{"id":567,"date":"2017-04-20T14:18:47","date_gmt":"2017-04-20T21:18:47","guid":{"rendered":"http:\/\/rccostello.com\/wordpress\/?p=567"},"modified":"2026-05-08T04:05:51","modified_gmt":"2026-05-08T11:05:51","slug":"reaction-flowsheets-process-intensification","status":"publish","type":"post","link":"https:\/\/www.rccostello.com\/wordpress\/process-intensification\/reaction-flowsheets-process-intensification\/","title":{"rendered":"Building Reaction Flowsheets Utilizing Process Intensification &#8211; Part 1"},"content":{"rendered":"<figure id=\"attachment_577\" aria-describedby=\"caption-attachment-577\" style=\"width: 923px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/Benzyl_Chloride_PFD-001-Rev-AX.bmp\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-577 size-full\" title=\"Benzyl Chloride with Process Intensification by R.C. Costello &amp; Assoc., Inc.\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/Benzyl_Chloride_PFD-001-Rev-AX.bmp\" alt=\"Photochlorination of toluene to produce benzyl chloride, benzal chloride and benzotrichloride\" width=\"923\" height=\"604\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/Benzyl_Chloride_PFD-001-Rev-AX.bmp 923w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/Benzyl_Chloride_PFD-001-Rev-AX-300x196.jpg 300w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/Benzyl_Chloride_PFD-001-Rev-AX-768x503.jpg 768w\" sizes=\"auto, (max-width: 923px) 100vw, 923px\" \/><\/a><figcaption id=\"caption-attachment-577\" class=\"wp-caption-text\">Benzyl Chloride Utilizing Process Intensification<\/figcaption><\/figure>\n<p>In the first of this two part of the series, we will show two\u00a0continuous chemical processes that utilize process intensification for\u00a0chemical reaction systems and unit operations.\u00a0\u00a0 The original processes were typically large bulky and spread out over significant plot space and also may have had high profiles.<\/p>\n<p>By introducing PI to these technologies a decrease in equipment occurs, a smaller lower cost plant can be build that achieves all the benefits process intensification that includes:<\/p>\n<ul>\n<li>Reduced energy use;<\/li>\n<li>Decreased capital expenditure;<\/li>\n<li>Lower plant profile (height);<\/li>\n<li>Smaller plant footprint (area);<\/li>\n<li>Environmental advantages; and<\/li>\n<li>Safety benefits.<\/li>\n<\/ul>\n<p>In the first process, we will show the continuous photochlorination of toluene for the production of Benzyl Chloride.\u00a0 Photochlorinations are some of the most interesting reactions in organic chemistry in that the catalyst is ultra violet (UV) light only.<\/p>\n<figure id=\"attachment_573\" aria-describedby=\"caption-attachment-573\" style=\"width: 528px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination.png\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-573\" title=\"Chemistry for the Photochlorination of Toluene using Process Intensification\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination.png\" alt=\"Photochlorination of Toluene to produce Benzyl Chloride\" width=\"528\" height=\"149\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination.png 1280w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination-300x85.png 300w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination-768x217.png 768w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/04\/1280px-TolueneChlorination-1024x289.png 1024w\" sizes=\"auto, (max-width: 528px) 100vw, 528px\" \/><\/a><figcaption id=\"caption-attachment-573\" class=\"wp-caption-text\">Chemistry for the Photochlorination of Toluene<\/figcaption><\/figure>\n<p>Liquid toluene enters the bottom of a vertical <a href=\"http:\/\/rccostello.com\/spinning_tube.html\">HOLL-REACTOR<\/a><sup>\u00ae\u00a0<\/sup>reactor while chlorine enters the side of the unit where the stator is metal.\u00a0 Just above this metal section the stator is glass.\u00a0 This is necessary because the glass allows 454 angstrom UV light to catalyze the reaction.\u00a0 The <a href=\"http:\/\/rccostello.com\/spinning_tube.html\">HOLL-REACTOR<sup>\u00ae<\/sup><\/a><a href=\"http:\/\/www.hollpartners.com\/\"><sup>\u00a0<\/sup><\/a> produces such high shear that the bubbles generated are extremely small.\u00a0 Since this reaction is driven by gas liquid contact it occurs very fast and within a short vertical reactor with the interstitial surface area generated.\u00a0 Depending on the molar ratio of chlorine to toluene besides benzyl chloride, benzal chloride and benzotrichloride can be produced.\u00a0 In addition, there may be unreacted toluene coming out of the reactor.\u00a0 The discharge of the reactor flows to a knockout pot and the vapor flows to an HCl adsorption system and any residual chlorine goes to a caustic scrubber.\u00a0\u00a0 The mixed chlorides liquid is pumped to a divided wall distillation system.\u00a0 Here the toluene comes off the top of the column and is recycled back to the front of the process.\u00a0 Product comes out of the 2<sup>nd<\/sup> outlet and benzal chloride and benzotrichloride come out of the 3<sup>rd<\/sup> and 4<sup>th<\/sup> outlets respectively.\u00a0 Depending on the molar ratios one product can be favored over the other.\u00a0 With Micromotion mass flow meters the molar ratio can easily be adjusted on the fly to optimize one product over the other. \u00a0Typically the number of distillations needed to perform a separation are n-1 where n is the number of components. Thus in a traditional plant we would need 3 columns because there are 4 components. With the divided wall column we need 1 column.<\/p>\n<p>Let <a href=\"http:\/\/rccostello.com\">COSTELLO<\/a> help you with the process intensification of your chemistry and the <a href=\"http:\/\/rccostello.com\/skid_mounted_plant.html\">modularization<\/a> of your plant.<\/p>\n<p><strong>Phone: 310-792-5870 Email: rcca@rccostello.com<\/strong><\/p>\n<p><strong>Website: <a href=\"http:\/\/rccostello.com\/\">rccostello.com<\/a><\/strong><\/p>\n","protected":false},"excerpt":{"rendered":"<p>In the first of this two part of the series, we will show two\u00a0continuous chemical processes that utilize process intensification for\u00a0chemical reaction systems and unit operations.\u00a0\u00a0 The original processes were typically large bulky and spread out over significant plot space and also may have had high profiles. By introducing PI to these technologies a decrease [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":577,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[1,92],"tags":[13,14,94,93],"class_list":["post-567","post","type-post","status-publish","format-standard","has-post-thumbnail","category-modular-plants","category-process-intensification","tag-engineering","tag-engineering-solutions","tag-holl-reactor","tag-process-intensification","entry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Reaction Flowsheets for Process Intensification Design<\/title>\n<meta name=\"description\" content=\"How to optimize reaction flowsheets using Process Intensification. Learn to integrate steps and enhance reactor performance through modular design.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.rccostello.com\/wordpress\/process-intensification\/reaction-flowsheets-process-intensification\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Reaction Flowsheets for Process Intensification Design\" \/>\n<meta property=\"og:description\" content=\"How to optimize reaction flowsheets using Process Intensification. 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