The Economic Significance of Thermal Process Engineering in Chemistry
The invisible force driving efficiency, sustainability and competitiveness in the chemical industry
The Invisible Force of the Chemical Industry
In the heart of chemical parks lies an invisible driving force that transforms raw materials into valuable everyday products: thermal process engineering. This discipline forms the foundation of countless production processes, from the manufacture of plastics and pharmaceuticals to the development of sustainable energy solutions.
While the chemical industry continues its recovery in 2025 with a projected global production increase of 3.5%, thermal separation processes play a crucial role in the sector's economic competitiveness and ecological sustainability 5 . This article highlights how the targeted use of heat and mass transfer processes not only enables chemical production but also significantly contributes to efficiency improvements and cost reduction in the industry.
Global Production Growth
3.5%
Projected for 2025
Process Efficiency
Key Driver
For competitiveness
Sustainability
Crucial Role
In ecological transformation
Fundamentals of Thermal Separation Processes
Thermal process engineering fundamentally deals with the separation of substance mixtures through the targeted application of heat and mass transfer 2 . In mixtures of at least two components, these processes are used to selectively change the composition and obtain valuable starting or end products with the desired purity.
The economic importance of these processes lies in their ubiquity: Almost every chemical process requires separation of components at some point in its value chain, whether in the purification of raw materials, the isolation of intermediate products, or the recovery of the pure end product. The efficiency of these separation processes directly influences energy costs, yield, and profitability of the entire production.
Distillation and Rectification
Utilizing different volatilities of components for separation of liquid mixtures, for example in petroleum refining 2 .
Absorption and Adsorption
Removal of unwanted gaseous components using solvents or surface accumulation on solids.
Drying and Evaporation
Removal of moisture from solids or concentrating solutions by solvent removal 2 .
Crystallization
Separation and purification of substances through formation of solid crystals 2 .
Economic Drivers and Industry Trends 2025
The chemical industry is undergoing significant transformation in 2025, shaped by various economic factors and strategic orientations. According to a Deloitte analysis, companies are increasingly focusing on cost efficiency and operational excellence to survive in a competitive environment 5 .
Cost Pressure and Plant Rationalization
Many chemical companies have announced cost reduction programs in recent years, including efficiency improvements in plant and office operations, process redesign, and in some cases staff reductions and plant closures 5 .
This trend is particularly evident in Europe, where chemical plants struggle with high energy costs and inflationary pressure. Many European facilities face natural gas prices approximately 70% above pre-energy crisis levels, disadvantaging the region in cost competition 5 .
Investments in Future Technologies
Semiconductor Chemicals
Fastest-growing segment driven by automotive electronics and AI data centers 5 .
Energy Transition
Materials for battery storage, clean hydrogen and renewable energy systems.
Circular Economy
Processes for chemical recycling and waste utilization.
Global Chemical Production Forecasts 2024-2025
| Region | Production Growth 2024 | Production Growth 2025 (forecast) | Main Challenges |
|---|---|---|---|
| Global | 3.4% | 3.5% | Demand fluctuations, overcapacities |
| Europe | Minimal | Slightly increasing | High energy costs, inflation |
| USA | Moderate | Stable | Demand in key markets |
| Middle East | Stable | Stable | Favorable energy and raw material prices |
Sustainability and Innovation
Thermal process engineering plays a key role in addressing the greatest challenges of our time: reducing greenhouse gas emissions and increasing resource efficiency. Modern research approaches aim not only to optimize established processes but to fundamentally transform them.
Bridging Research and Practice
Current studies demonstrate how data-driven approaches and artificial intelligence can bridge the gap between academic research and real-world challenges in chemical process engineering 3 . This holistic approach improves understanding of physicochemical processes and enables significant efficiency gains.
For example, researchers have used AI-assisted methods to optimize the operating conditions of a two-stage heat pump to achieve the highest possible absorption temperature without performance losses 3 . This type of optimization is crucial for improving the efficiency of thermal energy recovery systems and contributes to reducing CO₂ emissions.
Innovative Materials and Processes
Self-Healing Materials
Special concretes with embedded microcapsules that release healing agents upon crack formation, extending plant lifespan 6 .
