@w#,ffiffiww@w#,ffiffiww: Needs For Strategic R&D in Support of Improved Energy Efficiency in The Processing Industries

Commission
of the EuropeanCommunities
@w#,ffiffiww@
Needsfor strategicR&Din support
of improvedenergyefficiency
in the processingindustries
Viewsof researchexperts
D. Reay,tP. A. Pilavachit
t
ProcessEngineeringResearchCentre
Harwell Laboratory
OxfordshireOX11 ORA
United Kingdom
'Commission
of the EuropeanCommunities
DirectorateGeneralfor Science,Researchand Development
Rue de la Loi 200
B-1049Brussels
ContractNo EN3E-01
58-UK
Final report
Researchfinanced by the Commissionof the EuropeanCommunities

as part of the 'Energy' R&D programme
Energy conservation
!'
Directorate-General
Science,Researchand Development
1989 E U R 1 1 9 2 0E N
Publishedby the
COMMISSION OF THEEUROPEAN COMMUNITIES
Directorate-General
InformationIndustriesand Innovation
Telecommunications,
L-292OLuxembourg
LEGALNOTICE
Neitherthe Commission
of the EuropeanCommunities nor any personactingon-
is responsible
behalfof the Commission for the usewhichmightbe madeof the
followinginformation
Cataloguingdata can be found at the end of this publication
Luxembourg:
Officefor OfficialPublications
of the EuropeanCommunities,
1989
ISBN92-825-9231-6 Cataloguenumber:CD-NA-11920-EN-C
Brusselso Luxembourg,
@ ECSC-EEC-EAEC, 1989
PrintedinPrinted
BelgiumBelgium
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l€It crystallization 66
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TabIes
1. Distri.hrtion of energpr consrrrFtion in indrstry. 29
2. M a.reasi for inrrestigaticr in Stage 2 arisirg 30

irnenrierls irnenrierls
tte tteirdlstrial irdlstrial
frcrn frcrn 1.1.
in inStage Stage
ArpendiesArpendies
A. A.Initial Initial
letcers letcers
senc senc
to tointewierees. intewierees. - - 3434
31 31
B. B.Llst Llst
of ofe!€efts e!€efts dEing dEing
oosulted oosulted tlp tlpourse ourse suneit. suneit.3!i3!i
of ofthe the
INIrcDUSTICNINIrcDUSTICN
the the irtdstries, irtdstries,

Prooess Prooess erch.rdirq erch.rdirq
steel, steel,
aount aountfor for
about about of ofirrirstrialirrirstrial
50t 50t
erErgy erErgy in inthe the
usage usage EEC. EEC.the the
lalgest lalgest
of oft}ese t}ese
in intenns tenns
of ofenergyenergy
' ' consrpt.ion consrpt.ion
is isdrenticals, drenticals,
folloqed folloqed
by by
non--zretallic non--zretallic
rninerals, rninerals,
food food
and and
drhk,drhk,
paper paper prirrtirrg, prirrtirrg,
ard ard non-ferro:s non-ferro:s
nEtals nEtals
ard ard
ter<tiles. ter<tiles.
Ttte distri.brtion
Ttte distri.brtion
ofof
energy energy
consr.urption by consr.urption
by
irrnrstriar irrnrstriar
sebtor sebtor
in inthe the
EEc nErber
EEc nErber
sEates sEates
in in1gg4 isis
1gg4
strolnr in
strolnr
inTable Table
1.1.
I?E I?E
EECisEECisanxio:s anxio:s
to tohelp help
tlese tlese
irristries irristries
inprove inprove
tlre tlre
witlr witlr
rtrr-ictrrtrr-ictr
they they
use use
enetg[r. enetg[r.
the thep:rpose p:rpose plesent plesent
of ofthe the str-ldy str-ldy
is isto toasaertain asaertain
whatwhat
strategic strategic
ReDrEeds
ReD rEeds
to tobe be
dore dore
in insr4port sr4port
of ofthis this
objectirr€. objectirr€.
Sine Sine
energyenergy
pollution pollution
consurption consurption
ant ant are are
freqr:ently freqr:ently
lirrtced, lirrtced,
the thefuplications fuplications
forfor
pollutlon pollutlon
abatsrEnt abatsrEnt
are are
also also
oonsidered.oonsidered.
the the
study study
is isbeing being
aordxted aordxted
in intrp trp
stages. stages.
In InStaEe StaEe views views
f f tJre tJre of ofird:sCryird:sCry
on on
strategic strategic
RSDneeds
RSD needs
!€re !€re
so.€tlt.. so.€tlt..
Ttre resr:lt
Ttre resr:lt q<ercise q<ercise
of ofthat, that, rdas ardas
aset set
ofof
rcqm|ended rcqm|ended
areas areas
for for with with
disqrssion disqrssion researc*r researc*r
er{perts, er{perts,
repEodrcedrepEodrced
herre as
herre
as
Table Table
2.2.
In InStage Stage
II II a afurther further
series series
of ofiatenriews iatenriews
has hasbeen been
cordrcted cordrcted
with with
leadirgleadirg
prirnaril.y prirnaril.y
researchels, researchels, frm frm lJlriversities lJlriversities
ard ard
Researclr Researclr
rnstitut€s, rnstitut€s,
rfio rfio
areare
ac*rnwfe@A ac*rnwfe@A
erperts erperts
in inthe thepriority priority
tcpics tcpics
listed listed
in inTable Table
2. 2.IlireIlire
objectives objectives
of ofstage stage
rI rIrEle rEleto todefire defire precisery precisery
nore nore r+hat resealeh
r+hat resealeh
rEedg rEedg
toto
be bedore dore
on ontlrese tlrese
tc6rics, tc6rics,
tftat tftat
tle tlenein nein
areas areas
of ofaFplication aFplication
arrt arrt
erergyerergy
benefits benefits
are arelikely likely
to tobe, be, !{hat !{hat
ant ant the the
strength strength
of ofEurqersEurqers
current current position position
researdr researdr is isin inthese these
fierds fierds
cqrpaled cqrpaled
co co parts parts
other other of ofthethe
rprld. rprld.
ltris ltris
doq-nent doq-nent
is isthe the repot repot
on onStage Stage
II.II.
Ttre rcthod
Ttre rcthod
adopted adopted
for for
the the wasras
$rnrcy $rnrcywasr
as
follons:follons:
- - a aretter retter
(rprodred (rprodred
as as
lpperdix lpperdix
N Nrras rras
sert sert
to tothe the
researrtrer researrtrer
@herned.@herned.
ltris ltris
letter letter
set set
the the
sene sene
for for
the the
subseguent,visit,.visit,.
subseguent,
- - a ardslt rdslt
was nra&
was nra&
to totJte tJte
eryert eryert
arrt arrt
a adisqrssicr disqrssicr
was held
was held qr qr
based based
tltetlte
letter.letter.
- - a a record record
ras ras pf pfthe the
na& na& disq:ssion disq:ssion
ard ard
the the
reord reord
agrreedbetrcer
agrreedbetrcer
thosethose
@lerrsd.@lerrsd.
aFperdix aFperdix
BB preserts preserts
a aoqrprete oqrprete
rist. rist.
of, of,
the the
eryErts eryErts
oonsulted. oonsulted.
AAreferenereferene
is isgiven given
oode oode for for
eadL eadL
rdridr rdridr
allo's allo's
the the
origil origil
of ofccnnrsnts cited
ccnnrsnts
cited
in inthethe
rcport rcport
to to
be be
identified.identified.
-1-
G{EMIEALREACIOBSREACIOBS
G{EMIEAL
fn fn
the the irdrstries irdrstries
chenric:l chenric:l tle tleheart heart proess proess
of ofevery every reactor-reactor-
is ist}te t}te
inprorrenents inprorrenents
Substantial Substantial in inthe the
energy energy
of ofthe theorerall. orerall. cancan
Process Process
rnadeby
be be by
rnade prodlct prodlct
inproving inproving yield yield
ard ard in inthe the
selectivity selectivity reactor, reactor, byby
or or
recn:cing recn:cing
the thetenperature tenperature
or orpressure pressure
at atutridr utridr
the the is isrcqlrired rcqlrired
reactor reactor toto
AA
operaLe. operaLe.cdmon cdmonway of
way ofachieving achieving is isthe the
fuprovenents fuprovenents
sudr sudr develogrcnt develogrcnt
ofof
whidr whidr
catafysts, catafysts, a apriority priority
is isalready already in inanother another
thele thele CECCEC
prograrme prograrme wilt wilt
and and not not
be be fi,rrttrer fi,rrttrer
considered considered [Io!',ever, [Io!',ever,
here. here. significanusignificanu
ilprwerents ilprwerents
to toenelgy enelgy
efficiencry efficiencry
are are possible possible
also also through through
the thedevelopentdevelopent
of ofnovel novel of ofreactor reactor
tlpes tlpes or or refiner€nts refiner€nts types. types.
of ofexistirg existirg It It is isthis this
therethere
of ofnovel novel
or orirrproved irrproved with with
reactors reactors which which
ue ue
are are here. here.
oncerned oncerned Actention Actention
isis
prirnarily prirnarily
focr:ssed focr:ssed cpntinuous cpntinuous
on on drsrdcal drsrdcal because itbecause
reactors, reactors, it is isthethe
operated operated
continuously continuously b$k b$k plants plants
drenrierr drenrierr dridr dridr
a:re the
a:rethelargest largest ofof
consxers consxers
in inthe the
errergy errergy clrenric:]s clrenric:]s
irxnistry.irxnistry.
Eur@e Eur@e
has has
a astrong strong
re-seardt re-seardt
tradition tradition reaction reaction
in indrenical drenical engineering engineering
arxtarxt
its itsopertise opertise
is isat atleast least
the the
equal equal parts parts
in inotter otter
of oftiat. tiat. of oftle tleworld.world.
Ihere Ihere
is isno no
shortage shortage
of ofideas ideas
amng amng n:ropean n:ropean
leadiJq leadiJq n|csE ofof
researdErs, researdErs, n|csE
whqn harre
whqnsErong
harre sErong with with
links links the the jrdrstry.jrdrstry.
drerdcal drerdcal
Ttre Ttre
follodng follodng
ideas ideas prt, prt,
nere nere fon,vard fon,vard
for for
novel novel reactors.reactors.
clsnicaf clsnicaf
reactors reactors
a) a)Cheoical Cheoical with with
simultaneous simultaneous ard ard
reaction reaction of ofthethe
separation separation
prod.rct, prod.rct,
desired desired e9 e9
by by adsorption, adsorption,
selective selective nembraneseparaEion oror
nembrane separaEion
(2N (2N
distillation distillation E, E,zn. zn.. flris
2K, 2K, . rould rould
flris - - fimitedfimited
eqrili-briun eqrili-briun
enable enable
reactions reactions
to tobe bedrirren drirren
to toco(pletion co(pletion pass, pass,
in ina asingle single therdcy therdcy
aroidingaroiding
recirculation recirculation
of ofunreacted unreacted
feed feed
rateri.aLs. rateri.aLs.
The @nceFt,
The has has
beenbeen
@nceFt,
demonstrated demonstrated
on ona aslllall slllall plant plant
pilot pilot scale scale nrethanol nrethanol
for for (A4; (A4;
synthesis synthesis aa
teclno'econqnic teclno'econqnic wit}r wit}r
coqrarison coqrarison process process
tle tleornrcntional ornrcntional shoned ashoneda75t75t
red:ction red:ction
in incircrrlation circrrlation
energy, energy,
a a50t 50trecirction recirction uateruater
in incoolfug coolfug
rcqut€fiEnt., rcqut€fiEnt.,
a a25* 25* in insteam pro<!:ced
iacrease iacrease steam pro<!:ced
for for ard ard
e4lort e4lort a a5-10t5-10t
in inraw raw
redrction redrction materials materials
cons-lrption cons-lrption of of
tonne tonne
IEr IEr prodrct. prodrct.
OtherOther
potential potential
applications applications
are are
armonia armonia (overall (overall
synthesis synthesis sarring sarring
energy energy ofof
5-10 5-10 gas gas
of ofnatural natural
tonnes tonnes per per100 tonnes
100 tonnes
of ofannrcnia) annrcnia)
arxi arxi
onsecr.rtirrconsecr.rtirrc
processes processes
rdere rdereirmediate irmediate
rsroval rsroval
of ofthe the prodrct prodrct
desiiied desiiied prerrcnt prerrcnt
can can lossloss
by by
fi:rtfer fi:rtfer (eg naleic
reaction reaction (eg naleic prod:ction).prod:ction).
anhydride anhydride
-2-
bl bl llovel llovel permit, permit,
utridr utridr
reactors reactors the theconcentration concentration
of ofreactants reactants
to tobebe
increased increased
s:bstantiallv, s:bstantiallv,
thereby thereby
redrcfug redrcfug
the the
enelgy enelgy
dgnarrl dgnarrl
forfor
separations separations (ZrI, (ZrI,
rec1lclfurg rec1lclfurg
ard ard 2kr. 2kr.An An uould uould
exarple exarple paftialpaftial
be be
oddation oddation r.rhere ttre
reactors, reactors, r.rhere
ttre
o:<f,gen@nentration
o:<f,gen @nentration
tEs tEsto tobe be nellnell
kept kept
belor belor
ttle ttle
stoidricnetric stoidricnetric
Umit, Umit,to toavoid avoid
the therisk risk
of ofan anelglosion.elglosion.
Elirnination Elirnination
of ofethylane ethylane
recycle recycle
on ona a1001000tornes1001000 tornes year year
per per ettrylereettrylere
plant plant
oxide oxide uould uould
sarrc er€rgD,
sarrc north er€rgD, north
f2.5 f2.5 per per
ndllion ndllion (AD. (AD.
fear fear It It waswas
s.qgested s.qgested
that that riay riay
one one of ofachierring achierring world world
ttris ttris be beto tola\re la\re
a aF-lreF-lre
hydrocarbon hydrocarbon
feed feed
ard ard
s.6ply s.6ply
the. the.
o:<1genon o:<1gen
on
a asolid solid
catalytic catalytic t*ridrt*ridr
carrier carrier
rdould be rdould
be
ci:,qrlated ci:,qrlated
f,or f,or
e.:<ternal e.:<ternal (2k).(2k).
reoxidation reoxidation
pr€ssure pr€ssure
c) c) I.on I.on dr@ dr@ rrpnolithic rrpnolithic
catal\t,ic catal\t,ic
!€actors !€actors
for for proessproess
ctremier ctremier
particularfy particularfy
reactions, reactions, for for
cperations cperations
inrrolving inrrolving
large large
alrnunts alrnunts
of ofreqrclereqrcle
(2A). (2A).
I?tis I?tis
tlpe tlpe
of ofr€actor r€actor
is isused used
for for
enrission enrission
control control
on oncar car
s*lausts,s*lausts,
where where presslrire presslrire
low low drcp drcp
is isessential essential
to toavoid avoid erqireerqire
efficiency, efficiency,
hrt hrt
it it lEs lEs
not not1let, beerr
1let, applied qr qr
beerr applied the thefarge farge
scafa scafa
in inthethe
proess proessirristries. irristries. to topacked bed
Corgarea Corgarea packed
bed
catatlttc catatlttc
reactors,reactors,
npnolith-ic npnolith-ic
Feactols Feactols
lrave lrave
a anudr nudr pressure pressure
lqrer lqrer per per
drop drop unit, unit,
reactorreactor
\rolt'rrE \rolt'rrE
hrt hrt
nay nay a agEeater gEeater
require require volure volure
reactor reactor to toadrieve adrieve
the the
sanrgsanrg
qrversion. qrversion.Ihe Ihe
ret ret in inpresstne presstne
sa\ring sa\ring &€p &€pls lstlpically tlpically
i.n i.n
the the
rangerange
20t 20tto to50t. 50t.In In to toqerations qerations
arnitiqr arnitiqr irnrolvfug irnrolvfug
a alarge large
recpfe recpfe
ofof
unreact€d unreact€d
feed, feed,
the thedroe[t' droe[t' pd'entiauy pd'entiauy
is isalso also aFpucable aFpucable
toto
afEer*rrners afEer*rrners
on on
$aste $aste
incinerators, incinerators,
eg egfor for of ofpCBs.pCBs.
destrustion destrustion
d) d)Phd.rreactors Phd.rreactorsrJse figft

rJsefigft
bstead bsteadof ofheat, as
heat,as
thelr thelr
enelgy enelgy
soure.soure.
Ccrrparcd to Ccrrparcd
toaorventional aorventional
leactors, leactors,
they they
can canoffer offer
veri/ veri/
high high
selectivityselectivity
ard ardinqeased inqeased yield yield witlr witlr
together together substantial substantial
errergy errergy
savirqs savirqs
tlrror.lgfltlrror.lgfl
cperation cperation
at atanbient anbient (2A). (2A).
te@eratuaes te@eratuaes Hot€ver, Hot€ver,
the therEed rEed glassglass
to touse use
in intheir theiraonstnction aonstnction
limits limits
tlgr tlgr
to toreactions reactions
car"ried car"riedat atncderacencderace
cut cut
PrestsLEest,ard ard
arpther arpther
PrestsLEest, etFert etFert
t}tor$t t}tor$t
tlat tlattney tney
nould nould
not not
beccrc beccrc
esrcrricesrcrric
uttil uttilthere thereis isa adrastic drastic
durqe durqe prie prie
in inthe the of ofelectricity electricity
relative relative
toto
fossil fossil (2P). (2P).
filels filels etrplications etrplications
Pd.entiat Pd.entiat furctude furctude
rsnrval rsnrval
of oft0x t0x
fnmfnm
eJ*rausCgfases, eJ*rausC gfases,
photo'?o\rnerisation, photo'?o\rnerisation,
F*roeoF-o:{idationfor for
selecCiveselecCive
F*roeoF-o:{idation
slnthesis slnthesis
of ofhigtrrrafue higtrrrafue
organics organics
arxt arxt
destrucfion destrucfion
of oflow low
levels levels
of, of,
organicorganic
polluEuts polluEutsin innafer.nafer.
the the
npst npst
likery likery
ror.rte ror.rte of ofqrvential qrvential
to toinprorrwrt, inprorrwrt, tlpes tlpes
of ofr€actor r€actor
ras ras
feltfelt
to to
be be
da,elcgrcnt da,elcgrcnt
of ofinproved inproved
nrattenatical nrattenatical
ltEdels. ltEdels. penrdtpenrdt
e,qfld e,qfld
Ihese Ihese
precise precise
rcre rcre of ofaesign aesign
cptirnisation cptirnisation ard ard
itrpFred itrpFred
siaulatim siaulatim
of ofa<tstirga<tstirg
r€acBors. r€acBors.
Gr Gr
large large
tnrorrgh[rrt, tnrorrgh[rrt,
energrlnintensive energrlnintensive
reactors, reactors,
evell evell
narginafnarginaf
fuprovarents fuprovarents
irr irr
efficierrcy efficierrcy
can canyield yield
substantial substantial
erprgy erprgy
sarrirgs. sarrirgs.
rhe rhe
arcasarcas
efiere efiere greatest greatest
the the ga.iru ga.iru
rere rere
tlou*rt tlou*rt
to to possible possible
be be are are
as as
foUqfs.foUqfs.
a, a,Hrdrocarbon Hrdrocarbon
crad<inq crad<inq
furna@s furna@s
14 14zl{r. zl{r.
Here Here
the the
rped rped
is isto tointegrateintegrate
adranced adranced
firrrnce firrrnce
sinulation sinulation
trpdefs trpdefs
wittr wittr
adrraned adrraned
o:ac*ing o:ac*ing
reactionreaction
nodels. nodels.
Ele Ele
djectirre djectirre grcater grcater
rcu.td rcu.td
be be tle tle.{ooired.{ooired
selectiviBy selectiviBy
for for
pEodrt pEodrt
tlrotrgtr tlrotrgtr
oFtinal oFtinal
tailoring tailoring
of ofthe the
tEaC tEaC profile.profile.
flux flux
-3-
b) b) MJlti{hase MJlti{hase (8, (8,?Ir1, ?Ir1,
r.eactors r.eactors 2X, 2X,
?'1, ?'1, 2e, 2e,
2*1. 2*1. principal principal
the the need need
is isforfor
inproved inproved
understanding understanding
of ofthe the of ofrnrlti-phase rnrlti-phase
hydrodynanics hydrodynanics reactors,reactors,
pa:ticularly pa:ticularly
tle tleprediction prediction
of ofinterfacial interfacial
a:cea. a:cea. rea(torsrea(tors
M:ltiahase M:ltiahase
include include
trid<le trid<le
bed bed
reactors, reactors,
spalged spalged
or oragitated agitated
bn:bble bn:bble
reactors,reactors,
3-ptrase 3-ptrase
fluid fluid
bed bed
reactors, reactors, reactors reactors
Er:ay Er:ay arrl arrl
liqui&Iiquid liqui&Iiquid
readors.readors.
the theertrerts ertrerts generally generally

