Ganzheitliche Verfahrensentwicklung und ‐optimierung aus industrieller Sicht

This paper describes the way in which processes are currently developed and optimized within a chemical firm, paying attention to all aspects of the production process. The use of mathematical models and simulation alongside laboratory and plant experiments has proved successful for well understood processes. For new processes that are not as well understood, knowledge‐based process synthesis tools offer advantages over optimization‐based synthesis methods, which select particular designs from a predefined superstructure. Methods of mathematical programming are used in production logistics.     

Scale-up-Probleme bei der experimentellen Verfahrensentwicklung

Scale-up problems in experimental process development. The experimental process development of a new product can be performed in test facilities of varying dimensions. Small miniplants from a laboratory scale up to larger pilot plants, in which a few tons of product per day can be produced, are used. The scale-up factors, the risks involved in process and construction design, and a possible necessity of a limited production are important criteria for the size of the first technical realisation of the new process. The following examples highlight some special problems and their solutions in the experimental process development. Whereas a process, involving mainly fluids can be developed relatively well in a miniplant (laboratory scale), it is normally necessary to work on process development for a solid product involving difficult solid handling in a larger pilot plant. At the end of the paper some other scale-up criteria for process design are explained.     

Die Rolle des Experiments in der Verfahrensentwicklung

Experiments in process development . Design data for the improvement of existing plants or for the development of new chemical processes are determined by experiments in laboratories or pilot plants. These frequently expensive testruns should lower the scaling-up risk for industrial plant and should ensure its long-term functioning and its economy. The various methods of scaling-up and the influence of errors are discussed. Some examples will show how an exact planning of the experiments can minimize the costs of development and product.     

Qualitätssicherung bei der Verfahrensentwicklung

Quality assurance in process development. Important decisions pertaining to quality assurance in the chemical industry are already made during process development for new products and improvement of existing processes. This article describes new methods for achieving quality assurance in various phases of process development, both for the process itself and for the desired products. Examples from process engineering with fluids and solids serve to demonstrate the contributions of process engineers to the development of stable and robust processes with regard to quality assurance.     

Einsatz von mathematischer Simulation und Miniplant-Technik in der Verfahrensentwicklung

Use of mathematical simulation and miniplant techniques in process development . An integrated study of synthesis and workup or of entire processes is often required in the development of chemical processes. This leads to a large number of possible solutions, of which the most economic one must be selected. This variety can only be mastered at reasonable expense with the aid of present-day techniques. Examples are presented to show how just a few economic possibilities can be selected and optimized from the plethora of alternatives in simulation calculations based on just a few properties of the materials involved. Economics is the basis of all evaluation. Use of miniplants is considered in the second part of the article, and costs and time-expenditure are compared with those for industrial pilot plants. Planning and evaluation of experiments raise the effectiveness of this empirical work. Problems of scale-up are considered, and the advantages of physico-chemically sound scale-up models are demonstrated.     

Verfahrenstechnische Möglichkeiten zur Verringerung des Anstiegs von Kohlendioxid in der Luft

Engineering Solutions for Limiting the Increase of Carbon Dioxide in Air This article describes engineering solutions for limiting the increase of carbon dioxide in air. Fossile power plants are taken as a model for the source of CO₂. The global mass balance shows that the oceans play a most important role in the storage of the CO₂. The hypothesis is that it is not the absolute value of carbon dioxide concentration that is the real problem but rather its change. Keeping this in mind the present emissions should not be converted but stored for future times. This strategy is called ?hiding the CO₂“. The reduction of the emission is not very likely. It is believed that present actions to reduce the private power consumption will not really change the situation. A number of strategies for the sequestration of CO₂ are reported in the contribution. One proposal is to use shallow waters which form a thermohaline current for the sequestration. In this case, the injection of CO₂ is quite simple but the carbon dioxide travels hundreds of years in a deep sea current. Several scenarios are discussed for the fate of this CO₂‐enriched current. The environmental impact is briefly reported. This contribution describes the actual research needs, taking into account that similar research in Japan and in the U.S. is much more developed.