Journal of Flow Chemistry
Volume/Issue:
Volume 1: Issue 2
Cost Analysis for a Continuously Operated Fine Chemicals Production Plant at 10 Kg/Day Using a Combination of Microprocessing and Microwave Heating
Authors:
F. Benaskar Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by F. Benaskar in
Current site
Google Scholar
PubMed Close
,
A. Ben-Abdelmoumen Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by A. Ben-Abdelmoumen in
Current site
Google Scholar
PubMed Close
,
N. G. Patil Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by N. G. Patil in
Current site
Google Scholar
PubMed Close
,
E. V. Rebrov School of Chemistry and Chemical Enginering, Queen's University Belfast, Stranmillis Road, BT9 5AG, Belfast, UK

Search for other papers by E. V. Rebrov in
Current site
Google Scholar
PubMed Close
,
J. Meuldijk Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by J. Meuldijk in
Current site
Google Scholar
PubMed Close
,
L. A. Hulshof Applied Organic Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by L. A. Hulshof in
Current site
Google Scholar
PubMed Close
,
V. Hessel Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by V. Hessel in
Current site
Google Scholar
PubMed Close
,
U. Krtschil Institut für Mikrotechnik Mainz GmbH, Chemical Micro and Milli Process Technologies, Carl-Zeiss-Strasse 18–20, 55129, Mainz, Germany

Search for other papers by U. Krtschil in
Current site
Google Scholar
PubMed Close
, and
J. C. Schouten Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, P. O. Box 513, 5600, Eindhoven, MB, The Netherlands

Search for other papers by J. C. Schouten in
Current site
Google Scholar
PubMed Close
Pages:
74–89
Online Publication Date:
20 Dec 2011
Publication Date:
20 Dec 2011
Article Category:
Research Article
DOI:
https://doi.org/10.1556/jfchem.2011.00015
Keywords:
cost analysis; microwave technology; microprocessing; flow chemistry; catalyzed systems; Ullmann-type C–O coupling; aspirin synthesis
Restricted access

Abstract

An extended cost study consisting of 14 process scenarios was carried out to envisage the cost impact of microprocessing and microwaves separately or in combination for two liquid-phase model reactions in fine-chemicals synthesis: (1) Ullmann C–O cross-coupling reaction and (2) the aspirin synthesis. The former, a Cu-catalyzed substitution reaction, was based on an experimental investigation, whereas the latter, a noncatalyzed aromatic esterification reaction, was based on literature data. The cost of 4-phenoxypyridine production, as a pharmaceutical intermediate in the synthesis of vancomycin or vancocin, was compared with that of the synthesis of aspirin, a key example of large-scale fine-chemical production plants. The operating costs in the Ullmann synthesis were found to be related to material-based process (reactant excess, pretreatment, and catalyst synthesis), whereas those in the aspirin synthesis appeared to be related to downstream-based process (workup, waste treatment). The impact of an integrated microwave heating and microprocessing system on profitability was demonstrated with respect to operational cost and chemical productivity. Different modes of microwave heating and catalyst supply were studied and compared with conventional oil-bath-heated systems in batch and continuous processes. The overall costs including profitability breakthrough for a competitive market price of product were obtained from various combinations of heating and processing. In case of the Ullmann synthesis, the CAPEX (capital expenditure) was negligible compared to the OPEX (operational expenditure), whereas in the aspirin synthesis, the CAPEX was found around 40%, both at a production scales of 1–10 kg/day using proposed upscale methods. The source of the catalyst strongly determined the profitability of a continuously operated Ullmann process due to its effect on the chemical performance. Higher energy efficiencies could be attained using single-mode microwave irradiation; however, the energy contribution to the overall cost was found to be negligible. Different scenarios provided a cost-feasible and profitable process; nevertheless, an integrated microwave heating and microflow processing led to a cost-efficient system using a micropacked-bed reactor in comparison to wall-coated microreactor, showing a profit margin of 20%.

Supplementary Materials

    • Supplementary Material
  • Collapse
  • Expand
Cover Journal of Flow Chemistry
Journal of Flow Chemistry A Journal of the Flow Chemistry Society
Print ISSN:
2062-249X
Online ISSN:
2063-0212

To see the editorial board, please visit the website of Springer Nature.

Manuscript Submission: HERE

For subscription options, please visit the website of Springer Nature.

Journal of Flow Chemistry
Language English
Size A4
Year of
Foundation		 2011
Volumes
per Year		 1
Issues
per Year		 4
Founder Áramlásos Kémiai Tudományos Társaság
Founder's
Address		 H-1031 Budapest, Hungary Záhony utca 7.
Publisher Akadémiai Kiadó
Springer Nature Switzerland AG
Publisher's
Address		 H-1117 Budapest, Hungary 1516 Budapest, PO Box 245.
CH-6330 Cham, Switzerland Gewerbestrasse 11
Responsible
Publisher		 Chief Executive Officer, Akadémiai Kiadó
ISSN 2062-249X (Print)
ISSN 2063-0212 (Online)

Monthly Content Usage

Abstract Views Full Text Views PDF Downloads
Jun 2024 24 0 1
Jul 2024 17 0 0
Aug 2024 12 0 0
Sep 2024 18 0 0
Oct 2024 24 0 0
Nov 2024 6 1 1
Dec 2024 3 0 0