Process Intensification: A Necessary Leap for Nigeria’s Petrochemical and Gas Processing Industries
Femi Olorunnaiye, a seasoned process engineer with extensive global experience, advocates for the adoption of process intensification in Nigeria’s petrochemical and gas processing sectors. He emphasizes that this technological advancement is no longer a futuristic concept but a crucial requirement for an industry striving to enhance safety, reduce emissions, minimize costs, and optimize value extraction from processed molecules. Olorunnaiye argues that in a world increasingly focused on efficiency, competitiveness, and sustainability, process intensification is not merely an option but the only path forward. The core principle is achieving more with less: less energy, less environmental footprint, and fewer emissions, while simultaneously maximizing output, safety, and reliability.
Traditional approaches, once acceptable in an era of cheap fuel and lax environmental regulations, are now deemed inefficient, expensive, and environmentally detrimental. Olorunnaiye highlights the stark reality of these inefficiencies by citing his review of a refinery distillation section in the Niger Delta, where energy consumption was a staggering 35% above the intended level. This excessive energy use stemmed from multiple flash drums, extensive reboiler piping, and unresponsive control systems, all contributing to energy waste and reduced stability. These inefficiencies, he explains, create a cascading effect. When stabilization takes hours, reboiler heat duty falls short, and control loops are slow, the plant incurs financial losses and faces heightened safety risks.
Process intensification, at its core, involves streamlining operations by consolidating separate steps into a single integrated process, redesigning equipment to enhance transfer rates, and employing compact, modular systems to achieve the same functionality with a smaller footprint and lower energy consumption. This approach represents a paradigm shift from conventional methods, promising significant improvements in efficiency and sustainability.
Several globally proven examples illustrate the potential of process intensification. Reactive distillation, for instance, combines chemical reaction and separation within a single column, eliminating the need for separate units. Dividing wall distillation further streamlines the process by replacing two or three towers with a single, more efficient unit. Membrane separations offer an energy-efficient alternative to traditional distillation, while micro-channel reactors enable rapid conversion with minimal inventory. These innovations exemplify the transformative power of process intensification in optimizing resource utilization and minimizing environmental impact.
Olorunnaiye explains the advantages using reactive distillation as an example. By integrating reaction and separation, capital costs are reduced, heat integration becomes more efficient, and the likelihood of leaks or failures decreases. The result is a safer, leaner, and more efficient operation, highlighting the practical benefits of adopting these advanced techniques.
However, Olorunnaiye cautions that process intensification requires corresponding advancements in instrumentation and controls to be truly effective. The increased interconnectedness of operations under intensified processes means that disturbances propagate more rapidly, leaving little room for error. He recounts an instance at a gas processing site where the installation of modular intensified reactors was undermined by outdated and infrequently recalibrated pressure and temperature transmitters. This mismatch resulted in unstable operations and frequent shutdowns, demonstrating the crucial role of accurate and responsive instrumentation in managing the complexities of intensified processes. The lesson is clear: intensification demands precise monitoring and rapid response capabilities. Instrumentation serves as the nervous system of the plant, and any lag in its performance can compromise the entire system. This aspect is particularly critical for Nigeria as it strives to achieve its ambitious goal of eliminating routine gas flaring by 2030. Effective instrumentation and control systems are essential for managing the complexities of intensified processes and ensuring safe and efficient operations, ultimately contributing to the nation’s environmental sustainability targets.
