alterego project presentation
TRANSCRIPT
ALTEREGO
Alternative Energy Forms for Green Chemistry
1
• EU-FP7-THEME [NMP.2012.3.0-1] • Highly efficient chemical syntheses using
alternative energy forms
• Alternative Energy Forms for Green Chemistry • Grant agreement no: 309874 • Project duration: 01/01/2013-30/06/2016
ALTEREGO
Objectives and approach
3
INTEGRATION
INTENSIFICATIO
N
ALTERNATIVE ENERGIES
Ultrasound
Microwaves Plasma
INTENSIFIED REACTORS
Mesoscale Tubular Reactors
Micro- and Millireactors
Oscillatory Flow Reactors
Reactive Distillation
INDUSTRIAL APPLICATIONS
Methanol synthesis from CO2
DEC and EMC synthesis with reactive distillation
Paracetamol and APIs crystallization
Advanced Advanced Pharmaceuticals Pharmaceuticals
SynthesisSynthesis
Green Fuel and Green Fuel and Chemicals SynthesisChemicals Synthesis
INTEGRATION
INTENSIFICATIO
N
ALTERNATIVE ENERGIES
Ultrasound
Microwaves Plasma
INTENSIFIED REACTORS
Mesoscale Tubular Reactors
Micro- and Millireactors
Oscillatory Flow Reactors
Reactive Distillation
INDUSTRIAL APPLICATIONS
Methanol synthesis from CO2
DEC and EMC synthesis with reactive distillation
Paracetamol and APIs crystallization
Advanced Advanced Pharmaceuticals Pharmaceuticals
SynthesisSynthesis
Green Fuel and Green Fuel and Chemicals SynthesisChemicals Synthesis
TU Delft (coordinator): Andrzej Stankiewicz KU Leuven: Tom Van Gerven, Georgios Stefanidis TU Dortmund: Andrzej Gorak, Dorota Pawlucka University of York: Duncan Macquarrie Smart Material: Jan Kunzmann SAIREM: Marilena Radoiu Janssen Pharmaceutica: Peter Van Broeck Akzo Nobel: Tony Kiss, Riaan Schmul
Consortium U
nive
rsiti
es
Tech
Su
ppl
End
user
s
To develop processes activated by alternative energies in the fields of fuels synthesis and pharmaceuticals synthesis Reverse Water-Gas Shift and biomass gasification activated by (microwave) plasma Ethyl methyl carbonate (EMC) and Diethyl Carbonate (DEC) from methanol via
reactive distillation activated by microwaves and ultrasound API synthesis - demethylation of 3-methoxybenzylammonium bromide - activated
by microwaves Paracetamol production in millireactors (cooling crystallization) assisted by
ultrasound Reactive extraction of p-nitrophenolate in microreactors assisted by ultrasound Enzymatic reactive distillation to produce butylbutyrate with ultrasound
General aim
Appl
icat
ion
area
s
TUDO TUD
YORK SAIREM
JP
JP KUL TUD
SAIREM
AN TUDO TUD
SAIREM SM
Advanced pharmaceutical synthesis
Green fuel synthesis
Technologies
Dem
onstration
WP 1 WP 3 WP 2
WP 5
WP 4
KUL TUD
TUDO JP
SM
TUD AN
SAIREM
Data generation Mechanisms and models
Equipment design and scale up
General Work Plan
Ultra-sound
Micro-waves
Plasma
Expected impact
• Technological Application of ultrasound, microwaves and plasma to
smartly use long known capabilities: to boost the selectivity, conversions and speed of reaction and separation Enable widespread application via development of
technological know-how on efficient reactor & process design & optimization: discovery and description of the mechanisms involved in the effects of the external fields on the reactions, mass transfer and separation phenomena
Expected impact
• Economic/Social Shorter reaction times reduction in lead time
reduction in cost Increased selectivity of reactions increase in material
yield raw material savings Improvement in separation efficiency cost reduction Miniaturization of equipment reduction in investment
cost
Overall improved resource & energy efficiency Increased sustainability
Expected impact
• Environmental Reduction in emissions & waste increase in
resource & energy efficiency via usage of alternative energy sources Reduction in manufacturing footprint &
environmental impact
• Low pressure – low-power microwave plasma reactor to study CO2 splitting and rWGS
1st generation plasma reactor (200 W, 100 mbar)
Plasma-assisted processes
2,25E+20
1,50E+20
1,0E+18
5,1E+19
1,0E+20
1,5E+20
2,0E+20
2,5E+20
0 100 200 300 400
Ele
ctro
n de
nsity
(1/m
3 )
Length Reactor (mm)
Waveguide
No Waveguide
1,35 1,42
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
0 100 200 300 400
Elec
tron
Tem
pera
ture
(eV)
Length Reactor (mm)
Waveguide
No Waveguide
• Co-axial waveguide plasma reactor to extend the plasma flame and residence time in the plasma zone
Model-based plasma reactor design
2nd generation plasma reactor
20 kWth Feed: lignin (0.5 mm particles) 40% cold gas efficiency @ 90% lignin conversion <1 mol% methane Negligible CO2 emission (plasma agent: air/N2) Scalable process (2.45, 0.92 GHz)
Initial atmospheric plasma reactor configuration Redesigned downstream reactor assembly
3rd generation plasma reactor
batch flow
high speed camera
US generator and amplifier
transducers, horns, baths, other means?
Off-line or on-line separation & analytics
(LDA, HPLC, GC)
Ultrasound-assisted processes
13
Matching work on transducers and amplifiers
Reliability tests Development of modular
design to match continuous processing
Ongoing work on US technology
14
(Source: Smart Material)
MW-assisted crystallisation
• Heat input by MW to dissolve smaller crystals more homogeneous CSD
15
(Source: Sairem )
Summary
• Plasma-, microwave- and ultrasound-based processes have been studied a lot of kinetic and process data is missing first scale-up examples ready
• Several of them currently under revision with end-users; technico-economic study ongoing
• Matching of energy supplying devices with process equipment is crucial
Appl
icat
ion
area
s
TUDO TUD
YORK SAIREM
JP
JP KUL TUD
SAIREM
AN TUDO TUD
SAIREM SM
Advanced pharmaceutical synthesis
Green fuel synthesis
Technologies
Dem
onstration
WP 1 WP 3 WP 2
WP 5
WP 4
KUL TUD
TUDO JP
SM
TUD AN
SAIREM
Data generation Mechanisms and models
Equipment design and scale up
General Work Plan
Ultra-sound
Micro-waves
Plasma
Acknowledgements EC: Carmine Marzano (PO) and Bob Valeras (PTA)
TU Delft: Andrzej Stankiewicz, Herman Kramer, Guido Sturm, Rohit Kacker, Xavier KU Leuven: Tom Van Gerven, Georgios Stefanidis, Leen Braeken, Leen Thomassen,
Jeroen Jordens, Bjorn Gielen, Jinu John, Gunjan Agrahari TU Dortmund: Andrzej Gorak, Dorota Pawlucka, Mirko Skiborowski, Philip Lutze,
Matthias Wierschem, Katrin Werth, Alexander Niesbach, Felizitas Rall, Petra Marciniak
University of York: Duncan Macquarrie, Mario de Bruyn, Vitaly Budarin Smart Material: Jan Kunzmann, Frank Wolfram Sairem: Marilena Radoiu Akzo Nobel: Tony Kiss, Riaan Schmul Janssen Pharma: Peter Van Broeck, Luc Moens, Thomas Rammeloo, Rob Geertman
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