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State of the art review of process intensification technologies related to solids handling Abstract Process intensification (PI) is a process development involving dramatically smaller, continuous mode processing equipment that leads to higher selectivity, reduced waste, higher energy efficiency, reduced capital costs, reduced inventory, improved intrinsic safety, and better response times. Despite these advantages, PI is still largely applied to gas/liquid and liquid/liquid systems. For powders and bulk solids, which make up the processes involved in a broad spectrum of industries (from mineral processing to pharmaceuticals), PI implementation is frequently “blocked” mainly by the presence of particulate solids that could clog small channels, as well as cause fouling. To address this issue, a fundamental understanding of PI technologies that are applicable to solids handling must firstly be established. This review presents the state-of-the-art of PI technologies in solids handling. Many of the relevant PI technologies have been classified in one of the following categories: rotating technologies, mechanically-agitated technologies, miniaturised technologies, electromagnetic fields, and multifunctional technologies. Where appropriate, each technology presented also highlights the scaling-up potential of specific processes when converting from batch to continuous processing, as well as the approach in achieving energy efficiency, both of which represent important benefits of PI implementation. Other technologies, not directly identifiable as PI technologies but which are of direct relevance to the industrial case studies within the IbD project have also been included. The outcome of the review is summarised in Figure 1 where the state-of-the-art technologies have been grouped under a range of solids handling applications. The fouling and clogging issues together with possible remediation strategies have also been addressed to a limited extent in this review; this will be the subject of a more comprehensive, separate review by another IbD project partner. A number of PI technologies exhibiting promising potential for the case studies have been identified for processes involving milling, mixing, granulation/particle coating and drying. The use of multifunctional equipment combining various operations such as mixing/granulation/drying can also be envisaged. iPDF Image | Solids handling for intensified process technology
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