(177d) A Framework for Synthesis of Operable Process Intensification Systems

To survive the competitive global market with increasing concerns on environmental risk and resource shortage, the chemical process industry is actively seeking new ways to boost process and energy efficiency, enhance process flexibility and safety, while reducing waste and emissions. Process intensification (PI) has been identified as a promising means to address these challenges by embracing innovative process solutions which may be out of the box of current industrial practice [1,2]. Efforts have also been made from process systems engineering perspective to provide systematic approaches and tools for PI design, optimization, and operational analysis [3-5]. One representative example is the phenomena-based synthesis [6-8] which enables flexible and synergistic integration of multi-functional physicochemical phenomena paving the way to systematically discover intensified process alternatives.

However, several major gaps remain unresolved and hinder the advancing of computer-aided process intensification. These include but not limited to: (i) lack of theoretical understanding of intensified systems, e.g. the synergy between different phenomena, the intensification potential vs thermodynamic/kinetic-based ultimate bounds; (ii) lack of physically and computationally compact phenomena-based representation approach which enables efficient screening of the resulting combinatorial design space; and (iii) lack of a generally accepted methodology to integrate PI synthesis with operability, inherent safety, and controllability at early design stage.

In this work (as part of RAPID SYNOPSIS and COMPLETE Projects [9,10]), we propose a holistic framework to deliver optimal and operable PI systems by synergizing steady-state phenomena-based design, operability analysis, and dynamic operational optimization. Within this framework, we will also explore some of the answers towards a fundamental theory for PI. The basis of this framework lies in the Generalized Modular Representation Framework [11], which is a phenomena-based synthesis strategy using compact modular building blocks to represent chemical processes. The Gibbs free energy-based driving force constraints formulation will be discussed in detail, which theoretically empower the design of intensified systems towards the ultimate bounds identified by attainable region theory [12]. We will also highlight the conjunctive and distinct thermodynamic basis of GMF driving force constraints with other driving force approaches in open literature [13]. Given the optimal design solutions generated via GMF, the other key components of the proposed framework include: (i) an integrated GMF-Flexibility-Safety synthesis strategy [14] to synthesize process designs with desired inherent safety performance and feasible operation under uncertainty; (ii) explicit model predive control via the PAROC framework to ensure dynamic operation under disturbances [15]; and (iii) simultaneous design and control optimization to close the loop by minimizing total annualized cost while maintaining desired operability and inherent safety performances [16]. A case study on methyl tert-butyl ether production will be presented to demonstrate the full framework on delivering intensified and operable reactive separation systems. Multiple process solutions are generated with different design structures as a result of the cost and operability tradeoffs.

References

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9. SYNOPSIS – Synthesis of Operable Process Intensification Systems. AIChE RAPID Institute Research & Development Project (DE-EE0007888-09-03). Principle Investigator: Pistikopoulos, E. N.
10. COMPLETE – Computer-aided, Model-based Process Intensification Learning, Training, and Education. AIChE RAPID Institute Education & Workforce Development Project. Principle Investigator: Hasan., M. M. F.
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