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Ind. Eng. Chem. Res.

2010, 49, 11131–11141 11131

Industrial Requirements for Thermodynamics and Transport Properties


Eric Hendriks,*,† Georgios M. Kontogeorgis,‡ Ralf Dohrn,§ Jean-Charles de Hemptinne,|
Ioannis G. Economou,⊥ Ljudmila Fele Žilnik,# and Velisa Vesovic∇
Shell Global Solutions, Shell Technology Centre Amsterdam, Grasweg 3, 1031 HW Amsterdam, The
Netherlands, Centre for Energy Resources Engineering (CERE), Department of Chemical and Biochemical
Engineering, Technical UniVersity of Denmark, DK-2800, Lyngby, Denmark, Bayer Technology SerVices
GmbH, Process Technology, Kinetics, Properties & Modeling, Building B310, D-51368 LeVerkusen, Germany,
IFP, 1& 4 AVenue de Bois-Préau, 92852 Rueil-Malmaison Cedex, France, The Petroleum Institute, Department
of Chemical Engineering, P.O. Box 2533, Abu Dhabi, United Arab Emirates, National Institute of Chemistry,
Department of Catalysis and Reaction Engineering, P.O. Box 660, SI-1001 Ljubljana, SloVenia, and
Department of Earth Science and Engineering, Imperial College London, London SW7 2AZ, United Kingdom

This work reports the results of an investigation on industrial requirements for thermodynamic and transport
properties carried out by the Working Party on Thermodynamic and Transport properties (http://www.
See https://pubs.acs.org/sharingguidelines for options on how to legitimately share published articles.

wp-ttp.dk/) of the European Federation of Chemical Engineering, EFCE (http://www.efce.info/). A carefully


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designed questionnaire was sent to a number of key technical people in companies in the oil and gas, chemicals,
and pharmaceutical/biotechnology sectors. Twenty-eight companies have provided answers which formed
the basis for the analysis presented here. A number of previous reviews, specifically addressed to or written
by industrial colleagues, are discussed initially. This provides the context of the survey and material with
which the results of the survey can be compared. The results of the survey have been divided into the themes:
data, models, systems, properties, education, and collaboration. The main results are as follows. There is
(still) an acute need for accurate, reliable, and thermodynamically consistent experimental data. Quality is
more important than quantity. Similarly, there is a great need for reliable predictive, rather than correlative,
models covering a wide range of compositions, temperatures, and pressures and capable of predicting primary
(phase equilibrium) and secondary (enthalpy, heat capacity, etc.) properties. It is clear that the ideal of a
single model covering all requirements is not achievable, but there is a consensus that this ideal should still
provide the direction for future development. The use of new methods, such as SAFT, is increasing, but they
are not yet in position to replace traditional methods such as cubic equations of state (especially in oil and
gas industry) and the UNIFAC group contribution approach. A common problem with novel methods is lack
of standardization, reference data, and correct and transparent implementations, especially in commercially
available simulation programs. The survey indicates a great variety of systems where further work is required.
For instance, for electrolyte systems better models are needed, capable of describing all types of phase behavior
and mixtures with other types of components. There is also a lack of data and methods for larger complex
molecules. Compared with the previous reviews, complex mixtures containing carbon dioxide associated
with a wide range of applications, such as capture, transport, and storage are becoming interesting to a number
of survey participants. Despite the academic success of molecular simulation techniques, the survey does not
indicate great interest in it or its future development. Algorithms appear to be a neglected area, but improvements
are still needed especially for multiphase reactive systems (simultaneous chemical and physical equilibrium).
Education in thermodynamics is perceived as key, for the future application of thermodynamics in the industry.
A number of suggestions for improvement were made at all three levels (undergraduate, postgraduate, and
professional development) indicating that the education is correctly perceived as an ongoing process.

1. Introduction instance, for the design of separation processes the issue is


acute, as often more than 40% of the cost of the process is
Accurate knowledge of thermophysical properties of fluids
related to the separation units.1 As well as having impact in
plays an important role in cost-effective design and operation
of chemical and biochemical plants. Broadly speaking, the the design and operation of processes,1 the importance of
thermodynamic properties determine the feasibility of a given thermodynamics in product design,2-5 green and environ-
process, while the transport properties have a major impact mental engineering,6-8 applied nanotechnology/material
on sizing of the equipment. The requirement for accuracy science,9,10 and biotechnology11-14 was recently elucidated.
and reliability varies depending on the application. For Due to the diversity of products and applications, the need
for accurate and reliable thermodynamic and transport
* To whom correspondence should be addressed. E-mail: property data, over a wide range of mixtures and conditions,
eric.hendriks@shell.com.

Shell Technology Centre Amsterdam.
is apparent.

Technical University of Denmark. These observations led in 2007 to the creation of a new
§
Bayer Technology Services GmbH. Working Party (WP) within the European Federation of Chemi-
|
IFP.

The Petroleum Institute.
cal Engineers (EFCE), with the following objectives:
#
National Institute of Chemistry. 1. To promote thermodynamic, transport, and physical

