Applications -- 3.4 Case Studies: SDR Application for Green Chemical Processing and Synthesis -- 3.4.1 Cationic Polymerization using Heterogeneous Lewis Acid Catalysts -- 3.4.2 Solvent-free Photopolymerization Processing -- 3.4.3 Heterogeneous Catalytic Organic Reaction in the SDR: An Example of Application to the Pharmaceutical/Fine Chemicals Industry -- 3.4.4 Green Synthesis of Nanoparticles -- 3.5 Hurdles to Industry Implementation -- 3.5.1 Control, Monitoring and Modelling of SDR Processes -- 3.5.2 Limited Process Throughputs -- 3.5.3 Cost and Availability of Equipment -- 3.5.4 Lack of Awareness of SDR Technology -- 3.6 Conclusion -- Nomenclature -- Greek Letters -- Subscripts -- References -- 4 Micro Process Technology and Novel Process Windows - Three Intensification Fields -- 4.1 Introduction -- 4.2 Transport Intensification -- 4.2.1 Fundamentals -- 4.2.2 Mixing Principles -- 4.2.3 Micromixers -- 4.2.4 Micro Heat Exchangers -- 4.2.5 Exothermic Reactions as Major Application Examples -- 4.3 Chemical Intensification -- 4.3.1 Fundamentals -- 4.3.2 New Chemical Transformations -- 4.3.3 High Temperature -- 4.3.4 High Pressure -- 4.3.5 Alternative Reaction Media -- 4.4 Process Design Intensification -- 4.4.1 Fundamentals -- 4.4.2 Large-scale Manufacture of Adipic Acid - A Full Process Design Vision in Flow -- 4.4.3 Process Integration - From Single Operation towards Full Process Design -- 4.4.4 Process Simplification -- 4.5 Industrial Microreactor Process Development -- 4.5.1 Industrial Demonstration of Specialty/Pharma Chemistry Flow Processing -- 4.5.2 Industrial Demonstration of Fine Chemistry Flow Processing -- 4.5.3 Industrial Demonstration of Bulk Chemistry Flow Processing.

4.6 Conclusion -- Acknowledgement -- References -- 5 Green Chemistry in Oscillatory Baffled Reactors -- 5.1 Introduction -- 5.1.1 Continuous versus Batch Operation -- 5.1.2 The Oscillatory Baffled Reactor's 'Niche' -- 5.2 Case Studies: OBR Green Chemistry -- 5.2.1 A Saponification Reaction -- 5.2.2 A Three-phase Reaction with Photoactivation for Oxidation of Waste Water Contaminants -- 5.2.3 'Mesoscale' OBRs -- 5.3 Conclusion -- References -- 6 Monolith Reactors for Intensified Processing in Green Chemistry -- 6.1 Introduction -- 6.2 Design of Monolith Reactors -- 6.2.1 Monolith and Washcoat Design -- 6.2.2 Reactor and Distributor Design -- 6.3 Hydrodynamics of Monolith Reactors -- 6.3.1 Flow Regimes -- 6.3.2 Mixing and Mass Transfer -- 6.4 Advantages of Monolith Reactors -- 6.4.1 Scale-out, Not Scale-up? -- 6.4.2 PI for Green Chemistry -- 6.5 Applications in Green Chemistry -- 6.5.1 Chemical and Fine Chemical Industry -- 6.5.2 Cleaner Production of Fuels -- 6.5.3 Removal of Toxic Emissions -- 6.6 Conclusion -- Acknowledgement -- Nomenclature -- Greek Letters -- Subscripts and Superscripts -- References -- 7 Process Intensification and Green Processing Using Cavitational Reactors -- 7.1 Introduction -- 7.2 Mechanism of Cavitation-based PI of Chemical Processing -- 7.3 Reactor Configurations -- 7.3.1 Sonochemical Reactors -- 7.3.2 Hydrodynamic Cavitation Reactors -- 7.4 Mathematical Modelling -- 7.5 Optimization of Operating Parameters in Cavitational Reactors -- 7.5.1 Sonochemical Reactors -- 7.5.2 Hydrodynamic Cavitation Reactors -- 7.6 Intensification of Cavitational Activity -- 7.6.1 Use of PI Parameters -- 7.6.2 Use of a Combination of Cavitation and Other Processes -- 7.7 Case Studies: Intensification of Chemical Synthesis using Cavitation -- 7.7.1 Transesterification of Vegetable Oils Using Alcohol.

