Integration and Optimization of Unit Operations

Review of Unit Operations from R&D to Production: Impacts of Upstream and Downstream Process Decisions

1st Edition - June 23, 2022
Imprint: Elsevier
Editor: Barry A. Perlmutter
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 5 0 2 - 7
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 2 3 6 1 8 - 5

The chemical industry changes and becomes more and more integrated worldwide. This creates a need for information exchange that includes not only the principles of operation but al… Read more

Integration and Optimization of Unit Operations

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The chemical industry changes and becomes more and more integrated worldwide. This creates a need for information exchange that includes not only the principles of operation but also the transfer of practical knowledge.

Integration and Optimization of Unit Operations provides up-to-date and practical information on chemical unit operations from the R&D stage to scale-up and demonstration to commercialization and optimization. A global collection of industry experts systematically discuss all innovation stages, complex processes with different unit operations, including solids processing and recycle flows, and the importance of integrated process validation. The book addresses the needs of engineers who want to increase their skill levels in various disciplines so that they are able to develop, commercialize and optimize processes. After reading this book, you will be able to acquire new skills and knowledge to collaborate across disciplines and develop creative solutions.

Cover image
Title page
Table of Contents
Copyright
Contributors
About the editor
Preface
Chapter 1: Crystallization
Abstract
1.1: Fundamentals and laboratory scale process development
1.2: Pilot scale crystallization studies
1.3: Commercialization of crystallization processes
References
Chapter 2: Fermentation and downstream processing: Part 1
Abstract
2.1: Introduction
2.2: Microbiology and biochemistry basics
2.3: Fermentation media and environment
2.4: Growth kinetics and substrate utilization
2.5: From vial to production fermenter
2.6: Oxygen transfer and utilization
2.7: Mixing in aerobic fermentation vessels
2.8: Sterilization
2.9: Heat generation
2.10: Scale-up
References
Chapter 3: Fermentation and downstream processing: Part 2
Abstract
3.1: Fermenter design
3.2: Fermenter instrumentation, control and operation
3.3: Continuous culture
3.4: Downstream processing
3.5: Concluding remarks
Nomenclature
References
Chapter 4: Liquid filtration
Abstract
4.1: Do you need a filter?
4.2: Lab testing before you choose the filter
4.3: Choosing the filter
4.4: The ABCs of liquid filtration
4.5: The mechanics of liquid filtration
4.6: Troubleshooting
4.7: The filter cake
4.8: Preventative maintenance program
Further reading
Chapter 5: Cake-building filter technologies
Abstract
5.1: Batch processing of filter cakes
5.2: Contained filter presses for cake washing, dewatering, and drying
5.3: Nutsche filter and filter dryers
5.4: Continuous processing of filter cakes
Chapter 6: Centrifugation
Abstract
6.1: Centrifuge choice and analysis of available equipment
6.2: Typical centrifuge operation
6.3: Technical considerations of equipment selection
6.4: Other considerations of centrifuge operation
6.5: Final remarks
Chapter 7: Dryers
Abstract
7.1: Purpose of drying
7.2: Dispersed solid-liquid system
7.3: Drying processes
7.4: Convective drying with hot gas
7.5: Conductive and radiative drying
7.6: Evaporation of liquid from a solid packing
7.7: Drying facilities
7.8: Troubleshooting
References
Chapter 8: Pressure filter dryer
Abstract
8.1: General considerations of using a pressure filter dryer
8.2: Principles of the pressure filter dryer
8.3: Filter choice and analysis of available equipment
8.4: Technical considerations of equipment selection
8.5: General operation of a pressure filter dryer
8.6: Final remarks
Chapter 9: Process automation systems
Abstract
9.1: Process automation in production facilities
9.2: Process control system (continuous process)
9.3: Process control systems (batch process)
9.4: Safety instrumented systems
9.5: Alarm management systems
9.6: Machinery protection
9.7: Measurement, and other fun things to do with instruments
9.8: The effect of technology on process automation
Chapter 10: Process automation life cycles
Abstract
10.1: Planning for process automation
10.2: Front end engineering design
10.3: Delivery phase, detailed engineering, and procurement
10.4: Installation and commissioning
10.5: Automation system operation and obsolescence
10.6: Conclusion
Chapter 11: Process automation platforms
Abstract
11.1: Background
11.2: Staffing of a manufacturing facility
11.3: Finding the balance
11.4: The new paradigm of autonomous operations
11.5: Upgrading the level of automation
11.6: Where to start when considering investment in higher levels of autonomy
11.7: Conclusions
Chapter 12: Mixing and blending
Abstract
12.1: Introduction: Why mixing matters
12.2: Upstream considerations
12.3: The second shaft
12.4: The third shaft
12.5: Additional mixer design considerations
12.6: Rheology considerations
12.7: Overmixing is just as bad as undermixing: Know the finishing point
12.8: Reliable scale-up
12.9: Mechanical aspects and troubleshooting
12.10: Case study: Why push toward efficiency?
12.11: Final remarks
References
Further reading
Chapter 13: Process development and integration by mathematical modeling and simulation tools
Abstract
13.1: Fundamentals and workflow
13.2: The steps for building a mathematical model
13.3: Steady-state and dynamic simulations
13.4: Process simulation for optimization
13.5: Process development workflow for continuous manufacturing
13.6: Correlation between CQAs, CPPs, CMAs
References
Chapter 14: Process safety
Abstract
14.1: Lab-scale operations
14.2: Pilot plant operations
14.3: Production scale operations
References
Chapter 15: Process commissioning
Abstract
15.1: Commissioning
15.2: Competency
15.3: Checks prior to the start of commissioning
15.4: Commissioning protocols
15.5: Specific process engineering responsibilities
15.6: Handover of the plant to the user
15.7: Overall recommendations for process engineers
Appendix: Example Commissioning Protocol for a new Hydrochloric Acid Tanker Offloading Pump
Chapter 16: Holistic process integration and optimization: Large-scale hybrid process applications
Abstract
Acknowledgments
16.1: Introduction
16.2: Life cycles of generic activities for large-scale bulk chemicals production
16.3: Systems integration design for specialty products manufacture and sales
16.4: Gated process development with digital interlinks
16.5: Digital control life cycles of integrated large-scale production plants
16.6: Environmental impact monitoring and control
16.7: Systems integration of plant operations within eco-industrial parks
16.8: Conclusions
References
Chapter 17: From idea to 1 million ton year commercial plant
Abstract
17.1: The framework
17.2: The execution
17.3: At last: Safety first
Chapter 18: Scale-up challenges: Examples from refining and catalysis
Abstract
18.1: Challenges in refining scale-up
18.2: Challenges in catalyst scale-up
18.3: Decision gate for catalyst scale-up
References
Chapter 19: Scale-up challenges: Wastewater
Abstract
19.1: Challenges in wastewater treatment
References
Chapter 20: Hemp/biomass process steps
Abstract
20.1: Hemp cultivation overview
20.2: Extraction
20.3: Innovations and other extraction technologies
20.4: Cannabinoid isolation
20.5: Conclusions
References
Chapter 21: Techno-economic analyses
Abstract
21.1: Introduction
21.2: Technology assessment
21.3: Making cost-of-manufacturing estimates during the early stages of a project
21.4: Putting the costs together: Example problems
21.5: Handling uncertainties during early project stages
21.6: Combining costs with revenues to compute economic indicators
References
Chapter 22: Project management
Abstract
22.1: Introduction
22.2: The project engineering process
22.3: Predictive tools
22.4: Industries served by process engineers
22.5: Process plant components
22.6: Process safety and process engineering work flow
22.7: Putting it all together with practical knowledge
22.8: Engineering: In-house resources and EPC firms
22.9: Project execution
Chapter 23: Decommissioning
Abstract
23.1: Options for decommissioning
23.2: How to begin decommissioning
Index

