An overview of process systems engineering approaches for process intensification: State of the art

Tian, Yuhe; Demirel, Salih Emre; Hasan, M. M. Faruque; Pistikopoulos, Efstratios N.

doi:10.1016/j.cep.2018.07.014

Title: An overview of process systems engineering approaches for process intensification: State of the art

Abstract

Process intensification offers the potential to drastically reduce the energy consumption and cost of producing chemicals from both bulk and distributed feedstocks. This review article aims to offer an extensive survey on state-of-the-art process systems engineering (PSE) approaches for process intensification. From both academic and industrial perspectives, this paper provides an overview of the development of various process intensification technologies, specifically those under the categories of separation, reaction, hybrid reaction/separation, and alternative energy sources. A current status analysis in the areas of modeling and simulation is then provided. An indicative list of PSE publications specialized on process intensification is presented to illustrate the progresses made so far towards the deployment of novel process intensification technologies. We also highlight some recent advances for the modeling, design, and synthesis of intensified systems, as well as for the assessment of their controllability/operability/safety performance. As a result, key open questions in these areas include: (i) how to systematically derive intensified designs, and (ii) how to ensure the operability and optimality of the derived intensified structures while delivering their expected functionality.

Authors:

Tian, Yuhe ^[1]; Demirel, Salih Emre ^[1]; Hasan, M. M. Faruque ^[1]; Pistikopoulos, Efstratios N. ^[1]

Texas A & M Univ., College Station, TX (United States)

Publication Date:: Wed Aug 22 00:00:00 EDT 2018

Research Org.:: RAPID Manufacturing Institute, New York, NY (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office; National Science Foundation (NSF)

OSTI Identifier:: 1642446

Grant/Contract Number:: EE0007888; CBET-1606027; CBET-1705423

Resource Type:: Accepted Manuscript

Journal Name:: Chemical Engineering and Processing

Additional Journal Information:: Journal Volume: 133; Journal Issue: C; Journal ID: ISSN 0255-2701

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 42 ENGINEERING; Process intensification; Process systems engineering; Process synthesis; Process optimization; Process operability

Citation Formats


                    Tian, Yuhe, Demirel, Salih Emre, Hasan, M. M. Faruque, and Pistikopoulos, Efstratios N. An overview of process systems engineering approaches for process intensification: State of the art.  United States: N. p., 2018. 
Web.  doi:10.1016/j.cep.2018.07.014.

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                    Tian, Yuhe, Demirel, Salih Emre, Hasan, M. M. Faruque, & Pistikopoulos, Efstratios N. An overview of process systems engineering approaches for process intensification: State of the art.  United States.  https://doi.org/10.1016/j.cep.2018.07.014

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                    Tian, Yuhe, Demirel, Salih Emre, Hasan, M. M. Faruque, and Pistikopoulos, Efstratios N. Wed .  
"An overview of process systems engineering approaches for process intensification: State of the art".  United States.  https://doi.org/10.1016/j.cep.2018.07.014.  https://www.osti.gov/servlets/purl/1642446.

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@article{osti_1642446,

  title        = {An overview of process systems engineering approaches for process intensification: State of the art},

  author       = {Tian, Yuhe and Demirel, Salih Emre and Hasan, M. M. Faruque and Pistikopoulos, Efstratios N.},

  abstractNote = {Process intensification offers the potential to drastically reduce the energy consumption and cost of producing chemicals from both bulk and distributed feedstocks. This review article aims to offer an extensive survey on state-of-the-art process systems engineering (PSE) approaches for process intensification. From both academic and industrial perspectives, this paper provides an overview of the development of various process intensification technologies, specifically those under the categories of separation, reaction, hybrid reaction/separation, and alternative energy sources. A current status analysis in the areas of modeling and simulation is then provided. An indicative list of PSE publications specialized on process intensification is presented to illustrate the progresses made so far towards the deployment of novel process intensification technologies. We also highlight some recent advances for the modeling, design, and synthesis of intensified systems, as well as for the assessment of their controllability/operability/safety performance. As a result, key open questions in these areas include: (i) how to systematically derive intensified designs, and (ii) how to ensure the operability and optimality of the derived intensified structures while delivering their expected functionality.},

  doi          = {10.1016/j.cep.2018.07.014},

  journal      = {Chemical Engineering and Processing},

  number       = C,

  volume       = 133,

  place        = {United States},

  year         = {Wed Aug 22 00:00:00 EDT 2018},

  month        = {Wed Aug 22 00:00:00 EDT 2018}

}

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Figure 1: Number of research articles from modeling and simulation perspective on seven process intensification technologies

