Autonomous Hydrodistillation with a Digital Twin for Efficient and Climate Neutral Manufacturing of Phytochemicals

Abstract

Hydrodistillation is traditionally a green technology for the manufacturing of natural products that are volatile. As well as acknowledged process intensification methods such as microwave support for energy efficiency to move towards climate neutral operation, digital twins combined with process analytical technology for advanced process control enables reliable operation of an optimal operation point regarding lowest cost of goods, as well as lowest global warming potential equivalent. A novel process control enabled by digital twin technology has shown to reduce the ecological footprint of the extraction by up to 46.5%, while reducing the cost of extraction by 22.4%. Additionally, skilled operator time is reduced, and the sustainable plant material is utilized most efficiently. The approach is ready to apply, but broad industrialization seems to be held back by unclear business cases and lack of comprehension of decision makers. This is in drastic contrast to the political demand for climate neutrality goals and the cost pressure by worldwide completion.