Front Cover -- Process Intensification -- Copyright Page -- Contents -- Foreword -- Preface -- Acknowledgements -- Introduction -- References -- 1 A Brief History of Process Intensification -- 1.1 Introduction -- 1.2 Rotating boilers -- 1.2.1 The rotating boiler/turbine concept -- 1.2.2 NASA work on rotating boilers -- 1.3 The rotating heat pipe -- 1.3.1 Rotating air conditioning unit -- 1.4 The chemical process industry - the process intensification breakthrough at ICI -- 1.5 Separators -- 1.5.1 The Podbielniak extractor -- 1.5.2 Centrifugal evaporators -- 1.5.3 The still of John Moss -- 1.5.4 Extraction research in Bulgaria -- 1.6 Reactors -- 1.6.1 Catalytic plate reactors -- 1.6.2 Polymerisation reactors -- 1.6.3 Rotating fluidised bed reactor -- 1.6.4 Reactors for space experiments -- 1.6.5 Towards perfect reactors -- 1.7 Non-chemical industry-related applications of rotating heat and mass transfer -- 1.7.1 Rotating heat transfer devices -- 1.7.1.1 Liquid cooled rotating anodes -- 1.7.1.2 The Audiffren Singrun (AS) machine -- 1.7.1.3 John Coney rotating unit -- 1.8 Where are we today? -- 1.8.1 Clean technologies -- 1.8.2 Integration of process intensification and renewable energies -- 1.8.3 PI and carbon capture -- 1.9 Summary -- References -- 2 Process Intensification - An Overview -- 2.1 Introduction -- 2.2 What is process intensification? -- 2.3 The original ICI PI strategy -- 2.4 The advantages of PI -- 2.4.1 Safety -- 2.4.2 The environment -- 2.4.3 Energy -- 2.4.3.1 Early UK energy assessments -- 2.4.3.2 Current UK strategy on PI -- 2.4.3.3 A major European initiative -- 2.4.3.4 Support for PI in the US -- 2.4.4 The business process -- 2.4.4.1 The PI 'Project House' at Degussa -- 2.4.4.2 Benefits of PI for Rhodia -- 2.5 Some obstacles to PI -- 2.6 A way forward -- 2.7 To whet the reader's appetite.

2.8 Equipment summary - finding your way around this book -- 2.9 Summary -- References -- 3 The Mechanisms Involved in Process Intensification -- 3.1 Introduction -- 3.2 Intensified heat transfer - the mechanisms involved -- 3.2.1 Classification of enhancement techniques -- 3.2.2 Passive enhancement techniques -- 3.2.2.1 Treated surfaces -- 3.2.2.2 Extended surfaces -- 3.2.2.3 Swirl flow devices -- 3.2.2.4 Additives (for liquids and gases) -- 3.2.2.5 Surface catalysis -- 3.2.3 Active enhancement methods -- 3.2.3.1 Mechanical aids -- 3.2.3.2 Fluid vibration -- 3.2.3.3 Electrostatic fields -- 3.2.3.4 Rotation -- 3.2.3.5 Induced flow instabilities -- 3.2.4 System impact of enhancement/intensification -- 3.3 Intensified mass transfer - the mechanisms involved -- 3.3.1 Rotation -- 3.3.2 Vibration -- 3.3.3 Mixing -- 3.4 Electrically enhanced processes - the mechanisms -- 3.5 Micro fluidics -- 3.5.1 Electrokinetics -- 3.5.2 Magnetohydrodynamics (MHD) -- 3.5.3 Opto-micro-fluidics -- 3.6 Pressure -- 3.7 Summary -- References -- 4 Compact and Micro-heat Exchangers -- 4.1 Introduction -- 4.2 Compact heat exchangers -- 4.2.1 The plate heat exchanger -- 4.2.2 Printed circuit heat exchangers (PCHE) -- 4.2.3 The Chart-flo heat exchanger -- 4.2.4 Polymer film heat exchanger -- 4.2.5 Foam heat exchangers -- 4.2.6 Mesh heat exchangers -- 4.3 Micro-heat exchangers -- 4.4 What about small channels? -- 4.5 Nano-fluids -- 4.6 Summary -- References -- 5 Reactors -- 5.1 Reactor engineering theory -- 5.1.1 Reaction kinetics -- 5.1.2 Residence time distributions (RTDs) -- 5.1.3 Heat and mass transfer in reactors -- 5.1.3.1 Mass transfer -- 5.1.3.2 Heat transfer -- 5.2 Spinning disc reactors -- 5.2.1 Exploitation of centrifugal fields -- 5.2.2 The desktop continuous process -- 5.2.3 The spinning disc reactor -- 5.2.4 The Nusselt flow model -- 5.2.5 Mass transfer.