Imperial College London. property measurements, correlations, predictions, and simula-
10.1021/ie101231b  2010 American Chemical Society
Published on Web 10/12/2010
11132 Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010

tions in the academic and industrial chemical engineering to insufficient precision in the description of vapor-liquid
communities, the national societies, as well as among the equilibria (VLE) and liquid-liquid equilibria (LLE), as well
national and international funding agencies; as multicomponent LLE, using a single model with a single
2. To promote concerted education activities to Chemical parameter set. Many of the basic tasks noted by Zeck are related
Engineers in the areas of thermodynamics and transport to traditional, but still difficult, separation processes like complex
properties; (azeotropic, extractive) distillations, adsorption, or extraction.
3. To offer a suitable forum to Chemical Engineers for About the same time, Mathias and Klotz20 (Air Products) also
exchange of ideas, the development of new basic and applied considered that main-stream traditional issues such as multi-
research projects, and collaboration through the organization component liquid-liquid equilibria are far from solved. They
of conferences, workshops, and related activities; stated: “RelatiVe merits of these (classical, etc.) mixing rules
4. To promote and coordinate research activities at the are uncertain at present because research is in progress, but it
European level by identifying chemical systems and conditions is clear that the methods should be judged by whether they can
that are important for novel chemical processes and for which proVide good description of multi-component LLE e.g. for
data and/or correlations are nonexistent or inaccurate; water-alcohol-hydrocarbons”.
5. To publish quarterly an electronic newsletter summarizing Almost ten years after Zeck’s review, Dohrn and Pfohl21
recent developments in the field. (Bayer) emphasized that the general needs for thermodynamic
So far, the new Working Party (WP), entitled “Working Party data may differ substantially even within the same industrial
on Thermodynamics and Transport Properties” has published sector, in their case, the chemical industry. The answer to their
a review on the role of thermodynamics in the chemical question about the availability of thermophysical data elicited
engineering education in Europe and the USA.15 The objective responses ranging from “we don’t haVe enough data” to “we
of the current paper is to report on a second activity that was haVe enough data” including even “we haVe too many data”.
initiated by the WP, that is, to investigate the industrial needs Each of these statements was “justified” based on the avail-
for thermodynamic and transport properties. For this purpose, ability, or not, of relevant databases, of suitable models in
a WP task group on Industrial PerspectiVes prepared a process simulators or on the level of difficulty of a particular
questionnaire that was sent to a number of key technical people separation process. Data especially for multicomponent mixtures
in major oil and gas, chemical, and pharmaceutical/biotechnol- can be scarce and costly even for well-defined mixtures of
ogy companies. The responses received to this questionnaire industrial importance such as water-hydrocarbons-alcohols or
are analyzed and discussed in Section 3. glycols. Dohrn and Pfohl21 illustrated moreover, via examples,
To put the analysis in its historical perspective, we briefly how similar models may yield different design when used in
summarize a number of previous reviews that have been process simulators even for rather simple mixtures. For this
published in the last 20 years. Reviews emanating from both purpose, they modeled a mixture of ethyl benzene-styrene with
academic and industrial sources are presented and analyzed. the Soave-Redlich-Kwong (SRK) EoS. More examples were
given recently by Dohrn et al.22 showing that results may be
2. Literature Studies on Industrial Needs sensitive to the specific parametrization used in models. So the
evaluation of thermophysical property data should play an
Some of the early review articles from industry including
increasingly important role in industrial thermodynamics.
those of Tsonopoulos and Heidman16 (Exxon) and Zeck17,18
Agarwal et al.23 (Virtual Materials Inc.) in their review
(BASF) are almost 20 years old. They focus on the needs of
focused their attention on what they called “less attractive” (or
oil and gas and chemical industries, which have been tradition-
often neglected) properties such as heats of mixing, entropies,
ally the first industries to make wide use of thermodynamic data
excess volumes, and heat capacities. Such properties could be
and models. Tsonopoulos and Heidman16 emphasized the then
used for additional validation and model development, and the
very dominant role of cubic equations of state which they
authors investigated how cubic EoS (using either classical or
consider to be largely adequate for the needs of the oil and gas
advanced EoS/GE mixing rules) perform for these properties.
industry, due to their applicability to high pressures and
They conclude:
hydrocarbon-gas mixtures. The authors did not discourage the
“Traditional actiVity coefficient models such as NRTL
use of higher-order equations of state (EoS), which were
haVe limitations on the magnitude of the excess enthalpies
appearing at the time (such as PHCT), but they were of the
opinion that the petroleum industry would still use cubic EoS they can predict. How these models behaVe inside cubic
for years to come. Twenty-five years later, the cubic EoS remain EOS for the calculation of deriVed properties is not well
a ubiquitous working tool in the oil and gas industry. However, known and is disappointing sometimes. So, if you are
association models such as SAFT and CPA are gaining ground, modeling a system with significant excess enthalpies using
as the evidence is growing that they are successful for many a Gibbs free-energy-based EOS and you haVe a good VLE
petroleum engineering applications featuring water-hydrocarbon fit, this does not automatically ensure you haVe a good
mixtures, especially in the presence of (antihydrate) cosolvents oVerall model from an energy balance point of View.”
such as alcohols, as shown in the review of De Hemptinne et About the same time, articles on industrial needs specifically
al.19 (IFP). addressing polymer properties (from ASPEN24 and Bayer25)
In the early 90s, when interest in thermodynamics was appeared, illustrating that a large variety of models may be
regenerated by the new industrial sectors (materials, nanotech- required for designing polymer processes.
nology, and biotechnology), Zeck17 wrote: “There is still Simulator developers and providers have also frequently
considerable potential for improVement for phase equilibrium published their opinions on thermodynamic requirements. Carl-
thermodynamics eVen in long-established areas of the chemical son26 (ASPEN) discusses the importance of using the so-called
industry. With all the enthusiasm about the possibilities of decision or selection trees for selecting appropriate models
thermodynamics in new areas, it is necessary first to concentrate suitable for specific applications. He further discusses various
