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Modular Plants: Speed as the Key Success Factor for Chemical Businesses in the Future

We expect that speed and flexibility will be success factors for chemical businesses in the future. The example of Ryan Air illustrates the importance of focusing on value generation for the customers and how innovation in a business model can achieve it.

Modular plants offer the best processing solution giving both flexibility and speed; ownership may not be key in the future. To facilitate thisdesign modification between the modules and within the modules should be enabled with other aspects considered such as engineered spaces and access for maintenance and modificationsModule Type Package (MTP), a technology offered by Microinnova, enables a Plug-and-Play solution for processing plants (like USB for computers)It is important to also consider the changeover possibilitiesphysical movement and how the infrastructure is designed so that the equipment fits the processFurthermore, we also supply plant virtualization where we engage in the pre-testing of process conditions using digital twins/model predictive control, documentation of modifications with an implemented as-built/modified documentation, PAT and pre-HAZOP scenariosMoreover, we expect that some plants will consist mainly of pre-designed and pre-built package units in the future with a predicted 60-80% of the modules being pre-designed. An exception to this being specific reactors addressing a certain set of critical parameters that are designed bespoke for an individual process. A similar shift has been observed in the automotive industry, where cars are designed based on a platform concept. 

Learn more about how your chemical business can benefit from modular plants! »

 

Modular plants offer the best processing solution giving both flexibility and speed

 

Late-stage Fluorination by means of Continuous Manufacturing

Microinnova presents a new approach to execute fluorination reactions in a safe manner with conventional equipment on manufacturing scale. These processes can be realized by continuous fluorination reagent generators on manufacturing scale. Dr. Lorenzo Orsini, previously the former R&D director of Miteni has joined the continuous manufacturing team of Microinnova. Bringing with him, a historical global reference within the field of fluorine chemistry. With Lorenzo Orsini on board, Microinnova is able to offer a wide range of possibilities to develop bespoke fluorination processes. 

With a focus on high value, efficient and scalable applications, our fluorination solutions can provide easy-to-implement options for your manufacturing facility. Having a wider portfolio will allow the evaluation of novel synthetic strategies by considering all the possible advantages of a late-stage fluorination. The second important focus is on providing solutions that significantly simplify the safety risk management compared to a more common fluorine chemistry approach by replacing possibly hazardous processes with “in situ” reactivity. These processes can be realized by continuous fluorination units, which provide the desired reagents on demand at manufacturing scale. The on-site fluorination units can often be easily implemented in existing plant setups with an aim to provide more options and make hazardous chemistry safer, so that it can be transferred to medium level manufacturing infrastructures. This approach is more cost effective compared to the other commonly known techniques. 

Get in touch with our team to find out how to improve your fluorination capabilities! »

 

These processes can be realized by continuous fluorination reagent generators on manufacturing scale.

 

Capacity Boost by Batch-to-Conti Debottlenecking

Space economy is a typical issue fodebottlenecking projects. Since a continuous approach reduces mass and heat transfer distances up to a factor of 100, these solutions can easily be integrated into an existing batch environment. A number of different strategies can reduce or replace batch processing times. For example, a batch processing step can be translated into a continuous plant skid

In some cases, the mixing operation or even the reaction itself can be executed while filling the reactor. Reagents, especially hazardous ones, can be synthesized in situ. Large savings can be achieved in the field of acid-base-reactions, since they are characterized by a strong heat release. These kinds of processes can reduce residence times from hours to minutes, since they are limited by the heat exchange which can easily be controlled in a continuous device. Mobility of skids enables a flexible use in connection with different plants. Optimizing mass and heat transfer is an important factor in reducing the costs per kilogram, leading to an increased competitiveness.

Space economy is a typical issue for debottlenecking projects. Since a continuous approach reduces mass and heat transfer distances up to a factor of 100, these solutions can easily be integrated into an existing batch environment. A number of different strategies can reduce or replace batch processing times. For example, a batch processing step can be translated into a continuous plant skid.

 

Successful Audit

Our ISO recertification audit took place at the end of March.  We received special praise for the overall strategic planning of our management and their efforts to navigate the unprecedented COVID-19 situationIt was also specifically recognized that many our team members showed knowledge that goes beyond their specific areas of responsibility. We are glad that our team’s hard work was recognized and that we can continue providing our customers with excellently planned and executed processes and meticulously engineered plants. We received special praise for the overall strategic planning of our management and their efforts to navigate the unprecedented COVID-19 situation. It was also specifically recognized that many our team members showed knowledge that goes beyond their specific areas of responsibility. We are glad that our team’s hard work was recognized and that we can continue providing our customers with excellently planned and executed processes and meticulously engineered plants.

 

Manufacturing Success: Microinnova’s Case Studies

The benefits of smart continuous manufacturing and process intensification are much broader than previously expected. Through our trusted approach, Microinnova gives the chemistry what the chemistry needs by identifying the critical parameters for each process. By selecting the best technology via process intensification and the application of continuous flow technology, we enable one or more of the following advantages: higher yields, higher selectivity, reduction of operation steps, increased labor efficiency, higher safety, increased development speed, energy savings and more.

Chemical reactions which are tricky to handle, e.g. highly exothermic or toxic reactions become less of a threat and/or will be much easier to process in a robust and efficient manner. Also, mixing-sensitive reactions profit from a continuous approach and will perform much better than in a traditional batch process. Debottlenecking projects have demonstrated that continuous manufacturing could be effectively used to double capacity. In order to increase the visibility of the vast benefits of smart continuous manufacturing and process intensification, we have compiled a list of some of the plants we have designed and built for our customers. Even though processes are rather different, each solution generates a significant value for our customers. 

Take a look at our selection of Case Studies!


A list of some of the plants we have designed and built for our customers.