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Agency: European Commission | Branch: FP7 | Program: CP-IP | Phase: NMP-2008-3.2-1 | Award Amount: 16.82M | Year: 2009

The ultimate ambition of COPIRIDE is to develop a new modular production and factory concept for the chemical industry using adaptable plants with flexible output. This concept will be superior, intellectual property (IP) protected, and enable a much wider spread of know-how and education of this skill-intensive technology. Key functional enabling units are new production-scale, mass-manufactured microstructured reactors as well as other integrated process intensification (PI) reactors realising integrated processes. This will lead to a substantial reduction in costs, resources & energy and notably improves the eco-efficiency. To ensure the competitiveness of European (EU) manufacturing businesses, PI technology / know-how is transferred from leaders to countries (and respective medium & small industries) with no exposure in PI so far, but with a track record in sustainability, and to the explorative markets food and biofuels. A deeply rooted base will be created for IP rights (Copyright, = COPIRIDE) by generic modular reactor & plant design and new generic processes via Novel Process Windows, facilitating patent filing. Due to the entire modular plant concept comprising all utilities far beyond the reaction & processual parts - a holistic PI concept is provided, covering the whole development cycle with, e.g., safety & process control & plant approval. Features, inter alia, are fast plant start-up and shut-down for multipurpose functionality (flexibility in products), sustainable & safe production, and fast transfer from lab to production & business (time-to-market). Industrial demonstration activities up to production scale with five field trials present a good cross-section of reactions relevant to the EU chemical industry. The economic impact in COPIRIDE is 10 Mio /a (cautiously optimistic) to 30 Mio /a (optimistic) by direct exploitation. Indirect exploitation might sum up to 800 Mio /a (very optimistic) by other companies via technology transfer.

Agency: European Commission | Branch: H2020 | Program: MSCA-ITN-ETN | Phase: MSCA-ITN-2016 | Award Amount: 3.83M | Year: 2016

The European chemical industry faces some very serious challenges if it is to retain its competitive position in the global economy. The new industries setting up in Asia and the Near East are based on novel process-intensification concepts, leaving Europe desperately searching for a competitive edge. The transition from batch to continuous micro- and milliflow processing is essential to ensure a future for the European fine-chemicals and pharmaceuticals industries. However, despite the huge interest shown by both academia and industrial R&D, many challenges remain, such as the problems of reaction activation, channel clogging due to solids formation and the scaling up of these technologies to match the required throughput. COSMIC, the European Training Network for Continuous Sonication and Microwave Reactors, takes on these challenges by developing material- and energy-efficient continuous chemical processes for the synthesis of organic molecules and nanoparticles. The intersectoral and interdisciplinary COSMIC training network consists of leading universities and industry participants and trains 15 ESRs in the areas of flow technology, millifluidics and external energy fields (ultrasound and microwaves). These energy fields can be applied in structured, continuous milli-reactors for producing high-value-added chemicals with excellent yield efficiencies in terms of throughput, waste minimization and product quality that simply cannot be achieved with traditional batch-type chemical reactors. The chemical processes that are at the heart of COSMICs game-changing research are catalytic reactions and solids-forming reactions. COSMICs success, which is based on integrating chemistry, physics and process technology, will re-establish European leadership in this crucial field and provide it with highly trained young experts ready for dynamic careers in the European chemical industry.

Agency: European Commission | Branch: FP7 | Program: CP-IP | Phase: NMP.2013.1.1-1 | Award Amount: 12.34M | Year: 2013

BIO-GO-For-Production is a Large Scale Collaborative Research Project that aims to achieve a step change in the application of nanocatalysis to sustainable energy production through an integrated, coherent and holistic approach utilizing novel heterogeneous nanoparticulate catalysts in fuel syntheses. BIO-GO researches and develops advanced nanocatalysts, which are allied with advanced reactor concepts to realise modular, highly efficient, integrated processes for the production of fuels from renewable bio-oils and biogas. Principal objectives are to develop new designs, preparation routes and methods of coating nanocatalysts on innovative micro-structured reactor designs, enabling compact, integrated catalytic reactor systems that exploit fully the special properties of nanocatalysts to improve process efficiency through intensification. An important aim is to reduce the dependence on precious metals and rare earths. Catalyst development is underpinned by modelling, kinetic and in-situ studies, and is validated by extended laboratory runs of biogas and bio-oil reforming, methanol synthesis and gasoline production to benchmark performance against current commercial catalysts. The 4-year project culminates in two verification steps: (a) a 6 month continuous pilot scale catalyst production run to demonstrate scaled up manufacturing potential for fast industrialisation (b) the integration at miniplant scale of the complete integrated process to gasoline production starting from bio-oil and bio-gas feedstocks. A cost evaluation will be carried out on the catalyst production while LCA will be undertaken to analyse environmental impacts across the whole chain. BIO-GO brings together a world class multi-disciplinary team from 15 organisations to carry out the ambitious project, the results of which will have substantial strategic, economic and environmental impacts on the EU petrochemicals industry and on the increasing use of renewable feedstock for energy.