on performing the basic tasks”. The deficiencies of the techniques, such as family plots, for estimating missing param-
thermodynamic models, as Zeck saw them, were often related eters. In general, commercial simulators offer a lot of versatility
Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010 11133
to the end user, but this comes at a price of sometimes highlighted in industrial lectures (for example, by Natori, 2001,
bewildering choice of models, model varieties, mixing rules, at the PPEPPD conference in Kurashiki, Japan).
and parameter selection. A systematic investigation on industrial needs for both
Chen and Mathias,27 also from ASPEN, stated that in many thermodynamic and transport properties has been conducted
industrial systems polymers, electrolytes, sometimes surfactants, under the so-called Forum 2000 project, and the results are
and mixed solvents coexist, and this gives rise to multiple documented in a detailed report41 and several publications.42,43
simultaneous interactions. One of the major messages of their One important comment from Forum 2000, by Jim Olson
investigation is that many existing models have been developed (Dow Chemical), focuses on the need for reliable experimental
for each subsystem independently (for example, only for data for families of compounds which have not been systemati-
polymeric or electrolyte mixtures), and such independent cally studied:
developments should be abandoned if future models are to have “We can neVer conduct all the necessary experiments -
wide applicability. They further emphasize that there is a great but many data measurements are missing. For instance,
demand for thermodynamic models for complex products, such multi-functional chemicals such as alkanolamines, glycol
as consumer goods and bioprocesses. Another important issue ethers, excess properties like excess Volumes at Various
that is discussed is the industrial response to the developments temperatures, amides, liquid phase heat capacities,
in the field. Chen and Mathias27 argue that industry rarely enVironmental phase equilibrium, safety data e.g. flash-
updates or replaces its thermodynamic models with newer and point and auto ignition temperatures, simultaneous physi-
better correlations unless a clear advantage is evident. It often cal and chemical equilibrium, ...”
takes a long time, of the order of 10 years or more, for a new The need for reliable experimental data is the message that
model to be conceived, developed, validated, and accepted by is also strongly supported by other industrial-oriented reviews,
the industry. e.g., by Rhodes44 (Union Carbide) and Richon.45
One of the most recent and extensive industrial articles on Other important comments from the Forum 2000 work are
thermodynamic requirements is that by Gupta and Olson28 (Dow related to the need for accurate data and models for transport
Chemical). In particular, they state: properties. For example, Bill Wakeham stated: “Thermal
“Most past work focused on extensions of cubic VdW- diffusion, although an abstruse transport property, will turn out
type EoS ... This has occurred despite the now famous to be extremely important in oil reserVoirs, due to the large
recommendation of Henderson. No matter how sophis- T-differences”. He later added:
ticated a mixing rule, the use of Van der Waals-type cubic “What’s the data in tissue engineering that we need? If
equations of state force their inherent limitations on the you look at the way cancer tumours are sometimes
users. These are the ability to reasonably predict only remoVed, which is ultrasonic’s or microwaVes, this is all
the Vapour pressure of a select series of components and done by heating. The thermal conductiVity of the tissue
only an approximate modelling of the effect of liquid you heat, the heat capacity of that tissue, matters and
density and compressibility. Van der Waals-type cubic they don’t know it. Sometimes it is measured in Vitro
equations are unable to accurately model other liquid neVer in ViVo.”
phase properties, for example, enthalpy and heat capacity P. Mathias stated: “Transport properties are becoming
also phase equilibria at high pressures, particularly the increasingly important, but little attention has been deVoted to
mixture critical locus.” them”. He further made a point on solids: “When one actually
Gupta and Olson illustrate, via examples (simultaneous VLE does modelling, with particle sizes, the issues of nucleation and
growth are important. An area I think chemical engineers did
and LLE of alcohol-alkanes), that SAFT-type models should
many things 30 or 40 years ago, but there’s not been a lot
be preferred over cubic EoS for phase equilibria of polar
recently”.
mixtures.
A report for the Eureka project written by Moorwood29 So far, we have summarized some comments and opinions
(InfoChem) discussed status and requirements for thermody- based on the reviews of articles from industrial sources. Several
namic data for a very broad range of applications including reviews emanating from academia have also been published.
metals and agrochemicals. In addition, Bruin30 (Unilever) In particular, the review by Prausnitz and Tavares46 and more
recently a book by Kontogeorgis and Folas38 review a large
discussed some thermodynamic needs specifically related to food
number of thermodynamic models and present an outlook for
industry.
future developments. According to most of the academic
In the most recent joint industrial-academic work, O’Connell reviews, important advancements in thermodynamics are needed
et al.31 analyzed in detail a number of specific cases from a to address issues related to “post-modernism”,47,48 life sciences/bio-
thermodynamic perspective. Special emphasis was given to the technology,11-14,49,50 and chemical product development.2-5,9,10
need for simultaneous physical and chemical equilibria data, Moreover, there is a need to connect closely with other
for solvent selection for pharmaceuticals, and for formalde- disciplines of chemical engineering, such as mass and heat
hyde-water and CO2-water-alkanolamine mixtures. transfer, nucleation, and chemical kinetics. One example where
During the past decade, several articles have appeared from such an interdisciplinary approach would pay great dividends
industrial sources (Astra Zeneza, Mitsubishi, ASPEN, Merck, would be in the design of controlled drug release systems.
etc.) on thermodynamic requirements of the pharmaceutical The postmodernism trends in chemical engineering encom-
sector,32-37 particularly the need for accurate and reliable models pass the need for more “human aspects” in the curriculum. They
for solvent screening. A variety of models have been tested, emphasize the role that chemical engineering plays in society
ranging from modifications of UNIFAC and solubility param- and provide ample opportunity for thermodynamics. The near-
eters to modern versions of local composition models, such as future focus should be on addressing different environmental
NRTL-SAC,38 and methods based on quantum chemistry like and safety related aspects, for example, the use of supercritical
COSMO-RS39,40 and COSMO-SAC.38 The use of quantum fluids, the optimization of processes related to CO2 capture and
chemistry methods in pharmaceutical industry has been also storage, as well as modeling of loss-prevention scenarios.6-8,47,48
11134 Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010