irrtewierled irrtewierled good good
had had thks thkswith withthe thechendcats chendcats
indrstry.indrstry.
is isjnfosnal jnfosnal
there there contact contact
betrdeen betrdeen of ofthern thern
several several hlt hltnoL noLstrrjcerEedstrrjcerEed
coordination. coordination. between between
Coordination Coordination indrstry indrstry
ard ard
universities universities
or orreseardrreseardr
was was
i$sLitutes i$sLitutes seen seen
as asthe therost rost r,ay r,ay
effecEi\re effecEi\re of ofaddeving addeving goals, goals,
major major egeg
pilot-scale pilot-scale
develognent develognent
of ofno'vel no'vel reactor reactor
dremical dremical @ncepts @nceptsor orthe the
develo[xrentdevelo[xrent
of ofadvaned advanedsfin:lation sfin:lation
npdels npdels
irt irtareas areas as as
such such fi.rrnaces fi.rrnaces
crackinq crackinq andand
nulti-phase nulti-phase
reactors. reactors.
Consistent Consistent
and and CEC $pport
oordiratecl oordiratecl CEC $pport be be
could could veryvery
in infacilitatirq facilitatirq
irqlortanc irqlortanc cooperation cooperation
s:dr s:dr redrcirq redrcirq
tlrou$r tlrou$r financialfinancial
the the
to toindsery.indsery.
risk risk
-4-
I![FENBG::T SEPARATTCN
I![FENBG::TPRCrcESSESPRCrcESSES
SEPARATTCN
Selective Selective
Msorot.ionMsorot.ion
Selective Selective is isan an

adsorpcion adsorpcion alternatite alternatite
erElgriF'efficient erElgriF'efficient forfor
to todistillatiqr distillatiqr
of ofgases gases
separaeion separaeion ard ard
fight fight
hydrocalbons, hydrocalbons, azeotropes, azeotropes,
breakilg breakilg seParatfugseParatfug
isoners isonersother other
and and close close fiqlrids fiqlrids
boiUrrg boiUrrg recoverlt recoverlt
ard ard fro frodilutedilute
of ofaldtols aldtols
aqueous so},rtions. Conparea to
aqueous so},rtions. to
distitlation, distitlation,
Conparea energy energy a:re a:re
savirgs savirgs in inthe the
rargerarge
30t-90t 30t-90t
for for applications. applications.
sudr sudr uses uses
Other Other of ofselectirre selectirre are are
adsorption adsorption forfor
renrcval renrcval
the the of oftoxic toxic
ctrenicals ctrenicals
arxt arxt
other other frcrn frcrn
Pollutants Pollutants aqueous ard aqueous
ard
airair
streams, streams,
and and recovery recovery
tfE tfE of ofsolverts solverts traporrs.traporrs.
ard ard
Selective Selective
adsorycion adsorycion
is isan an $here $here
area area there there
has has
been been researcnr arxtarxt
intense intense researcnr
develogrcrt. develogrcrt.
activity activity tlSA ard
in intlE tlE tlSAard in inrecent recent
Japan Japan ard
fiears fiears ard
these these
courtriescourtries
o:rrently o:rrently a alead lead
enjoy enjoy wer wer in inqmercial qmercial
DrrcFe DrrcFe Ho|,rsner,Ho|,rsner,
applications. applications.
Errope Errope
has has good good
scne scne entles entles for for
adsorpcion adsorpcion
leseardr leseardris isstartirtg startirtg
add add to tocacdtcacdt
r.P.
!6st !6st
of oftlle tlle
erPerts erPerts
interriercd interriercd
tfror.Srt tfror.Srt
that that nDst nDst
the the furportanLfurportanL
pre-ccrpetitirre pre-ccrpetitirre goal goal
research research is isa aretho&loqrr retho&loqrr
for for new adsorbentsadsorbents
new
desicnino desicnino
for for
specific specific (?A, (?A,
2& 2& Al, Al,
b, b, 2el .2el will will
. Itris Itris reqrire:reqrire:
- - irrproved irrproved
prediction prediction
of ofmrlti-cocponert mrlti-cocponert
adsorption adsorption kineticskinetics
equiJ.ibria equiJ.ibria
arrt arrt
from from
sfuqle-cqrponene sfuqle-cqrponene
data,data,
- - inprorred inprorred
knorrl@e knorrl@e relation relation
of ofthe the betrcen betrcen prcpertiesprcperties
tranq)ort tranq)ort
effective effective
and and
adso$ent adso$ent
structureistructurei
- - inproved inproved
understardirq understardirq
of ofadsorpt,ion adsorpt,ion
fores.fores.
Adrances Adrances
in intlrese tlrese rpuld rpuld
areas areas aid aid
tailorirg tailorirg selectivity selectivity
the the of ofadsoftertadsoftert
nElterials nElterials
to tothe the
needs needs proess proess
of ofthe the by bycantroUing cantroUing structure structure
their their ardard
their their
dedcal dedcal adsorbent adsorbent
oonposition. oonposition.
t€w t€w forns forns
are are
also also to tobebe
elpected elpected
de\reloped, de\reloped,
for for
e<argle e<argle (2l0 (2l0
fi.bres fi.bres
adsorbinq adsorbinq adsorbiro adsorbiro
ard ard (24).(24).
rerbranes rerbranes
Orrent Orrent proesses proesses

adsorption adsorption r.sr:ally r.sr:ally
are are witlr witlr
in innature, nature,
seni+aedr seni+aedr trp trp
onon
rore rore beds beds
adsolbertt adsolbertt going going
in inseries series tnror4n tnror4n
sr@ssi\re sr@ssi\re of ofadsorFtlonadsorFtlon
c1lcfes c1lcfes
ard ard
regeneEtion. regeneEtion.
ltris ltris
leads leads high high
to to ciFital ciFital
cost, cost,
high high inr/Frrtoryinr/Frrtory
adso6ert adso6ert
arxt arxt in inq=rat,ian. q=rat,ian.
erplocity erplocity AtterFts AtterFts
to toderrele derrele
a atruly truly
@ntirilro,rs@ntirilro,rs
process process
adsorpcion adsorpcion in inttE ttEpast past
hatJe intjalved
hatJe intjalved
cdtiJluous cdtiJluous of ofsolidssolids
trarEport trarEport
beL'"een adsorption
beL'"een adsorption
ard ard vessels, vessels,
reqereration reqereration uitJr uitJr prSlers prSlers
sevsre sevsre ofof
adsorbent adsorbent
attrition attrition
anf anf AA tnrlv tnrlv
brealcage. brealcage. ontinuous ontinuous proessproess
adsorption adsorption
t{ttidr t{ttidr
did didnot not
irwolr,e irwolr,e
witlr witlr
fi:<ed fi:<ed
beds beds
of ofsollds sollds
or or
solids solids bet}€errbet}€err
transport transport
vessels vessels
would would
be bevery very (2A). (2A).
welcore welcore a aproaess proaess
Sudr Sudr night night
oneivably oneivably
followfollow
t}te t}te
develogrent develogrent
of oftulcular tulcular aenbranes. aenbranes.
adsorFtion adsorFtion Aleer:natlrrely, Aleer:natlrrely,
lf lf advanedadvaned
adsorberts adsorberts
@uld @uld be benade nade
nore nore to toattrition attrition
reslstant reslstant ard ard
breakaoe. breakaoe.
fluidisedfluidised
ard ard
rovirg rovirg
bed bedprocesses processes
for for rould rould
adsorFtim adsorFtim
ontiru.urs ontiru.urs practicablepracticable
bege bege
(2A).
-5-
the the
cost cost
of ofnbdern nbdern
hi$rly hi$rly
selective, selective,
higr higr
capacity capacityart<orbents art<orbents
asas
suctr suctr
loleorlar loleorlar
sieves sieves
terds terds
to tobe be
very very
higtr higtr
and and tlris tlris
can can
aclversely aclversely
affect affect
thethe
eonqnics eonqnics
of ofselective selective
adsorption. adsorption.
AFplication AFplication proc€ss proc€ss
of ofthe the rlould rlould
bebe
greatly greatly
aided aided if if nerw high
nerwhighselectivity, selectivity,
trigfi trigfi
capacity capacity
adsorbents adsorbents
could could
bebe
cterreloped cterreloped
frcrn frcrn
low lowcost cost
raw raw (?A\ (?A\
naterials naterials ?lsl. ?lsl.
2b| 2b|
..
Tte Ttedesicn desicn

of offixed fixed
bed bedadsorbers adsorbers
sCill sCill
tends tends
to tobe be
fairly fairly
anpiricr't,anpiricr't,
reflecting reflecting
the theuncertairties uncertairties
in incurr.errt curr.errt
engineerilg engineerilg
nrcdels. nrcdels.
Inproved Inproved
modelsmodels
are arerequired required
for forregeneration regeneration
kjnetics kjnetics 2Rl, 2Rl,
1Vy 1Vy m.r.l_ti-coq)onentm.r.l_ti-coq)onent
non-isothennal non-isothennal (2A, (2A,
adsorpCion adsorpCion ?b't ?b't
and and
rapid rapid pressure pressure
cycling cycling s*ings*ing
adsorption adsorption (?A, (?A,
processes processes 2el. 2el.Also Also nerrtioned nerrtioned
uere uere
the the
conqrlete conqrlete
lack lack
ofof
nodels nodels
for forncving ncving
bed bed (2b) (2b)
adsorbers adsorbers and and
the the
fuportance fuportance
of ofaccr:rate accr:rate
nodelUsgnodelUsg
of ofthe the
fluid fluid
flow flow
distrila:tion distrila:tion
irr irrboth both
adsorbers adsorbers
and and (2D).(2D).
regenerators regenerators
There There
are area asulcstant.ial sulcstant.ial
nuriber nuriber groups groups
of ofuniversity university engaged engaged
il il adsorptionadsorption
research research
5l 5lErrrope Errrope
and and
hrropean hrropean
ctrendcal ctrendcal
ccnpanies ccnpanies increasirrgl.y increasirrgl.y
are are active.active.
llowever, llowever,
there thereis isno nostnrctured stnrctured
collaborat.ion collaborat.ion
bet,,leen bet,,leen
researclers researclers
in insrhaCsrhaC
ought ought
to tobe bea arulti-disciplinary rulti-disciplinary
effort effort
and and
CEc CEc suFport suFport
could could
be beinstn:nentarinstn:nentar
5n 5nadrievi-ng adrievi-ng
ttris. ttris.Ttre Ttre
need need
ac acpresenL presenL
is isseen seento tobe be
mainly mainly
for forbench-scalebench-scale
and and pilot pilotscr'le scr'le
srnall srnall research. research.
llene, llene,since since
tlre tlre
resoures resoures
arrairable arrairable
are.are.
Iikely Iikely
to tobe be limited limited
they theywould would
be bebetter better on on
E)ent E)ent stpporting stpporting
a anr.nnber ofof
nr.nnber
conparatively conparatively projects projects
npdese npdese rather rather
than, than,for forexanple, exanple,
buildilg buildilg
a alarge largeard,ard,
pilot pilot
eqrensive eqrensive plant. plant. Researders Researders
iI iI adsorption adsorption a apa.rt.iorlar pa.rt.iorlar
have have need need
forfor
jnstruurentation, jnstruurentation,
advanced advanced for forin-situ in-situ
eg eg nEasurerrenis nEasurerrenis
of ofciernical ciernical
corpositioncorposition
and and
surface surface
$EnonEna; $EnonEna;it it was was
noted noted
tltat tltat
such such
iJlstnnentation iJlstnnentation
can can
be be veryvery
opensive.
lElt Crvstallization
l€rt l€rtcrystallization crystallization

is isan an energry-effi.cient, energry-effi.cient,
way wayof ofseparating separating
ancl ancl
E:rifyingE:rifying
organic organic
ccwpor:nds ccwpor:nds
having having poilts poilts
nelting nelting -50t -50t
betreen betreen +200t. +200t.
arxt arxt the theenergyenergy
consuned consuned
is isan anorder order
of ofrragnicude rragnicude
liuer liuer
tlun tlun
for fordistillation, distillation,
ci:e ci:e
to tothethe
ratent ratent
heat heat
of offi.rsion fi.rsion
being beingnucl". nucl".
lorer lorer
than than
that that
of ofeva;rcration eva;rcration
arxl arxl
nrch nrch
lessless
reflur( reflur(
being being
re4ired. re4ired. r\pical r\pical
could could
be bethe theseparation separation
andand
p.rrification p.rrification
of ofdjnitrotoluene, djnitrotoluene,
fatty fatty
acids, acids,
maleic maleic
acid, acid,
adipic adipic
acidacid
phenols phenols
and andnaphthols. naphthols.Purification Purification
of ofra!,, ra!,,
material-s material-s polynerpolyner
for forthe the
irxnsky irxnsky
is iseconcrnicaLly econcrnicaLly
prcrnisilg. prcrnisilg.
l€lt l€ltcrystallization crystallization
is isecologicallyecologically
beneficial beneficial
cqrpared cqrpared
to tocrystallizaeion crystallizaeion
frcrn frcrn
solution solution
because because
tlrere tlrere
is isnono
waste waste
liquor liquor
for fordisposal. disposal.
llonever, llonever,
its itsindrstrial indrstrial
ha',re ha',re
beenbeen
harpered harpered
by by trigh trigh
capital capitalcosts costs poor poor
arxl arxl eq:igrent, eq:igrent,
reliability; reliability;
also, also,
Iack Iack
ofof
haeic haeic
knowledge knowledge
reans reanstjrat tjrat
eqrigrent eqrigrent
sr:ppriers sr:ppriers
have have
had hadto touse usean an
anpiricalanpirical
approach approach
to todesign designfor fornew newapplications, applications,
sqretjres sqretjres
with withdisappointingdisappointing
results.
-6-
Researctr ln lnrlElt rlElt
Researctr in intlE tlE
crpEruzatiqr crpEruzatiqr E E cor:ntrles cor:ntrles tn tntltetlte
ls lsentred entred
and
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ltears ltears Japan has \tery \tery
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researrfi researrfi ard ard
cntt€s cntt€s tnajor tnajor
four four irri.tstrial irri.tstrial rrellrrell
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tne hrgesthrgest
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of ofjrrirstrial jrrirstrial
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applications applications but but
crystallizaEion, crystallizaEion, consicbringconsicbring
Japanese effort
the the Japanese ttris ttris
effort euld euld irt irt
rclt rcltdtarqe dtarqethethe
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develognent enoineerinq enoineerinq of ofthe the
npdels npdels based based
Process, Process, onon
of
understandins understandins
scientific scientific of
the the irn
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olved' rculd
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reliability reliability ntricfi ntricfi can can
eqrigent eqrigent
lElt lEltsi/stallization si/stallization be be ardard
desi$ed desi$ed
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r.p. r.p.
scaled scaled reed reed
is isa aPaftiqrlar Paftiqrlar for for
better better of ofthethe
understarding understarding
on on
dtemisttl, dtemisttl,
of ofsysten systen
influence influence cwstal cwstalnucleation nucleation qr€'htth kiretics,
atd atd qr€'htth kiretics,
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technique technique nrake rapid
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in insitu situ
sizesize
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reasurerrEnts reasurerrEnts micron micron
200 200 in ina a20-30* 20-30*
cri/stals cri/stals It Itlulldlulld
slurry). slurry).
al.so al.so
be be helpfirl helpfirl
very very Dhase diaqrams
if if soli&liquid soli&liquid Dhase diaqrams now be
could could now predictedpredicted
be
jn jnthe the
theoretically theoretically way that
way that \raPo|lr \raPo|lr
liquid-equililrria liquid-equililrria (2T).(2T).
predicted predicted
are are
of of
rclt rcltcryseaJ.lization cryseaJ.lization
disadvantage disadvantage
Gre Gre if if tle tlemi:Gure mi:Gure
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a tne yield
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if if the the
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coq>rises coq>rises AA ard ardB' B' nelt nelt
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pure pure
give give
will will AA ptus ptus
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li.tnits li.tnits yield yield
of ofA- A-IdeasIdeas
a:re reeded
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reeded separatilg separatilg A./B enrtectic
ttte ttte A./B (2T).(2T).
enrtectic
Sr:percrit, ical ExtractionExtraction

