Modular and Intensified – Reimagining Manufacturing at the Energy-Chemistry Nexus and Beyond

Today's manufacturing is based on ample fossil fuel sources, large and centralized plants, and high waste intensity. Climate change, aging infrastructure, dwindling resources, increasing population, changing geopolitical landscape, and the COVID-19 pandemic have laid bare the frailties of the current global supply chain. While there is still place for centralized production, geographic variation in renewable energy sources and sustainable feedstocks calls for a flexible approach towards smaller-scale and more decentralized production. With the pressing need for decarbonization of power generation and the chemical value chain, flexible manufacturing will play a major role in redefining the energy-chemistry nexus. Intensification and modularization are identified as the key enablers for such a transition. A sample case study based on valorization of hydrogen sulfide extracted from sour gas is presented to demonstrate the potential economic favorability of modular chemical process intensification. Our work shows that a net profit of US$97 million can be achieved over a five-year operational period when compared to a conventional process. A complementary evaluation of green solvents is also provided to further improve the sustainability of the proposed solution.