5.2.6 Heat transfer -- 5.2.7 Film-flow instability -- 5.2.8 Film-flow studies -- 5.2.9 Heat/mass transfer performance -- 5.2.10 Spinning disc reactor applications -- 5.2.10.1 Strategic considerations -- 5.3 Other rotating reactors -- 5.3.1 Rotor stator reactors: the STT reactor -- 5.3.2 Taylor-Couette reactor -- 5.3.2.1 Applications -- 5.3.3 Rotating packed bed reactors -- 5.4 Oscillatory baffled reactors (OBRs) -- 5.4.1 Gas-liquid systems -- 5.4.2 Liquid-liquid systems -- 5.4.3 Heat transfer -- 5.4.4 OBR design -- 5.4.5 Biological applications -- 5.4.6 Solids suspension -- 5.4.7 Crystallisation -- 5.4.8 Oscillatory meso-reactors: scaling OBRs down -- 5.4.9 Case study -- 5.5 Micro-reactors (including hex-reactors) -- 5.5.1 The catalytic plate reactor (CPR) -- 5.5.1.1 Steam reforming -- 5.5.1.2 Methane reforming -- 5.5.1.3 Fischer-Tropsch synthesis -- 5.5.2 HEX-reactors -- 5.5.2.1 The Alfa Laval plate heat exchanger reactor -- 5.5.2.2 The HELIX reactor -- 5.5.2.3 The PCR - printed circuit reactor -- 5.5.2.4 The multiple adiabatic-bed PCR -- 5.5.2.5 The chart compact heat exchanger reactors -- 5.5.3 The corning micro-structured reactor -- 5.5.4 Constant power reactors -- 5.5.4.1 Case study -- 5.6 Field-enhanced reactions/reactors -- 5.6.1 Induction-heated reactor -- 5.6.2 Sonochemical reactors -- 5.6.2.1 Biological applications of ultrasound -- 5.6.3 Microwave enhancement -- 5.6.4 Plasma reactors -- 5.6.5 Laser-induced reactions -- 5.7 Reactive separations -- 5.7.1 Reactive distillation -- 5.7.2 Reactive extraction -- 5.7.3 Reactive adsorption -- 5.8 Membrane reactors -- 5.8.1 Tubular membrane reactor -- 5.8.2 Membrane slurry reactor -- 5.8.3 Biological applications of membrane reactors -- 5.9 Supercritical operation -- 5.9.1 Applications -- 5.10 Miscellaneous intensified reactor types -- 5.10.1 The Torbed reactor -- 5.10.1.1 Applications.