Sr:percrit,
ical
llris llris process process

is isa asetrnration setrnration was was
wtrictr wtrictr in inHrqe Hrqe
i$rented i$rented ard ard its itsfirst'first'
fornt fornt
(the (the
application application
irxirseriaL irxirseriaL here here frun frun
of ofcaffeine caffeine
e:<traction e:<traction usirqusirq
coffee coffee
ca$on ca$on
sr.percricical sr.percricical rtrile rtrile
dioxi&). dioxi&). ttrere ttrere ancunt ancunt
is isstill stilla aceltajr celtajr ofof
going going
research research on on years years
in inreerrt reerrt
in inErrope, Errope, a arnrdt rnrdt
bigEer bigEer ttas ttas
effort effort beenbeen
rEunted rEunted UsA ard
in inthe the UsAard
Japan Japan
ard ardthese these ale ale
cor:ntries cor:ntries nc|v'rncre
nc|v' adtrarced
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t}|artt}|art
Hltope Hltope aspects.aspects.
in inseveral several
In In with with
aooFarison aooFarison E:<cracEion, rrslrq
Liqd*Liquid Liqd*Liquid rrslrq
E:<cracEion, ftuid ftuid
a asupercritical supercritical tlastlas
actrraneagesfor for
both both
actrraneagesregereration regereration
of ofthe the ard ard
solvenE solvenE rate rate
irrcreased irrcreased of ofmassmass
transfer. transfer. In In
the theregion region point point
critical critical
of oftJre tJre of ofthe the sohrent, sohrent,
bothboth
pressure pressure
arrt arrt
tenperature tenperature have have on on
effect effect
a asigrrif,icant sigrrif,icant the the ofof
solubility solubility
species speciesin inthe thesol\rent, sol\rent, scaU scaU
that, that,
so so in interperature terperature
dungas dungas ardlor ardlor
PressurePressure
can can drange drange
solubilities solubilities
try try of of100 100
a afactor factor or or 1000. 1000.
e\ren e\ren l'tl.ls, l'tl.ls,
the the soltr€rtsoltr€rt
can can easily easily
be be
regererated regererated
by bylettfutg lettfutg
&yrn &yrn pressutre pressutre
the the by bya asnall snall anornt, anornt,
ardard
if if tlris tlris
is isdone done a aselective selective
in instages stages of ofdifferert. differert.
deposition deposition sohtes sohtes can canbebe
adrierred. adrierred.
ffigh ffigh
nuss nuss ratses beLween
EransfeE EransfeE ratses tte phases phases
beLween
tte are are
adrieved adrievedbecause aa because
sr.percritical sr.percritical has has
fluid fluid a alotr lotr (close (close
visosity visosity to tothat thatof ofa agas) gas)ard arda ahighhigh
nass nass diftusivity diftusivity those those
Fetreen Fetreen a agas gas
for for ard ard
a aliq:id). liq:id).ltE ltEnatnnatn
disadrrantage disadrrantage
of ofs.percritical s.percritical dtpared dtpared
extractim extractim to toliquid-llqdd liquid-llqdde:Gncticte:Gnctict
is isthe the pressuresi pressuresi $fiidl $fiidl
used used high high
are are eru€h eru€h nake nake
to to the the of oflargelarge
constructiott constructiott
equigrent equigrent
eq=nsive.eq=nsive.
cormercia-L cormercia-L
to todate date
include include
tle tlesctraction sctraction
of ofcaffeine caffeine
fromfrom
coffee coffee with with
beans beans sr4>ercritical sr4>ercritical
carbon carbon
dioxide, dioxide,
ilcreasilg ilcreasilg
the the
recovery recovery
ofof
crude crude porous porous
oir oirfrdn frdn rocks rocks
with with
srpercritical srpercritical
carbon carbon
dioxide dioxide
or ornitrogen,nitrogen,
and and
extraction extraction
of oflube lube
oil oile:<tract e:<tract
frcrn frcrn
vacrrurn distillation
vacrrurn distillation
residres residres
with with
aa
s-percrit.ical s-percrit.ical
ligtrt ligtrt
hydrocarbon.hydrocarbon.
Inproved Inproved
energy energy efficiency efficiency
is isnot not
the the usr:al usr:al
reason reason
for fordevelogrent develogrent
of ofaa
supercritical supercritical pro@ss, pro@ss,
o<traction o<traction although althoughit it nray nray
sonetjnes sonetjnes
be bean an
addedadded
benefit,. benefit,.
For For tlre tlre
drernicals drernicals
incfr:stry incfr:stry
tlre tlre
nain nain attraction attraction
is isthe the
very very
highhigh
selectivity selectivity
the the can can
Proess Proess jn jnthe the
achieve achieve separacion separacion
of ofsolutes solutes
from from
ccnplexccnplex
mixtures. mixtures.
rt, rt,is ispaft.ioirarly paft.ioirarly
suitable suitable
for fortlre tlre
setrxration setrxration
of ofrarge rarge
mclecuLarmclecuLar
ueight, ueight,
heat-sensitive heat-sensitive
nrateriars nrateriars
for forwtrich wtrich
distilration distilration
wourd wourd
have have
to tobebe
under under
vaculrn. vaculrn.the theuse use
of ofnon-toxic non-toxic
carbon carbon
dioxide dioxide
is isa astrong strong
attraction attraction
forfor
the the
food food
and and
biotechrrology biotechrrology
ild:stries.ild:stries.
the the
mose mose
iJrPortant iJrPortant
researctr researctr
need need
is isfor forbetter better of ofprectictirrq prectictirrq
nethods nethods phasephase
equi.liSria for miltures near the critical potnt of the solvent (?N, A4, ZJ.,
2f) 2f)
- - Ttris Ttris to toprocess process
is iscnrciaL cnrciaL concept.ion, concept.ion,
deverogrert deverogrert
and anddesign designand and
atat
present present
virtually virtually
alL alL
new new
achrances achrances
iJl iJl
this this
area area
originate originate
in intlre tlre
usA. usA. hbrkhbrk
is isal-so al-so
needed neededon on
inprovi-ng inprovi-ng
our our
understandirq understandirq
of ofthe the
action action
of of"Cn$aingr€""Cn$aingr€"
(additional (additional
cornPor€nts, cornPor€nts,
usually usually
witl witlvolatility volatility
internediate internediate
betueen betueen
that thatofof
tle tlee:<lra(tant e:<lra(tant
gas gas
ard ard naterial naterial
tlre tlre to tobe be
extracted, extracted,
whictr whictr
inprove inprove
thethe
pouer pouer
dissolvilg dissolvilg gas) gas)
of ofthe the (2R). (2R). Finally, Finally,
there there
is isan an
urgent urgent
need needfor forthethe
der,erogrent der,erogrent
and andeperilentar eperilentar
testing testing
of ofmass mass
transfer transfer
models models
for forthe the
rncstrncst
comon comon phase phase
contacEing contacEing
devices devices
used usedwith with
sr:percritical sr:percritical
solvents solvents(2X, (2X,
R);R);
this thisiaformation iaformation
is isreeded reeded
for forcontacting contacting
egrj-glent egrj-glent
design design
and and sc:re-upr sc:re-upr
andand
o:rrently o:rrently
it it is isnot not
knoin knoin
r,ehether r,ehether
it it is ispossible possible
to touse use
extensions extensions
ofof
conventionar conventionar
approadres approadres
or orwhether whether
a aconpretely conpretely
ner.r approach
ner.r approach
is isreqr:ired.reqr:ired.
LiquiGliquid E <traction
Liquicriquid Liquicriquid
erxlraction erxlraction
is isa aroell roell process process
estabrished estabrished for forserecti\reserecti\re
of ofsolutes solutesfron fron
liqrrid liqrrid
mi-:<tures. mi-:<tures.
Ttre Ttre
rnixture rnixture
is isconeacted coneacted
with with
anan
inmiscjble inmiscjble
solvent solvent
in in!,trich !,trich
t.Ire t.Ire
desired desired preferentially preferentially
solute solute dissolves, dissolves,
andand
tlEn tlEn
in ina aseparate separate
vessel vesseltlte tlte
soLvent soLvent
and and
the the
extracted extracted
solute solute
are aresepa-ratedsepa-rated
by bydistilration distilration
ard ardthe the solveht solveht
returned returned
for forre-use. re-use.
rf rf there there
is isa arargerarge
differ-grce differ-grce
in invotatility votatility
betweerr betweerr
the the
sol-ute sol-ute
and and
solvent solvent
this thisdistillationdistillation
will willbe be easy easyand and
t}te t}te
o'erali o'eraliprocess process
nay nay
req'ire req'ire
less less
energy energyutan utanthethe
alternacive alternacive
of ofa abatch batchdistiuacion distiuacion
operation operation
or ora asequen@ sequen@ of ofcontinuouscontinuous
distillation distillation
coh.urrrs. coh.urrrs.
Horeler, Horeler,
capital capital
costs costs
nEry benEry
be
higfrer, higfrer,
equignerrt equignerrt
designdesign
rectlods rectlods
are are less less
rcu rcuestablished establishedaftJ aftJ
an an
erpensive erpensive
solvent solvent
nay nay
have haveto tobebe
used. used. I'lre I'lre
maijl maijl
to todate date
tnve tnve
been been
for forselective selective
extraction extraction
ofof
alornatics in oil refirreries, extract.ion of high rrlrlecrlla! weight rnateriars in
tle fine d€nicals irxn:sky and sepa.ration of fission pr€drcts in nucrear
fuer fuer
reprocessing. reprocessing.rt€ rt€food foodand andbiotecinology biotecinology
inch.stries inch.stries
are arestrowingstrowing
corrsiderable corrsiderable
interest interest
for foro<tracgion o<tracgion
of ofheat.-sensit,ive heat.-sensit,ive
rnateriaLs.rnateriaLs.
-8-
E.|r€Fe has has
E.|r€Fe reseaKfi reseaKfi
a astlong stlong h h fi$l+fiquld fi$l+fiquld
traditlqt traditlqt BoEfiBoEfi
e*raction. e*raction.
Japan Japan
ard ard
the the States States
txrited txrited are are
ttu€ht ttu€ht
to tobe be ElrEWe in
behird behird ElrEWe a.rea,a.rea,
intlris tlris
rfiere rfiere
r€ r€
trEirtain trEirtain oopetitirre oopetitirre
a asignificant significant (2O.(2O.
adtantage adtantage
Tho principal
Tho principal needs rlel€
researdl researdl needs rlel€ l?rese rrere
identified. identified. l?reserrere
adaptive adaptive
cont'ro1cont'ro1
svstens svstens
for for
liqui&liquid liqui&liquid colurns colurns
e:Graction e:Graction ard ard nethods nethods
inororrcd inororrcd of of&sicrt&sicrt
ard ard
scale-r.o scale-r.o
based based
on on
bendr bendr
scale scale (2J). (2J).
tescs tescs
dtaracterisatio dtaracterisatio In In
both both
casescases
the the prrutpetitlve prrutpetitlve
findan€ftaf findan€ftaf ar,e similar.
ar,e
lequircrcnts lequircrcnts
researdt researdt IheseIhese
similar.
arre;arre;
- - beeter beeter
urderstardhg urderstardhg physics physics
fi:ndaneftaf fi:ndaneftaf
of ofthe the rnass transfer,transfer,
of of rnass
dr€let, dr€let, ard ard
brealep brealep
droplet droplet
@alesere,'@alesere,'
- - better better
nrerscardirg nrerscardirg
of ofthe the
mle mle
of ofsrrfae srrfae in inbendFscalebendFscale
illgEities illgEities
dEracterisation dEracterisation
teststtestst
- - &lrelcpent &lrelcpent
of ofnrc&Is nrc&Is
for for
tte tte
hfdrodynandcs hfdrodynandcs agitatedagitated
of ofrcdtanically rcdtanically
qrt qrtctors ctors
to toallon allon bench bench
frq! frq!
scalerp scalerp t€sts t€sts
co co equipent;equipent;
full-scale full-scale
- - practical practical
selection selection
tednrtqrs tednrtqrs solvents solvents
for for ger:ncAynanricger:ncAynanric
based based
on on
dels delsof ofp[nse p[nse
eqtrilibria.eqtrilibria.
It Itr{as r{as
rrc'ted t}Bt
rrc'ted
t}Bt prqosed prqosed
tJre tJre rprk rprk olrntt olrntt
on on is islikely likely
hyurodynanics hyurodynanics toto
lequln lequln
achraned achraned
flor flor
rncdeUirgt rncdeUirgt
drtrter drtrter ard ard
achnned
FcElrans FcElrans oFeicaf
achnned oFeicaf
sensorsensor
tedrnnqEs tedrnnqEs
for for
reasr:rerents reasr:rerents
in intwoehase twoehase mi:<tures.mi:<tures.
fiqdefiqdd fiqdefiqdd
the the
tnain tnain
beneficiaries beneficiaries
of ofttris ttris wer,e tJuughe
researdr researdr wer,e tJuughe to tobe be
likely likely the the
firefire
dsnicals dsnicals phannaceucicals phannaceucicals
ard ard ird.rstries. ird.rstries.
C,reater C,reater in ineqtriFenteqtriFent
ertainty ertainty
&sign &sign
ard ard better better
scaletp, scaletp, no&fs no&fs
sjrrulatiqr sjrrulatiqr ancl adaptive
ancl adaptive forfor
ontrollers ontrollers
plants plants
mtleiarod:ct mtleiarod:ct rpuld rpuldspeed up up
speed
the the of offigd&liqtridfigd&liqtrid
tr-netration tr-netration
erGractiur erGractiur
tednotogry tednotogry
in intfEse tfEseindrstries. indrstries.
Enerry Enerry
savirgs savirgs restrlt restrlt
ccndd ccndd lf lf itit
repleced repleced
\rzrcr.rlndi*iUation.
\rzrcr.rln di*iUation. ltEre ltEre also also
ccnrld ccnrld poUution poUution
be be abatrenBabatrenB
benefits benefits
tmrgtr tmrgtr r.rseof
the the r.rse
offiquiefiquid fiquiefiquid for for
e*,raction e*,raction purification purification
the the ofof
efflrsrts.efflrsrts.
-9-
FIJRT.IACES.
KIf,NS
FIJRT.IACES.
KIf,NS
A[.D A[.D
C'VENSC'VENS
Eqtdpent. Eqtdpent.
sudr sudr glass-rnaki4r glass-rnaki4r
as as fi:rnaes, fi:rnaes,
brid<{al<ing brid<{al<ing
kilns, kilns,
ercnt ercnt kilns kilnsandand
bakitrg bakitrg are are
ovens ovens very veryenerglairtensirre. energlairtensirre.
A Acaimnn caimnn
tlgre tlgrebrbidr brbidr
ererged erergedfronfron
witl. witl.
diso.rssions diso.rssions several several was was
e:{Elts e:{Elts that that
trpre trpre designs designs
er€rglr€fficient er€rglr€fficient couldcould
be beanticipa.ted anticipa.ted
frcrn frcrn
the the appropriate appropriate of ofadvanced advanced
use use flor flornpdellinq npdellinq
tedni$restedni$res
to too<arnire o<arnire process process
alternative alternative and and firrnace firrnace (b, (b,251, 2a,
confiqurations confiqurations 251,2a, 2dl 2dl
..
The The
nodels nodels
should should
be be 3-dfurcnsional 3-dfurcnsional
ard ard include include
strould strould fluid fluid
{3ranics, {3ranics,heatheat
and and
mass mass
transfer transfer
and and drerric:] drerric:] ehere ehere
npdels npdels
reaction reaction It It will willbebe
aFpropriate. aFpropriate.
partiorlarly partiorlarly
irportant irportant
to toconpare conpare predictions predictions
tlreir tlreir with with qrafityqrafity
good good
dFerfurcntal dFerfurcntal
data data
cbtairled cbtairled
either either
on on pilot, pilot,
plants plants plants.plants.
or orfuIl-scale fuIl-scale
A<fuanced A<fuanced
laser laserdiagnostic diagnostic are are
tectrriques tectrriques likely likely
to tobe berequired required
for forobtainirgobtainirg
sudl sudl
data. data.ff ff successfuI successfuI
npdels npdels
can canbe bedeveloped, developed,
this this facilitate facilitate
rculd rculd thethe
anserirrg anserirrg if" if" questions questions
of of"r*rat "r*rat uould uould
arrl arrl enable enable
corgnrtenai&d corgnrtenai&d
oglorationogloration
of ofno\rel no\rel
erergFsaving erergFsavingequiFerrt equiFerrt
arxl arxl
operational operational
concepts.concepts.
ft.her ft.her
researctr researctr
reeds reeds
nentioned nentioned
by by
irutividnl irutividnl $ete:$ete:
e:q>erts e:q>erts
- - devetopent devetopent
of offuprored fuprored
nethods nethods
of oforeheatino oreheatino
olass olass raw raw
firrnae firrnae materialsmaterials
using using
vraste vraste
heat heat
frcn frcn
the the
firrnae firrnae
exfEust exfEust (2X, (2X,
gases gases 2a);2a);
- - develogrent develogrent
of ofan an
e)<pert e)<pert for forglass glass
svstem svstem firrnace firrnace (2a),(2a),
control control
- - iryrotrercnts iryrotrercnts
to tothe the
desigrr desigrr
of ofcenent cenent
kiLn kiLn preheaters preheaters
cvclone cvclone to toredrce redrce
thethe
power power
fan fan (2O: (2O:NB NB
reguired reguired ltris ltris
is isa}:eady a}:eady
the the
subject subject projectsprojects
of oftwo two
withir withir
the the
cEC cEC
Eriergy Eriergy
Consenration Consenration
Progrannre).Progrannre).
- - exploration exploration
of ofneer neer
energtFsa\rirg energtFsa\rirg
bakinq bakinq
oven oven (2U). (2U).
conoepts conoepts (NB ltrisltris
(NB
could could
require require
the the
use use
of ofaciraned aciraned
flor flornndeUirg nndeUirg I, I, IntenrierrIntenrierr
lSt"ge lSt"ge
rpll .
Energy Energy
savings savings
in inthe the
region region
of of18* 18* glass-naki5g glass-naki5g
for for fi.rrnaces fi.rrnaces
ard ard
25*25*
for for
baking baking
o\rens were quoted quoted
o\renswere predictions predictions
as as of ofnhat nhat
aoLfld be
aoLfld
be
achie\red achie\red
by by
rerrer
desigrs desigrs
based based
on on fildanental fildanental
urderstarxlirg urderstarxlirg
aruf nDdellfug.nDdellfug.
aruf
-10-
DRYRSDRYRS
Drying Drying
ac@unts ac@unts
for forat atleast least
10* 10*
of ofthe the
energlr energlr of ofthe the
consxption consxption drenticalsdrenticals
(ail. (ail.It It also also
irdstry irdstry for for
a@rnts a@rnts a as:bstantial s:bstantial
arcunt arcunt
of oferergy erergy
usage usage
inin
tJre tJre process process
other other irrirstries irrirstries jn jnttris ttris
oonsidered oonsidered surrrey. surrrey.
Drrope Drrope
carrently carrently
hashas
position position
a aleading leading in indryfurg dryfurg
researdl, researdl,
hrt hrt ts tsincreasirq increasirq
there there activity activity
inin
l.lorth l.lorth
Aerica Aerica
arrt arrt
Japan.Japan.
ebout ebout of ofqrrrent qrrrent

90t 90t irxtstrial irxtstrial
drlers drlers
are are
of oftjre tjre
oorvection oorvection usirq usirq
t1pe, t1pe, hothot
air airas as
the the nedfula. nedfula.
dryinq dryinq the theg|l.eatest g|l.eatest
souroe souroe
of ofenergry irefficiercy
energry irefficiercy
is istj|etj|e
wasted wasted
leat leat
irr irr edraust, edraust,
the the air. air.Ttlere Ttlere
m.rld m.rld
be be sigrdficant, sigrdficant,
energ[, energ[,
savhgs savhgsbyby
sreerheated sreerheated
usirg usirg steam as steam
as
the the medir.minmedir.m
drying drying ina atdal tdalrecycfe recycfe (2R).(2R).
systeln systeln
Sudr Sudr wqrld wqrld
drlters drlters also also
have have
enviroruental enviroruental
artvantages tnro+h artvantages
tnro+h
re<!:edre<!:ed
snissions snissions good good
ard ard fire fireard ard protection. protection.
eplosion eplosion ll&E\rer, ll&E\rer,
$rey $rey
aoulcl aoulcl
not notbebe
used used
for for prodrcts prodrcts
heat-sensltive heat-sensltive because of because
ofthe the der^rpoint
hi*r hi*r der^rpoint
of ofsWg$eateasWg$eatea
stean; stean; would would
ttris ttris severely severely
restrict restrict use use
their their in inthe thefood food
irdstry, irdstry,
hrthrt
there there
o.rld o.rld ride ride
still stillbe be areas areas
of ofapplication application proess proess
in inother other irdrstries.irdrstries.
AA comercial comercial
dqer dqer of oftlris tlris
tlpe tlpehas has
been been
derref@ed in derref@ed
inSreden Sreden
for for
dryingdrying
prodrcfs. prodrcfs.
forest forest Research in Research
inthis this is ispfanned pfanned
area area at atthe the
Griversity Griversity
ofof
f\arlsn$e.f\arlsn$e.
Contact Contact
dryira dryira
can canoffer offer red:ctions red:ctions
eneryy eneryy orrer orrer
@mrection @mrection
drldng, drldng,
tfrro4frtfrro4fr
eli.nirntirq eli.nirntirq
the the
e,<haust air. e,<haust
air.Vao.nn Vao.nn
@ntact @ntact with with
drfrs drfrs locps locps
closed closed a:rea:re
also also
rore rore
@ntaired @ntaired
ard ard
emrirornentally emrirornentally
seor:c. seor:c.
Reseatdr Reseatdr
into into
equipnentequipnent
design design
tus tus
arfiraned arfiraned
osi&rabfy osi&rabfy in inthts thts
alea alea yrears and
reert, reert,
over over yrears and
it it is isnovrnovr
rpre rprea anatter natter
of ofa1plytrq a1plytrq
tlris tlris
knowl.edgeinknowl.edge (29. (29.tbEver, tbEver,
infrd:stry frd:stry @ntact@ntact
dr1ers dr1ers
usually usually
have havea ahiSier hiSier
cqital cqital@st @stthan thanonreetion onreetion
drfrs drfrs
because becauseofof
tbe tbelelati\rely lelati\rely
lovr lovr
leat leat
tnnsfer tnnsferoefficient oefficient
betr,een betr,een
the the
heaefug heaefug
surface surface
ardard
tle tlemist mistnaterial. naterial.
lilovel lilovel
eouiErEnt eouiErEnt
con@ts con@ts r*ridr r*ridr
overore overore probleroproblero
tlris tlris
rruld rruld
make @ntact,
make @ntact,
dryirs dryirs
rcre rcre
equnic:lly equnic:llyattracEirre attracEirre
ard ard
tene tene ontrilrrteontrilrrte
to tofitprsned fitprsned
energy energy
efftciency. efftciency.
Cte Cte$tdr $tdr
@noeft @noeft
is isthe the
vacur-urfluid
vacur-ur
fluid
bedbed
drver drver
clrttainirp clrttainirp
irtrcrsed irtrcrsed
tpatiro tpatiro
coils, coils,
rdridt rdridt been proved
has has been provedon on
tfre tfre
benctrbenctr
scale scale
brt brt Dec1.rirespilot,
rpn rpn pilot,
Dec1.rires
scale scale (29).(29).
tesEing tesEing
Ttrele Ttrele
is issttll sttlla aconsiderable considerable
need need
for for
ircroved ircroved
nn&Is nn&Is
of ofcqrventional cqrventional
typestypes
of ofspection spection
drver drver
sudt sudt
as as
spny spny
drlprs, drlprs,
rdary rdary
&yers &yers pne-un*,icpne-un*,ic
ard ard
cornrcyirtg cornrcyirtg
dryers dryers(2nl. (2nl.
Better Better
models will
models
will
altow altow
dryer dryer
&signers &signers
ard ardusers users
toto
erplore erplore
a awider widervariety variety
of ofoptions, options, to toplant plant
leadfuq leadfuq rdridr rdridr
is iscloser closer
to tothethe
opEiruo opEiruo
fircm fircm
an an eneqy eneqy
ard ard
cryital cryital vier4nint vier4nint
ost, ost, t*ric*r t*ric*r
ard ard has has
aa
rcdraed rcdraed
risk risk (2& (2&
of offailtue failtue a0. a0.Better Better
nrcde]s will
nrcde]s
will
also also
lead lead
to toirrpriorredirrpriorred
aqtrol of dryers (2m).
Crc Crc
s.pport s.pport
rnr rnr
f,d f,d
benefit benefit
all allthe the
highfi*tecf highfi*tecf
areas areas
of ofteseardt. teseardt.
ForFor
researdr researdr
invorvirg invorvirg
the the
&leropuent &leropuent
of ofrt€n egriFFnt,
rt€n egriFFnt,
@ncePts @ncePts
it it rulld rulld
redrceredrce
rislc rislc
the the to toindrstr:ial indrstr:ial
acnpannes fur\rofved.
acnpannesfur\rofved.
For Forreseardr researdr
cr crdryer dryer
rcdelfingrcdelfing
ard ard rflC rflC
utt:rol, utt:rol, sLEport sLEport
@ufd @ufdbad bad
to toa arpt€ rpt€
@oldfuraLed progEa!ilre
@oldfuraLed progEa!ilre
of ofrorlc,rorlc,
tlEr€by tlEr€by
a\roidfug a\roidfug
d4lication d4lication
ard ard
shortcnilg shortcnilg
tle tletfurescale tfurescale
for forachieningachiening
results.results.
- 1 1-
PROCESSINIE\iSIFICATIOI{INIE\iSIFICATIOI{
PROCESS
Proess Proess is istbe tbe

intensification intensification given given
nare nare to tomiaiaEurisation miaiaEurisation
of ofdrernic:ldrernic:l
plant plant to torecbce recbce
irr irrorder order capital capital
@sts, @sts,
sa\re sa\re ard, ard,
E)ace E)ace in incertail certail
cases,cases,
redre redre of ofhazardous hazardous
inventories inventories rnaterial.s. rnaterial.s.
The Theresulthg resulthg
equipent, equipent,
isis
usually usually
radier'lly radier'lly
different different
to toconventiorEl conventiorEl
equipnent, equipnent,
so soirrplanrentfuq irrplanrentfuq
itit
outside outside
the the may may
laboratory laboratory have have
considerable considerable
rislcs rislcs
attadred attadred
at atfirst. first. IldsIlds
has has
htdered htderedapplication application
of ofthe the
technol€lr.technol€lr.
'l}vo 'l}vo were were