7.7.2 Selective Synthesis of Sulfoxides from Sulfides Using Sonochemical Reactors -- 7.8 Overview of Intensification and Green Processing Using Cavitational Reactors -- 7.9 The Future -- 7.10 Conclusion -- References -- 8 Membrane Bioreactors for Green Processing in a Sustainable Production System -- 8.1 Introduction -- 8.2 Membrane Bioreactors -- 8.2.1 Membrane Bioreactors with Biocatalyst Recycled in the Retentate Stream -- 8.2.2 Membrane Bioreactors with Biocatalyst Segregated in the Membrane Module Space -- 8.3 Biocatalytic Membrane Reactors -- 8.3.1 Entrapment -- 8.3.2 Gelification -- 8.3.3 Chemical Attachment -- 8.4 Case Studies: Membrane Bioreactors -- 8.4.1 Biofuel Production Using Enzymatic Transesterification -- 8.4.2 Waste Water Treatment and Reuse -- 8.4.3 Waste Valorization to Produce High-added-value Compounds -- 8.5 Green Processing Impact of Membrane Bioreactors -- 8.6 Conclusion -- References -- 9 Reactive Distillation Technology -- 9.1 Introduction -- 9.2 Principles of RD -- 9.3 Design, Control and Applications -- 9.4 Modelling RD -- 9.5 Feasibility and Technical Evaluation -- 9.5.1 Feasibility Evaluation -- 9.5.2 Technical Evaluation -- 9.6 Case Studies: RD -- 9.6.1 Biodiesel Production by Heat-Integrated RD -- 9.6.2 Fatty Esters Synthesis by Dual RD -- 9.7 Green Processing Impact of RD -- 9.8 Conclusion -- References -- 10 Reactive Extraction Technology -- 10.1 Introduction -- 10.1.1 Definition and Description -- 10.1.2 Literature Review -- 10.2 Case Studies: Reactive Extraction Technology -- 10.2.1 Reactive Extraction for the Synthesis of FAME from Jatropha curcas L. Seeds -- 10.2.2 Supercritical Reactive Extraction for FAME Synthesis from Jatropha curcas L. Seeds -- 10.3 Impact on Green Processing and Process Intensification -- 10.4 Conclusion -- Acknowledgement -- References -- 11 Reactive Absorption Technology.

11.1 Introduction -- 11.2 Theory and Models -- 11.2.1 Equilibrium Stage Model -- 11.2.2 HTU/NTU Concepts and Enhancement Factors -- 11.2.3 Rate-based Stage Model -- 11.3 Equipment, Operation and Control -- 11.4 Applications in Gas Purification -- 11.4.1 Carbon Dioxide Capture -- 11.4.2 Sour Gas Treatment -- 11.4.3 Removal of Nitrogen Oxides -- 11.4.4 Desulfurization -- 11.5 Applications to the Production of Chemicals -- 11.5.1 Sulfuric Acid Production -- 11.5.2 Nitric Acid Production -- 11.5.3 Biodiesel and Fatty Esters Synthesis -- 11.6 Green Processing Impact of RA -- 11.7 Challenges and Future Prospects -- References -- 12 Membrane Separations for Green Chemistry -- 12.1 Introduction -- 12.2 Membranes and Membrane Processes -- 12.3 Case Studies: Membrane Operations in Green Processes -- 12.3.1 Membrane Technology in Metal Ion Removal from Waste Water -- 12.3.2 Membrane Operations in Acid Separation from Waste Water -- 12.3.3 Membrane Operation for Hydrocarbon Separation from Waste Water -- 12.3.4 Membrane Operations for the Production of Optically Pure Enantiomers -- 12.4 Integrated Membrane Processes -- 12.4.1 Integrated Membrane Processes for Water Desalination -- 12.4.2 Integrated Membrane Processes for the Fruit Juice Industry -- 12.5 Green Processing Impact of Membrane Processes -- 12.6 Conclusion -- References -- 13 Process Intensification in a Business Context: General Considerations -- 13.1 Introduction -- 13.2 The Industrial Setting -- 13.3 Process Case Study -- 13.3.1 Essential Lessons -- 13.4 Business Risk and Ideas -- 13.5 Conclusion -- References -- 14 Process Economics and Environmental Impacts of Process Intensification in the Petrochemicals, Fine Chemicals and Pharmaceuticals Industries -- 14.1 Introduction -- 14.2 Petrochemicals Industry -- 14.2.1 Drivers for Innovation -- 14.2.2 Conventional Technologies Used.

14.2.3 Commercially Applied PI Technologies.