Electrified process intensification for refining using MW-PROCESS-INTENSIFY

Overview

MW-PROCESS-INTENSIFY™ is an industrial microwave platform for intensifying refining processes through selective dielectric heating. Instead of conventional bulk thermal heating, the technology targets polar compounds such as water and phospholipids directly. This enables accelerated phase separation, reduced chemical usage, and minimized energy consumption. Refining applications include degumming, neutralization, and pre-deodorization, where precise control helps limit thermal degradation and improve energy efficiency. The platform can also be used upstream for cell disruption to increase extraction yields.

Technical specifications

Key features:

• Uses a 915 MHz microwave frequency for deep penetration and efficient heating
• Selectively heats polar impurities while leaving non-polar neutral oil largely unaffected
• Eliminates on-site gas combustion, reducing CO₂ emissions significantly
• Provides energy efficiency of approximately 18 kWh/ton compared to 150 kWh/ton with traditional gas heating
• Reduces fouling and helps preserve valuable compounds such as tocopherols

The platform is implemented with standard industrial components such as magnetrons and stainless steel reactors, supporting reliable and scalable deployment. Engineering documentation is already developed. A 12.5 t/h prototype has been validated, confirming the scientific principles and flow dynamics.

Technology readiness level

The current TRL is 5, supported by successful prototype validation demonstrating fundamental functionality. Plans are in place to build and test a pilot unit at an industrial site, with the goal of elevating the TRL to 6. This will involve integrating the module in a low-risk “bypass” configuration to assess yield, energy efficiency, and quality improvements. Future phases focus on scaling up the technology for full-plant deployment.