Chemical Process Engineering

- Impact of using a 'Novel Process Windows' concept on the CAPEX costing of a hypothetical large-scale chemical process
Micro- and milli process technologies constitute innovative continuous chemical approaches with highest impact on process intensification, dedication to sustainability, and large uptake by the chemical industries (European Roadmap of Process Intensification, 2008). Core device and system technology is here microstructured reactors with outer dimensions from fist to shoebox-size, meanwhile covering the whole range from laboratory (e.g. 1 l/h for single-phase liquid flows) to pilot (e.g. 100 l/h) range and even expanding in some cases to production scale (1000 l/h and more). The portfolio of IMM's reactor hardware includes also other innovative reactor concepts such as foams, tube and capillary reactors, etc. Integration of such devices to systems, e.g. to integrated micromixer-micro heat exchangers or even complete fuel processors, is IMM's expert knowledge. Core processing technology is Novel Process Windows (see e.g. www.dbu.de) which is an approach to tailor processes to have maximal use of the very high heat and mass transfer capacities of the microstructured reactors, while considering the need for shortening residences, e.g. to match throughput issues.

- Pilot integrated micromixer-heat exchanger reactor for organic processes at IMM
This includes, among others, high-p,T processing, processing of hazardous materials and in the explosive regime, and reactions coupled via instable intermediates
Drivers for use are shorter time-to-market, higher scale-out predictability, higher degree of plant modularity, less stringent legislation, and the option for easy plant demounting & transportation (Deibel, CHEManager 2, 2006). Two main fields of application at IMM are fine chemistry / pharmacy and fuel processing (for fuel cells). A few investigations target even at making bulk chemicals. Besides this, focus is given to the manufacture of disperse systems such as emulsions and smart and functional materials such as pigments or dyes, encapsulated drug delivery systems, or OLED materials. Initial investigations cover personal care and food applications.
Fine Chemical Processes and Plants