areas areas identified identified
as ashaving having potential, potential,
the the processprocess
for forfuprovirg fuprovirg
incnstry incnstry
energy energy efficiency. efficiency.
the thefirst firstof oftJese tJeseis isintensified intensified
evaporators.evaporators.
A Acentrifirgal centrifirgal has has
evaporator evaporator been been y*ridt y*ridt
irnrented irnrented is isli*e li*ea acom€ntionalcom€ntional
falfhg falfhgfilrn filrn
evaporator evaporator
turted turtedon on its itsside side with with
t}e t}eheat heat platesplates
a\clnnge a\clnnge
s,piffdrg s,piffdrg
about about a acentral central
axis. axis.Dilute Dilute feed feed
is isintradrc€d intradrc€d
at atthe the aentre aentre
ofof
eadr eadrplate plateard ard is isflung flung
outwards outwards
by by tle tlecentrifrryal centrifrryal
force, force,e,vaporating e,vaporating
as asitit
goes, goes,
vrith vrith
tl|e tl|e
conentrated conentrated
liqror liqrorbeirg beirgcoUected coUectedat atthe the rjn. rjn. Sinoe Sinoe
thethe
entrifirgal entrifirgalforce force
can can nnny nnny
be be tirrEs tirrEs
the the aeleration aeleration drc drcto togravity, gravity,
t}let}le
liquid liquid
filn filncan can be benurdr nurdr
tninner tninnerthan than in ina a@rnrentional @rnrentional
falling falling
filnfiln
e\raporator, e\raporator,
feadfurg feadfurg
Lo Loa arnrdr rnrdr
higher higherheat heat transfer transfer (28).(28).
coefficient, coefficient,
E:ploitation E:ploitation
of oft}ris t}ris
fupro'ved fupro'ved
heat heat perfonnance perfonnance
u:ansfer u:ansfer could couldtpically tpically
leadlead
to toa adoubling doubling of oftle tlenurber nurber
of ofeffects effects in ina agiven given Celq)erature Celq)erature
intenral intenral
for foraa
rulti-ffe<t rulti-ffe<t e\raporator, e\raporator,
or ora ahafvfuq hafvfuq of ofthe thepressure pressure
ilrclease ilrclease
!€qufued !€qufued
overover
the thecoq>ressor coq>ressorin ina avapour vapour e e porator. porator.
ccnpression ccnpression Scne Scnefirrdanental firrdanental
r'ork r'ork
hashas
been beenclrne clrne
on on fluid fluiddynanics dynanics
arrl arrl
evaporation evaporation
frqn frqntldn tldn
filnrs filnrs
on on spirtnilrgspirtnilrg
discs, discs,
brt brtmrh mrh nork nork
tttcre tttcre is isneeded neededalorg alorgthese these
lires liresto tooptirnise optirnise
tJre tJre
design.design.
Ihe IheCfue Cfueis isnow now al.so al.so
right right
for forconstnrction constnrction
of ofa asmall smallpilot piloturit urit(2E).(2E).
t.lxe t.lxe
second second is isinnovative innovative
a:rea a:rea intensified intensified
reactors. reactors.
As Aso<arples, o<arples,
one oneof ofthethe
prcposed prcposed
erytelts erytelts intensified intensified
seftirg seftirgreactors reactors
for forsulptr.idic sulptr.idic
mherals mheralsusingusing
oqrgen oqrgen
trJre trJre or oro:qlgerFenricled o:qlgerFenricled plasna plasna
air, air,and and proessirg proessirg
leactors leactors
for fortletle
t:leatnlent t:leatnlent
of ofrecycled recycled
drst drstor orr€tallurgie-t r€tallurgie-t
residjes residjes prinara prinara
or orfor for seltirlgseltirlg
(2i). (2i).these these
operations operations intensified intensified
reactors reactors
Uould Uould
operate operate
at atm,rdr m,rdr
hi$rerhi$rer
tery)eratules tery)eratules
than thanc€rventionaJ. c€rventionaJ.
reactors, reactors,
thereby thereby
actrielrirrg actrielrirrg
high high
reaction reaction
ardard
lEat lEattlansfer tlansfer
rates. rates. In Inturf,r, turf,r, pelartit pelartit
would would
tnese tnese hiSr hiSrfeed feed
rates rates \rert/\rert/
ard ard
short shortresi&re resi&retiles tileswiti witiredtced redtced
ccnpJ.exity, ccnpJ.exity,
irynn irynn
ed edetrelgy etrelgy
efficierry,efficierry,
iJrpro\red iJrpro\red
erwironrrErrtaL erwironrrErrtaL
dEracteristics dEracteristics
arrt arrt
redrcd redrcdcapital capital
oost.oost.
l€thematicrt l€thematicrt
ard ardphysical physical
rpdefUng rpdefUngof ofthese these
corple.l( corple.l( processes processes
iatensified iatensified isis
urgently urgently
r€eded.r€eded.
Erlcpe Erlcpe
has has been been
the thepioneer pioneer proess proess
in in<brcfoping <brcfoping int€nsificatl.on int€nsificatl.on
aonoepEsaonoepEs
for fortlte tlte
chsnic:] chsnic:]
irrtrstry, irrtrstry,
hrt hrtthere there
is isnon non
a areal real
danEer danEer
that, that,
tJre tJre
first,first,
comercial comercial appU.cations appU.cations
will willoan:r oan:r
elser*ere. elser*ere.
European European is isgererallygererally
irrh:stry irrh:stry
unwilling unwilling
Eo Eofrlrld frlrld
the the
develqrent develqrentof ofradical radical
ne$r eqtigrFrrt
ne$r eqtigrFrrt
witlroutwitlrout
substantial substantial
help helpfrcrn frcrn
er<t'ernaL er<t'ernaL
fundirq fundirq
agencies agencies
sudr sudr
as asthe the
@C. @C. Sudr Sudrhelphelp
to toget get
is isessential essential over overthe the'activation 'activation
energy energy (2E). (2E).
barrier" barrier" In Inthethe
netallurgical netallurgical prccesses prccesses
fiel4 fiel4innovative innovative aFpear aFpear
not not
frm frmE\rrq)e, E\rrq)e,
USA oror
USA
Japan Japanhrt hrtfrcrn frcrn
relatively relatively
snall snall witb witb
cowtries cowtries higily higily prinary prinary
adyanaed adyanaed fletalsfletals
Jld:stries, Jld:stries,
eg eg Finlarxi, Finlarxi,
Canada Canada
arrt arrt (2i).(2i).
Austral,ia Austral,ia
-12_
EDUATGDFI.OW
EDUATGD
loDEI,LIlEloDEI,LIlE
FI.OW
AA of ofa-reas trave
rurber rurber trave been
a-reasbeen i&ntified i&ntified
in intJris tJris as as
sttdtt sttdtt lijcefy lijcefy
belrlg belrlg toto
berefic berefic actvaned actvaned
frqn frqn npdeUirg npdeUirg
fforr fforr using using
the the of of
sethods sethods W&aEign4lgluldW&aEign4lgluld
gereral, gereral,
dvrianics. dvrianics.
In In a.re high
ttese ttese a.re high
tecperatu,re tecperatu,re with with
Proesses Proesses fluid fluid
flowflow
patterns patterns
ntr-idr ntr-idr
are are likely likely
to tobe beboth both
turfuIent turfuIent higttly higttly
ard ard ExarplesExarples
cctplex. cctplex.
include include
intensified'leaccors, intensified'leaccors, kilns kilns
fr.rrnaes, fr.rrnaes, ard ard
orrens. orrens. tn tn
IttProv€Gnts IttProv€Gnts
allall
of, of,
these these to toperfornrance, perfornrance,
relative relative
systens systens fi:el fi:el
econcny ard ard
ervirofirentalervirofirental
econcny
irrpact irrpact
deperd deperd
on on increasingfy increasingfy
&taited &taited of ofthe the
ur*rstarding ur*rstarding irterplay irterplay
becweenbecween
the the
ccrTplex fluid
ccrTplex
fluid heat heat
flors, flors, ard ardrnass transfer
rnass transferarrl arrl reaction.reaction.
chetdcel chetdcel
Accordilgly, Accordilgly,
several several in inacnrancedflow
experts experts flow
acnranced rere rere
mdellirq mdellirq toto
@nsulted @nsulted
rfiat rfiat
disover disover is isneeded for
researdr researdr qrgrtational qrgrtational
for
needed dynantics aodes
ftuid ftuid dynantics
to tobebe
aodes
appfied appfied
sueessfully sueessfully with with
arrt arrt @nfidene @nfideneto totlese tlese of ofequiFerrt.equiFerrt.
tltres tltres
the the
main main liere liere
rEeds rEeds to to
seen seenbe be following:following:
the the
- - fuprorred fuprorred
grid grid
gereration gereration
telni.qres telni.qres tncdeUirq tncdeUirq
to tofacilitate facilitate of ofcorplexcorplex
gesetries (2C);
predictions predictions
of ofnpdel npdel
ccnparison ccnparison wittr wittr
field field laboratory laboratory
or or rrEasurctlents;rrEasurctlents;
visual visual
inprored inprored pr€dictions pr€dictions
presentation presentation
of of to tofacilitate facilitate witlrwitlr
coparison coparison
erperinental daCa (2C);
rultijlcid rultijlcid
soh,ers soh,ers
to tospeed rp
speed
rp proedtes proedtes
soLrtion soLrtion 2jl;2jl;
QAt QAt
nore nore
adranced adranced
mcdelffug mcdelffug
of offluid fluid (2O, (2O,
turbdene turbdene Dt Dt
tt
rpre rpre
ad\rancednccbl-lfug
ad\rancednccbl-lfug
of ofthe the particles particles
interaction interaction
of of rith rith
twbrlenttwbrlent
flore flore with with
arrl arrl 'uralls, 'uralls,
olcainir|g olcainir|g particle particle
ard ard beharriour beharriour
ae ae palticlepalticle
high high
(2O, (2O,
aoncntrations aoncntrations
2j'l 2j'l
..
Ttp Ttp
advaned advaned rncdels rust,
flow flow rncdelsbe be
rust, with with
copled copled proess proess
achnned achnned np&ls np&ls
an{ an{
inin
nany nany
casesr, casesr,
adrnnced adrnnced
crnbusCion crnbusCion
nrodels nrodels qrgrters qrgrters
(fi). (fi). Porerarl Porerarl are are
rleededrleeded
for for
carryirg carryirg
out out ro&l ro&l
the the calo.[ations calo.[ations
ard ard laser laser
adraned adraned diagrnsLicsdiagrnsLics
techrriqres techrriqres
are are
us:ally us:ally
req.rircd req.rircd
for for
the the
acquisicio acquisicio
of ofrealistic realistic
elperianrtalelperianrtal
daEa ondaEa
on plant. plant.
aperatfutg aperatfutg Itte Itte
benefits benefits
frqn frqn rprk rprk
srdr srdr ruould arise
ruouldarise
in intro tro
nrailnrail
(2C)ii(2C)
ways ways
- - tnror$r tnror$r
enabffuq enabffuq
esig'ers esig'ers \trat \trat
to toansaEr ansaEr lf'qEstions lf'qEstions
dtl.dl dtl.dl
drld drld
leadlead
to toirproted irproted
designs designs
and and
facilit"ate facilit"ate
the thederrelogrent derrelogrent
of ofnovel novel
eqiprErt,eqiprErt,
cqlcPEsicqlcPEsi
- - tlEot!$ tlEot!$
hefpirq hefpirq
to tosolve solve plart plart
aperatfug aperatfug ptslqns ptslqns
ntridr ntridr
rmy rmy trarring trarring
be be aa
&leterious &leterious qr qr
effect effect enelgll' enelgll'
effictency effictency
and and qttrol.qttrol.
erwirorurentat erwirorurentat
-13-
ft ft was was
estinated estinated
by by
one one
eryett eryett aFpl-ication aFpl-ication
that that nrcdels nrcdels
of ofzucoessful- zucoessful- to tot}ret}re
afore*entioned afore*entioned
egripent egripent
could could
result result
il il energy energy
savings savings - - 30t 30t
of of20* 20* in inmanymany
cases cases
Cogether Cogether
with with
redled redled
levels levels
of oftIO< tIO< partiorlates partiorlates
ard ard gases.gases.
in iner&aust er&aust
(zd't.
lhis lhisarea area

of ofr.esearch r.esearch
is islikely likely
to toad\rance ad\rance
rapid.Iy rapid.Iy
over over
the thener<t ner<t
decade decade
d:ed:e
to torapid rapid
ircreases ircreases pov{er pov{er
in incofigrting cofigrting ard ard
rapid rapid in int}re t}re
advances advances norriavasivenorriavasive
instrueneation instrueneation
required required
for foroq:erinental oq:erinental
data data acqr.risition. acqr.risition.
Tlrere Tlrere
isis
Eulopean Eulopean
activity activity
in inactvanoed actvanoed
flow flow nrcdelling nrcdelling
at atthe therurcne rurcne
butbut
it it is ispoorly poorly
coordinated coordinated
and andEhere Ehere
is isvery very prblished prblished
little littlework work processprocess
on on
irdrstry irdrstry
agrlications agrlications
ottrer ottrer
than than (2C). (2C).
conricustion conricustion Tfiere Tfiere
is isa anajornajor
corrputationaf corrputationaf
fluid fluid
dynanics dynanics
effort effortin inthe the
United United States States
brt brtit it ag)ears ag)ears
to tobebe
direcf.ed direcf.ed
largely largely problens. problens.
at ataerospace aerospace Japan Japan to toget get
is isstarting starting jnjn
acCive acCive
this this
area area
and and
an an
irportant. irportant.
feature feature
of oftlre tlre
Japanese Japanese
work workis istheir their
beeterbeeter
visual visual predictions. predictions.
of ofnpdel npdel Europe Europe
has has
Che Che to togaiigaii
oH)ortunity oH)ortunity
a aworld world in in$re $re
lead lead aFplication aFplication
of ofcorputational corputational
ffuid ffuid to toprocessprocess
dyrrarnics dyrrarnics
engireerhg engireerhg but but
Problens, Problens, tbis tbis
will willonly only
be beaclrieved aclrieved
if if there there
is isa asustajnedsustajned
and and
coordilated coordilated
attack attack
on ontlE tlEproblsns problsns
by byseveral several
entres entresacting acting
inin
collaboration. collaboration.
Consistent Consistent
and and
coordhated coordhated
cEC cEC
sr4port sr4port
would would
be beextrerelyextrerely
valuable valuable
Jn Jn
seorring seorring
this this
collaboration.collaboration.
- 14-
DYIGMIC CF
DYIGMICSIM'TATICI{ 6fLEX
CF 6fLEX
PRMESSESPRMESSES
SIM'TATICI{
actrargs actrargs
Consi&rable Consi&rable ha\re tna&
ha\re been in intIE tIE
been tna& Past Past in inthe the
deca& deca& ofof
fiteloFl€rt' fiteloFl€rt'
progrrans progrrans
aoflFucer aoflFucer for for steady steady sinrlation
state state of of
actrPlete
sinrlation proesses
actrPlete proesses
ardard
dynamic dynamic plant plant
of ofsirgle sirgle
sinulation sinulation Witlr Witlr
items. items. the the incleasirqincleasirq
raPidty raPidty
availability availability ocrputfug ocrputfug
of ofdreqp dreqp infustry infustry
P@,er, P@,er, see see
can can in inexterdirgexterdirg
berefits berefits
the the
range range
of ofQrramic Qrramic of ofplant. plant.
to toflror.Ps flror.Ps
sim.rlation sim.rlation arrCeven
itsns itsns arrC even
ootrpleteootrplete
Processes.
Dynamic process
Dynamicprocess will willinProre inProre
sirnrlation sirnrlation elrergy elrergy by by follot'rirqfollot'rirq
the the
nEans:
- - &finfuq &finfuq @ntrol @ntrol

cpeimal cpeimal lts ltsco co
sdE sdE a aproaess proaess
nairltaijr nairltaijr desired desired
at atthe the set'set'
poinL;poinL;
- - cbffudng cbffudng
optimal optimal for for rrariables rrariables
concrol concrol
traiectories traiectories in indisontirucusdisontirucus
proesses, proesses,
or or
for for
novirq novirq
as as possible possible
as as
efficiently efficiently frqn frqn opcirrtalopcirrtal
one one
steady steady followirg followirg
to toanother another
state state ijr ijra acontinuous continuous
a adlarqe dlarqe €{t €{t
aa
Pr'oessr Pr'oessr
feedstock;feedstock;
drange drange
in in
- - trainino trainino
ooerators ooerators flpst flpst
in intl|e tl|e harxffing harxffing
efficient efficient sih:ationssih:ations
of ofcritical critical
sudl sudl alanns, alanns,
as as breakdouns breakdouns
ard ard shutdostns.shutdostns.
ecergency ecergency
AA str.rCywas
case case qroted
was qroted
str.rCy in inwhictl whictl
the the
tfute tfute for for
required required irr irr
a aPlant Plant a aoiloil
refinery refinery
to torcach rcach sEate sEate
steady steady a adtangie in
after after dtangie feedsEock was
incnde cnde was
redrcedredrced
feedsEock
frcinr thirty
frcinr thirty
hours hours tlo tlohours hours
co co of ofan an
by by optimal optimal sdletrEsdletrE
@ntrol @ntrol
&\refoped &\refoped
usilg usilg
a adynanric sinnrlaeion
dynanric sinnrlaeion (2G). (2G).
pac*age pac*age Dynanic Dynanic cancan
sinnrlation sinnrlation
also also in inpollution pollution
result result abaterrEnUthrou$
abaterrEnU
throu$ prodrction prodrction
redced redced ofof
naterial naterial
off-specification off-specification wtrile wtrile plant plant
the the restored restored
is isbeing being oFtfut'aloFtfut'al
to tothe the
sEeady siate
sEeady siate
or ornoved noved
fron fron
ore ore steady steady
optlnal optlnal to toanotber.anotber.
state state
sdE sdE rrhictr rrhictr

researclr researclr
reeds reeds riere riere irr irr to toachieve achieve
order order
idenEified idenEified goalsgoals
these these
rere as follcrus:
a) a)kprorred kprorred
ao.rgrtirg ao.rgrtirg for for
recbcins recbcins
stracegies stracegies eire, eire,
cfiputfuto cfiputfuto useuse
ilclnding ilclnding
of of@. @. ttris ttris pe.rmit pe.rmit
will will mre mreurple< urple<
Proe$tesProe$tes
to tobe be at atreasonable reasonable
sinulated sinulated @sc @scard ard
l!|lre l!|lre r@ls r@ls
realistic realistic of of
distri.hrEeddistri.hrEe
syseens syseens
sudr sudr
as as
tubular tubular ard ard
leactors leactors beds beds
adsofter adsofter be be
cg cg used used 2fl 2fl
l2Gt l2Gt ..
bl bl lGtlrcds lGtlrcds
for for
calqrlatirg calqrlatirg traiecton, traiecton,
octimal octimal
t}e t}e beLrEen trotro
of ofa asvstsn svstsn beLrEen
steadv steadv (irrcfuding (irrcfuding
states states ard ard takirg takirg of ofthethe
a@unt a@unt
sfut-dolrn), sfut-dolrn),
start-r.p start-r.p
constraints constraints
Practical Practical sudr sudr pro(!rcc pro(!rcc
as as quality, quality,
equipent equipent andand
Umitations Umitations
safety (2C, re. 2Yr.
c) c) forfor
, , e.rpecially e.rpecially
hardffrtg hardffrtg
large large
sets sets
of ofeqraticrs eqraticrs integer integer
irrrrofvfuq irrrrofvfuq
both both ard ard
corthorscorthors
variabLes variabLes
tell tellas as
as as a alarge large
ard ard
disqnti-nrlties disqnti-nrlties ru&er ru&er
of ofrsrlinearrsrlinear
constraints constraints
7070
lre, lre,
_15_
d) Better Better prwertv prwertv
thenpchrnamic thenpchrnamic predictioo predictioo
nethod.s nethod.s
for forhigNy higNy
noridealnorideal
nixtures, nixtures,
eg egsolutions solutions
of ofpolyrers, polyrers,
electrolltes electrolltes
and andpolar polar
gases. gases.
AtAt
present present
there there is isconsiderable considerable
uncertajnty uncertajnty predictionspredictions
these these
anC anC
tllis tlliswill willlead lead
to tooorrespondjlg oorrespondjlg
uncertainties uncertainties
ard arderrors errors
in inEheEhe
prpcess prpcess
dynamic dynamic predictions predictions
sirnrlation sirnrlation (2f) (2f)
..
e) DLnarnic DLnarnic
rodelliag rodelliag illeraction illeraction
of ofthe the of ofccnpressors, ccnpressors,
turbines turbines pr-nospr-nos
and and
with with
eaclr eaclr
other other with with
arxl arxl otirer otirer
systen systen
ccfiIrcnents, ccfiIrcnents,
eg egvessels, vessels,
pipelines,pipelines,
etc etc(2c). (2c).Ttris Ttris
is isa aneglected neglected
but but potentially potentially
inportant inportant
a:rea a:rea
of ofcontrolcontrol
systsn systsn
design. design.A Agood good dlinanic dlinanic
ncdel ncdelwould would
be beof ofvalue value
in insizing sizing
systemsystem
ccrq)onents, ccrq)onents,
staff staff
traJrirg traJrirg(ahrareness (ahrareness
of ofsysten systen
response) response)
and and
ac€identac€ident
(r'rrtat. (r'rrtat.
prevention prevention happens happens
if" if" sinnrlation). sinnrlation).
The The
current current
approach approach
to tothesethese
problens problens
is isto tobe beconselxrative, conselxrative,
rdtrich rdtrich
often often
leads leads
to toover-sized over-sized
plant,plant,
operacj.ng operacj.ng
at atFart-load Fart-load
far farfrom from point point
tile tile of ofnraxirn-unefficiency.efficiency.
nraxirn-un
Europe Europeis isorrrently orrrently