Kralisch D.,Friedrich - Schiller University of Jena | Streckmann I.,Friedrich - Schiller University of Jena | Ott D.,Friedrich - Schiller University of Jena | Krtschil U.,Fraunhofer Institute of Microtechnology Mainz | And 10 more authors.
ChemSusChem | Year: 2012

The simple transfer of established chemical production processes from batch to flow chemistry does not automatically result in more sustainable ones. Detailed process understanding and the motivation to scrutinize known process conditions are necessary factors for success. Although the focus is usually "only" on intensifying transport phenomena to operate under intrinsic kinetics, there is also a large intensification potential in chemistry under harsh conditions and in the specific design of flow processes. Such an understanding and proposed processes are required at an early stage of process design because decisions on the best-suited tools and parameters required to convert green engineering concepts into practice-typically with little chance of substantial changes later-are made during this period. Herein, we present a holistic and interdisciplinary process design approach that combines the concept of novel process windows with process modeling, simulation, and simplified cost and lifecycle assessment for the deliberate development of a cost-competitive and environmentally sustainable alternative to an existing production process for epoxidized soybean oil. Transfer window: A holistic concept for sustainable process development through process intensification due to microprocess technology in combination with novel process windows is presented. Process modeling and simulation linked with simplified cost and lifecycle assessment provide valuable information to guide the ongoing design of a continuously running pilot-process for the epoxidation of soybean oil (see picture). Copyright © 2012 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Viviano M.,Christian Doppler Laboratory | Viviano M.,University of Salerno | Glasnov T.N.,Christian Doppler Laboratory | Reichart B.,Christian Doppler Laboratory | And 2 more authors.
Organic Process Research and Development | Year: 2011

Three different continuous flow strategies for the generation of important 4-aryl-2-butanone derivatives including the anti-inflammatory drug nabumetone [4-(6-methoxy-2-naphthalenyl)-2-butanone] and the aroma compounds raspberry ketone [4-(4-hydroxyphenyl)-2-butanone] and its methyl ether [4-(4-methoxyphenyl)-2-butanone] were evaluated. All three protocols involve the initial preparation of the corresponding 4-aryl-3-buten-2-ones via Mizoroki-Heck, Wittig, or aldol strategies, which is then followed by selective hydrogenation of the C=C double bond to the desired 4-aryl-2-butanones. The synthetic routes to 4-aryl-3-buten-2-ones were first optimized/intensified on small scale to reaction times of 1-10 min using batch microwave heating technology and then translated to a scalable continuous flow process employing commercially available stainless steel capillary tube reactors. For the synthesis of 4-(4-methoxyphenyl)-3-buten-2-one a further scale-up using a custom-built mesofluidic mini-plant flow system capable of processing several liters per hour was designed to further expand the scale of the process. The final hydrogenation step was performed using a fixed-bed continuous flow hydrogenator employing Ra/Ni as a catalyst. © 2011 American Chemical Society.

Agency: European Commission | Branch: H2020 | Program: RIA | Phase: FETOPEN-01-2016-2017 | Award Amount: 3.90M | Year: 2017

