(209a) Rapid Advancement in Process Intensification Deployment (RAPID) – US Efforts to Establish a Modular Chemical Process Intensification Manufacturing Institute

When it comes to improving energy efficiency and lowering investment requirements in the process industries, modular chemical process intensification (MCPI) has been a long-standing concept. In general, though, energy-intensive industries have not adopted MCPI nor deployed it in manufacturing facilities because of several barriers:

• high capital costs and risk involved in committing to new processes

• high complexity of an intensified, modular system, without simplifying standardization techniques

• a lack of software and design tools to develop intensified processes

• minimal workforce knowledgeable in the design and operation of systems.

The US Department of Energy announced an open funding opportunity announcement to establish a modular chemical process intensification institute with the goal of overcoming these barriers. AIChE and partner institutions established the RAPID Manufacturing Institute in support of this funding opportunity announcement. The status, goals and mission of RAPID will be presented in this paper.

RAPID’s (Rapid Advancement in Process Intensification Deployment) vision overcomes these challenges and rapidly advances and deploys process intensification (PI) and modular technologies in U.S. manufacturing. And, RAPID will do so while developing a skilled workforce and creating an organization that it sustainable for the long term. RAPID focuses on impactful projects championed by our broad network of over 120 institutions including corporations, universities national labs, nonprofits and other government agencies, while leveraging resources such as Manufacturing Extension Partnerships. All of RAPID’s programs will benefit from the proven management of the American Institute of Chemical Engineers (AIChE).

RAPID’s mission centers on advancing MCPI technologies to reduce energy consumption, improve process efficiencies and lower investment requirements required by manufacturing. In doing so, RAPID will enhance the competitiveness of U.S.-based energy intensive industries. RAPID’s goals include:

• transitioning innovative technologies into efficient, high-performing manufacturing capabilities that meet DOE metrics

• developing an advanced MCPI workforce, while strengthening U.S. competitiveness

• generating a diverse supply chain that includes small and medium-sized suppliers

• creating a sustainable and inclusive industrial network for continued technology development, deployment and commercialization

• becoming the globally-recognized leader in MCPI technologies

Critical success factors include development of modular system standards; simulation and modeling tools for the design and MCPI capital cost estimation; educational programs to train engineers, technicians and operators; and risk reduction through testbeds for scale-up.