at atleast least
Ehe Ehe
equar equarof ofttre ttre
usA usAanl anl
is isatread atread
of of.Tapan .Tapan
inin
the the fi.eld fi.eld process process
of ofdynanic dynanic (2G). (2G).
sinmlaticn sinmlaticn European European
university university
researchresearch
in inthis thisarea area
tends tends well well
to tobe be sr4ported sr4ported
\l \l ildrstry, ildrstry,
which which
regards regards
it, it,as as
anan
jrportant jrportant
field. field.ceftarn ceftarn r:nirersity r:nirersity
of ofthe the tearns tearns
have have proprietaryproprietary
developed developed
dynanic dynanic padcages padcages
sirulation sirulation which which
are arebeing beingsold sold
connercially. connercially.
TlrisTlris
accereraees accereraees
the the penetration penetration
of ofthe thetecrniques tecrniques
into into
indrstry indrstry
brt. brt.
it it introducesintroduces
an an ere{oent ere{oent
of ofccnpetition ccnpetition
betueen betueen
the theunirrersity unirrersity whictr whictr
tearLs tearLs courd courdhjnderhjnder
efforts efforts
to toacirierre acirierre
an aninternational international
coordilated coordilated
collaborat.ion collaborat.ion
unless unlessseveralseveral
teams teams to tor^rork r^rork
agreed agreed together together
to todevelop develop prodgct.. prodgct..
a aconmon conmon sould sould
T6is T6is aFpearaFpear
to tobe be acivantageous acivantageous
in inthe the
case case
of oftlre tlre
srnaLler srnaLler
teams teams
and and
cEC cEC
sr-port. sr-port.
couldcould
help helpproncte proncte
it.it.
-16-
SE"I'LATIOI{ SE"I'LATIOI{
OF OF
BATO{ BATO{
SASIEII,ISSASIEII,IS
Batdr Batdr
operations operations
account account
for forabout about
20* 20*of oferElgy erElgy
use use
in inthe the
clrernicalsclrernicals
irxlustry. irxlustry.
Scne Scne will willbe be
of ofthis this in incarparatively carparatively
large large plantsplants
singl*prodrct singl*prodrct
sudt sudt
as asthose those polvrer polvrer
for forbulk bulk prodrrction. prodrrction.
the the
rernailder rernailder
will willbe be
in inwtnt wtnt
cancan
be be
broadly broadly
classified classified
as as fine fine
tlre tlre clrerricals clrerricals
sector.sector.
the thefjre fjreclsdcals clsdcalsse<tor se<tor

is isorrrenely orrrenely
Che Che gncowing parC
fastest fastest gncowing
parC
of oftlretlre
dprnicals dprnicals
indrstry indrstry
in inE,rrope. E,rrope.
It It consists consists
mainly mainly
of ofsnall snall
ruIti?roduct,ruIti?roduct,
plants plants
prodrcing prodrcing
conparatively conparatively
low lowtcnnages tcnnages
of oftrigfi trigfi
added-value added-value
materials.materials.
It€ It€kelmote kelmote
is is flexibilitv, flexibilitv,
wit.L wit.L
tlre tlre plant plant
sane sane probably probably
being being
rcquired rcquired
toto
proctrc€ proctrc€
sereral sereral
different different
drcrnicals drcrnicals
chring chring
the the
course course year. year.
of ofthe the Energy Energy
isis
a am,rdr m,rdr
snLler snLlerproportion proportion
of ofthe themanufacturilg manufacturilg
cost cost tlnn tlnn
is isthe the
case caseforfor
large, large,
contiruously contiruously
operated operated
bulk bulk plants, plants,
chsnic:t chsnic:t so soenergy energy
tendstends
to tobe beneglected neglected
h h fhe fhedrenic:ls drenic:lsnranufacturing.nranufacturing.
Research Research at atpresent present

attention attention is isfocrrssed focrrssed
mailry mailry
on on productionproduction
optimising optimising
sdted:les sdted:les
and and
deveropirq deveropirq
optirnar optirnar
control. control.
scheres scheres plant plant
for forindividral individral units,units,
e€t e€t
r*rctors, r*rctors,
distillation distillation
colums columsetc. etc.In Initself itself will willprcbabty prcbabty
th-is th-is ha\re ha\re
aa
beneficial beneficial
effect effect
on onenelgy enelgy
efficiencry efficiencry
througtr througtr plant plant
urproving urproving utilisationutilisation
and and
shortenhg shortenhg
heating heating
tines. tines.lloroever, lloroever,
nrcre nrcre
can canundor:btedly undor:btedly
be be
done.done.
the the
research research
needs needs
identified identified
by bytlre tlre
e.qterts e.qterts
intenriewed intenriewed
are are
sunnarisedsunnarised
below.
a) ExEension ExEension
of oftle tleconcepts concepts
of ofenerqv enerqv process process
and and (pinctl(pinctl
inteqration inteqration
tednology), tednology),
whiclr whiclr
hav,e hav,e
been been
fuIIy fuIIy
derreloped derreloped processes, processes,
for forcontiruous contiruous toto
batdr processes (2f, 2n). ltris will reqr-rire a new analysis takirrg fuU
ac@unt ac@unt
of ofvariation variation
of ofprocess process
conditions conditions
with with
tine, tine,
and and
also also
a anewnew
rcthodology rcthodology
for forevaluatilg evaluatilg
trade-offs trade-offs
betrieen betrieen
enercv enercv plantplant
inteqration, inteqration,
utilisat.ion and flexibilitv. the berrefits in energy tenns would probably
be begreatest greatest
on onbulk bulk plants plants
baLdr baLdr prod.rcing prod.rcing
relat.ively relat.ively qriantities qriantities
large large ofof
lor,r.added lor,r.added
procilct procilct
sudr sudr
as as
edible edible
oils oilsand and (2n) (2n)
polyners polyners
brlk brlk ..
b) A Anethodologiy nethodologiy
for forsvnthesis svnthesis
of ofnew new
batclr batclr
orocesses, orocesses,
whele whele
energyenergy
will willbe be
one one
of ofthe the
fad,ors fad,ors
taken taken
into into
ac@unt ac@unt
systsnati.rlly.systsnati.rlly.
c) AA process process
batdl batdl sifiLrlator sifiLrlator
based based
on on
operirrentally operirrentally
rrcrified rrcrified
dvnamic dvnamic
rncdelsrncdels
of hdivictral plant items (2c). I&:tly tJtis strould be linked to
sdedrlirg sdedrlirg
Prodrction Prodrction algorithms algorithms
for foroptimisation optimisation
ofof
wilisation, wilisation,
and and to toe.pert e.pert
systens systens process process
for for ancl ancl
equigrert equigrert
selectionselection
ard ard
design. design.
fir"is fir"is
would would
alrow alrow
a anuclr nuclr
ncre ncre
rapid rapid of ofprooess prooess
assessrent assessrent arxlarxl
plant plant
design design
alternatives alternatives
frqn frqn
ttre ttre
energy energy viewpoint viewpoint
efficiency efficiency wouldwould
and and
also also
facilitace facilitace
the thedevelogrent develogrent
of ofenergy-efficienE energy-efficienE
optirEl optirEl
controlcontrol
sci€fies.
-17 -
of of&sicm &sicm
d) d)Danlognent Danlognent fgr fgr
criteria criteria thennal thennal usitlo usitlo
srtst€ns srtst€ns
st.mlv st.mlv
utlllCv utlllCv aa
sinsle sinsle
tpat tpat nEdiun
transfer transfer nEdiun
for for
both both
tEating ard
tEating aooffutg
ard &ties
aooffutg (21).(21).
&ties
gEeac najoriey
the the gEeac najoriey of ofbatdr batdr are are
Processes Processes qt qt in inthe the
carried carried t€ttperaturet€ttperature
-50t -50t
rarqe rarqe to to104t. 104t. tJter[EI tJter[EI
Oorpentional Oorpentional systems use
ucility ucility use
sEeam,sEeam,
systems
vrater vrater
and andcJtilled cJtilled glycol, glycol,
ethytene ethytene in inseqrene seqrene
freq:ently freq:ently on ont}te t}te
sarEsarE
ltris ltris
nessel. nessel. leads leads
to tocross cross wravailabilitywravailability
of ofutilities, utilities,
contamilation contamilation
a atleating tleating
ctrrfurg ctrrfurg
of ofcoolants coolants (nfridr (nfridr
cYcle cYcle proess proess
is isa apotential potential hazard)hazard)
far far
and and q>tirnal q>tirnal
frcrn frcrn control. control.the the factor factor
latter latter to toan an
leads leads inability inability
toto
proctrce proctrce
uniform uniform possible possible
least least
iI iI tlre tlre
batches batches whidt whidt
tfue, tfue, has has adverseadverse
an an
fupact fupact
on onbatch batchyields, yields, ard ard
utilisation utilisation
equiFneit equiFneit hene hene
energyenergy
ltre ltre
efficiency. efficiency. heat heat
of ofa asingle single
use use transfer transfer wttid wttid
nediun nediun sPans thethe
sPans
rarge rarge for for
of ofteflperature teflperature proessing proessing
a agiven given ttas ttas
application application prqosedprqosed
beer beer
as as problern, problern,
to tothis this
a asolution solution bJt bJt rnany utans!"ered
ate ate
tl€re tl€re rnany questionsquestions
utans!"ered
about, tlos,
about, sudr a autility utility
tlos, sudr systeln systeln be be
stould stould (21).(21).
designed designed
et etplesent plesent
Elrope Elrope
is isahead of rest rest
ofthe the
ahead of oftte tte in inproess proess
torld torld integrationintegration
ard ard
batch batch the the
optimisation. optimisation.
sdrectrlinq sdrectrlinq UsA is is
UsAahead of ofEuroPe in
ahead EuroPe
inbaEdt baEdt
PlantPlant
brt brt
Eurolre Eurolre
sinulation sinulation t.p.t.p.
is iscatctrirq catctrirq
pro€ss pro€ss
Batch Batch new field in innrhiclr activicy
new field
is isa arelatj.vely relatj.vely
sinrrlation sinrrlation nrhiclr activicy
isis
growing growing
rapidly rapidly
dre dre increasing increasing
rapidly rapidly
to tothe the irdrstrial irdrstrial in infirefire
interesc interesc
AA
nranufacturing. nranufacturing.
ctrernicals ctrernicals stnrtured stnrtured betlreen betlreen
@llaboration @llaboration ardard
incbstry incbstry
universities universities
or or instiEuLes, instiEuLes,
resear.cfr resear.cfr betr+eenspecialists
ard ard in indifferentdifferent
betr+een specialists
problenr, problenr,
of ofthe the
aspects aspects rruld rruld very very
be be ard ard
CEn $ppoft
berreficial berreficial CEn $ppoft @rld @rld bebe
il il adriwing adriwing
instrwental instrwental tlris.tlris.
-18-
D(PERI D(PERI
SYSIEII4SEOR
SYSIEII4S
PROGSS
EOR PROGSS
O\IIBOL eND eND
O\IIBOL
PROD(EIIOIMICGEUB\rIPROD(EIIOIMICGEUB\rI
There Thereis isconsiderable considerable at atpresene presene

interest interest in ineryert eryert
syst€rns syst€rns processprocess
for for
control controlfollowing following
the the
successfi.rl successfi.rl
devefoperrt devefoperrt
of ofsardr sardr
a asysten systen
for forcontrollingcontrolling
kiln kiln(28). (28).
a aoerlent oerlent ltris ltris was was
syse€m syse€m develo@ develo@ to toprovideprovide
originally originally
reaL-tjlre, reaL-tjlre, loop, loop,
closed closed stpervisory stpervisory
control control
of ofa alarge largecenejlt. cenejlt.
kiln. kiln. In Inthethe
absence absence
of ofan an process process
adequate adequate nrcdel, nrcdel,
a afr.rzzy fr.rzzy
logic logic
tlpe tlpe yras yras
aFproach aFproach used usedtoto
capture capture
the theerpirical erpirical of ofgood good
knovrledge knovrledge olErators olErators
in insets sets
of ofrules. rules.
thesethese
mles mles use useobserrrations obserrrations
of offactors factors
such suchas askiljl kiljlte[perature te[perature
and and gasgas
exfraust exfraust
oxt/gen oxt/gen to tomake make
content content alpropriate alpropriate
adjustrents adjustrents
to totlE tlEfuel fuel
and andfeed feed
raterate
controller controller
set setpojnts. pojnts.
the thebasi.c basi.c was was
idea idea to totry tryto toactrieve actrieve
100? 100?
of ofthe thetiretire
qr.tality qr.tality
tlle tlle provided provided
of ofcperation cperation by bytlre tlre
bese bese operators. operators.
The The
systen systen
has hasbeenbeen
an anoutstanding outstanding
success success
and andhas has
led ledto tosubstantial substantial
energy energy
savings, savings,
inprovedinproved
prod:ct prod:ct
guality guality
and and
a are<lrct.ion re<lrct.ion
in inlO,( lO,(
in intlle tlle gas.gas.
extEust. extEust.
There There
is isnor nor
interest interest
in inerraluat,ion erraluat,ion
of ofrule-based rule-based
closed closed
IoopIoop
e:(pelt e:(pelt
svster,s svster,s
for fora awider wider of ofplant plant
rangre rangre processors processors
and and tllis tlliswaswas
and and
reccrTrended reccrTrended
a:i a:i priority priority
a aresearclr researclr (2E}). (2E}).
The The
areas areas
sugEested sugEested glassglass
included included
firrnaes, firrnaes,
blast. blast.
firrnaces, firrnaces, plant plant
drelni.^l drelni.^l and and
oil oilrefineries.refineries.
A Asecond secondpriority priority

is isthe the
irqcrporation irqcrporation
of ofrealtire realtire
into into
ruIe-based ruIe-based
expertexpert
svstems svstems
in inorder order
to toe.:<terd e.:<terd
the theapproadr approadr
into into plant plant
intelligent. intelligent. rncnitcring.rncnitcring.
ltris ltris
raould raould
be bebased based
around around
rule$ased rule$ased
trend trend
analysis analysis
so so progiress progiress
that that towardstowards
an anq)set q)setcondition condition
could could
be be 3rrc1:fpropriate
detected detected 3rrc1 :fpropriate
aceion aceion
taken taken
before before
anan
aLarm aLarmsituation situation
is isreached. reached.
ltre ltre to toproject project
ability ability plarrt plarrt
perfornrance perfornrance
on on
thethe
basis basisof oftrend trend
anal!'sis anal!'sis
could could
also also
be bevery very
usefirr usefirr pranni.ng pranni.ng
for for and and
sclredrliagsclredrliag
of ofq>erations, q>erations,
including including
plant plant (?8, (?8,
nailterrance nailterrance ?J\, ?J\,
2ol 2ol
..
Another Another
r.eseardr r.eseardr
need need
is isthe the
develotrrent develotrrent
of ofnptlrods nptlrods
for forvalicatilq valicatilq
sensorsensor
inputs and assessino situations in tlre face of r:ncertainty, eg unreliable or
lnissing lnissing jnputs jnputs
sensor sensor (2K) .(2K)
. firere firere
is iso:rrently o:rrently
a afashion fashion proci.rcingproci.rcing
for for
software software
wtrich wtrich parallel parallel
uses uses processing processing rnimic rnimic
.to .to the the
ilterconnect.ions ilterconnect.ions
of oftlretlre
hunan hunan
brajr brajr
and and
develogrents develogrents
in inthis this
fierd fierd prwide prwide
may may a abetter better
frarework frarework
forfor
problero problero
solving solving
in in$re $re
face face (2o).(2o).
of ofuncertailty uncertailty
so so far far
re rehave have
beer beertalkirq talkirq
about about
nrle-based nrle-based
erpert erpert
systems systems
r,itrtc}l r,itrtc}l
aim aimtoto
capture capture
tle tleenpirical. enpirical.
lnowledge lnowledge
of ofthe the
best bestp1ant. p1ant.
operators. operators.
AA ncrencre
ambitious ambitious
cbjective, cbjective,
wtridr wtridr
shoutd shoutd yield yield
ultinrately ultinrately greater greater would would
savings, savings, bebe
to totry tryto toconstr:uct constr:uct
an ane>trert e>trert
system system
containkg containkgtle tledeeper deeper
knovrledoe knovrledoe
which whichanan
pr-oess pr-oess
e4perienced e4perienced e.nqireer e.nqireer
would would
use useif if he her"rere r"rere
operatilg operatilg prant. prant.
tlle tlle rt rt isis
cqrlocn cqrlocn
operience operience
tllat tllat
lrhen lrhen
tlle tlle
cPeration cPeration
in intaken taken
over over
by bypr@ess pr@ess engineers,engineers,
for forexanpre exanpre
when when
the the go go
operators operators on onstrike, strike,
sigrnificant sigrnificant
u-proverents u-proverents
inin
prant prant
efficienq/ efficienq/
and andperformance performance
occlrr. occlrr.
This Thisarises arises
because because
the theprocessprocess
engineers engineers
use use
a anu:dr nu:dr
deeper deeper
knowledge knowledge
of ofphysics, physics,
clpnistry clpnistry
and ande-rigileering,e-rigileering,
usrally usrally
encapsurated encapsurated
in ina anental nental
npdet npdet prant, prant,
of ofttre ttre to toguide guide
their theirreasoningreasoning
ard ardactions. actions.
Tle Tle
conr,entional conr,entional systemsn systemsn
"erpert "erpert agrroach, agrroach,
wtether wtether
rul.e-trasedrul.e-trased
or orfrane'based, frane'based,
is isincapabre incapabre
of ofrepresenting representing
kno,vl@e kno,vl@e
of ofthis this
depth depthandand
- 19-
oqrplerdty oqrplerdty
ard ardthe the
sirplistic sirplistic proedres proedres
inferere inferere in inuse use
crrrently crrrently canrd,canrd,
cope cope with with
realistically realistically the the ard ard
ccnprcnrises ccnprcnrises r.rtridr r.rtridr
decisions decisions bave bave tttade.tttade.
to tobe be
Iong Iong
range range
RID RID focus focus
should should on on ways ways
devisirq devisirq to tosohre sohre problen problen
tlris tlris (2F).(2F).
Ttris Ttris
is isan an dere dere
alea alea USA is
the the USAisorrrently orrrently
rnrdr rnrdr
rrcre rrcre
acEi\re acEi\re Errape.Errape.
t}tan t}tan
Tte Tteprincipal principal at atplesenc plesenc
need need is ist}at t}atthere there be be
strould strouldgood goodccnrrunicationccnrrunication
between between in intfre tfre
resea.rders resea.rders in inorder order
field field <i.plicaEion <i.plicaEion
to toavoid avoid ardard
of ofeffort effort
to toaid aid of ofi&as.
cross-feltilization cross-feltilization i&as.Only wten
Only wten
the the
basic ooncepts
basic havehave
ooncepts
will willthere there
efiErged efiErged be be a aneed need
for fora astnrctuled stnrctuled
coordinat.ion coordinat.ion to tospeedspeed
of ofeffort effort
practical practical
rp rptheir their develogrent develogrent
and andirpfsrEntation; irpfsrEntation; is istlte tlte
tltat tltat at atdtidtdtidt
stage stage
cEC cEC r^tould r^tould
stryport stryport be berost rost
useful useful(2F).(2F).
As Asan aninternediate internediate

