Advancing Process Intensification in Petrochemical and Specialty Chemical Manufacturing – A Mini Review
DOI:
https://doi.org/10.63746/njtd.v22i5.4018Keywords:
Process Intensification, Modular Processes, Specialty chemical, Energy efficiency, Petrochemical IndustryAbstract
The chemical process industries face increasing pressure to improve efficiency and reduce environmental impact. Process intensification (PI) has emerged as a top strategy to achieve step-change improvements in performance and sustainability by fundamentally reimagining process design. PI involves radically redesigning processes and equipment to integrate functions, boost transfer rates, and eliminate inefficiencies, thereby shrinking the footprint of operations while improving energy and material utilisation. Researchers have touted PI as “the most promising way to achieve sustainable development” in sectors like oil and gas. This approach promises cleaner, smaller, and more efficient processes that meet economic and environmental objectives simultaneously. However, despite many novel PI technologies reported in the literature, relatively few have seen broad commercial adoption in petrochemical and chemical plants so far. Bridging this gap through practical design methodologies and demonstrated industrial successes is a critical challenge. This review discusses key process intensification strategies (integrated unit operations, advanced distillation technologies, novel reactors, membrane systems, and modular processing) and how they are transforming petrochemical and speciality chemical manufacturing. It also examines the benefits achieved through PI and the challenges that must be overcome to fully realise its potential.
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