Many recent investigations39,40,51-53 point to the increasing


importance of quantum chemistry especially in the form of
models like COSMO-RS and COSMO-SAC for thermodynamic
calculations and especially screening purposes for a wide range
of situations, mostly at low pressures.
The role that the molecular description increasingly plays in
modern thermodynamics has been emphasized by Prausnitz:9
“Thermodynamics is often most useful when directed at
deVeloping model for new situations, where our quantita-
tiVe understanding is seriously inadequate. Pioneering
molecular thermodynamics is concerned not with im-
proVements where primary understanding has already
been achieVed, but with shedding light on situations where
as yet, we know little. For many practical problems, old
theories are sufficient proVided that they are used with
courage and imagination.”

3. Questionnaire and the Survey


The task group Industrial PerspectiVes appointed by the Figure 1. Responses to the questionnaire classified by industrial sector.
EFCE Working Party on Thermodynamics and Transport Some responders work in more than one category.
Properties (EFCE WP) prepared a questionnaire comprised of
seven questions that are presented in Appendix 1. The questions the right product with specific thermophysical properties (i.e.,
ranged from simple yes/no answers to the ones that were open- solvent design).
ended where any issue related to thermodynamic and transport The “supply” from the thermodynamic community is pre-
property requirements could be addressed. sented in Figure 2 as a triangle that should respond to these
The overall purpose of the survey was to: needs: the response is the “package” that includes models,
• Review the situation in industry with respect to thermody- parameters, and algorithms. Ideally, this model should be unique,
namics and transport properties requirements. The emphasis was independent of the type of system or operating conditions. To
primarily to collect information on European industry, although construct this ideal package, the three vertices of the triangle
some companies from the USA, Japan, Thailand, Brazil, and must be considered:
South Africa were also included in the survey;  Upper left: what is the molecular system under inVestiga-
• Identify limitations in current approaches; tion? There is a plethora of mixtures of industrial interest, and
• Provide specific recommendations on R&D work (to be it is more or less impossible to include every conceivable
initiated by the EFCE WP and individual researchers in this combination. A reasonable approach would be to rely on good
area). description of thermophysical properties of pure species and
A list of possible companies that could take part in our survey use modeling tools to obtain the properties of the mixtures. The
was created with the contact names collected by the coauthors industrial interest changes with time, as a result of new
of this paper, and the invitations were sent out. Fifty-nine developments, new processes, and new products. Currently, there
companies in total from sixteen different countries were is an emphasis on CO2, electrolytes, and polyfunctional mol-
contacted, and the reminders were sent out to increase the ecules. Many molecular systems are compositionally well-
number of responses. In total, 28 replies were received, which defined, but this is not always the case. For instance, for
represents a 47% response rate. Most responses were from reservoir fluids the detailed molecular composition is usually
European but globally operating industries. Figure 1 illustrates not available, hence some additional characterization is needed.
the industrial sectors of the companies that have responded to  Upper right: what is the property required? Although VLE
the survey. remains the most common, other types of phase equilibria (LLE,
SLE) are nowadays also in demand. Furthermore, there is an
4. Results increasing need for enthalpic properties (heat of mixing, heat
capacities, etc.) and transport properties. The traditional cubic
Although it is rather difficult to categorize and summarize EoS is of limited use for this purpose,28 and one requires more
an overwhelming number of answers received, an attempt is sophisticated models that are not necessarily available in every
made to summarize the essential features by means of Figure package.
2.  Lower corner: data. The most traditional approach is to
Figure 2 shows on the left the industrial requirements claim that there are not enough data or to use the available data
regarding thermodynamics and transport properties, summarized without any analysis of their accuracy or reliability. Although
by a few keywords. The requirements are usually short-term, it is true that for a large number of systems the data are scarce,
and this is probably why there is a resistance in trying out when the data are available one should ask the question
recently developed advanced tools, such as SAFT EoS and according to Dohrn and Pfohl:21 “do we have the correct data
molecular simulation (“first concentrating on basic tasks”). Yet, (that means useful in view of the applications)?”
the industrial requirements often relate to complex thermo- At the very right of Figure 2, the various state-of-the-art
physical systems, hence the reliance in some instances on simple predictive tools that the thermophysical property community
“rule of thumb” approaches, which are believed by industry to can use, to respond to the industrial needs, are illustrated.
give a good indication of trends. Finally, industrial needs require Molecular simulation plays an essential role, as well as quantum
either (i) the knowledge of thermophysical properties at given chemistry, as both have shown great advances in terms of both
operating conditions or (ii) in product design the ability to design development and applications. In the near future, other com-
Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010 11135

Figure 2. Schematic illustration of the position of thermodynamic tools for the oil and gas, chemical, and process industries.

