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Process Intensification

Definition of Process Intensification

The aim of process intensification is to drastically increase the efficiency of processes (chemical and non-chemical). For instance, the most basic idea for a chemical synthesis could be to shorten reaction times and to increase the yield.

Important approaches for process intensification include:
  • reduction of process steps
  • acceleration of heat and mass transfer
  • use of micro process engineering
  • supply of non-classical energy forms (microwave, ultrasound, etc.)
  • utilisation of extruder
  • rotor stator
  • membrane or cascade systems
  • application of plug flow
  • new methods in methodology process control and operation

These are examples among a large amount of possible solutions. The key point is to choose the best technology for the investigated process.


“Choosing the right process intensification tool for each specific challenge to maximize positive outcome”


Process Intensification


A wide field of applications is opened up for flow chemistry, ranging from basic highly exothermic or cryogenic processes, to gas phase reactions in explosive regimes and highly corrosive chemicals (conc. HF, conc. HCl, conc. HSO₄), as well as to the production of emulsions or particles with narrow size distributions up to complex chemical transformations involving a variety of by-products, intricate kinetics in all possible physical states.


Microreactors: Micro-chemical Engineering

Micro chemical engineering has been gaining significant importance in the field of chemical engineering over the last decade. In micro chemical plants chemical reactions are carried out in three-dimensional structures with inner dimensions in the range of micrometers (µm). Serving, for example, the idea of higher process safety towards toxic or explosive substances, meanwhile significantly improving yield, selectivity and quality of the product, is causing micro chemical engineering to be regarded as one of the key technologies in the chemical and pharmaceutical industry.

Microinnova already successfully supplied customers with processes at lab and production scale. One large scale process for a fine chemical manufacturer dealt with a several tons per hour productivity and another process for a big pharma company handled a 200 l/h ATEX (zone 1) and a GMP-compliant flow process.

Microinnova Engineering GmbH
Europapark 1
8412 Allerheiligen bei Wildon - AUSTRIA

T +43 3182 626 26-0

M office@microinnova.com