Barry A. Perlmutter

Barry A. Perlmutter is President of Perlmutter & Idea Development LLC, P&ID. He has 40 years of technical engineering and business marketing experience in solid-liquid separation, filtration, centrifugation, and process drying. His skills focus on process solutions, innovation strategy and business development and market expansion. Barry has published and presented worldwide and is responsible for introducing many European technologies into the marketplace. He is an author of Elsevier’s “Solid-Liquid Filtration: Practical Guides in Chemical Engineering” and a new E-book “Framework for Selecting Automated Filtration Technologies for Clarification Applications .” Barry began his career with the US Environmental Protection Agency and then entered the world of solid-liquid separation at Pall Corporation. For eleven years, he continued at Rosenmund Inc. as VP of Engineering and Sales including Comber and Guedu Dryers and Ferrum Centrifuges. From the process industries, Barry joined Process Efficiency Products, now part of Amiad USA, as a Director of Marketing and Sales for the manufacturing of filtration, separation and adsorption technologies for cooling tower and HVAC water, process fluids, and water and wastewater treatment. He then became President & Managing Director of BHS-Filtration Inc. (BHS-Sonthofen Inc.) where he grew the filtration, drying, mixing and recycling business of BHS for more than 20 years including the integration of AVA GmbH dryers. His current company, P&ID, allows Barry to provide consulting services for process and project development with operating companies and business development, marketing & sales strategies for process technology suppliers. He received a BS degree in Chemistry from Albany State (NY) University, MS degree from the School of Engineering at Washington University, St. Louis and an MBA from the University of Illinois, Chicago.

Affiliations and expertise

President of Perlmutter & Idea Development LLC., North Carolina, U.S.A.

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