New Scale-up Technologies for Hydrogenation Reactions in Multipurpose Pharmaceutical Production Plants

The classical scale-up approach for hydrogenation reaction processes usually includes numerous laboratory- and pilot-scale experiments. With a novel scale-up strategy, a significant number of these experiments may be replaced by modern computational simulations in combination with scale-down experiments. With only a few laboratory-scale experiments and information about the production-scale reactor, a chemical process model is developed. This computational model can be used to simulate the production-scale process with a range of different process parameters. Those simulations are then validated by only a few experiments in an advanced scale-down reactor. The scale-down reactor has to be geometrically identical to the corresponding production-scale reactor and should show a similar mass transfer behaviour. Closest similarity in terms of heat transfer behaviour is ensured by a sophisticated 3D-printed heating/cooling finger, offering the same heat exchange area per volume and overall heat-transfer coefficient as in production-scale. The proposed scale-up strategy and the custom-designed scale-down reactor will be tested by proof of concept with model reactions. Those results will be described in a future publication. This project is an excellent example of a collaboration between academia and industry, which was funded by the Aargau Research Fund. The interest of academia is to study and understand all physical and chemical processes involved, whereas industry is interested in generating a robust and simple to use tool to improve scale-up and make reliable predictions.

Anaerobic Digestion of Wastewater Sludge and Alkaline-Pretreated Wheat Straw at Semi-Continuous Pilot Scale: Performances and Energy Assessment

During the last decade, the application of pretreatment has been investigated to enhance methane production from lignocellulosic biomass such as wheat straw (WS). Nonetheless, most of these studies were conducted in laboratory batch tests, potentially hiding instability problems or inhibition, which may fail in truly predicting full-scale reactor performance. For this purpose, the effect of an alkaline pretreatment on process performance and methane yields from WS (0.10 g NaOH g−1 WS at 90 °C for 1 h) co-digested with fresh wastewater sludge was evaluated in a pilot-scale reactor (20 L). Results showed that alkaline pretreatment resulted in better delignification (44%) and hemicellulose solubilization (62%) compared to untreated WS. Pilot-scale study showed that the alkaline pretreatment improved the methane production (261 ± 3 Nm3 CH4 t−1VS) compared to untreated WS (201 ± 6 Nm3 CH4 t−1VS). Stable process without any inhibition was observed and a high alkalinity was maintained in the reactor due to the NaOH used for pretreatment. The study thus confirms that alkaline pretreatment is a promising technology for full-scale application and could improve the overall economic benefits for biogas plant at 24 EUR t−1 VS treated, improve the energy recovery per unit organic matter, reduce the digestate volume and its disposal costs.

Oxyfuel Combustion of a Model MSW—An Experimental Study

The oxyfuel combustion of a model MSW (municipal solid waste) under various conditions was carried out in a lab-scale reactor. The aim was to study the behavior of MSW and identify challenges and opportunities associated with the development of this technology in the context of integration with CCS (carbon capture and storage). The experimental results show the effects of the oxidizer composition on the combustion process. Complete combustion can be attained under a variety of oxyfuel conditions, and the differences highlighted with O2/CO2 as an oxidizer compared with O2/N2 do not constitute showstoppers. MSW oxyfuel combustion hence offers a great potential for the combined (1) treatment of waste (contaminants’ destruction, volume, and weight reduction), (2) production of heat/power, and (3) CCS with negative CO2 emissions.