cbjectirrc cbjectirrc
betlleen betlleen
the the n[e+ased n[e+ased of oftoday today
systanrs systanrs ard ard
ttEttE
potentiaf potentiaf
@@ howledgefrased howledgefrased
systens systens
of ofthe longrterrn
the firture,
longrterrn firture,
it it rnsrns
that that
$Eqested $Eqested the the
separtrte separtrte of ofprocess process
disciplines disciplines engineerirq engineerirq
arxt arxt@rltrol@rltrol
engineering engineering
sltould sltould
be bebrougtrIt brougtrIt
cogeuter cogeuter userfriendly, userfriendly,
to todevelop develop tunabletunable
or oroperator operator
controllers controllers decision decision
sLFporU sLFporU based based
systems systems on on a acqbinatron cqbinatron ofof
process process
nbdels, nbdels,
control control
ncdels ncdels heuristic heuristic
a.rd a.rd (2F). (2F).
rrcdels rrcdels was was
ltris ltris vienedviened
with with
scne scne
scepticisn scepticisn
by by protagonists protagonists
the the of ofnle-based nle-based
systems, systems,arrt arrtclearlyclearly
the the of ofmatlenatical matlenatical
role role in ine){)ert e){)ert
rcdels rcdels for forproess proess
systsns systsns control control is isaa
controversial controversial
subject. subject. ereert ereert
One One felt feltthat that way way
the the fortcard fortcard
could could be betoto
process process
develop develop models models
based based
on onqualitative qualitative ohvsics, ohvsics,
or orsmbolic smbolic in inwhidlwhidl
qrantitative qrantitative
relationstrips relationstrips
are arereplaced replaced
5y 5y trerds trerds
Tratitative Tratitative ardard
retlrcrsticailogic retlrcrsticailogic
is isreplaceC replaceC
by bycausal causal (2o). (2o).
reasonirq reasonirq q,nlitativeq,nlitative
Tfris Tfris
prrysics prrysics
e:<pert e:<pert agproadr agproadr
was was
felt feltto tobe be
more more with with
cdpaeible cdpaeible er<pert er<pertsystsrs.systsrs.
CFtimisation CFtimisation
algorithms algorithms
wiII wiIIalso also
need needto tobe bederrefcped derrefcped
in inthe thesaflE saflE lray.lray.
-?f^-
.AD\IAI.T:ED
CIFLINE
.AD\IAI.T:ED
CIFLINE
SENSORSSENSORS
In Instage stage
1 1of ofthis this a ageneral general
study study was was
@nsensus @nsensus for:nd for:nd ird:strialird:strial
ancng ancng
cffpanies cffpanies
that that has haslagged lagged
deveJ,cgnent deveJ,cgnent
sensor sensor seriously seriously control control
befrird befrird theorytheory
derrelogrent. derrelogrent.
Tte Tte is isthat that
conseq:ence conseq:ence of ofaciranced aciranced
i.rplerencacion i.rplerencacion oontroloontrol
r"rfridr r"rfridr
strategies, strategies, inprove inprove
could could efficiency efficiency
energy energy is ishanperedhanpered
sigrrificantly' sigrrificantly'
by bylad< lad<
of ofadegrate adegrate to tomake make
sensors sensors r€asurelEnts r€asurelEnts
orline orline
tlre tlre needed needed
by bysudtsudt
control control It It was was
systerns. systerns. also also repeatedly repeatedly
sCated sCated that that
on-ljle on-ljle sust sust
sersors sersors bebe
acaEate, acaEate,
reliabJ-e, reliabJ-e,
rugged rugged
and and
reasonably reasonably
dreap. dreap. in inSLage SLage
Ttrerefore, Ttrerefore, 2 2aa
ntrnber ntrnber in insensor sensor
of ofe),rperts e),rperts have have
develog€nt. develog€nt. inter inter
been been ie'rred.ie'rred.
lbst lbst
of ofthe the needs needs
sensor sensor identified identified
by by jr jr one one
referred referred
ird:stry ird:stry way way
oror
to toon-liie on-liie
another another neasurenent neasurenent
of ofthe the of ofprocess process
cofiposiEion cofiposiEion streams,streams,
partiorJ.arly partiorJ.arly
in inhot, hot, or orrmlti-phase rmlti-phase
hostile hostile
dirtv. dirtv. In Insucisuci
envirofiIents. envirofiIents.
non-irvasive non-irvasive
envirorunents envirorunents would would
insEnnrentation insEnnrentation be be
advaniageous advaniageous a annbernnber
ard ard
possibilities possibilities
of ofinterestirq interestirq proposed proposed
r'iere r'iere by by
the the
e4erts. e4erts. Sote Sote
exatpJ.es exatpJ.es
areare
given given
below.below.
- - Ootical Ootical
tedrnio:es tedrnio:es
have have
been been
used used
sr:ccessfuIly sr:ccessfuIly
for forsote sotetine tine
forfor
measurerents measurerents2ahase 2ahase
on on flor'rs, flor'rs, flow flow
egr.mass egr.mass rate rateof ofdisperseddispersed
ptnse, ptnse,
paft.icle/droplet paft.icle/droplet and and
ancentration ancentration size size The The
distrilnrtion. distrilnrtion. a&enta&ent
of oflaser laser photo'detectors photo'detectors
avalandre avalandre
diodes, diodes, and and fi.bres fi.bres
opticaf opticaf offer offer
thethe
poterltial poterltial quite quite
for forlor lorcost, cost, nrgged nrgged
and andphysically physically
snall snall wtridtwtridt
eqripent eqripent
will willbe be
mldr mldr
r6re r6re to toprocess process
apprcpriate apprcpriate (2H, (2H,
plant plant 20, 20, 2Ql .2Ql
. AcnrancdAcnrancd
processirg processirg
inage inage nray nray
sofEware sofEware also also
help help (2h). (2h). is isa apartiorlar partiorlar
therle therle needneed
for forreseareh researeh
on onways ways pa*icle pa*icle
of ofreasuring reasuring size size inin
distrib$ion distrib$ion
dispersions dispersions
with with pa*icle pa*icle
a ahigh high (2O).(2O).
oncentration oncentration
- - !{ithin !{ithin nuclear nuclear

the the irdstly irdstlyt}rere t}rere
ha'.re ha'.re
been been
significant significant irrirr
developnents developnents
tie tieuse use
of ofultrasonic ultrasonic ir ir process process
for fornreasr.rrenents nreasr.rrenents
tecturiques tecturiques (2I0.(2I0.
plant plant
Reliable Reliable
non-irnrasive non-irnrasive
trEasure.rrEnts trEasure.rrEnts Ievel, Ievel,
of ofterperature, terperature, liqui&Iiquidliqui&Iiquid
arxt arxt
liqriGsolid liqriGsolid
interfaes interfaes
have have
alf alfbeen been using using
achierred achierred ulerasoniculerasonic
tecfrriqres.tecfrriqres.
ltte ltte
nenr nenr of ofprocess process
tectniq:e tectniq:e acor:stic acor:stic
nonitorinq nonitorinq
irnrolves irnrolves
ncuntjng ncuntjng
a asonicsonic
transcbcer transcbcer
on on of oftle tleprocess process
tfe tfeoutside outside vessel, vessel,
listenfug listenfug
to tot}ret}re
plant, plant,
operat,ing operat,ing by by processing processing
appropriate appropriate of oftle tlereceived received
signals signals
thethe
orrrent orrrent
state state process process
of ofthe the may may inferred. inferred.
be be Potential Potential
applicationsapplications
inchrde inchrde
the the
nonitoring nonitoring
of ofnixing, nixing,
dryins dryins grirdi-ng grirdi-ng
and and processes processes IleII IleII
as as asas
plant plant in inplant plant
nnnitorirg nnnitorirg
cordition cordition pafts pafts
witi witinovirg novirg (2H)(2H)
The The jndustry jndustry

nuclear nuclear has has pioneered pioneered
al.so al.so of ofqafina qafina
use use
the the rav. rav.
X-rav X-rav
andand
neutron neutron
teclniques teclniques
for fornon-invasive non-invasive
reasr:renerrts reasr:renerrts
of oftle tledrerdcaldrerdcal
of ofprocess process
coqrcsition coqrcsition streams. streams.
these these
techrdques techrdques
are arethol,lght thol,lght
to tohavehave
potent.iaL potent.iaL
considerable considerable in innorenuclear norenuclear (2lt).(2lt).
sitr:ations sitr:ations
-21 -
- - Arnnnces Arnnnces
in inseni-endrctor seni-endrctor ttarre led
derrices derrices ttarre
led
to toa asigrnificant sigrnificant
reci.rctiqr reci.rctiqr
inin
price price
the the of ofmicronve micronve
ccnponents, ccnponents,
tturs tturs
offering offering possibility possibility
tJre tJre ofof
micr,orravebased micr,orravebased
instrurentation instrurentation
at atan an rnarket, prie
a@peable a@peable prie(ZI).(ZI).
rnarket,
Microave Microave
techniqrcs techniqrcs
a:e a:e
believed believed
to tohave have potential potential
onsiderabte onsiderabte forfor
rcasurirg rcasurirg
the the
@nentration @nentration $ater $ater
of offiquid fiquid rater rater
or or rrapcnir in
rrapcnir
indrsty drsty
oror
dirty dirty
erwirornrents.erwirornrents.
lnother lnother where where

area area there there
is isconsiderable considerable
research research at atpr€sent pr€sent
interest interest is isfilmfilm
sensors sensors
for for
chenicaJ.s cottposition
chenicaJ.s cottposition
nrasurefiEnts nrasurefiEnts
on on process process
ird]strial ird]strial sEreanssEreans
(2z,1. .(2z,1
these these
rely rely
on on proess proess
the the strean strean
ccrlporEnt ccrlporEnt
of ofirlterest irlterest
drangirq drangirq
thethe
dreniaar dreniaar
state state
of ofa asubstanae substanae
laid laid
dcrdnasdcrdn
as
a afilm film
on on the the
sensor. sensor.ltEseltEse
sersors sersors
rust, rust,
be beplaed plaed ploess ploess
in int}e t}e strean strean tene tene
ard ard rnaynot rnay not
be be
srritablesrritable
for for
dirty dirty
or oraggzressirreernrironnents,
aggzressirre ernrironnents,
hrt hrt
if if this this a apr&len pr&len
is isnot not they they
cancan
e*tibit. e*tibit.
high high
select,ivity select,ivity
for for
conentration conentration
reasur.sEnts reasur.sEnts
of ofirrtivid.ralirrtivid.ral
cdponerts cdponerts
in ina ani:<tur,e. ni:<tur,e.
the the
rnain rnain
researcb researcb
needs needs
are areseen toseen tobe,.be,.
- - ilpro\red ilpro\red givirg givirg

naterials naterials better better
seled,ivity, seled,ivity,
repeatability repeatability
ardard
drabilitydrability
- - irproned irproned
sensor sensor
construction construction
teduriqJesteduriqJes
- - iryro\r€d iryro\r€d
unerseanO:rg unerseanO:rg
of ofdrearical drearical
reactions reactions
on on
sersorn sersorn
ard ard
iryrovediryroved
analysis analysis
of oft$e t$e wtridr wtridr
signals signals gerpr.lte.gerpr.lte.
they they
A Afi:rtter fi:rtter ntrictr ntrictr

tecinique tecinique is isbeing being
eplored eplored for for
ortirurous ortirurous
ctrernic.rctrernic.r
dlPosition dlPosition proaess proaess
trEa:ilre(Ent trEa:ilre(Ent strean strean is isflow flow
injection injection (2O. (2O.
analvsis analvsis InIn
ttris ttris
teduriqe teduriqe
a a\rery \rery
small small
sanple sanple
flor flor is isoontiruously oontiruously
withdrawn withdrawn
fmn fmn tlretlre
pro€ss pro€ss
sErean sErean
ard ard
injected injected
into into
a asnall snall flow flow passes passes
wtrictr wtrictr
of ofrcagent rcagent ttrror$rttrror$r
a atby tbyooiled ooiled
tr:be. tr:be.
At At
the thetr:be tr:be
cnltlet cnltlet
the theerGent' of erGent' ntridr ntridr
ofreaction, reaction, isis
ptloportiqEl ptloportiqEl
to tothe the
active active
species species
conentr:ation conentr:ation
in inthe the
sangrle, sangrle,
is isdeternileddeterniled
by bycolorirEtric, colorirEtric,
electroctrenrical electroctrenrical
or or nEann. nEann.
tlnrmal tlnrmal Sirnrltareor.s Sirnrltareor.s
analysis analysis
forfor
several several
@fiponents @fiponents
is isfeasi-ble. feasi-ble.
ItE ItE fttain fttain
resear<*r resear<*r
reeds reeds
are are sarplesarple
preparation preparation
ard ardinjection injection
tedrriqr:es, tedrriqr:es,
ntaldlrg thentaldlrg
the
systen systen
ncre ncre
rugged, rugged,
tadcffurgtadcffurg
a awider wider
rarge rarge
of ofapplicaticrs applicaticrs
ard ard
testfug testfug o\rer o\rer periods periods
exteltded exteltded on onfrrU-caLefrrU-caLe
plants.
In In
all allof ofthese these
areas areas
furternatioal furternatioal
coUaboratiqr coUaboratiqr
wittr wittr
consistent consistent
andand
@ordirated @ordirated
CECsLfort uas uas
CEC sLfort seen seen poteneially poteneially
to tobe be rra-l.uable.rra-l.uable.
very very
PartrErstrtps PartrErstrtps
nust nust
be be
foured foured
betr.een betr.een
Esealctters, Esealctters,
indJstrial indJstrial
drpaniesdrpanies
possessirg possessirg plancs plancs
the the m mL|tridt L|tridtinstrurents instrurents
tlre tlre can can
be be
tested tested
ard ard
instrurentinstrurent
nanufacturers. nanufacturers.
rnternational rnternational
ollaboration ollaboration
witlr witlr
cEC sLFpolt
cEC sLFpolt
rctrrd rctrrd
allon allon
aa
range range
of oftechniq:es techniq:es
ard ard
aFpricatiqrs aFpricatiqrs
to tobe be
deveroped deveroped
sinultaneously, sinultaneously,
and and
atat
the the
sare saretfue tfue plant plant
ngged ngged rrersions rrersions
of ofthe the qfld qfld
seisors seisors be be
engireered engireered
andand
tesEed. tesEed. nqrld nqrld
llris llris r4r practical
s"eed s"eedr4r practical
inplerentation inplerentation
in inind:stry.ind:stry.
-22-
@EI,;USICNS@EI,;USICNS
In Inall allthe the

areas areassurveyed surveyed a::e a::e
tfiere tfiere many many
oFportunities oFportunities
for forstrategic strategic
REDRED
wtridr wtridr
is islikely likely
to tolead leadto toirrplo\red irrplo\red
energy energy and and
efficiency efficiency corseqrentialcorseqrential
pollution pollution
abatsent abatsentin inthe the jncirstries. jncirstries.
process process principal. principal.
Tte Tte needs needs
andand
trighli$tted trighli$tted
opportr:nities opportr:nities by bythe the
erperts erperts listed
ar.e ar.e listed
below.below.
1. 1. GIEMICAL GIEMICAL
REACTORSREACTORS
a) a) Novel Novel wit}l wit}l

reactors reactors reaction reaction
sinultaneous sinultaneous and and of ofthe the
separation separation desireddesired
procirct, procirct, enabling enabling
tlereby tlereby - - limited limited
eglilibrium eglilibrium reactions reactions
to tobe be
drivendriven
to tocorqrletion corqrletion pass pass
in ina asingle single reactions reactions
or orconsecr:tirre consecr:tirre to tobe be
stoFped stoFped
atat
the the prodrct.prodrct.
desired desired
b) b) tilovel tilovel
reactors reactors pernit pernit
whidr whidr the the of ofreactants reactants
concentration concentration to tobebe
increased increased
sr:bstantially, sr:bstantially, rectrci,ng rectrci,ng
ttrereby ttrereby erergyt erergyt
the the forfor
dernard dernard
separations separations recltcling.recltcling.
and and
c) c) tlo\rel tlo\rel reactors reactors

catalyEic catalyEic lor lorpressure,drop, pressure,drop,
with with thereby thereby
red.rcingred.rcing
coqrression coqrression partiolarly partiolarly
costs costs in inrecycle recycle
systsns.systsns.
reactors.reactors.
d) d) Photociendcal Photociendcal
e) e) Eproved Eproved
npdels npdels
for forh1'drocarbon h1'drocarbonfirrnaces firrnaces nultiahasenultiahase
and and
reactors, reactors,
ther€blr ther€blr
facilitating facilitating
design design
and and
operation operation
for for yield yield
nraxinnnr nraxinnnr
ofof
proclrct proclrct
desired desired maxfui.un energtr
and and maxfui.un energtr
efficiency.efficiency.
2. 2. IOW ENMGY
IOW ENMGY PROCESSESPROCESSES
SEPARATTCN SEPARATTCN
2.1 Selective adsoratrion
a) a) A Arctnodology rctnodology
for fordesigrirg desigrirg
rer reradsorberts adsorberts
for forspecific specific
applications.applications.
will willreqri:e:reqri:e:
Itris Itris
** prediction prediction
fupro\r€d fupro\r€d of oftrrlti-orponent trrlti-orponent
adsorption adsorption ardard
eqriliJcria eqriliJcria
kiretics kiretics
frrrrl frrrrl
singlrcrqlonent singlrcrqlonent
data;data;
** loowledge loowledge
ifiprsved ifiprsved relation relation
of ofthe the betyeen betyeen
effective effective
Cr€nq)ortCr€nq)ort
properties properties
ard ard
adsorbert. adsorbert.
stnrctul€;stnrctul€;
rr fuproved fuproved of ofadsorption adsorption

unjerscarding unjerscarding forces.forces.
b) b) Devefopent Devefopent
of ofner ner pareiorlarly pareiorlarly
adsolbents, adsolbents, frorn frorn
lor lorcost cost
rartrart
naterials.
-23-
c) c) A A
tnrly tnrly
aontiruous aontiruous proess proess
adsorFtion adsorFtion withort withort
fir(ed fir(ed
beds beds
of ofsolids solids
oror
solids solids
transport transport \ressels.\ressels.
betreen betreen
dJ dJ Datelqrent Datelqrent
of ofadvaned advaned
adsorbents adsorbents
in ina arore rore form form
rugged ruggedfor for
use use
lnln
ftuidised ftuidised
rorrirg rorrirg
or or witlout witlout
beds beds attrition attrition
or or
breakage.breakage.
e) e) Eproved Eproved
engineerfurg engineerfurg
for for
rcdels rcdels regeneration, regeneration,
rapid rapid
cyclirg cyclirg
PSAPSA
pEo@sses ard
pEo@sses
ard
rultisponeft, rultisponeft,
norisothernat norisothernat
adsorption.adsorption.
Potentlal Potentlal
of ofselective selective incfrrde incfrrde
adsorpEion adsorpEion reco\rery reco\rery
of ofalooholsaloohols
frqn frqn
di}.rte di}.rte
aq.reors aq.reors
solutios; solutios;
breaking breaking
azeotropqs, azeotropqs, isrers isrers
separattrg separattrg andand
other other
close close
boifirg boifirg
fiqrids; fiqrids;
replaerent replaerent proaesses proaesses
of ofcryogenic cryogenic for for
hrlkhrlk
of ofgases gases
separaticr separaticr recovery recovery
ard ard gasest gasest
of ofirert irert rssval rssval
of oftocic tocic
drgnicalsdrgnicals
ard ard pollutants pollutants
other other frm frmaq:eors aq:eors
ard ardair airst!€ans; st!€ans;
reco\rery reco\rery
of ofsolvents solvents
ardard
vapours. vapours.
Cc.rparcd to distillation, distillation,
Cc.rparcd
to erergy erergy
savjrgs savjrgs
are are
in inthe the
rarge rarge
30 30
toto
90r.
2.2 lElt cnstaUization
a) a) Inprov€d Inprov€d
fildarcntal fildarcntal
understarding understarding
of ofcrystal crystal gtor,tJrgtor,tJr
rnrleation rnrleation
ard ard
kinetics, kinetics,
slueatfug slueatfug
ard ard
reorystallization.reorystallization.
b) b) EgirEerirg EgirEerirg
mo&ls mo&ls rEIt rEIt
of of crystallizers.crystallizers.
c) c) Oo$inatiqr Oo$inatiqr
of ofrelt relt
crlsLallizatim crlsLallizatim
wittr wittr
other other proesses proesses
separaticr separaticr forfor
a@leLe a@leLe
sefinration sefinration
of ofeutectic eutectic
s!,sterns.s!,sterns.
prediction prediction
d) d) ltEoEectical ltEoEectical ptrase aiagrans.aiagrans.
ptrase
of ofsoli&Ii.qtrid soli&Ii.qtrid
Ettairuent, Ettairuent, goals goals

of oftlpse tlpse will will
enable enable
&stgn &stgn
ard ard
optiadsation optiadsation
of ofreltrelt
proesses proesses
crystallization crystallization to toproeed proeed
rapidty. rapidty.
l€lt l€ltcr!,stallizatiqr cr!,stallizatiqr
lsls
applicable applicable
to toseparation separation
ard ardprrificatl-on prrificatl-on
of ofmaterials materials
ttanjrg ttanjrg pointspoints
telting telting
- - 50t 50t
betueen betueen arrd + +200f. 200f.
arrd fire fire qrsr.ued qrsr.ued
erergy erergy is isan anor&r or&r of of
nagnitudenagnitude
louer louer
tban tban
for fordistillatian. distillatian.
t€It t€Itsystatlizacion systatlizacion
is iseelog.ietfy eelog.ietfy
beneficialbeneficial
acrparcd acrparcd
to tocrystalltzation crystalltzation
from from
solution solution
because tlEre
because is isno no
tlEre rdaste liqrnrliqrnr
rdaste
for for
diqosal. diqosal.ilaFan ilaFan
is isF.ttinS F.ttinS
in ina ablg blg
REDeffort
RED effortin intJris tJris
are.are.
2.3 2.3
S\:percritical S\:percritical
extractionextraction
predict{cr predict{cr
a) a) Beeter Beeter phase phase
of of equilibria equilibria
for for
ni:<Errres rear
ni:<Errres
rear
the the
crtttcalcrtttcal
point.
b) b) BeEter BeEter
un&rstardirg un&rstardirg
of, of,
the the
effect effect
of ofentrainers entrainers
vrolatllity vrolatllity
or or andand
selectivity.selectivity.
cl cl lass lass
Eansfer Eansfer
rc&ls rc&ls
for for
sur sur contactirg contactirg
devles devles
rith rith
srpercriticalsrpercritical
solv€rts.
-24-
present present
Ttre Ttre poor poor
state state
of ofknowledge knowledge
il il these these
areas areas
is isa asigrrificant sigrrificant
barrierbarrier
to toexploitation exploitation process. process.
of ofthis this Potential Potential
i:rclude i:rclude
foodfood
processing, processing,
recovery recovery
of ofalcohols alcohols
and and water-sol:lcle water-sol:lcle
other other organj.cs organj.cs
fronrfronr
aqueour aqueour
solutions, solutions,
and andselective selective
of ofvery very
nanori/ nanori/
fractions fractions
fromfrom
mixtures. mixtures.
ccnplex ccnplex Energy Energy
reqr:irenent reqr:irenent
is isnudr nudr
less less
ttr,an ttr,an
for fordistillat.ion distillat.ion
butbut
capi.tal capi.tal
cost cost
is isusually usually
higher. higher.
Europe Europe
lags lags
behiad behiad
the the
USA.USA.
2.4 Liquid-Iiquid extraction
a) a) Better Better
design design
and and
scalsi-Ip scalsi-Ip
rTetlods rTetlods
for forcol-unn col-unn
contactors contactors
based based
on on
benctlbenctl
scale characterisation tests.
b) b) Maptive Maptive
control control
systens systens
for forcolunn colunn
contactors contactors
on on plants.plants.
multi-product multi-product
Liquid-fiquid Liquid-fiquid
avtraction avtraction
can canhave have
higher higher
selectivity selectivity
and and
a alower lower
energyenergy
requirenent requirenent
tlun tlundistillation distillation
for forson€ son€
separations separations
in inthe the
fjle fjlecfre.n-ica1s cfre.n-ica1s
andand
ptannaceuticats ptannaceuticats
inchrstries. inchrstries.
Tt Ttnray nray
aLso aLso
be be
usefur usefur
il il certain certain
circunstancescircunstances
for forliqr.rid liqr.rid purificaiion.purificaiion.
effluent effluent
3. 3. EURIIACES,KILNS
EURIIACES,
KILNS
AI\D AI\D
O\EN]SO\EN]S
a) a) Develofrent Develofrent
and and
axperirrental axperirrental
ded<ing ded<ing
of ofadvanced advanced
3-D 3-D
mcdels mcdels
ofof
aerodlmanics, aerodlmanics,
heaL heaL
and and
mass mass
transfer transfer
and and
drernical drernical
reactions. reactions.
SuchSuch
models would facilitaCe the answering of 'twfrat if?" glestion and would
enable enable
ccfiputer-a:-ded ccfiputer-a:-ded
eploration eploration
of ofnovel novel
equiprent equiprent
and and
operationaloperational
concepts.
b) b) Develognent. Develognent. of ofpreteat.ing preteat.ing