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Works referencing / citing this record:

Integrating superstructure‐based design of molecules, processes, and flowsheets
journal, January 2020

Schilling, Johannes; Horend, Christian; Bardow, André
AIChE Journal, Vol. 66, Issue 5
DOI: 10.1002/aic.16903

Modern Modeling Paradigms Using Generalized Disjunctive Programming
journal, November 2019

Chen, Qi; Grossmann, Ignacio
Processes, Vol. 7, Issue 11
DOI: 10.3390/pr7110839

Building Block-Based Synthesis and Intensification of Work-Heat Exchanger Networks (WHENS)
journal, January 2019

Li, Jianping; Demirel, Salih Emre; Hasan, M. M. Faruque
Processes, Vol. 7, Issue 1
DOI: 10.3390/pr7010023

Design of Extractive Reaction Systems
journal, October 2019

Rathgeb, Andrea; Palmtag, Andreas; Kaminski, Sebastian
Chemie Ingenieur Technik, Vol. 91, Issue 12
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Chemical engineering role in the use of renewable energy and alternative carbon sources in chemical production
journal, February 2019

Centi, Gabriele; Iaquaniello, Gaetano; Perathoner, Siglinda
BMC Chemical Engineering, Vol. 1, Issue 1
DOI: 10.1186/s42480-019-0006-8

The role of kinetics and heat transfer on the performance of an industrial wall‐cooled packed‐bed reactor: Oxidative dehydrogenation of ethane
journal, December 2019

Che‐Galicia, Gamaliel; López‐Isunza, Felipe; Corona‐Jiménez, Edith
AIChE Journal, Vol. 66, Issue 4
DOI: 10.1002/aic.16900

Intensification of Catalytic Processes through the Pellet Structuring: Steady-State Properties of a Bifunctional Catalyst Pellet Applied to Generic Chemical Reactions and the Direct Synthesis of DME
journal, December 2019

Bizon, Katarzyna; Skrzypek-Markiewicz, Krzysztof; Pędzich, Dominik
Catalysts, Vol. 9, Issue 12
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Towards the Grand Unification of Process Design, Scheduling, and Control—Utopia or Reality?
journal, July 2019

Burnak, Baris; Diangelakis, Nikolaos A.; Pistikopoulos, Efstratios N.
Processes, Vol. 7, Issue 7
DOI: 10.3390/pr7070461

Design of Extractive Reaction Systems
text, January 2019

Rathgeb, Andrea Melanie; Palmtag, Andreas; Kaminski, Sebastian
RWTH Aachen University
DOI: 10.18154/rwth-2019-10051

Integrating superstructure‐based design of molecules, processes, and flowsheets
text, January 2020

Schilling, Johannes; Horend, Christian; Bardow, André
RWTH Aachen University
DOI: 10.18154/rwth-2020-01442

Figures / Tables found in this record:

Table 14 (Continued) (p. 114)

Table 21 (Continued) (p. 125)

Table 21 (Continued) (p. 126)

Table 22 (p. 128)

Table 23 (p. 129)

Figures/Tables have been extracted from DOE-funded journal article accepted manuscripts.

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Title: An overview of process systems engineering approaches for process intensification: State of the art

Abstract

Citation Formats

Figures / Tables:

Structure, Energy, Synergy, TimeThe Fundamentals of Process Intensification journal, March 2009

An industrial view of process intensification journal, January 2009

Heterogeneous Catalytic Distillation - A Patent Review journal, November 2010

Process intensification: A perspective on process synthesis journal, June 2010

Process intensification: New understanding and systematic approach journal, March 2012

Phenomena-based modularisation of chemical process models to approach intensive options journal, January 2008

Novel applications of dividing-wall column technology to biofuel production processes: Applications of dividing-wall column technology to biofuel production journal, June 2013

Static Mixers in the Process Industries—A Review journal, August 2003

Reactive distillation: The front-runner of industrial process intensification journal, September 2007