Shape Memory Alloys
Intelligent metals that adjust their shape in response to temperature changes, used in aerospace and plant engineering.
Adaptive Heat Exchangers
Advanced designs that optimize heat transfer and reduce energy consumption.
Case Study: Wheat Straw Torrefaction Experiment
To concretely illustrate the contribution of thermal process engineering to sustainability, we examine a research project on the utilization of wheat straw 3 . This experiment addresses the serious environmental and health problems caused by open burning of wheat straw residues and seeks alternative uses.
Methodology
The experiment investigates the torrefaction process (a mild pyrolysis) of wheat straw under various reaction atmospheres. The goal is to improve the fuel properties of wheat straw to make it more attractive as a renewable energy source 3 .
Experimental Procedure:
- Wheat straw samples are crushed and brought to a uniform particle size
- Samples are heated in a special oven under controlled atmosphere
- Torrefaction occurs at temperatures between 200-300°C
- Residence time in the oven is systematically varied
- Torrefied samples are analyzed for their fuel properties
Process Parameters in Torrefaction
| Parameter | Variation Range | Purpose |
|---|---|---|
| Temperature | 200-300°C | Find optimal carbonization levels |
| Residence Time | 30-90 minutes | Determine process duration impact |
| Oxygen Content | 0-21% | Study oxidation effects |
| Particle Size | Fine to coarse | Analyze heat transfer effects |
Results and Analysis
Torrefaction significantly improves the energy density and combustion quality of wheat straw. The treated biomass exhibits higher calorific value, improved ignition and combustion properties, and reduced moisture absorption during storage 3 .
Analysis of process conditions shows that certain temperature-atmosphere combinations provide particularly advantageous results. The torrefied biomass pellets achieve calorific values comparable to low-grade coal, with simultaneously significantly reduced emissions of pollutants such as sulfur oxides.
Economic Assessment of Torrefaction
| Factor | Challenge | Solution through Torrefaction |
|---|---|---|
| Energy Density | Low energy density of raw straw | Increased mass and volume energy density |
| Storage Stability | Biological degradation during storage | More hydrophobic properties, reduced decomposition |
| Transport Costs | High volume with low weight | Lower transport costs per energy unit |
| Combustion Properties | Inefficient combustion with high emissions | More uniform combustion, lower emissions |
| Economic Viability | Low market value as waste product | Higher value as fuel or raw material |
The Process Engineer's Toolkit
Experimental and process engineering work in thermal process engineering requires specialized equipment and materials. The following presents essential components of a process engineer's "toolkit":
Distillation Columns
Separation of liquid mixtures through multi-stage distillation
Fractionation of petroleum components 2Drying Units
Removal of moisture from solids through targeted heat supply
Production of powdered chemicals 2Evaporator Plants
Concentrating solutions through selective solvent separation
Concentrating temperature-sensitive solutions 2Adsorption Systems
Removal of unwanted components through accumulation on solid surfaces
Purification of exhaust air streams, gas separation 2Crystallization Plants
Production of defined solid particles through controlled crystal formation
Production of pharmaceutical active ingredients 2Membrane Separation
Substance separation through selectively permeable barriers
Concentration of temperature-sensitive substancesConclusion: Thermal Process Engineering as Economic Driver
Thermal process engineering represents not only a technical discipline but an essential economic factor for the chemical industry. Its continuous development enables more efficient use of raw materials, reduces energy consumption, and creates the basis for innovative products and sustainable processes.
While the chemical industry continues to face volatile markets, cost pressure, and regulatory requirements in 2025, thermal process engineering offers essential solution approaches for these challenges. Through the integration of digitalization, artificial intelligence, and innovative materials, this traditional field is developing into a crucial enabler for the competitiveness and sustainability of the entire industry.
The economic significance of thermal process engineering will continue to increase in the coming years as it provides the key technology for addressing two central challenges: increasing operational efficiency in an increasingly competitive global landscape and implementing the ecological transformation toward a climate-neutral circular economy.
Operational Efficiency
Key to competitiveness in global markets through optimized processes and reduced energy consumption.
Ecological Transformation
Foundation for sustainable processes and products in a climate-neutral circular economy.