of ofnetllocs netllocs glass glass
ftrrnace ftrrnace
raw raw
materials materials
usingusing
waste waste
heat heat
from from fi:rnace fi:rnace
the the gases.gases.
e{haust e{haust
c) c) IrFrovererEs IrFrovererEs
to tothe the
design design
of ofcenent cenent
kila kila preheaters preheaters
cyclone cyclone to toreducereduce
power power
tle tlefan fan required.required.
d) d) Pilot-sqole Pilot-sqole
testjng testjng
of ofnovel novel
energy-savjng energy-savjng
bakfuq bakfuq
oven oven
concepEs.concepEs.
4. DRYRS
jn jnsr4:erheated sr4:erheated
a) a) Dryrng Dryrng with with
steam steam total total
recycJ.e.recycJ.e.
b) b) Norrel Norrel
tlpes tlpes
of ofcontacE contacEwi.th wi.th
dyer dyer substantially substantially
recbced recbced
capital capital perper
cost cost
unit unit
of ofthrougtrput.througtrput.
c) c) Better Better
o,peri:]ental- o,peri:]ental-
teciniques teciniques
and and
kinetic kinetic
moders moders
for forciaracterisingciaracterising
properties properties
dryinq dryinq of ofnaterials, naterials,
tlrereby tlrereby
facilitating facilitating
desi.gn desi.gn
for fornraxjnunnraxjnun
energiy energiy
efficienoT efficienoT prodLrct prodLrct
and and quaLity.quaLity.
d) d) Betrter Betrter
nndels nndels
for forccrrnrcn ccrrnrcn
tl[Es tl[Es
of ofdryer dryer
to tofacilitate facilitate
optirnaf optirnaf
design design
andand
operation.
-25-
5. 5. PRmESSTMENSTFTCATIOTTMENSTFTCATIOT
PRmESS
wlttr wlttr
m,rdr higher
evaporators evaporators
a) a) Intensified Intensified m,rdr higher
tEat tEat
transfer transfer thanthan
coefficients coefficients
gntentiornl gntentiornl
eqdF.EnC.eqdF.EnC.
rnrdr rnrdr
wittr wittr
read,ors read,ors
b) b) Intensified Intensified bigher bigher fiudr fiudr
rates, rates,
reaction reaction teatteat
}rigter }rigter
flues flues rrtrclr shorter
arxi arxi r:esidence r:esidence
rrtrclr shorter tines tines
tlran tlran eqripent.eqripent.
conventional conventional
6. 6. ADVANCED
3-DADVANCED
3-D !,DDEX,LIIG!,DDEX,LIIG
FIIff FIIff
topics topics
of ofthe the
Several Several abo\re Hould
listed listed abo\reHould
benefit benefit arnranced }{)
frcrn frcrn }{)trcdellirgtrcdellirg
arnranced
flons flons
of offluid fluid wittr wittr
cor4led cor4led heat heat rnass transfer,
ard ard rnass transfer, reactions reactions
dtemical dtemical and,and,
in inscne scne pbase pbase
diEErsed diEErsed
cases, cases, transport. transport. de\telotrnencs inin
lte ltefollowing following de\telotrnencs
adrand adrand flor flor
3-D 3-D i&ntified i&ntified
rrrcdefffuq rrrcdefffuq
rcre rcre as asdesirable desirable
by by e:pelts e:pelts
the the toto
it it to to
enable enable applied applied
be be to tothese these
srressflrlly srressflrlly topics:topics:
a) a) !6re !6re of of
wparison wparisonrcdel rcdel with with
Predictions Predictions fieldfield
and and
eperilents.eperilents.
grid grid
generation generation
b) b) Inproved Inproved to tofacilitate facilitate
tedrriques tedrriques of ofotple<otple<
nodeffirq nodeffirq
georctries.georctries.
c) c) Irprov€d Irprov€d
tubrlence tubrlence
rcdellirq.rcdellirq.
d) d) Irr[rrovecl npdeUing
Irr[rrovecl npdeUing
of ofthe the particles particles
inceraction inceraction
of of with with flonsflons
turbrlent turbrlent
with with
ard ard vralls, vralls, partj.cle partj.cle
of of
ard ard higtt higtt
belraviour belraviour
at at con€,ntrations.con€,ntrations.
visual visual
e) e) I@rsned I@rsned predictions predictions
of of to tofacilitate facilitate
Gcrq)arisonGcrq)arison
with with data.data.
eperfuental eperfuental
7. 7. Drnn!4tc srMrIArIcbI
Drnn!4tc srMrIArIcbI
0E co€LE(
0E sYsTEl4ssYsTEl4s
co€LE(
a) a) Irproved Irproved
ccngrtirq ccngrtirq for for
sErategies sErategies ccrgrting ccrgrting
red:cirg red:cirg tine, tine, useuse
includirq includirq
parallel parallel
of of ccrrtrlrrtirg ccrrtrlrrtirg will will
llris llris
tedrdques. tedrdques. tncre
Pennit Pennit tncre
ccrtPle:(ccrtPle:(
proesses proesses
to to
be be aosc aosc
at atreasonable reasonable
sirnrlated sirnrlated nore nore
ard ard rp&lsrp&ls
realistic realistic
disErilarted disErilarted
of of systanrs sucl as as
systanrs
sucl cubrlar cubrlar arxXadsorber
reactors reactors arxX to tobebe
beds beds
adsorber
used.used.
b) b) I,€thocls for
I,€thocls
for optitnal optitnal
calcrrlattng calcrrlattng
the the of ofa asystsn systsn
trajectory trajectory beEl€etr twotwo
beEl€etr
steadlr steadlr '(fuicludirq '(fuicludirq
scates scates and and
starc-t{) starc-t{) taJ<Ing arccunt
sfuc{o}rn), sfuc{o}rn), taJ<Ing arccunt
ofof
practical practical
@nstrajnts @nstrajnts prodrct prodrct
as as
s.ldr s.ldr quality, quality,
eqrigert eqrigert
li.nitations li.nitations
ardard
safety.
c) c) Inprorred nathematical
Inprorred nathematical for for
tecluriqres tecluriqres
optirnisation.optirnisation.
d) d) Better Better
tlemodynamfc tlemodynamfc prediction prediction
property property lrethods lrethods
for for
highly highly
noridealnorideal
rnir<tunes, eg
rnir<tunes, polFers, polFers,
solutions solutions
eg of of polar polar
ard ard
electrollrtes electrollrtes gases,gases,
thereby thereby
i-rprovirg i-rprovirg of ofsfuulatlons.sfuulatlons.
?'ality ?'ality
-26-
e) e) Dlmanic Dlmanic
ncdeUing ncdeUing
of ofthe the
irrteraction irrteraction
of ofcfiplessors, cfiplessors,
turbines turbines
ard ard
Euq>sEuq>s
with with
eadr eadr
other other
and and
with with
other other
syse€rn syse€rn
@(ponents, @(ponents, pipetilqc.pipetilqc.
vessels, vessels,
eg eg
8. 8. SIMJLATIOI,I OE'
SIMJLATIOI,I
BAICFI
OE' BAICFI
SYSIEI4SSYSIEI4S
a) a) E:<tension E:<tension
of ofenergy energyprocess process
and and irrtegration irrtegration
conaepts conaepts processes.processes.
to tobatdt batdt
b) b) A Anethodology nethodology
for forevaluating evaluating
trade-offs trade-offs
betroeen betroeen integration,integration,
energy energy
plant utilizaLion and flexi.bility.
c) c) A Anetlodology netlodology
for forsynthesis synthesis
of ofnew new processes.processes.
batdr batdr
d) d) A Agereral gereral
purpose purpose prooess prooess
batch batch sinulator sinulator
based based
on on
e4perfueneallye4perfueneally
verified verified
dynamic dynamic
unit unit
operation operation
ncdels.ncdels.
e) e) Design Design
criteria criteria
for fortlrermal tlrermal
uEility uEility
systslrs systslrs
using using
a asingle single
heat heat
transfertransfer
redir.rn redir.rn
for forboth both
heatilg heatilg
and and
crcoling crcoling
c!,rties c!,rties
in inorder order
to tofacil.itatefacil.itate
plant plant
optifial optifial operation.operation.
9. 9. D{PERt D{PERt
SYSIEI4SFAR
SYSIEI4S
FAR
PROGSS mvTROL
PROGSSmvTROL
A}.lD PRCD(.LTI0.I
A}.lD PRCD(.LTI0.I
}G}.BGB4ENT}G}.BGB4ENT
a) a) Erraluation Erraluation
of ofnrle-based nrle-based
closed closed
foop foop
elpert elpert
systerns systerns
for fora awider wider
range range
ofof
plant and processes.
b) b) [€thods [€thods
for forva]idati-ng va]idati-ng
sensor sensor
irrErts irrErts
and and
assessing assessing in inctrectre
situations situations
fae faeof ofuncertairrty, uncertairrty,
eg egwrreliable wrreliable
or ormissing missing
sensor sensor
input.input.
c) c) Incorporation Incorporation
of ofreal real jnto jnto
ejre ejre elpeft elpeft
systems, systems,
for forlrend lrend
eg eg arnlysis,arnlysis,
projection projection
of ofplant plant
perfornence, perfornence,
plannjlg plannjlg
and and
seqrrencing seqrrencing
of ofoperations.operations.
d) d) DevelotrEnt DevelotrEnt
and and
evaluation evaluation
of ofelpert elpert
systerns systerns
based based
on on
a atunable,tunable,
user-friendly user-friendly of ofprocess process
representaeion representaeion nrcdel, nrcdel, rndel rndel
control control ardard
heuristic rcdet.
10. 10.AD\A\TED AD\A\TED

OI\FLINE OI\FLINE
SENSORSSENSORS
a) a) $nall, $nall,
nrgged, nrgged,
laser laser
instrurentation instrurentation
for forindr:strial indr:strial
llEasure{|FJlts llEasure{|FJlts
onon
two-phase two-phase
flors, flors, mass mass
eg eg flon flon
rate rate phase, phase,
of ofdispersed dispersed particle/droptetparticle/droptet
clcncentration clcncentration
and and
size size partio.rlarly partio.rlarly
distrib:tion, distrib:tion, il il concentratedconcentrated
dispersions.
b) b) Small, Small,
n:gEed n:gEed
sensors sensors
based based
on on
ultrasonic ultrasonic
or ornicrowave nicrowave
techniqrres techniqrres
forfor
noo-irvasive noo-irvasive proaess proaess
ind.Etrial ind.Etrial neasursrents neasursrents
i-n i-n
hostile hostile
envirorurents.envirorurents.
c) c) tfuclear tfuclear
teclrriques teclrriques
for forclrenical clrenical
corposition corposition
fleasurerents fleasurerents
ind.rstrialind.rstrial
on on
process process
streans.streans.
-27 -
d) d) Filn Filn for for
drgrdcal drgrdcal
sensors sensors nea$rrsrEnts nea$rrsrEnts
corposition corposition on on
irdrstrial irdrstrial
ProessProess
streans:
* * ifiprorred ifiprorred givirq givirq

rnaterials rnaterialsbetter better repeatabiticy repeatabiticy
selectivity, selectivity, ardard
drrabilitydrrability
* * inproved inproved
serrsor serrsor
constnrction constnrction
tecfrriguestecfrrigues
* * inprorcd inprorcd of ofdrernical drernical

urderstandirq urderstandirq reactions reactions
on on fuprorcdfuprorcd
sensors sensors
arrl arrl
aralysis aralysis wttidt wttidt
of oftlp tlpsignals signals generate.generate.
they they
e) e) Rqged Rqged
flc'w flc'w
injection injection
ana}ysis ana}ysis
sensor sensor for for
drernical drernical
systens systens corpositioncorposition
fieasur€fiElrt fieasur€fiElrt
on on process process
irdrstrial irdrstrial screan6.screan6.
-28-
TABLE TABLE
11
Distrilnrtion of Enerw Consurr'ption in fndustrv
EUR-10 in 1984 (E\:rostat provisional data)
FIfi'lAL FIfi'lAL
SIERGYSIERGY
INDUSTRAL INDUSTRAL
SECTCRSECTCR zz
CCIIS$aPTICDI TOE x 10e
Steel 48 25.3
Chenrical s 35 18.4
Non-neta1lic rnileraLs 2L.6 11.4

(Cenent, ceranics, glass, etc)
Food Food dririkdririk

and and 15 7.9
Paper and printing 9.3 4.9
Non-ferrous netals 77 3.8
Te>rtiles 6.4 3.4
l4etal l4etal
manufacturemanufacture 1 8 .6 9.8
Otrtrers Otrtrers
and and
adjrrstnentsadjrrstnents 29 L5.2
LgA.2 100.0
-29-
TRBIE TRBIE
22
Reetrtelded Reetrtelded
areas areas
for forirnrcsticration irnrcsticration
in inStaoe Staoe
22
Aft}totltrt Aft}totltrt
areas areas
the the Iisted Iisted
belor belor
have have
beerr beerr
reoonnrer*d reoonnrer*d
on on
the the of ofpotentialpotential
basis basis
enerEy enerEy
berefits, berefits,
it it shorrld shorrld
be be
noted noted
that that
adtranes adtranes
in inthese these
areas areas
witlwitl
usrally usrally
also also to topoUution poUution
lead lead abatetErt abatetErt
berefits.berefits.
1. 1. Alternati\re Alternati\re
or orilr@ro\red ilr@ro\red
unit unit
cperations cperations
reaction reaction
arrl arrl routes. routes.
lnclltdlnqlnclltdlnq
adrraned adrraned
flon flon
modellino modellino
where where
arpropriate*arpropriate*
a) a) Chsnieal Chsnieal
reactors, reactors,
ircfdirq ircfdirq processes processes
etectrccl€nic-l etectrccl€nic-l and and
mrlti-phasemrlti-phase
syst€mssyst€ms
b) b) t^cff-energy t^cff-energy
tedtniques, tedtniques,
eg eggas gas
adsorption, adsorption,
nelt nelt
crystallization,crystallization,
Iiqui&liquid Iiqui&liquid
ard ard
s-percriticar s-percriticar
extractionextraction
c) c) Glass-fltakirry Glass-fltakirry
firrnaes, firrnaes,
cfient cfient
kilns, kilns,
brick-oaking brick-oaking
kihs, kihs,
baj<ing baj<ing
orrcns orrcns
arrXarrX
drlersdrlers
d) d) Proess Proess
intensificationintensification
2. Ener-cnrand proess sv*,enrs ncdels
a) a) Dynanic Dynanic
sirulation sirulation
of ofcorplor corplor
systems,systems,
irc.Ird.ing irc.Ird.ing
develognent develognent
of ofcontrolcontrol
strategiesstrategies
b) b)Sinulation Sinulation
batdr batdr
of of systems,systems,
inc},nfing inc},nfing proess proess
energy energy
and and integrationintegration
3. 3.Sersors, Sersors,
instnurentation instnurentation
and and
controlcontrol
a) a)E:FeEt E:FeEt process process
systens systens
for for ontrcl ontrcl prodrction prodrction
arrt arrt nanagercJrt,nanagercJrt,
b) b)erntared erntared
orline orline
sensors sensors
f,or:f,or:
- - rrcasurfuq rrcasurfuq
qositlon qositlon of ofproess proess
streansstreans
- - [Easurcnent [Easurcnent
in inrufti$rase rufti$rase
flors, flors, mass flsr
eg eg massflsrrate,rate,
qrentration qrentration
ard ard
size size
of ofparticles particles
ard ard
drqsdrqs
- - rcasuresEnts rcasuresEnts
in indiffiqrlt diffiqrlt
erwiromentserwiroments
- - plant plant
csrditiqr csrditiqr
uonitorirguonitorirg
NBNB
(t, (t, Ibat, Ibat, p.qs p.qs
ercfrangers, ercfrangers,
tpat tpat and and
oolilstlqr oolilstlqr
are are
not, not,
incrudecl incrudecl
tn tn
tits titsTableTable
sine sine
tley tley
are are
inPortant inPortant qrsenratisr qrsenratisr
energy energy topics topics
in intheir their
own rtght
own rtght
andand
onse4ently onse4ently
alre alre
the the
objects objects
of ofsqrarate sqrarate
suneys suneys
urder urder
tlE tlE
@ @EetgyEetgy
consenratiqr consenratiqr
PrcgEarrre. PrcgEarrre.
!tsnlcrarE !tsnlcrarE
separaticrs, separaticrs,
catalysts catalysts
ard ard
biocrgnicarbiocrgnicar
prcesses prcesses
are are
not not
irnh*d irnh*d
because they
because
they
are are
overed overed
unCer other
unCerother
CEECEE
Prcgrafl€s.Prcgrafl€s.
(ii! (ii!ernnnced ernnnced
fiow fiow
rc<bfurg rc<bfurg
t€ics t€icstra\re beer grqped grqped
tra\rebeer together together
witi witi
alternative alternative
oror
inProted inProted qer.'aticrs qer.'aticrs
nnit nnit and andrcactiqr rcactiqr
rcnrces because
rcnrces the
because
the rrtere rrtere
areas areas adrnnedadrnned
fl-cn fl-cn
rc&fUrg rc&fUrg
@uld @uld tF tF
to to greatest, greatest,
lead lead eneryf, eneryf,
inprorelents inprorelents
areare
either either
reactors reactors
or or
unit unit
cperatians.cperatians.
-30-
APPE.iDIX A
LetJer Sent to Researdt E>perts
Dear Dear
..
The TheProcess Process

