de - Beste verfügbare Techniken (BVT) - Umweltbundesamt
de - Beste verfügbare Techniken (BVT) - Umweltbundesamt de - Beste verfügbare Techniken (BVT) - Umweltbundesamt
Chapter 6 Achieved environmental benefits Continuous online monitoring (via calorimetry) of the processes delivers the following environmental benefits: • accurate processes end point detection – delivering improved product yield and reducing waste • accurate processes end point detection – improving plant utilisation and reducing energy costs associated with unnecessary prolonged batch times • identification of potential runaway reactions – reducing the associated environmental risks. An improved process temperature control of constant flux can improve reaction selectivity (and process conditions) and, hence, output quality and yield. A reduction in the amount of waste product is a natural consequence of this. Finally, constant flux utilises a fundamentally different approach to process temperature control. This delivers the following environmental improvements on the heat transfer fluid system: • reduction in the pumping energy required to circulate the heat transfer fluid, by over 90 % • reduction in the absolute heating and cooling energy required to control the heat transfer fluid temperature • reduction in the inventory of heat transfer fluid required – reducing the consumption of heat transfer fluid. Cross-media effects Wahrscheinlich keine. Operational data Constant flux can be operated in the same way as virtually any conventional stirred tank reactor: • volumetric capacity: from 100 ml to 100000 litres • material of construction: stainless steel, hastelloy, glass, glass-lined steel and other alloys • operating pressure: as required • operating temperature: as required • U values (the overall heat transfer coefficient) equivalent to, or better than, conventional jacketed batch reactors. Applicability Constant flux can be applied to virtually any batch vessel design on any scale. The designs are suitable for laboratory, pilot and industrial applications. The concept of constant flux can be applied to batch vessels running, e.g. chemical synthesis reactions, crystallisations, polymerisations and fermentations. Furthermore, the concept of constant flux can be applied to continuous reactors. However, development in this area is at an early stage. 402 Dezember 2005 OFC_BREF
Economics Chapter 6 The ability to monitor a process online will allow the process to be continually improved and optimised. This will deliver significant economic advantages in operational plant performance. The quantum of the economic advantage will, however, be determined by the particular process(es) and the nature of the plant employed. The capital cost of implementing constant flux is often small when compared to the operational benefits achievable. Driving force for implementation Within the pharmaceutical industry, the FDA’s Process and Analytical Technology (PAT) initiative is a key force in driving the adoption of analytical techniques in pharmaceutical manufacturing. Constant flux provides an accurate, simple and versatile analytical tool in the primary manufacturing environment. More generally, the economic benefits that constant flux can deliver (improved product yield and quality, and reduced operating costs) is driving increasing interest from a broad range of chemical manufacturers across a number of application areas. References to literature and example plants [109, Ondrey, 2005], [110, A. Desai and R. Pahngli, 2004], [111, Ashe, 2004], [112, Hairston, 2003], [113, Ashe, 2002] OFC_BREF Dezember 2005 403
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Chapter 6<br />
Achieved environmental benefits<br />
Continuous online monitoring (via calorimetry) of the processes <strong>de</strong>livers the following<br />
environmental benefits:<br />
• accurate processes end point <strong>de</strong>tection – <strong>de</strong>livering improved product yield and reducing<br />
waste<br />
• accurate processes end point <strong>de</strong>tection – improving plant utilisation and reducing energy<br />
costs associated with unnecessary prolonged batch times<br />
• i<strong>de</strong>ntification of potential runaway reactions – reducing the associated environmental risks.<br />
An improved process temperature control of constant flux can improve reaction selectivity (and<br />
process conditions) and, hence, output quality and yield. A reduction in the amount of waste<br />
product is a natural consequence of this.<br />
Finally, constant flux utilises a fundamentally different approach to process temperature control.<br />
This <strong>de</strong>livers the following environmental improvements on the heat transfer fluid system:<br />
• reduction in the pumping energy required to circulate the heat transfer fluid, by over 90 %<br />
• reduction in the absolute heating and cooling energy required to control the heat transfer<br />
fluid temperature<br />
• reduction in the inventory of heat transfer fluid required – reducing the consumption of heat<br />
transfer fluid.<br />
Cross-media effects<br />
Wahrscheinlich keine.<br />
Operational data<br />
Constant flux can be operated in the same way as virtually any conventional stirred tank reactor:<br />
• volumetric capacity: from 100 ml to 100000 litres<br />
• material of construction: stainless steel, hastelloy, glass, glass-lined steel and other alloys<br />
• operating pressure: as required<br />
• operating temperature: as required<br />
• U values (the overall heat transfer coefficient) equivalent to, or better than, conventional<br />
jacketed batch reactors.<br />
Applicability<br />
Constant flux can be applied to virtually any batch vessel <strong>de</strong>sign on any scale. The <strong>de</strong>signs are<br />
suitable for laboratory, pilot and industrial applications. The concept of constant flux can be<br />
applied to batch vessels running, e.g. chemical synthesis reactions, crystallisations,<br />
polymerisations and fermentations.<br />
Furthermore, the concept of constant flux can be applied to continuous reactors. However,<br />
<strong>de</strong>velopment in this area is at an early stage.<br />
402 Dezember 2005 OFC_BREF