Dividing wall columns in chemical process industry: A review on current activities journal, August 2011

Process intensification in the petrochemicals industry: Drivers and hurdles for commercial implementation journal, January 2010

Process Intensification journal, April 2002

Reactive separations for process intensification: an industrial perspective journal, March 2003

Green Chemical Engineering Aspects of Reactive Distillation journal, December 2003

Process Intensification journal, March 2005

In the frame of globalization and sustainability, process intensification, a path to the future of chemical and process engineering (molecules into money) journal, November 2007

The role of process intensification in cutting greenhouse gas emissions journal, November 2008

Process intensification and process systems engineering: A friendly symbiosis journal, January 2008

Towards a methodology for the systematic analysis and design of efficient chemical processes journal, November 2008

Modular Chemical Process Intensification: A Review journal, June 2017

Cavitational reactors for process intensification of chemical processing applications: A critical review journal, April 2008

Microwave and ultrasonic processing: Now a realistic option for industry journal, September 2010

Intensification of biodiesel production via ultrasonic-assisted process: A critical review on fundamentals and recent development journal, September 2012

A review on intensification of synthesis of biodiesel from sustainable feed stock using sonochemical reactors journal, March 2012

Intensification of Enzymatic Hydrolysis of Lignocellulose Using Ultrasound for Efficient Bioethanol Production: A Review journal, August 2013

Simulation of the spatial distribution of the acoustic pressure in sonochemical reactors with numerical methods: A review journal, May 2014

Enabling technologies built on a sonochemical platform: Challenges and opportunities journal, July 2015

A review of engineering aspects of intensification of chemical synthesis using ultrasound journal, May 2017

Intensification of desorption processes by use of microwaves—An overview of possible applications and industrial perspectives journal, January 2009

Microwave energy potential for biodiesel production journal, January 2013

A review on combustion synthesis intensification by means of microwave energy journal, September 2013

Integrated design of microwave and photocatalytic reactors. Where are we now? journal, August 2014

Energy, catalyst and reactor considerations for (near)-industrial plasma processing and learning for nitrogen-fixation reactions journal, August 2013

Biodiesel production through non-catalytic supercritical transesterification: current state and perspectives journal, June 2014

A review of ionic liquids towards supercritical fluid applications journal, November 2007

Integrated fuel processors for fuel cell application: A review journal, January 2007

Seven chemical separations to change the world journal, April 2016

Equipment improvement trends in distillation journal, June 2009

Design and Optimization of Fully Thermally Coupled Distillation Columns journal, October 2001

Dividing wall column—A breakthrough towards sustainable distilling journal, June 2010

Distillation technology - still young and full of breakthrough opportunities: Distillation technology journal, December 2013

Enhanced bioethanol dehydration by extractive and azeotropic distillation in dividing-wall columns journal, February 2012

Dividing wall columns: Fundamentals and recent advances journal, February 2010

Conceptual Design of Highly Integrated Processes - Optimization of Dividing Wall Columns journal, February 2017

Review of Retrofitting Distillation Columns Using Thermally Coupled Distillation Sequences and Dividing Wall Columns to Improve Energy Efficiency journal, January 2014

A control perspective on process intensification in dividing-wall columns journal, March 2011

Hydraulic design, technical challenges and comparison of alternative configurations of a four-product dividing wall column journal, October 2014

A cost-effective retrofit of conventional distillation sequence to dividing-wall prefractionator configuration journal, February 2018

Reactive DWC leading the way to FAME and fortune journal, May 2012

Membrane Distillation and Related Operations—A Review journal, January 2005

Membrane engineering in process intensification—An overview journal, September 2011

Fouling in membrane bioreactors used in wastewater treatment journal, November 2006

Scaling and fouling in membrane distillation for desalination applications: A review journal, January 2015

Fouling and its control in membrane distillation—A review journal, February 2015

Membrane Gas Separation: A Review/State of the Art journal, May 2009

Membrane Materials for Addressing Energy and Environmental Challenges journal, July 2012

State-of-the-art of reverse osmosis desalination journal, October 2007

Thermodynamics of hyperfiltration (reverse osmosis): criteria for efficient membranes journal, December 1966

Reverse osmosis desalination: Water sources, technology, and today's challenges journal, May 2009

A review of reverse osmosis membrane materials for desalination—Development to date and future potential journal, March 2011