putational techniques might become available including, for Simple examples mentioned in the survey include the inorganic
example, the ones dealing with nonequilibrium thermodynamics acids, like sulfuric acid, hydrochloric acid, and nitrous acid.
or calculation of transport properties directly from intermolecular (iii) The participants of the survey felt that the emphasis
potential. Industry is not yet fully aware of the applicability of should be given to more measurements on: (i) gas solubilities;
these computational techniques to address their requirements, (ii) high-pressure and high-temperature phase equilibrium data
which is why very few industrial comments on this issue were of nonideal mixtures; (iii) dilute conditions; (iv) solubilities and
found in our survey. It is thus the role of the academic diffusion in polymers; (v) reactive multiphase systems (CO2,
community to introduce the use of advanced computational H2S-water-alkanolamines); and (vi) electrolytes. Essentially,
techniques, by both further refining theoretical models and there is a need for high-quality data for a wide range of systems
showing that the results can be used as alternative, pseudoex- and conditions.
perimental data, or parameter provider. (iv) Data are also lacking in petroleum-related applications
In the next set of subsections, we present and analyze the for: (i) gas hydrate systems, e.g., hydrate formation with CO2
results obtained in the current survey. For ease of use, the main and H2, with additives, and with loss of hydrate inhibitor such
conclusions from the survey are presented in the bold font in as methanol and glycols; (ii) properties of heavy oils; (iii)
the first paragraph of each section. partition coefficient of gases in hydrotreatment conditions,
4.1. Data. There is an acute need for high-quality experi- especially in the presence of oxygenated fuels; (iv) heats of
mental data for both thermodynamic and transport proper- reaction and of adsorption; and (v) VLLE of complex natural
ties, including the phase and chemical equilibrium data. gas mixtures including water and electrolytes.
The high-quality data can only be obtained in a well- (v) There is an acute need for transport property data that
characterized experimental apparatus with a well-defined un- include viscosity, thermal conductivity, and diffusion coefficient
certainty level, which cannot be demonstrated to be inconsistent data. Especially, emphasis was put on the lack of data for
with other data or with theory. Although such instruments do electrolytes and ionic liquids. It was noted that even when some
exist, their use requires knowledge of their full-working transport property data do exist they do not cover an extensive
equation, and in some cases it requires a number of corrections, temperature and pressure range.
to account for the nonideality of the apparatus, to be made to (vi) The lack of data is made even more acute by the
experimental data. Thus, producing high-quality data is expen- observation that there are fewer research groups (at least in
sive and time-consuming, and not surprisingly, such data are Europe) that have well-equipped laboratories and have funding
scarce. It is important to emphasize that rather than focusing to devote time to measurements. The disappearance over the
on the amount of data available for a particular system one years of a number of research groups that were producing high-
should focus on gathering reliable data with well-defined quality data is a worrying trend, as without the high-quality
uncertainty levels that cover the phase space of interest. Such data the existing databases will become less useful as the
sets of high-quality data, that are mutually consistent, can then tendency to target quantity rather than quality will intensify.
be used as a benchmark data set for a particular system essential (vii) A number of participants indicated that when the data
for validating or developing predictive models and tools. need is clearly identified in view of specific industrial require-
More specific comments that were made in the survey were ment, companies do not hesitate to spend money to measure
as follows: the relevant properties. However, as these data are often
(i) For complicated molecules, containing multiple functional considered strategic, they are not always published. Note that
groups (e.g., hyper-branched polymers, dendrimers, micelles) policy of expecting to find a laboratory, when a particular need
that are used for fine chemicals, crop protection, and bioappli- arises, that can perform the high-quality measurements is
cations, very few phase equilibrium data exist in the open relatively short sighted. Producing high-quality data requires
literature. So group contribution methods are less accurate for continuity in terms of both maintaining apparatus and even more
these molecules, as there are no data to fit the required importantly maintaining research expertise, as the high-quality
parameters. measurements cannot be performed on a short-term basis by
(ii) For many traditional/bulk chemicals, a large number of inexperienced researchers.
data sets exist that do not agree with each other. Most of the (viii) The use of advanced computational tools, such as
data have been measured a long time ago in the apparatus whose molecular simulation or quantum chemistry, is sometimes
description does not allow for their proper levels of accuracy mentioned as an alternative to “producing” experimental data,
to be established. There is a lack of high-quality reference data but this approach is currently not commonly accepted by
to which model parameters can be fitted for process simulation. industry.
11136 Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010