5.10.2 Catalytic reactive extruders -- 5.10.3 Heat pipe reactors -- 5.11 Summary -- References -- 6 Intensification of Separation Processes -- 6.1 Introduction -- 6.2 Distillation -- 6.2.1 Distillation - dividing wall columns -- 6.2.2 Compact heat exchangers inside the column -- 6.2.3 Cyclic distillation systems -- 6.2.4 HiGee -- 6.2.4.1 Principal HiGee operating features -- 6.2.4.2 Phase inversion -- 6.2.4.3 Modelling of rotating packed beds -- 6.3 Centrifuges -- 6.3.1 Conventional types -- 6.3.2 The gas centrifuge -- 6.4 Membranes -- 6.5 Drying -- 6.5.1 Electric drying and dewatering methods -- 6.5.1.1 Microwaves -- 6.5.1.2 Radio frequency fields -- 6.5.2 Membranes for dehydration -- 6.6 Precipitation and crystallisation -- 6.6.1 The environment for particle formation -- 6.6.2 The spinning cone -- 6.6.3 Electric fields to aid crystallisation of thin films -- 6.7 Mop fan/deduster -- 6.7.1 Description of the equipment -- 6.7.2 Capture mechanism/efficiency -- 6.7.3 Applications -- 6.8 Electrolysis -- 6.8.1 Introduction -- 6.8.2 The effect of microgravity -- 6.8.3 The effect of high gravity -- 6.8.4 Current supply -- 6.8.5 Rotary electrolysis cell design -- 6.8.5.1 Instrumentation for the rotary cell -- 6.8.5.2 Static electrolysis cell -- 6.8.6 The static cell tests -- 6.8.6.1 Effect of electrode structure -- 6.8.6.2 Effect of electrode spacing -- 6.8.7 The rotary cell experiments -- 6.8.7.1 The effect of centrifugal acceleration -- 6.9 Summary -- References -- 7 Intensified Mixing -- 7.1 Introduction -- 7.2 Inline mixers -- 7.2.1 Static mixers -- 7.2.1.1 Mixing in the context of micro-fluidics -- 7.2.1.2 Example of a mixer heat exchanger -- 7.2.2 Ejectors -- 7.2.3 Rotor stator mixers -- 7.3 Mixing on a spinning disc -- 7.4 Induction-heated mixer -- 7.5 Summary -- References -- 8 Application Areas - Petrochemicals and Fine Chemicals -- 8.1 Introduction.

8.2 Refineries -- 8.2.1 Catalytic plate reactor opportunities -- 8.2.2 More speculative opportunities -- 8.3 Bulk chemicals -- 8.3.1 Stripping and gas clean-up -- 8.3.1.1 Chinese tail gas cleaning plant-acid stripping using an RPB -- 8.3.1.2 Acid stripping using HiGee at Dow Chemicals -- 8.3.1.3 Removal of NOx in industrial tail gas -- 8.3.1.4 Use of the 'Mop Fan' on an ammonium nitrate granulator dryer -- 8.3.2 Intensified methane reforming -- 8.3.3 The hydrocarbon chain -- 8.3.4 Reactive distillations for methyl and ethyl acetate -- 8.3.5 Formaldehyde from methanol using micro-reactors -- 8.3.6 Hydrogen peroxide production - the Degussa PI route -- 8.3.7 Olefin hydroformylation - use of a HEX-reactor -- 8.3.8 Polymerisation - the use of spinning disc reactors -- 8.3.8.1 Manufacture of polystyrene -- 8.3.8.2 Polycondensation -- 8.3.9 Akzo Nobel Chemicals - reactive distillation -- 8.3.10 The gas turbine reactor - a challenge for bulk chemical manufacture -- 8.3.10.1 Background -- 8.3.10.2 Factors affecting feasibility -- 8.3.10.3 Recuperative steam cooled gas turbine -- 8.3.10.4 Blade cooling with endothermic fuel -- 8.3.10.5 Gas turbine plus fuel cell -- 8.3.10.6 Reforming and reheat combusting in a gas turbine -- 8.3.10.7 Methane plate reformer coupled with a gas turbine -- 8.3.10.8 Partial oxidation gas turbine cycle (POGT) -- 8.3.10.9 Selected concepts -- Intercooling -- Recuperation -- Reheating -- 8.3.10.10 The 'Turbo-cracker' - an ICI concept -- 8.3.10.11 Cogeneration of ethylene and electricity -- 8.3.11 Other bulk chemical applications in the literature -- 8.4 Fine chemicals and pharmaceuticals -- 8.4.1 Penicillin extraction -- 8.4.2 AstraZeneca work on continuous reactors -- 8.4.3 Micro-reactor for barium sulphate production -- 8.4.4 Spinning disc reactor for barium carbonate production.

8.4.5 Spinning disc reactor for producing a drug intermediate.