Pervaporation and vacuum membrane distillation processes: Modeling and experiments journal, January 2004

A framework for better understanding membrane distillation separation process journal, November 2006

Conceptual Design of Distillation-Based Hybrid Separation Processes journal, June 2013

Membrane distillation: Recent developments and perspectives journal, January 2015

Reactive and membrane-assisted distillation: Recent developments and perspective journal, October 2013

Pervaporation and Vapor Permeation Tutorial: Membrane Processes for the Selective Separation of Liquid and Vapor Mixtures journal, January 2013

Pervaporation-based hybrid process: a review of process design, applications and economics journal, February 1999

Preparation of poly(vinyl alcohol)-sodium alginate hollow-fiber composite membranes and pervaporation dehydration characterization of aqueous alcohol mixtures journal, May 2006

Recent membrane development for pervaporation processes journal, June 2016

Membrane chromatography - an integrative concept in the downstream processing of proteins journal, July 1995

Review: Purification of proteins by membrane chromatography journal, February 1998

State-of-the-art review on hollow fibre contactor technology and membrane-based extraction processes journal, March 2013

Non-dispersive absorption for CO2 capture: from the laboratory to industry journal, March 2011

Membrane Contactors in Industrial Applications journal, March 2005

Robust Control of a Pressure Swing Adsorption Process journal, January 2011

Applications of Pressure Swing Adsorption Technology journal, July 2005

Structure, Energy, Synergy, TimeThe Fundamentals of Process Intensification
journal, March 2009

An industrial view of process intensification
journal, January 2009

Heterogeneous Catalytic Distillation - A Patent Review
journal, November 2010

Process intensification: A perspective on process synthesis
journal, June 2010

Process intensification: New understanding and systematic approach
journal, March 2012

Phenomena-based modularisation of chemical process models to approach intensive options
journal, January 2008

Novel applications of dividing-wall column technology to biofuel production processes: Applications of dividing-wall column technology to biofuel production
journal, June 2013

Static Mixers in the Process Industries—A Review
journal, August 2003

Reactive distillation: The front-runner of industrial process intensification
journal, September 2007

Dividing wall columns in chemical process industry: A review on current activities
journal, August 2011

Process intensification in the petrochemicals industry: Drivers and hurdles for commercial implementation
journal, January 2010

Process Intensification
journal, April 2002

Reactive separations for process intensification: an industrial perspective
journal, March 2003

Green Chemical Engineering Aspects of Reactive Distillation
journal, December 2003

Process Intensification
journal, March 2005

In the frame of globalization and sustainability, process intensification, a path to the future of chemical and process engineering (molecules into money)
journal, November 2007

The role of process intensification in cutting greenhouse gas emissions
journal, November 2008

Process intensification and process systems engineering: A friendly symbiosis
journal, January 2008

Towards a methodology for the systematic analysis and design of efficient chemical processes
journal, November 2008

Modular Chemical Process Intensification: A Review
journal, June 2017

Cavitational reactors for process intensification of chemical processing applications: A critical review
journal, April 2008

Microwave and ultrasonic processing: Now a realistic option for industry
journal, September 2010

Intensification of biodiesel production via ultrasonic-assisted process: A critical review on fundamentals and recent development
journal, September 2012

A review on intensification of synthesis of biodiesel from sustainable feed stock using sonochemical reactors
journal, March 2012

Intensification of Enzymatic Hydrolysis of Lignocellulose Using Ultrasound for Efficient Bioethanol Production: A Review
journal, August 2013

Simulation of the spatial distribution of the acoustic pressure in sonochemical reactors with numerical methods: A review
journal, May 2014

Enabling technologies built on a sonochemical platform: Challenges and opportunities
journal, July 2015

A review of engineering aspects of intensification of chemical synthesis using ultrasound
journal, May 2017

Intensification of desorption processes by use of microwaves—An overview of possible applications and industrial perspectives
journal, January 2009

Microwave energy potential for biodiesel production
journal, January 2013

A review on combustion synthesis intensification by means of microwave energy
journal, September 2013

Integrated design of microwave and photocatalytic reactors. Where are we now?
journal, August 2014

Energy, catalyst and reactor considerations for (near)-industrial plasma processing and learning for nitrogen-fixation reactions
journal, August 2013

