Case study: Measurements of density, heat capacity, viscosity and thermal conductivity on heat transfer fluids up to 250°C

Case study: Measurements of density, heat capacity, viscosity and thermal conductivity on heat transfer fluids up to 250°C

Specialty Chemicals, Oil and Gas, Fine Chemicals

PROJECT DESCRIPTION

Our customer wishes to characterize thermophysical properties (heat capacity, vapour pressure, viscosity, density, thermal conductivity, etc.) of new heat transfer fluids used in a wide range of temperatures.

TECHNICAL CHALLENGES

Our teams of experts conducted tests on the fluids with in mind the temperature dependence of each property in order to optimise the number of experimental points to reduce the cost for the client.

RESULTS

A complete mapping of physical properties to provide technical datasheet of each thermal fluid.

viscosity-curve
thermal-conductivity-curve
heat-capacity-curve
Case study: Deactivation test on catalysts

Case study: Deactivation test on catalysts

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Fine Chemicals

PROJECT DESCRIPTION

Our customer wishes to know the kinetic of deactivation of its catalyst under industrial conditions in order to adapt the sizing of corresponding process accordingly. In addition to this, the definition of the frequency of replacement of the catalyst was also an issue to secure productivity.

TECHNICAL CHALLENGES

Test should be performed continuously over hundreds of hours on a reactive mixture under conditions which precisely represent the operating conditions (temperatures over 250°C and pressures of 6 bar).

The test needed to implement a dedicated bench to test the catalyst in continuous mode.

OUR METHODOLOGY

  • Design and development of a continuous reaction bench equipped with a tubular reactor working in conditions close to those of the process (6 bar and 250°C).
  • Regular sampling from the reactor for 30 days.
  • Analysis of the samples to obtain a follow-up of the kinetic of deactivation.
  • Definition of a reliable kinetic model integrating a term of deactivation.

RESULTS

Sizing of the process is adapted according to this new model. The frequency of replacement of catalyst is also defined on the basis of the model.

This model allows to secure the annual production of several thousand tons of products.

Case study: Sample production at high level of purity

Case study: Sample production at high level of purity

Fine Chemicals

PROJECT DESCRIPTION

A client has developed a new chemical product whose synthesis is carried out on Client plant. For a specific market, specifications of product requests a 95% purity, knowing that main by-product is an isomer of the product. Existing unit is not designed to reach such a purity.

Client request is to define technical feasibility of the purification and the sampling of the pure product.

OUR METHODOLOGY

Processium compared two possible purification technologies: melt crystallization and distillation. It appeared that vacuum distillation led to best results regarding yield and purity.

Using its own laboratory equipment, Processium distillated 5 kg of raw product on batch mode on a 30 theoretical stages column, at 5 mbar. At the end, 3.6 kg of product at 95.5% purity were produced.

RESULTS

Processium produced requested quantity and quality of product to allow its Client to supply the end-users for product validation.

Case study: Solvent recovery process development

Case study: Solvent recovery process development

Fine Chemicals

PROJECT DESCRIPTION

The Project is to design and to develop a new unit able to separate two solvents (alcohol and ketone) mixed with salts and water with a 99.9% specification on purity.

OUR METHODOLOGY

The methodology developed by Processium was based on:

  • Issue a thermodynamics diagnosis.
  • Process synthesis to propose processes based on pressure swing distillation, liquid-liquid extraction, extractive distillation and azeotropic distillation.
  • Sizing of the best process.
  • Laboratory and pilot scale validation of process sizing.
  • Production of samples.

RESULTS

On the basis of technical package issued by Processium, the new unit had been built is still running.

Case study: Risk assessment of a chemical reaction thermal runaway

Case study: Risk assessment of a chemical reaction thermal runaway

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Fine Chemicals

PROJECT DESCRIPTION

The Client wishes to implement a new chemical reaction on industrial site under the SEVESO directive.

Processium brought them its know-how into thermal analyses to evaluate the risks of thermal runaway of this reaction.

TECHNICAL CHALLENGES

The challenges met in this project are the following ones:

  • Non-available physico-chemical data,
  • Complex products implementation,
  • Measurements under pressure up to about 5 bar.

OUR METHODOLOGY

Processium carries out this study from drawing-up the specifications to the measurements of all properties:

  • Vapor pressure of reagents and products,
  • Thermal stability: decomposition temperature (Tonset), time to maximum rate (TMRad),
  • Reaction kinetics,
  • Reaction enthalpy,
  • Heat capacity,
  • Maximum Temperature of the Synthesis Reaction (MTSR),
  • Nature and gas flow released during the reaction.

RESULTS

The measured data define the level of criticality of the chemical reaction and equipment size to minimize risks.

Case study: Vapor-liquid equilibria of solvent and light hydrocarbons

Case study: Vapor-liquid equilibria of solvent and light hydrocarbons

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Paints and Coatings, Fine Chemicals

PROJECT DESCRIPTION

The objective of this study is to acquire data to design an extractive distillation process for separating light hydrocarbons.

TECHNICAL CHALLENGES

A key element of success in the study is the measurement of vapor-liquid equilibria at pressures of 2 to 5 bar, to determine the liquid and vapor compositions in a mixture of heavy and light components (boiling point difference > 230°C).

