<strong>Optimisation of an esterification reaction</strong></br>Case Study

Optimisation of an esterification reaction
Case Study

Specialty Chemicals, Fine Chemicals
PROJECT DESCRIPTION Our client produces polymers by polyesterification on several sites all over the world. He wants to reduce esterification time by optimizing mixing of reactants and distillation of light products. This has to be done for each site. PROJECT METHODOLOGY Processium diagnoses the hydrodynamics regime of each reactor. Based on hydrodynamics regime and impeller design, Processium proposes other impellers. A sizing of each new impeller is proposed. Solutions are compared and ranked. A new impeller and its sizing is chosen with the client. Distillation mode are not the same, depending on the site. Especially, regulation mode are not the same. Processium proposes a standard of regulation mode to ensure process robustness. A new packing is also proposed, to ensure distillate quality. RESULTS The process is optimized via change of impellers…
Read More
<strong>Measurements of density, heat capacity, viscosity and thermal conductivity on heat transfer fluids up to 250°C</strong></br>Case Study

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

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.
Read More
<strong>Deactivation test on catalysts</strong></br>Case Study

Deactivation test on catalysts
Case Study

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.…
Read More
<strong>Debottlenecking of batch process</strong></br>Case Study

Debottlenecking of batch process
Case Study

Specialty Chemicals
PROJECT DESCRIPTION The Client produces ester in a batch process (reaction + distillation column). Processium services were requested to enhance unit productivity by decreasing the duration of each batch. Improvement of co-product quality is also requested and part of the Project. OUR METHODOLOGY The first task issued by Processium was a statistical study on process data issued from SNCC to identify the reasons for dysfunction among all parameters (quality of reactants, temperature, stoechiometry, …). This study highlighted several parameters responsible of malfunctions of the unit. Thanks to the management of these identified parameters during production, productivity increased of 5%. Following this first study, Processium conducted a new study based on kinetics and thermodynamics measurements, development of corresponding models and process optimization using ASPEN simulation. RESULTS Unit had been debottlenecked (10%) without…
Read More
<strong>Odour removal</strong></br>Case Study

Odour removal
Case Study

Specialty Chemicals
PROJECT DESCRIPTION The Client uses distillation to purify an added value product. One of the impurity is an odorous molecule that causes two limitations: the product can not be supplied for specific application because of the smell given to the product by the odorous impurity, in order to limit the quantity of odorous impurity in the product, the yield of purification has to remain low. The Client asks to Processium to identify a technical solution to retain the odorous impurity  in the bottom of the distillation column. OUR METHODOLOGY To be able to propose technical solutions, Processium developed the following methodology: identification of a technical solution (bibliography, internal know-how), screening of existing activated carbons using in-house database including exhaustive data on possible suppliers, development of a design of experiments to minimize…
Read More
Case study: Challenging a newly developed process

Case study: Challenging a newly developed process

Specialty Chemicals
PROJECT DESCRIPTION The Client has developed a new process to treat a waste stream: possible unit operations are chosen, theoretical mass and thermal balances are available, theoretical sizing is also available, CAPEX and OPEX estimate is issued. The Client asks to Processium to challenge the developed process in order to secure its operability, its productivity and to minimize uncertainities during its industrialisation OUR METHODOLOGY For each unit operation, Processium studies: the relevance of the technology, its performances (expected yield and purity), Its limitations. The process, as a whole, is studied to fully understand the product specifications, the yield, and all process limitations. RESULTS Processium issued a recommendation report containing explanation on: an "alert" on impurity accumulation on a recycling loop, a risk of reaction on activated carbon, an uncertainty on thermodynamics (impact…
Read More
Case study: Sample production at high level of purity

Case study: Sample production at high level of purity

Specialty 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…
Read More
Case study: Ethanol recovery

Case study: Ethanol recovery

Specialty Chemicals
PROJECT DESCRIPTION A Client’s process produces an effluent containing water and two solvents (including Ethanol). The Client asks Processium to design processes for Ethanol recovery on one hand, and both solvents recover on the other hand. The objective is to compare options: recover Ethanol on its own and the other solvent by a CMO, invest on new unit to recover both solvents on site. OUR METHODOLOGY After a process synthesis phase, Processium was able to propose three processes: Recovery of Ethanol at low quality and low costs. Recovery of Ethanol at high quality. Recovery of both solvents at process specifications. These processes are compared to custom manufacturing for solvents recovery. The 3 processes were designed and compared: CAPEX, OPEX, and robustness vs. yield and purity. RESULTS On the basis of this processes comparison,…
Read More
Case study: Solvent recovery

Case study: Solvent recovery

Specialty Chemicals
PROJECT DESCRIPTION The Project is to design and to develop a new unit able to separate three solvents (alcohols) mixed with salts and water with a 99.5% specification on purity. OUR METHODOLOGY The methodology developed by Processium was based on: Issue a thermodynamics diagnosis (azeotrope between two alcohols in one hand and water on the other hand). Process synthesis to propose processes based on pressure swing distillation, liquid-liquid extraction (including solvent selection), extractive distillation and azeotropic distillation. Sizing of the best process. Laboratory and pilot scale validation of process sizing. RESULTS On the basis of technical package issued by Processium, the new unit had been built is still running.
Read More
Case study: Design and development of process to recover alcohols

Case study: Design and development of process to recover alcohols

Specialty Chemicals
PROJECT DESCRIPTION A Client produces a chemical component through following reaction: Formol + Alcohol → Main Product + Water One of the streams of the process is a mixture formol-alcohol-water. Water has to be removed, purified and sent back to environment, alcohol and formol have to be purified and sent back to reactor. The Client asks Processium to design and develop the process to recover each component. The designed process will be integrated to existing process. The stakes deal with environment and reactor debottlenecking. OUR METHODOLOGY One of the main constraints of the Project deals with formol instability; Depending on concentration and temperature, formol turns into methylene glycol and oligomers. Processium studies driving forces to separate the components (differences between physical properties), and formol conversion kinetics. Several solutions are identified to separate…
Read More