Hrgineering Hrgineering
Researdr Researdr
Centre Centreat attla::qell tla::qell
Iaboratory Iaboratory
has has
beer beerasked asked
toto
condrcL condrcL
a asurvey survey process process
of ofcertain certain irdrstries irdrstries
researclr researclr
needs needs
on onbehalf behalf
of oftletle
@nn-ission @nn-ission
of ofthe the European European A Aletter letter
Conrn:nities. Conrn:nities. frorn frorn European European
the the Ccnmission Ccnmission
isis
in inconfinnation confinnation
enclosed enclosed of ofttris. ttris.fire fire is isto toassess assess
irrtent irrtent the thepresent present
positionposition
of, of,and and
firLure firLure
requirerent. requirerent.
for, for,strategic strategic
RED in insupport support
RED of ofefficient efficient
use use
ofof
enelgy enelgy
and and for forpollution pollution
its itsinplications inplications in inthe the
abaterenc abaterenc jnd.striesjnd.stries
process process
withijt withijt
Europe; Europe; is, is,precorpetitive precorpetitive
tllat tllat R&D wtddt
R&D wtddt wiII wiIIcoce coce
to tofnritioifover fnritioifover
aa
of of5 5- - 10 10
period period years years may may
ard ard then then have have fupact fupact
scxre scxre on on process process
the the fudrstries.fudrstries.
In Intjre tjre
first firststage stage
of oftfris tfris
survey survey r*erre r*erre
diso.rssions diso.rssions held held
with with
16 16leadirg leadirg
indrstriaLindrstriaL
... ...olFanies olFaniesfron fronvarious various
rrErnber rrErnber of oftle tleEEC, EEC,
staLes staLes 4 4European European
indstry indstryfederationsfederations
ard ardthree three
researdr researdr
ilstitutions. ilstitutions.
Following Following
tlese tlese ertairr ertairr
discr:ssions discr:ssions eopics eopics
ha\reha\re
been beenselected selected
as as
beirq beirq
of ofthe the priority priority
tdghest tdghest and and are are
tllese tllese listed listed
in intI€tI€
attached attached
Table.Table.
In Intrre trre
second second
stage stage
of oftle tlesunrcy sunrcy will willbe be
cliso.rssions cliso.rssions with with
held held leadingleading
researrhers researrhers
in ineadr eadr
of oftlese tlesetopics topicsin inorder order
to todefine definetlle tlle jrportant jrportant
rost. rost. researehreseareh
needs needsin ineadr eadrareas areas
nnre nnreprecisely. precisely. the the would would
researctr researctr be be to tohave have
er1pected er1pected a ahi*thi*t
degree degreeof ofno\relty no\relty
ard ard results results
tlle tlle nould nould
be be
opected opected to tobe be general general
atd atdto tobear bearonaona
nriety nriety of ofprod.rct,s prod.rct,s
and andproesses. proesses. will willlead lead
lte ltesurvey survey to toa aposition position
paperpaper
utridr utridr
will willbe bepresented presented
to tot}te t}te
CEC at CECatthe the of of1987. 1987.
erd erd Infodnation Infodnation paperpaper
for fortlre tlre
wil] wil]tre tre
gathered gathered
irr irra aseries series
of ofintenriews intenriews $re would
ard ard $re would like liketo toirwite irwiteyou youtoto
participate participate you you
sirroe sirroe are are an an
ad<nowle@ed ad<nowle@ed jI jI aE aE
eryert eryert least leastone one prioritypriority
of ofthe the
tcpics tcpicsas aslisted listed
in inthe the Table. Table.If If you youagree, agree,
a areseardrer researdrerfrom from will willvisit,visit,
lla:r,ell lla:r,ell
you youfor fora adiscussion. discussion. A Arecord record
of ofthe the will willbe be
diso.rssion diso.rssion to toyou you
subnitted subnitted forfor
editilg, editilg, rnay rnay
arxt arxt subseqr:ently subseqr:ently
be beincl:ded incl:ded
as as
an anAgrpendix Agrpendix
to tothe theposition positionpaper.paper.
parEs parEs
Any Any of ofthe thedisqrssion disqrssion you you
wtridr wtridr uould uould want. want.
not not included included
in inthe the Appe.ndix Appe.ndix
willwill
be bekept keptconfidential.confidential.
-31 -
Ihe Ihe
ain ain
of ofthe the
intenriew intenriew
will will
be be
to toobtain obtain
an an
ovenrierr ovenrierr
of ofthe the
needs needs
ardard
possiJrilities possiJrilities qpeciality qpeciality
in inlour lour as as see see
lrou lrou Ttre follcning
tlsn. tlsn. Ttre questions questions
follcning arrearre
posed posed
as asa afranework franework
for for
the the
disanssion:disanssion:
1. 1.Erqn Erqn vierpoint vierpoint
the the of ofinproving inproving
the the
energy energy
efficiency efficiency proessproess
of ofthe the
irrirstries, irrirstries,
r.itrat are
r.itrat
are j.rportant. j.rportant.
tle tlencst ncst research research
reeds reeds prioritypriority
in inthe the
topic(s) topic(s)
listed listed
in inthe the you you
in inrrtddr rrtddr
Table Table an an
are are elpert?elpert?
2. 2. If Ifthese these goals goals
researdr researdr are are
adderred, adderred,
srhat $onld
srhat $onld
be be nrain nrain
tlre tlre a:reas of,of,
a:reas
whaCenergy
ard ard whaC energy
benefits benefits
arxl arxl potlutionpotlution
associated associated
abaterrEnt berefits
abaterrEnt
berefits
rculd rculd possible?possible?
becoe becoe
3. 3.Mtidt Mtidt
aspects aspects
of ofFt&Dwithin
Ft&Dwithin topic(s) topic(s)
lorrr lorrr ale ale
rcst, rcst,
liJcely liJcely
to toaclrranoerapidlyrapidly
aclrranoe
over over
the the
ne:<t decade?decade?
ne:<t
4. 4.tfttat, manpover
tfttat, manpover
ard ard
facilities facilities Europe possess
does does Europe possess
for for inyour your
REDinRED topic(s)?topic(s)?
Are Are
ttere ttere gaps gaps
irportart irportart wtridr wtridr
should should
be be
fil.Ied? fil.Ied?
What al.e
Whatal.e (eg(eg
oonpetitors oonpetitors
Japan or Japan
or
the the
tlSA) tlSA)
dohg dohgin inthese these
areas?areas?
5. 5.9[ridt 9[ridt
of oft]ese t]ese
areas areas
of ofREDwittrin
RED wittrin
nircpe nircpe
!'urld !'urld
benefit benefit
rncst, flcnrflcnr
rncst,
International International
cooperation cooperation
with with
onsistent onsistent
ard ard
co-ordinatsed co-ordinatsed
CECsl4port
CEC sl4port
ofof
strategic strategic
research?research?
6. 6.gtrat gtrat
practical practical
benefits benefits
r,lould r,lould
arise arise
frcn frcn
this this tfirat, tfirat,
s4port? s4port? resor:res resor:res
rculdrculd
ree&d ree&d
be be to toadrieve adrieve
tnese tnese
benefits?benefits?
7. 7.9{ould yott yott
9{ould
be beinterested interestedpa*icipated pa*icipated
tn tn in inin ininternational international
linlcd linlcd
researc*rresearc*r
actions actions
with with
@nruniQr @nruniQrsLEport sLEport
for for
cost cost pEojects pEojects
sttarirq sttarirq in inyorr yorr
tqic(s)?tqic(s)?
Please Please
note note
that that
tltis tltis
letter letter
in inno no
courits courits Cqnnission Cqnnission
the the to toconcLude aa concLude
@ntrart.@ntrart.
lih lih
urderstard urderstard
that, that,
of oft}re t}re
tcpics tcpics
listed listed
in inthe the
Table, Table, priraipal priraipal
lour lour area area
ofof
elpertise is ......- '
AA nenber nenber
of ofthe the
liara'elL liara'elL will will
staff staff oontact oontact
ry rytekptrorp tekptrorp
lrou lrou in inthe the
nerG nerG
fen fen
daysdays
to toanarqe anarqe
a avisit visit
aC sorre
aC ruCually
sorre ruCually
convenient convenient
tinrg.tinrg.
Yars Yars
sinerefysinerefy
David David
ReayReay
llhnager, llhnager,
hoess hoess
Engfureerfug Research
Engfureerfug
Research
Cent].eCent].e
enc encI€tter I€tter
frotl frotl
Dr Dr
StlulcStlulc
cccc
PS PS
tne tne
Ccnnrission of
Ccnnrission
ofthe the
nrrcpean nrrcpean
Conunities Conunities
is isseflfing seflfing
1rgurirrbr
1rgu rirrbr
sepante
-- sepante
@\,er@\,er
scae scae
aditional aditional qr qr
infosnation infosnation
its itsastivities astivities
in inerergy erergy
consenraeion. consenraeion.
-32-
COMMISSION
OF THE
E U R O P E A NC O M M U N I T I E S
OIRECTORATE€EN€RAL
FOR SCIENCE.RESEARCH
ANO OEVELOPM€NT
JOINT RESEARCHCENTRE
XII-E
0 67
TO MTOM IT HAY CONCERI'I
The UK Atouic Energy AuthorlEy (UIGEA) Research Establlshmenc ar

Har:well ls carryl.ng out for the European Cornmunlties a study on the
state of the art of strateglc R & D ln support of eiflclenr use of
energy and tts lnpltcations for pollutlon abatenent ln rhe process
lndustrles. As a resulE an lnventory will be made to report what needs
to be done ln R & D ln thls field.
On the basls of this s c u d y E h e C o u r m l s s L o nt s s e r v i c e s intend to examlne

the interes t ln , and the opportunlty f or , carrylng out such R ,! D work
ln an Lnternatlonal j olnc v e n c u r e , w t c h C o r u r u nL c y s u p p o r t af forded to
partlclpating research organlsatlons.
The PurPose of this letter is to lnform you about the uIGEA study and
to seek your co-operatlon ln tcs execucLon.
/L /,*,/,*,
/L
A. STRTIB
Dl r e c c o r
Head of Che Non-Nuclear Energy
R and D Prograume
Provisioatt tddrsss: felephonc: Telcr: fclegraphic addrcl,t:

Ruc cte le Loi 2(l Oirect linc: 2!1... . . coM€U f'21877 COMEUR Sructolt
8-1049 €lrussclr Tdeghooe erchangc:235 tt ll
(AtEadEd (AtEadEd
TRBTE TRBTE to tol€tter)l€tter)
for for
areas areas
Reonrended Reonrended investiqation investiqation 2r2r
in inStaG StaG
liseed liseed
aleas aleas
Aftholrgtr Aftholrgtr
the the harrc beerr
belor belor harrc reconrended
beerr on on
the the
reconrended of ofpotentialpotential
basis basis
be be
ic icshould should
benefiCs, benefiCs,
energy-efficiency energy-efficiency that that
noted noted in inthese these
advanes advanes willwill
areas areas
usually usually lead lead
also also to toPoUution PoUution benefics.benefics.
abatenEnt abatenEnt
1. 1.Neemaeive Neemaeive reacEion reacEion

and and
ooerations ooerations
or orinprsved inprsved
unit unit includinctincludinct
routes, routes,
where aEDr@riateaEDr@riate
np&llinq np&llinq
flohr flohr
advaned advaned where
incfuditq incfuditq
reactors' reactors'
d d Ctsnical Ctsnical processes processes
electrochendcal electrochendcal rulti-phaserulti-phase
ard ard
systenssystens
b) b)Lorr.€rergy Lorr.€rergy
sqraration sqraration eg eggas gas
tedrdques, tedrdques, nelE nelE
crletallization,crletallization,
adso4>tion, adso4>tion,
arxt arxt
liqri+liqdd liqri+liqdd extractionextraction
zuperuicical zuperuicical
kilnsl kilnsl
cercnt cercnt
fi.rrnaoes, fi.rrnaoes,
c) c)Glassrnaking Glassrnaking kilns, kilns,
balcirq balcirq
brid<rnaking brid<rnaking ardard
svens svens
dryersdryers
iatensificat,ioniatensificat,ion
d) d)Prccess Prccess
prcaess prcaess
2. 2.Enerd/ Enerd/
ard ard rrcdelsrrcdels
svstens svstens
a) a)Dlpaotic Dlpaotic
si-milation si-milation incfudiry incfudiry
syst€rns, syst€rns,
of ofcorplex corplex of of@ntrol@ntrol
&rel@nent &rel@nent
strategiesstrategies
systernsi, fu'cludirg
of ofbatclr batclr
b! b! Sinulation Sinulation systernsi,fu'cludirg
energy energyproess proess
ard ard integrat'ionintegrat'ion
ard ard
controlcontrol
instruentation instruentation
3. 3. Sensors. Sensors.
a) a)E:q)ere systqns process process
for for
E:q)ere systqns prodrction prodrction
control control
ard ard rnanagffintrnanagffint
-lc) -lc)Adreted Adreted
orlire orlire for:for:
sersors sersors
- - neasur:lg neasur:lg
oonposition oonposition
of ofproess proess streamsstreams
- - rcasurslEnt rcasurslEnt
in inruItiSnse ruItiSnse flo'ls, flo'ls,
eg egnnss nnss
flo,u flo,u
rate,rate,
ard ard
@nentration @nentration size size
of ofparticles particles
ard ard
dropsdrops
- - rcaswsrents rcaswsrents
in indiffiolt diffiolt
environnEntsenvironnEnts
- - plant plant nonicorirgnonicorirg
cordition cordition
** tbat tbat pwps pwps

teat, teat,
e!(changers' e!(changers' aonhrstiqr aonhrstiqr
ard ard are are
nd, nd,
irEfuded irEfuded Tabl€Tabl€
in int}ris t}ris
are are
they they
sjne sjne surr€lrs surr€lrs
of ofsq)arate sq)arate
sr:bjects sr:bjects ur&r ur&r
the the Energy ConsenratictConsenratict
CE CE Energy
prqtrame. prqtrame.
t€nbrane t€nbrane catalysts catalysts
separations, separations, biochemic'l biochemic'l
ard ard P!€cesses P!€cesses ndnd
at€ at€
irrcIl*d irrcIl*d
because they
because
they
are are urder urder
covered covered d,her d,her
CE CEProgrcqlEs.ProgrcqlEs.
-34-
APPETOIX BB
APPETOIX
Experts Experts
inte:nriered inte:nriered
d.tring d.tring
t}e t}ecor:rse cor:rse
of ofthe the
survey survey
are are
referenced referenced
in inthethe
main main
eelrt' eelrt'
as asfollor.'s:follor.'s:
Referene Referene Er<pertEr<pert
?A ?A Dr Dr BB DD CritterrCen, CritterrCen,
Unirrcrsity Unirrcrsity
of ofBath Bath (LJK)(LJK)
BB lt lt D D W ttaspel,
W ttaspel,
Sira Sira Limited Limited ((JK)((JK)
2C 2C Prof Prof PP ltutclrinson, ltutclrinson,
Cranfield Cranfield Institute Instituteof ofTednology Tednology OK)OK)
?D ?D Dr Dr GG L LOrarini, Orarini,
flanell flanell (I'JK)(I'JK)
Iaboratory Iaboratory
EE Dr Dr CC Rarnshaw, Rarnshaw,
Irperial Irperial Chsnical Chsnical
Indrstries Indrstries (tJK)(tJK)
2F 2F Dr Dr J Jw w Ponton, Ponton,University University of ofEdinburgh Edinburgh (UK)(UK)
2G 2G Puof Puof RR t{ t{H H
Satgent., Satgent.,Inperial InperialCollege College
of ofScience Science andand
Tectrologry Tectrologry(tJK)(tJK)
AA Dr Dr RR DD Watkirs, Watkirs,
tlar*ell tlar*ell (UK)(UK)
Laboratory Laboratory
2l 2l Prof Prof B BLimhoff, Limhoff, UnirrersiLy UnirrersiLyof of!4anclrester !4anclrester ofof
Institutc Institutc
Science Science and andTechnolory Technolory rcK)rcK)
2J 2J Prof Prof HH Angelino, Angelino,Institut Institut dr drGenie GenieCtrlnique, Ctrlnique, (F)(F)
Toulouse Toulouse
2K 2K MA M ARojey, Rojey, Institute Institute Frangais Frangais
dr drPetrole Petrole (F)(F)
A. A. Prof Prof P PI€ I€Goff, Goff, INPL,. INPL,. (F)(F)
lwrcy lwrcy
^l ^l Prof Prof MM Pernrt, Pernrt,INPL, INPL, Nancy Nancy(F)(F)
aI aI Prof Prof Tondeur, Tondeur,$lPL, $lPL, l{ancy l{ancy(F)(F)
20 20 Prof Prof Dr Dr F FDnst, Dnst, unirrersiey unirrersiey (D)(D)
of ofErlangerFlfurnlcerg ErlangerFlfurnlcerg
EE Prof Prof Dr Dr Ing IngHH H'cffinarn, H'cffinarn,
unirrersity unirrersity (D)(D)
of ofErlangen-tfusrtcerg Erlangen-tfusrtcerg
2Q 2Q Dr Dr lrEl lrEl
A AScheuer, Scheuer, Forsclu:ngsinstitut Forsclu:ngsinstitut
der der zsentijrd.Etrie,zsentijrd.Etrie,
Drsseldorf Drsseldorf (D)(D)
2R 2R Prof Prof Dr Dr Ing IngE EU U Sdrliin&r, Sdrliin&r, Unirrersity Unirrersity
of ofKarlsnrtre Karlsnrtre(D)(D)
25 25 Dr Dr Ing IngJ JUlrictr, Ulrictr,
tfrrirrersity tfrrirrersity
of ofBremen Bremen (D)(D)
2T 2T Dr Dr GG J JArkenbout, Arkenbout,T!t) T!t) (Nt)(Nt)
2V 2V Ir Ir P PSluiner, Sluiner, Itrp Itrp(NL)(NL)
7f 7f Prof Prof K KR R htesterterp, htesterterp,lt|enCe lt|enCe
Univelsity Univelsity (NL)(NL)
nn Prof Prof Ebcnent, Ebcnent,
University University of ofGent Gent (B)(B)
?X ?X Prof Prof RR Jottnrd, Jottnrd, UniversiC6 UniversiC6 f*ibre f*ibre
de deBruxelles Bruxelles (B)(B)
2Y 2Y Prof Prof B BlGLitventzeff, lGLitventzeff, tJnir.rersity tJnir.rersity
of ofLiege Liege (B)(B)
22 22 Dr Dr !€ssi !€ssi tlauri, tlauri,
Enirierclre, Enirierclre, lbnte lbnte
Rotondo Rotondo (I)(I)
2a 2a Dr Dr Ing IngToninato, Toninato,
Stazione Stazione gperi.nrentale gperi.nrentale
dei dei Vetro, Vetro,
Mlrano,Mlrano,
Venezia (I)
bb Prof Prof E ECosta, Costa,
ttrrirrersidad ttrrirrersidad
C.:orplutense, C.:orplutense, (Sp)(Sp)
I.{adrid I.{adrid
2c 2c Prof Prof L LE\rigjaner, E\rigjaner, politechnica politechnica
Wrirrersidad Wrirrersidad di diCatalunia,Catalunia,
Batelona Batelona (SP)(SP)
2d 2d Prof Prof DD F FG G DEao, DEao, Insituto Insituto Sr.perior Sr.perior
Tecnico, Tecnico, (P)(P)
Lisbon Lisbon
2e 2e PIof PIof A AE ERodrigues, Rodrigues, of ofporto porto
lrriversity lrriversity (p)(p)
2f 2f Prof Prof A AFredenslrrd, Fredenslrrd, Tectrric^r Tectrric^r
University University (DK)(DK)
of ofDenrnark Denrnark
29 29 Dr Dr A ASorensen, Sorensen, Tectrnical TectrnicalUniversty Universty
of ofDerunark Derunark (DK)(DK)
?h ?h Prof Prof A AJ JlGrabelas, lGrabelas, University Universityof ofTtressaloniki Ttressaloniki(6)(6)
2L 2L Prof Prof A Albntopoulos, lbntopoulos, l,lational l,lational
Teclurical Teclurical
University University (GR)(GR)
of ofAtlens Atlens
2) 2) Prof Prof NN Markatos, Markatos,
National National Technical Technical
UniversiLy UniversiLy (G)(G)
of ofAtjra'ls Atjra'ls
2k 2k Prof Prof CC GG Vayenas, Vayenas,
University University of ofPatras Patras (GR)(GR)
2L 2L Dr Dr NN !turphy, !turphy,
Universiry Universiry College College
D$fin D$fin (I)(I)
hh Mr Mr RR E EBatu, Batu,Harrell Harrell laboratory laboratory(('[()(('[()
Ar Ar lit lit I I C CIGnp, IGnp,ttanrell ttanrelllaboratory laboratory(LK)(LK)
2o 2o Dr Dr F FJakob, Jakob, @, @,l.tar@ussis l.tar@ussis (F)(F)
2p 2p Ir Ir Jt( Jt(A Alhohbour, lhohbour,llll llll (NL)(NL)
_35_
European - Commission
Communities
EUR11920- Needsfor strategicR&Din supportof improvedenergy

efficiencyin the processingindustries-
Viewsof researchexperts
D. Reay,
D. P. A.
P. A.
Reay, PilavachiPilavachi
Officefor OfficialPublications
Luxembourg: of the EuropeanCommunities
1989- lll, 35 pp. - 16.2x 22.9cm
Energyseries
EN
tsBN92-825-9231-6
1920-EN-C
number:CD-NA-1
Catalogue
Price(excluding
VAT)in Luxembourg
: ECU5
Interviewshavebeenconducted, in universitiesand researchinstitutes, with

42 leadingexpertswho are at the forefrontof researchin the priorityfields
Throughtheseinterviews,
identified. it hasbeenpossible to definemorepre-
ciselywhatpre-competitive
research needsto be donein eachol thesefields,
whatthe mainapplicationareasand energyefficiency benefitsare likelyto
be, and whatthe strengthof Europe'scurrentresearchpositionis in these
fieldscomparedto otherpartsof the world.
In alltheareassurveyed therearemanyopportunities R&Dwhich
forstrategic
is likelyto lead to improvedenergyefficiencyand consequentialpollution
abatement in the processingindustries.

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Commission

Researchfinanced by the Commissionof the EuropeanCommunities

Cataloguingdata can be found at the end of this publication

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A Afi:rtter fi:rtter ntrictr ntrictr

In Inall allthe the

a) a) Novel Novel wit}l wit}l

c) c) tlo\rel tlo\rel reactors reactors

2.1 Selective adsoratrion

rr fuproved fuproved of ofadsorption adsorption

2.2 lElt cnstaUization

Ettairuent, Ettairuent, goals goals

2.4 Liquid-Iiquid extraction

b) b) Develognent. Develognent. of ofpreteat.ing preteat.ing

10. 10.AD\A\TED AD\A\TED

* * ifiprorred ifiprorred givirq givirq

* * inprorcd inprorcd of ofdrernical drernical

Distrilnrtion of Enerw Consurr'ption in fndustrv

EUR-10 in 1984 (E\:rostat provisional data)