4.2. Models. 4.2.1. Scope of the Models. There is a need developed to gain better understanding, and molecular simula-
for reliable thermodynamic and transport property models tions are suggested to improve the prediction of thermophysical
for a Wery wide range of systems. properties and phase equilibrium.
The participants of the survey put the special emphasis on: (ii) The GC models in general are used and are needed in
(i) Need for models for phase equilibria and transport many contexts that do not necessarily involve predicting phase
properties, preferably within a single framework, that cover all behavior, for instance, for computer-aided product design,
the components and conditions of interest and with good inter- properties of heavy compounds (even for pure species: melting
and extrapolation capabilities in temperature, pressure, and temperature, vapor pressures, etc.), solvent screening, emulsions,
composition. and oxygenated compounds. Thus, the full phasing out of GC
(ii) The framework should be targeted toward making use of models in favor of modern models is not yet imminent.
generalized and simple equations of state for nonpolar, polar, (iii) SAFT-based models are promising tools, but the requests
associating, and high boiling substances and their mixtures, with from the industrial community for these models are multiple:
sufficient accuracy for industrial purposes. • Characterization methods for oils, asphaltenes, and similar
(iii) The number of available models in the literature should complex mixtures;
be reduced by recommending either a unique model or a small • Speed must be improved for routine applications (see also
number of models. Today, specialists in industry are required next point on standardization);
to recommend the best modeling approach for a specific • Recommended pure-component and binary parameters
application, and the number of available models or versions of should be collected and made available;
the same model are sometimes bewildering. • True improvements over classical cubic EoS should be
More specifically, the survey results indicated: demonstrated, especially for multifunctional, complex, and
(i) The models should cover the requirements of very diverse associating compounds like oxygenated compounds (biofuels);
industrial fields: (a) oil and gas including heavy oil, mercury • The model should be applied to truly important new areas
compounds, syngas, asphaltenes (currently poorly characterized), including polymers and electrolytes;
and organic sulfur compounds; (b) chemicals including complex • Standardization is needed. This is further discussed in
oxygenated chemicals related to biofuels, ionic liquids, surfac- section 4.2.3.
tants, and polymers; (c) biotech including biopolymers, phar- 4.2.3. Availability of the Models. Standards are very
maceuticals, and building blocks; (d) colloids including emul- important for thermodynamic models.
sions, surfactants, food additives, emulsifiers, adhesives, and The term “Standards” has been used and understood in
gels; and (e) metal and mining. The applications were by and different (sometimes complementary) contexts, both in imple-
large dependent on the industrial sector, but the following mentation and model validation:
processes were particularly emphasized as in need of good (i) Models should be present in simulators for active use by
models: flow assurance (gas hydrates, asphaltenes, and wax); industry, otherwise, they may be forgotten. CAPE-OPEN is a
separation methods other than distillation/extraction, e.g., useful (and standard) tool for integrating user developed unit
adsorption and chromatography; and crystallization. operations and thermodynamics packages in commercial process
(ii) As can be seen from the above list, requirements and simulation programs, but it is still not fully developed and
expectations for models are not only diverse but also very supported. One of the comments in the survey was that the
extensive. Clearly current models cannot cover or meet all areas analytical derivatives are needed. The tool should be improved
of interest and expectations. However, an interesting issue is further, allowing exchange of thermodynamic packages belong-
that there is a feeling that models are incomplete or lacking ing to different process simulators.
even in areas which might have been considered “mature”. For (ii) The number of new models is enormous, even within the
instance, for bulk chemicals it was felt that a very important same family. For instance, there are numerous versions of SAFT.
system of ammonia-water-sulfuric acid is poorly addressed Sometimes different results are obtained with what should be
by any of the available models. In the oil and gas area, the the same model. Proper coding and validation are extremely
presence of mercury and sulfur compounds was equally badly important to ensure full reproducibility of the results. This should
catered for by the modeling community. There is a feeling that also be performed by other researchers rather than just by those
an analysis of the different requirements and expectations carried involved in the model development.
out for each industry sector would be useful. The question arises how can this be accomplished? It is worth
(iii) A lack of high-precision EoS for a number of systems investigating some process that would lead to a proper com-
was noted. parison of models. A first step in such a process could be the
4.2.2. Theoretical Foundation of the Models. Traditional agreement to use some standard well-accepted databases for
and novel models are equally important, and developments validation purposes. A second step would be the agreement on
in both should continue. criteria for model validation which could be used by all
Model approaches used in industry range from traditional developers. In particular, the model developers should try to
group-contribution (GC) models especially UNIFAC to modern present, in a few comprehensive articles, all equations of their
approaches such as COSMO-RS and SAFT. The general models including a thorough evaluation. The codes can be made
consensus is that: publicly available, but a good accompanying documentation
(i) The development of both UNIFAC and COSMO-RS would be necessary.
should continue as they are both very useful for industrial 4.2.4. Algorithms. Implementation of the thermodynamic
applications. There was a suggestion that some work should be models requires reliable flash and related algorithms, and
carried out to combine them, by for instance making use of although significant developments have been made in the past
group contributions for the sigma profiles of COSMO-RS. The (e.g., Michelsen and Mollerup54), new challenges are appearing,
prediction of UNIFAC and COSMO-RS should be compared in particular, the need for very fast and robust calculations for