ONE-FLOW translates vertical hierarchy of chemical multistep synthesis with its complex machinery into self-organising horizontal hierarchy of a compartmentalized flow reactor system a biomimetic digital flow cascade machinery with just one reactor passage. To keep horizontal hierarchy manageable, orthogonality among the consecutive reactions needs to be increased. The winning point of nature is to have invented catalytic cascades. ONE-FLOW will uplift that by enabling the best bio- and chemocatalysts working hand in hand. 4 synthetic flow cascades (metabolic pathways) and 1 flow cascade driven by automated intelligence (signaling pathway) will produce 4 Top-list 2020 drugs. The Compartmentalized Smart Factory will develop organic, inorganic, and mechanical compartmentalization. The Green-Solvent Spaciant Factory will fluidically allow the use of interim reaction spaces (spaciants). The Systemic Operations Factory will aim at full orthogonality using data-base guided ultimate process harmonization. The Digital Machine-to-Machine Factory will alter the landscape of chemical synthesis by virtue of the Internet of Chemical Things. Automated machine-to-machine data transfer enables relegation of process monitoring to central computer systems under the oversight of chemists. The Fully Continuous Integrated Factory will develop a commercial platform technology under the auspices of sustainability-driven process-design evaluation, making amenable the new kind of processing to all chemists. ONE-FLOW has massive impact potential: i) 38 billion Euro production cost saving; ii) 300 million EUR cost saving per drug; iii) address diseases with 500 billion Euro medication costs; iv) increase market share of emerging high-tech SME players by 10% in 10 years; v) open new windows of opportunity (personalized medicine) with 200-500 million Euro per disease; and vi) achieve 40% female share on a senior scientist level (ONE-FLOW: 34% senior, 57% junior).

Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: NMP-2007-3.2-2 | Award Amount: 3.72M | Year: 2008

Capillary electrochromatography (CEC) combines the high separation efficiency of capillary electrophoresis with high performance liquid chromatography (HPLC) and provides a powerful tool for the separation of a wide range of both neutral and charged components. The proposed integration of this technology and the rotating system of annular chromatography into a continuous annular electrochromatography (CAEC) would increase the throughput up to 20,000 times whilst maintaining an efficiency of more than 100,000 theoretical separation stages per meter. This extends the range of applicability from analytical purposes towards safe and flexible ultra small-scale production of extremely high-value-added products early on in the development stages. The project is thus expected to significantly enhance the sustainability of pharmaceutical and chemical production by providing equipment for highly intensified purification processes. The development of CAEC units as a new generation of extremely flexible high-performance process equipment requires specialised engineering skills and high-precision manufacturing techniques. A wide range of applications will be offered by the development of tailored stationary phases while an improved understanding of the complex processes occurring at different scales is used to model the performance of the CAEC system. An elaborated prototype including on-line sensors and a sophisticated process control concept will be developed and validated under industrial conditions during a demonstration phase. This will guarantee a fast uptake of the projects results and allow for an approved industrial production of the new process equipment within 1 to 2 years after the end of the project. The consortium includes an end user from pharmaceutical industry to ensure the relation to practice as well as highly innovative equipment manufactures capable of producing the required devices and standardised components at affordable costs.

Kirschneck D.,Microinnova Engineering GmbH
Chemical Engineering and Technology | Year: 2013

An innovative concept for the characterization of situations or problems (drivers) where the application of continuous flow processing, microreactor and/or other intensification technologies lead to the desired solutions is presented. An overview of techniques and equipment (tools) currently available for developing intensified processes is given as well as some examples of how they can be implemented in the engineering of chemical plants in kilo-lab, pilot-, and full-size manufacturing scale. These drivers and tools are described and depicted by easy-to-understand icons, and strategies for the development of continuous processes are explained. Short summaries of three different case studies demonstrate the economic advantages and potentials of intensified flow processing in manufacturing scale. Finally, the current approach to avoid inflexibility of systems operated in continuous mode is reported and how pilot and manufacturing plants can be realized with a special focus on modularity and multi-purpose functionality. © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

This work presents a new innovative concept, how basic manufacturing needs of small and medium scale manufacturing tasks can be moved to a higher level of efficiency. The basic idea of the concept is to combine the long time known performance of continuous processing with the flexibility of today's common batch synthesis. The concept uses a modularized continuous plant concept, where the needed flexibility is provided by first rearrangement of the processing s modules and second modularity within each module to adjust it according to the needs of each chemical reaction. This ? gives the possibility to reach a continuous processing performance by means of a flexible multi purpose plant.

Reichart B.,Christian Doppler Laboratory | Tekautz G.,Microinnova Engineering GmbH | Kappe C.O.,Christian Doppler Laboratory
Organic Process Research and Development | Year: 2013

Applying continuous flow processing in a high-temperature/high-pressure regime, n-alkyl chlorides can be prepared in high yields and selectivity by direct uncatalyzed chlorodehydroxylation of the corresponding n-alcohols with 30% aqueous hydrochloric acid. Optimum conditions for the preparation of n-butyl and n-hexyl chloride involve the use of a glass microreactor chip, a reaction temperature of 160-180 C (20 bar backpressure) and a residence time of 15 min. © 2012 American Chemical Society.

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