Funded by: Federal Ministry for Economic Affairs and Energy (BMWi)
Project Management: PTJ Jülich
Project ID: 03ET1471A
Time: 01.01.2017 - 31.12.2019
The majority of production processes in process industry are operated batch-wise. This technique allows an increased flexibility, but, on the other hand, shows significant disadvantages, such as unsteady product quality, increased cleaning efforts, reduced options for heat integration, and therefore a poor energy footprint. The cooperative project "Scalable production technology of micro-scale and milli-scale for energy-efficient, continuous production in process industries" aims to implement a transition from batch to continuous production by using milli- and micro-scale components, and integrated measurement methods. By using modularization of whole systems or system parts, as well as methods of process simulation, analysis and control, and currently developed spectroscopic real-time measurement, a development of scalable processes in lab-scale can be achieved.
In the course of the previous cooperative project µKontE the practicability of a continuous process of specialty chemicals and biotechnology in lab-scale was proven. These investigations are used as foundation for transfer to further products, usage in industrial-scale, and integration into production.
The project Mi2Pro includes cooperation with the companies AURO Pflanzenchemie AG, Amino GmbH, Merck KGaA und Cargill Deutschland GmbH, as well as the University of Mannheim and the Karlsruhe Institute of Technology.
Workpackage 7.1: Repatriation in amino acid production
In cooperation with Amino GmbH the reconditioning of residue streams from the production process for pharmaceutical amino acids is examined. Due to the usage in pharmaceutical industry the process underlies standards by law and GMP. Furthermore, this process deals with highly corrosive media and, therefore, requires increased efforts of maintenance.
The focus for a continuous process for this procedural task lies on a modularized process, which offers an economical improvement by saving energy and resources, and protecting the environment.
Workpackage 7.2: Continuous campaign production of paints as varnishes and glazes
This subproject specifically derives from the idea to develop a continuous process for varnishes and glazes from the company AURO Pflanzenchemie AG, Braunschweig. This process alteration from batch to a modular and continuous operating just-in-time production leads to an increasing flexibility on volatile customer demands. Hence, several products can be manufactured and customized in the same lab-apparatus in a continuous campaign manner. Collected data are utilized for material and energy flow balances, product specific operation values, process evaluation, as well as to transfer these data to other process alterations in this field.
Workpackage 7.3: Concept development for an integration of multi-process plants in existing manufacturing
This work focuses on the integration of continuous production processes into existing batch-environments. This technology opens up possibilities to reduce minimum production rates, inventories, and cleaning expenditure. In cooperation with AURO Pflanzenchemie AG the boundary conditions for the planning of the integration of micro-continuous processes into batch-environments are examined, as well as the influence of customer requests.
Contact: Dipl.-Ing Nils Warmeling; Mandy Paschetag, M. Sc.; Natalie Schwerdtfeger M. Sc., Prof. Dr.-Ing. Stephan Scholl