as the actual range of applicability and accuracy appears to be flashes, the presence of multiple phases, and reactive systems.
very system-dependent. Molecular modeling should be further Further, there is a need to improve the stability test, the most
Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010 11137
time-consuming element of the multiphase calculations. Un- (iv) Extrapolations to high temperatures and pressures are
fortunately, the field does not seem to be of active interest to often needed, for instance, for gas solubilities in water-
the thermodynamic community. hydrocarbon-CO2 mixtures that could involve salts and other
4.3. Systems. The most popular systems appear to be chemicals. The proposed correlations should have sensible
electrolytes, CO2, and larger, polyfunctional molecules. extrapolation behavior.
These systems appeared repeatedly in a survey in different A number of other properties were mentioned as important
contexts from a number of companies belonging to different for specific applications:
sectors. (i) SLE is crucial for a variety of separation processes, e.g.,
In particular: crystallization, as well as for mineral stability and hydrate
(i) There is a need for improved description for electrolyte formation in the oilfield.
systems that go beyond e-NRTL.38 The emphasis should be on (ii) Surface phenomena (adsorption) are typically equilibrium
describing all types of phase behavior (VLE/LLE/SLE) covering phenomena that play an important role in a number of
also electrolyte mixtures with water, other organic chemicals applications.
(i.e., mixed solvents), and hydrocarbons (natural gas), over (iii) Chemical reactions (formation properties).
extensive temperature and pressure ranges, up to high salt None of these properties are currently well catered for by the
concentrations. Electrolyte models are multiparameter models, thermodynamic community.
and modern e-EoS38 may be a way to go; however, much Nonequilibrium properties: combined thermodynamic/
remains to be done. There is a need to bring electrolyte transport effects and appreciation of nonequilibrium effects
thermodynamic models to a level comparable to other fields. are important.
The need for improved electrolyte models is common among a (i) There is a need for combined models for predicting
wide range of industries. thermodynamic and transport properties, reaction rates, and
(ii) There is a lack of data and models for larger molecules, diffusivities. There is a need for a good procedure to disentangle
complex molecules, biomolecules (biopolymers, proteins, phar- reaction kinetics and mass transfer where both processes
maceuticals, gels), or molecules that contain multiple functional contribute.
groups (polar and associating ones) that are used as food additives. (ii) Is it possible to predict transport properties from
(iii) CO2 mixtures with water, polar chemicals (methanol, thermodynamic data alone? Can we reliably estimate thermal
glycols) including mixed solvents, H2S, N2O, O2, hydrocar- and transport properties from limited vapor pressure and density
bons, and (alkanol) amines appear of importance to a wide data?
range of applications (gas hydrates, oil and gas, CO2 capture, (iii) There is a need for models for predicting properties,
transport, and storage). Of special importance to a number especially transport properties of complex products present
of participants was that the description of the system covers in many fields of process industry, such as viscosity index
very extensive temperature and pressure ranges. The CO2- of lubricant base oils from composition and octane/cetane
containing systems also include electrolytes, as CO2-brine numbers.
(+ rock mineral) systems are of great interest in CCS (CO2 (iv) What is the effect of nonequilibrium behavior? It is not
capture and storage) applications. A number of the systems always clear whether a system is in thermodynamic equilibrium
described are chemically reactive which further complicates or not.
their thermophysical description. (v) There are cases where thermodynamic predictions may
4.4. Properties. Multiple thermodynamic properties are be quite misleading because of slow reaction kinetics, or poor
of importance. mass transfer, e.g., predicting inorganic scale deposition.
It was frequently stated in the survey that simultaneous (vi) In many processes, the nonequilibrium part can be of
description of different thermodynamic properties and phase importance, e.g., nucleation in crystallization and gas hydrate
equilibrium types is of great importance. Internal thermodynamic formation.
consistency of the generated data by a given model is nowadays (vii) It would be of great industrial interest to develop
as essential as accuracy and reliability. This is especially fundamental nonequilibrium thermodynamic approaches for
important as the thermodynamic models are often used as part predicting transfer across boundaries (for replacing the empirical
of the simulator by a different set of software developers who “transfer efficiency” equations).
are not necessarily aware of all the nuances of a particular 4.5. Education. What is the role of education in thermody-
thermodynamic model. namic modeling for process and product design? There is a clear
Hence, thermodynamic modelers should no longer be satisfied agreement among the participants in the survey that education
with models that for instance give only good VLE results at is the key for an appropriate use of thermodynamics in industry.
low pressures but are either untested or fail for other properties Three different levels of education are relevant in this context,
and regions of the phase space. each with different requirements:
In particular, the results of the survey indicated that for (i) Undergraduate education: it is essential that engineers in
equilibrium properties: operating companies know some basic thermodynamics but even
(i) Simultaneous description of VLE and LLE (+ VLLE) is more importantly that they are aware of the limitations of their
of interest with the same model and the same parameter set, understanding. This is especially relevant as black-box type
especially for complex multicomponent mixtures. simulators are routinely used these days.
(ii) So is the simultaneous description of the phase behavior (ii) Professional development: with the advent of new
and derivative properties (e.g., heats of mixing). technologies (simulators) or as a result of job changes, people
(iii) Special attention should be given to dilute systems may be confronted with new challenges after several years of
(infinite dilution), and the description of the system should be professional experience. The field of thermophysical properties
mutually consistent with the description at higher concentra- is evolving rapidly, and there is a need for industry professionals
tions. to keep up with the latest developments.
11138 Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010