OUR METHODOLOGY

We undertook this study by:

  • Developing efficient analytic methods,
  • Developing a suitable experimental strategy to acquire measurements in line with customer’s project and time constraints.

RESULTS

The measurements were carried out successfully in our labs, and Processium was able to provide:

  • A feedback on notable issues encountered, particularly degeneration of seals or corrosion problems
  • Data values which allowed our customers to better understand their process, and for the licensor to anticipate autonomously any future maintenances. A considerable profit in maintenance was achieved with this study.
Case study: Vapor-liquid-liquid equilibria of vegetable oil/methanol/glycerol

Case study: Vapor-liquid-liquid equilibria of vegetable oil/methanol/glycerol

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Paints and Coatings, Fine Chemicals

PROJECT DESCRIPTION

Our client conducted a study of biodiesel conversion and separation in which our teams provided essential thermodynamic expertise for the design of the process.

TECHNICAL CHALLENGES

The objective of this study was to obtain liquid-liquid-vapour equilibria measurements for a complex mixture. This study involved:

  • Thermodynamic measurements on viscous mixtures at high pressure
  • Very complex sampling protocol as a result of the differences in volatility of the compounds (methanol-glycerol) and the operating conditions

A complex analysis process due to the nature (vegetable oil) and the physical properties of the compounds

OUR METHODOLOGY

Processium successfully completed this study by using:

  • A customized experimental strategyallowing timely data acquisition in line with client project requirements
  • Objectivity and a wider perspectivein interpreting the obtained results to precisely understand the behaviour of client compounds.

RESULTS

The measurements allowed definition of the thermodynamic behavior of products mixture in a large range of temperature (60 to 200°C). This data acquisition allows client to successfully design its reactors.

Case study: Prediction of physico-chemical data

Case study: Prediction of physico-chemical data

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Paints and Coatings, Fine Chemicals

PROJECT DESCRIPTION

Our client, a manufacturer of synthetic oils, wishes to determinate the vapor pressure and the boiling point of oil’s constituents in order to design and optimize their production processes.

TECHNICAL CHALLENGES

The challenges met in this project are the following ones:

  • Presence of considerable number of compounds in each oil, whose properties are unknown (high cost for carrying out measurements)
  • Difficulty of separation and purification of these synthetic oils: it is impossible to access to pure compound

OUR METHODOLOGY

The method of physico-chemical data prediction, specifically developed for this project, allows to free itself from properties measurement of these products. It consists in the following steps:

  • Definition of a customized decomposition method for these synthetic oils
  • Evaluation and sorting of available data based on the specifications. The e-thermoTM software developed by Processium allows to reach and sort out quickly the data
  • Development of the most performing model to represent the customer products
  • Validation of the reliability of the model
  • Development of the experimental design to strengthen the reliability of the model for certain types of molecules and extend the field of applications
  • Measurement of complementary data of vapor pressure and boiling point
  • Final update of the model

RESULTS

The use of this static approach allows:

  • A gain of time for the selection of the prediction model
  • An optimal selection of the molecules to characterize (pressure range of interest, distribution of functional group…) in order to improve the model

This model is currently used by our client for its ongoing projects.

Case study: Solvent selection

Case study: Solvent selection

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Paints and Coatings, Fine Chemicals

PROJECT DESCRIPTION

Our client has developed a production process of organic acids by fermentation. Organic acids need to be extracted and purify from the broth using a solvent extraction technology.

TECHNICAL CHALLENGES

In order to satisfy client requirements for its Project, Processium had to to identify a bio-based solvent for the extraction of acids and able to preserve microbes used for fermentation.

OUR METHODOLOGY

The methodology developed by Processium for the successful development of the Project had been developed as follow:

  • screening of in - house database containing more than 1,000 industrial solvents data sets,
  • identification of additional candidate determined thanks to a specific Computer Aided Molecular Design tool,
  • modeling of solvent properties and prediction of missing data,
  • identification of 5 solvents and measurement of distribution coefficients,
  • performance evaluation of solvents on Processium own extraction pilot scale unit,
  • sizing of corresponding unit at industrial scale,
  • CAPEX and OPEX estimate for the purification process.

RESULTS

Thanks to Processium methodology, solvent selection and associated purification technology had been defined technically and economically.

Case study: Salts solubility in water

Case study: Salts solubility in water

Industrial Biotechnlogy, Specialty Chemicals, Oil and Gas, Natural Ingredients, Paints and Coatings, Fine Chemicals

PROJECT DESCRIPTION

Our customer wishes to know the solubility of a solid inorganic salt in an aqueous solution at 80 °C. The influence of pH of this solution on the solubility of the salt must be estimated.
Measures are led at 3 different hydrogen potential by going from pH 4 (acidic), pH 7 (neutral) and to pH 9 (basic).

TECHNICAL CHALLENGES

  • Why do we speak about challenges? For two main reasons:The solubility of the salt in the liquid is very high. The first difficulty is to identify an analytical methodology adapted to the inorganic solid. ICP-AES had been selected as the most accurate technique for the analysis of this molecule and was successfully used.
  • Thermogravimetry study was coupled with a specific chemical analysis to insure reliability of the supplied results because of the combination of these two analytical methods.

OUR METHODOLOGY

  • We use an equipment able to realize measures at high temperatures until 150 °C.
  • The quality of the supplied results is validated by a repeatability procedure within the frame of REACH standards.