(299a) The Benefits of Process Intensification and Solvent Recovery Utilizing Various Separation Technologies

Solvent recovery is critical for cost reduction, waste minimization, and regulatory compliance in chemical, pharmaceutical, and specialty manufacturing industries. This paper explores various separation technologies—including thin film evaporators (TFEs), distillation columns, falling film evaporators, rotary evaporators, and membrane-based separations—evaluating key performance metrics such as energy efficiency, separation effectiveness, and scalability.

Emphasizing process intensification (PI), the study examines hybrid systems, heat integration, and surface modifications to enhance separation performance and reduce operational costs. Case studies from pharmaceutical solvent reuse, polymer recycling, and petrochemical refining highlight the benefits of process intensification, including improved mass transfer, lower energy consumption, and a smaller footprint.

Supported by experimental and industry data, this paper provides practical insights for engineers seeking to optimize solvent recovery. This paper will demonstrate that integrating PI with advanced separation technologies will provide a framework for designing more efficient, sustainable, and economically viable recovery processes and offer actionable recommendations for industrial implementation.