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Sustainable chemical processes should be designed to combine the technological advantages and progress with lower safety risks and minimization of environmental impact such as, for example, reduction of raw materials, energy and water consumption, and avoidance of hazardous waste and pollution with toxic chemical agents. A number of novel eco-friendly chemical technologies have been developed in the recent decades with the help of the eco-innovations approaches and methods such as Life Cycle Analysis, Green Process Engineering, Process Intensification, Process Design for Sustainability, and others. An emerging approach to the sustainable process design in process engineering builds on the innovative solutions inspired from nature. However, the implementation of the eco-friendly technologies often faces secondary ecological problems. The study postulates that the eco-inventive principles identified in natural systems allow to avoid secondary eco-problems and proposes to apply these principles for sustainable design in chemical process engineering. The research work critically examines how this approach differs from the biomimetics, as it is commonly used for copying natural systems. The application of nature-inspired eco-design principles is illustrated with an example of a sustainable technology for extraction of nickel from pyrophyllite.
In recent years, the application of TRIZ methodology in the process engineering has been found promising to develop comprehensive inventive solution concepts for process intensification (PI). However, the effectiveness of TRIZ for PI is not measured or estimated. The paper describes an approach to evaluate the efficiency of TRIZ application in process intensification by comparing six case studies in the field of chemical, pharmaceutical, ceramic, and mineral industries. In each case study, TRIZ workshops with the teams of researchers and engineers has been performed to analyze initial complex problem situation, to identify problems, to generate new ideas, and to create solution concepts. The analysis of the workshop outcomes estimates fulfilment of the PI-goals, impact of secondary problems, variety and efficiency of ideas and solution concepts. In addition to the observed positive effect of TRIZ application, the most effective inventive principles for process engineering have been identified.
Sustainable design of equipment for process intensification requires a comprehensive and correct identification of relevant stakeholder requirements, design problems and tasks crucial for innovation success. Combining the principles of the Quality Function Deployment with the Importance-Satisfaction Analysis and Contradiction Analysis of requirements gives an opportunity to define a proper process innovation strategy more reliably and to develop an optimal process intensification technology with less secondary engineering and ecological problems.
Growing demands for cleaner production and higher eco-efficiency in process engineering require a comprehensive analysis of technical and environmental outcomes of customers and society. Moreover, unexpected additional technical or ecological drawbacks may appear as negative side effects of new environ-mentally friendly technologies. The paper conceptualizes a comprehensive ap-proach for analysis and ranking of engineering and ecological requirements in process engineering in order to anticipate secondary problems in eco-design and to avoid compromising the environmental or technological goals. For this purpose, the paper presents a method based on integration of the Quality Func-tion Deployment approach with the Importance-Satisfaction Analysis for the requirements ranking. The proposed method identifies and classifies compre-hensively the potential engineering and eco-engineering contradictions through analysis of correlations within requirements groups such as stakehold-er requirements (SRs) and technical requirements (TRs), and additionally through cross-relationship between SRs and TRs.
The research work analyses the relationship of 155 Process Intensification (PI) technologies to the components of the Theory of Inventive Problem Solving (TRIZ). It outlines TRIZ inventive principles frequently used in PI, and identifies opportunities for enhancing systematic innovation in process engineering by applying complementary TRIZ and PI. The study also proposes 70 additional inventive TRIZ sub-principles for the problems frequently encountered in process engineering, resulting in the advanced set of 160 inventive operators, assigned to the 40 TRIZ inventive principles. Finally, we analyse and discuss inventive principles used in 150 patent documents published in the last decade in the field of solid handling in the ceramic and pharmaceutical industries.