What are the current trends and innovations in process intensification research and development?

2 Hybrid processes

Another trend in PI research and development is the integration of different process steps or technologies into hybrid processes that can synergize their benefits and overcome their limitations. For instance, hybrid processes can combine thermal, mechanical, chemical, or biological processes to achieve better separation, purification, or conversion of complex mixtures or streams. Some examples of hybrid processes are reactive distillation, which combines reaction and distillation in one column; supercritical fluid extraction, which uses a fluid at high pressure and temperature to extract valuable compounds from biomass; and hydrothermal liquefaction, which converts wet biomass into bio-oil under high temperature and pressure.

3 Process intensification by design

A third trend in PI research and development is the application of systematic and holistic design methods and tools that can identify, evaluate, and optimize PI opportunities and solutions. These methods and tools can include process synthesis, analysis, simulation, optimization, and control techniques that can explore the design space, identify trade-offs, and select the best PI alternatives. Some examples of process intensification by design methods and tools are PI indicators, which measure the degree of PI achieved by a process; PI screening tools, which compare different PI options based on multiple criteria; and PI optimization frameworks, which optimize the structure and parameters of PI processes.

4 Digitalization and automation

A fourth trend in PI research and development is the incorporation of digitalization and automation technologies that can enhance the operation, monitoring, and control of PI processes. These technologies can include sensors, actuators, controllers, data acquisition, analysis, and visualization systems, artificial intelligence, machine learning, and internet of things. These technologies can enable real-time feedback, adaptive control, predictive maintenance, remote operation, and smart decision making for PI processes. Some examples of digitalization and automation technologies for PI are smart sensors, which can measure multiple process variables and communicate with other devices; digital twins, which are virtual replicas of PI processes that can simulate and optimize their performance; and cyber-physical systems, which are networks of physical and computational components that can interact and coordinate with each other.

5 Sustainability and circularity

A fifth trend in PI research and development is the alignment of PI objectives and outcomes with the principles of sustainability and circularity. This means that PI processes should aim to minimize their environmental impact, maximize their resource efficiency, and contribute to the circular economy. This can involve using renewable or waste-derived feedstocks, energy sources, and catalysts; reducing greenhouse gas emissions, water consumption, and waste generation; recovering and reusing valuable materials and energy; and creating new products or services from waste streams. Some examples of sustainability and circularity aspects of PI are biorefineries, which convert biomass into multiple products and energy; carbon capture and utilization, which convert carbon dioxide into useful chemicals or fuels; and waste-to-value, which transform waste streams into value-added products or energy.