Biodiesel production through non-catalytic supercritical transesterification: current state and perspectives
journal, June 2014

A review of ionic liquids towards supercritical fluid applications
journal, November 2007

Integrated fuel processors for fuel cell application: A review
journal, January 2007

Seven chemical separations to change the world
journal, April 2016

Equipment improvement trends in distillation
journal, June 2009

Design and Optimization of Fully Thermally Coupled Distillation Columns
journal, October 2001

Dividing wall column—A breakthrough towards sustainable distilling
journal, June 2010

Distillation technology - still young and full of breakthrough opportunities: Distillation technology
journal, December 2013

Enhanced bioethanol dehydration by extractive and azeotropic distillation in dividing-wall columns
journal, February 2012

Dividing wall columns: Fundamentals and recent advances
journal, February 2010

Conceptual Design of Highly Integrated Processes - Optimization of Dividing Wall Columns
journal, February 2017

Review of Retrofitting Distillation Columns Using Thermally Coupled Distillation Sequences and Dividing Wall Columns to Improve Energy Efficiency
journal, January 2014

A control perspective on process intensification in dividing-wall columns
journal, March 2011

Hydraulic design, technical challenges and comparison of alternative configurations of a four-product dividing wall column
journal, October 2014

A cost-effective retrofit of conventional distillation sequence to dividing-wall prefractionator configuration
journal, February 2018

Reactive DWC leading the way to FAME and fortune
journal, May 2012

Membrane Distillation and Related Operations—A Review
journal, January 2005

Membrane engineering in process intensification—An overview
journal, September 2011

Fouling in membrane bioreactors used in wastewater treatment
journal, November 2006

Scaling and fouling in membrane distillation for desalination applications: A review
journal, January 2015

Fouling and its control in membrane distillation—A review
journal, February 2015

Membrane Gas Separation: A Review/State of the Art
journal, May 2009

Membrane Materials for Addressing Energy and Environmental Challenges
journal, July 2012

State-of-the-art of reverse osmosis desalination
journal, October 2007

Thermodynamics of hyperfiltration (reverse osmosis): criteria for efficient membranes
journal, December 1966

Reverse osmosis desalination: Water sources, technology, and today's challenges
journal, May 2009

A review of reverse osmosis membrane materials for desalination—Development to date and future potential
journal, March 2011

Pervaporation and vacuum membrane distillation processes: Modeling and experiments
journal, January 2004

A framework for better understanding membrane distillation separation process
journal, November 2006

Conceptual Design of Distillation-Based Hybrid Separation Processes
journal, June 2013

Membrane distillation: Recent developments and perspectives
journal, January 2015

Reactive and membrane-assisted distillation: Recent developments and perspective
journal, October 2013

Pervaporation and Vapor Permeation Tutorial: Membrane Processes for the Selective Separation of Liquid and Vapor Mixtures
journal, January 2013

Pervaporation-based hybrid process: a review of process design, applications and economics
journal, February 1999

Preparation of poly(vinyl alcohol)-sodium alginate hollow-fiber composite membranes and pervaporation dehydration characterization of aqueous alcohol mixtures
journal, May 2006

Recent membrane development for pervaporation processes
journal, June 2016

Membrane chromatography - an integrative concept in the downstream processing of proteins
journal, July 1995

Review: Purification of proteins by membrane chromatography
journal, February 1998

State-of-the-art review on hollow fibre contactor technology and membrane-based extraction processes
journal, March 2013

Non-dispersive absorption for CO2 capture: from the laboratory to industry
journal, March 2011

Membrane Contactors in Industrial Applications
journal, March 2005

Robust Control of a Pressure Swing Adsorption Process
journal, January 2011

Applications of Pressure Swing Adsorption Technology
journal, July 2005

Optimization of a Pressure-Swing Adsorption Process Using Zeolite 13X for CO ₂ Sequestration
journal, January 2003

Optimization of Pressure Swing Adsorption and Fractionated Vacuum Pressure Swing Adsorption Processes for CO ₂ Capture
journal, October 2005

Optimization and Control of Pressure Swing Adsorption Processes Under Uncertainty
journal, March 2012

Methane Separation from Coal Mine Methane Gas by Vacuum Pressure Swing Adsorption
journal, April 2003