(iii) Postgraduate education: the complexity and the wide cases. Most models have serious problems when applied to
applicability of thermodynamics leads to a need for specialists (poly)electrolyte systems, mixed solvents relevant for gas
within a given company, typically educated to a PhD level, to treatment using amines, and new solvents like ionic liquids.
act as an internal expert on thermodynamic and transport The simultaneous presence of polymers, electrolytes, and
property issues. biomolecules is also an area where none of the models
4.6. Collaborations. Data collected revealed that: perform adequately. These are areas where important revi-
(i) The R&D organization in the various companies is sions and improvements are needed. It is particularly interest-
generally rather strong: 25 out of 28 companies have a research ing that deficiencies in current electrolyte models are apparent
lab, and 9 of them have a research subsidiary. even for models used in commercial simulators, as illustrated
(ii) Most of the companies that took part in the survey have in a recent joint academia-industry project.57 Emphasis on
bilateral collaborations with universities. The average level of electrolytes and polymers is found in both previous and the
collaboration fulfills close to 10% of the total research need. current investigation. New in our survey is the special interest
Some companies rely quite heavily on it. in predicting the thermophysical properties of mixtures
(iii) 25 out of 28 companies participate in consortia. Yet, containing CO2. This is a direct result of climate change
the willingness to participate in joint R&D programs is concerns and the development of sustainable technologies,
surprisingly conservative with only 14 out of 28 indicating in particular, the CCS.
a clear yes. Regarding the capabilities of thermodynamic models, we can
(iv) The area for joint collaboration is rather diverse: from state that the advent of SAFT-family models has certainly
gathering new data to developing parameter tables (UNIFAC contributed to better representation of a wide range of systems
consortium is often cited as an example). (nonpolar, polar, associating, polymers, etc.) and the simulta-
neous representation of various phase equilibrium types, e.g.,
5. Conclusion: Discussion and Comparison to Previous VLE and LLE. On the other hand, there is a clear impression
Studies from the survey that certain important issues, also emphasized
in the earlier industrial studies, have been overlooked. Good
A short discussion is provided in this section contrasting the
examples are the multicomponent multiphase equilibria espe-
results of our industrial survey and those from the literature
cially for prediction purposes and the accurate description of
that were presented in section 2.
derivative properties (e.g., heat capacity, speed of sound,
An important common feature of current and previous enthalpy of mixing) together with phase behavior. Clearly, these
investigations (see for example a recent discussion45) is the issues need to be considered and included in future develop-
need for experimental work which will result in high-quality ment-model validations.
measurements that are accurate, reliable, and thermodynami-
Some of the previously published industrial reviews empha-
cally consistent. In many cases, the real accuracy of published
sized molecular simulation techniques as enabling technology
experimental data is far lower than the accuracy given by
which can supplement the experimental data or act as pseu-
the authors, as discussed by Peper et al.56 The importance
doexperimental data at temperatures and pressures where
of practical expertise of the experimentalists in obtaining
experiments are difficult. However, the participants of the current
high-quality data has been highlighted by Dohrn et al.55 in
survey were not particularly encouraging the further develop-
their recent review on experimental methods for high-pressure
ments of molecular simulation, which is a rather disappointing
phase equilibria. Often, the qualification of the staff and their
state of affairs.
familiarization with the technique have a stronger influence
on the accuracy of experimental results than the choice of Algorithms appear to be a neglected area in many of the
the experimental method or the equipment. Our survey shows previous publications, but the results of the current survey
that there is a clear need for qualified laboratories with illustrate that the improvements are clearly needed, especially
experienced staff to provide experimental measurements. As for multiphase and/or reacting systems (simultaneous physical
many companies seek to reduce in-house facilities for routine, and chemical equilibria).
nonexploratory type of measurements, this need will likely According to the current survey, implementation is an
increase. Universities have also reduced their experimental important issue to the industrial users. In the previously
activities. The key problem is that performing high-quality published reviews, this aspect was not emphasized greatly,
measurements requires accumulation of many years of although the importance of CAPE-OPEN58 standard has been
experience for which funding has to be secured. The different mentioned. The issue of having standardized and validated
funding bodies in many instances do not see this type of models is particularly highlighted in the current survey. The
activity as leading edge research and in the present climate new models are published very frequently, but unfortunately
decline to fund it. Furthermore, the pain-staking effort leads most, if not all, of these models are tested against only a
to a rather limited publication output. Nevertheless, data are few data sets. A large, standardized set of data against which
lacking for a wide range of systems from “simple” common all models may be tested will be of great benefit, as it will
mixtures up to multifunctional chemicals, complex com- allow models to be compared on equal footing. It will also
pounds originating from biomass, ionic liquids, polymers, be of benefit to those developing the models, as the validation
and pharmaceuticals. Surprisingly, the data are still very against agreed industry benchmarks could lead to the
scarce for solubility of water in CO2 at high pressures and reduction of cycle time from development to industrial use.
for mixtures that involve inorganic acids or ammonia. A final original issue raised by the current survey is the need
Another common feature of the current survey and the for education and the possible role the EFCE WP can play in
previous ones is that reliable models are needed and that this. A number of suggestions of improving the undergraduate
the predictive character is essential, but many existing models level courses were made. Thermodynamics of process simulation
are essentially correlative. Thus, SAFT, COSMO-RS, and should be taught with the emphasis on how generic simulators
UNIFAC (GC) approaches should be further developed, and work, without necessarily going into peculiarities of a particular
it appears unlikely that a single tool will be sufficient in all simulator, unless a particular simulator is used in class. It is
Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010 11139
important to get across how to distinguish between reliable and Acknowledgment
unreliable thermodynamic data and practices. However, the main
We acknowledge the contribution from all industry experts
issue raised is how to make engineers more aware of the
who replied to the survey and thank them for their effort, without
practical consequences of “right and wrong” thermodynamics. which this paper could not have been written.
In particular what type of problems require initiation of proactive
research and under what circumstances would quick empirical
fixes suffice. Appendix 1. The Survey Questionnaire
Overall, the gap between the industrial requirements and the Below are listed the questions asked in the EFCE Working Party
data availability has not appreciably shrunk over the years. It Task group on Industrial Perspectives Questionnaire. All ques-
is not immediately clear how this gap can be closed especially tions are to be considered in relation to physical properties,
in the present economic climate. The first step is to once again thermodynamics, and transport properties.
try to bring the relevant stakeholders closer together.
As an example of possible actions, the French working party Question 1. Your company’s business
Thermodynamique des procédés organizes small scale one-day
meetings on specific topics such as education, molecular What are the main businesses of your company? (Put Yes or
thermodynamics, and use of databases. The objective is to create No)
learning and exchange opportunities between the academic and Exploration and production
Refining
the industrial communities. Specific potential actions from these
Bulk chemicals
meetings are the installation of a Web site for exchange between
Fine chemicals
educators and a Web-based information system for molecular
Natural gas
thermodynamics issues.
Power generation
Other examples include the organization of workshops such Pharmaceuticals
as the one recently organized between our working party and Agrochemicals
the German ProcesNet working party. Such workshops should
be tailored so that they address some of the numerous
questions raised above. At the same time, they can act as a Question 2. Limitations in thermodynamics and transport
properties
forward looking forum where the industry can articulate their
medium- and long-term needs and open a dialogue with data What do you consider as the limitations in thermodynamics
and model generators. and transport properties in addressing your company’s chal-
The issue of having large, standardized set of data against lenges?
which all models may be tested is also a very pertinent one Products
that needs addressing. Although, there are databases (NIST- Processes
TRC, Dechema-Detherm, Danner and Gess59) that are used by Data
individuals, their use is still not widespread enough. Models
Process simulation
Of equal importance is the definition and availability of Reservoir simulation
standardized models. In our view, this requires for each such CO2 sequestration
model the publication of a paper, perhaps in a dedicated Enhanced oil recovery
journal, containing all that is needed to perform the calcula- Extraction and processing of discounted (opportunity) crudes
tions and reproduce results. This includes all the equations (heavy oil, high sulfur crudes, high acid crudes...)
and parameter values needed to achieve this and results for Gas processing
a number of defined input cases. However, discussions on Long-range transport
the merits of the model and comparison to experimental data Add as many as you wish
should be left out. The model can then receive a unique
identifier which together with this definition paper can serve
as the reference. It would also be very useful to publish the Question 3. R&D in thermodynamics and transport
implementation of this model including the parameters as properties
open source code, preferably together with the definition. The How is the R&D organized in your company?
vendors of commercial software should refer to these standard
Do you have your own research laboratories?
models in their documentation and clearly state when and
where they deviate from them. The same holds for authors Do you have a research subsidiary?
discussing a comparison of their results against those obtained Do you subcontract your research?
with standard models. What proportion of the work is subcontracted to academic
We see this paper as the first step in reinitiating the teams?
dialogue between the interested parties which can lead to a
more effective collaboration that can close the current gap Question 4. Collaboration
between the requirements and the availability of thermody-
namic and transport property data and models. We feel that Consortia or other collaborative work in thermodynamics and
the EFCE WP should play an important role in this process, transport properties.
acting as a conduit between the academia, industry, and Do you participate in consortia?
decision makers. If so, in which areas?
11140 Ind. Eng. Chem. Res., Vol. 49, No. 22, 2010

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