Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations

Tian, Yuhe; Pistikopoulos, Efstratios N.

doi:10.1021/acs.iecr.8b04389

Title: Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations

Abstract

In this work, we present an integrated approach to synthesize process intensification systems with guaranteed flexibility and safety performances. The synthesis of intensified equipment/flowsheets is addressed through the Generalized Modular Representation Framework (GMF), which utilizes an aggregation of multifunctional mass/heat exchange modules to represent chemical processes. Thus, the optimal design options are investigated as mass- and heat-transfer opportunities using superstructure-based optimization techniques without a prepostulation of plausible configurations. To ensure that the designs can be operated under a specified range of uncertain parameters, a multiperiod GMF representation is developed based on the critical operating conditions identified by flexibility test. Risk assessment, accounting for equipment failure frequency and consequence severity, is incorporated as a constraint into this synthesis model to derive inherently safer designs. The resulting safely operable intensified systems, which are represented via phenomenological modules, are then identified as corresponding equipment-based flowsheets and validated with steady-state simulation. We demonstrate the proposed approach through a case study for the production of methyl tert-butyl ether. Here, the results indicate that safety and operability considerations can result in significant changes in the structural and operating parameters of the optimal intensified design configuration.

Authors:

Tian, Yuhe ^[1];

^[1]

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

Publication Date:: Fri Dec 21 00:00:00 EST 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

OSTI Identifier:: 1642449

Grant/Contract Number:: EE0007888

Resource Type:: Accepted Manuscript

Journal Name:: Industrial and Engineering Chemistry Research

Additional Journal Information:: Journal Volume: 58; Journal Issue: 15; Journal ID: ISSN 0888-5885

Publisher:: American Chemical Society (ACS)

Country of Publication:: United States

Language:: English

Subject:: 37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY; Physical and chemical processes; Optimization; Separation science; Distillation; Liquids

Citation Formats


                    Tian, Yuhe, and Pistikopoulos, Efstratios N. Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations.  United States: N. p., 2018. 
Web.  doi:10.1021/acs.iecr.8b04389.

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                    Tian, Yuhe, & Pistikopoulos, Efstratios N. Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations.  United States.  https://doi.org/10.1021/acs.iecr.8b04389

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                    Tian, Yuhe, and Pistikopoulos, Efstratios N. Fri .  
"Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations".  United States.  https://doi.org/10.1021/acs.iecr.8b04389.  https://www.osti.gov/servlets/purl/1642449.

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@article{osti_1642449,

  title        = {Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations},

  author       = {Tian, Yuhe and Pistikopoulos, Efstratios N.},

  abstractNote = {In this work, we present an integrated approach to synthesize process intensification systems with guaranteed flexibility and safety performances. The synthesis of intensified equipment/flowsheets is addressed through the Generalized Modular Representation Framework (GMF), which utilizes an aggregation of multifunctional mass/heat exchange modules to represent chemical processes. Thus, the optimal design options are investigated as mass- and heat-transfer opportunities using superstructure-based optimization techniques without a prepostulation of plausible configurations. To ensure that the designs can be operated under a specified range of uncertain parameters, a multiperiod GMF representation is developed based on the critical operating conditions identified by flexibility test. Risk assessment, accounting for equipment failure frequency and consequence severity, is incorporated as a constraint into this synthesis model to derive inherently safer designs. The resulting safely operable intensified systems, which are represented via phenomenological modules, are then identified as corresponding equipment-based flowsheets and validated with steady-state simulation. We demonstrate the proposed approach through a case study for the production of methyl tert-butyl ether. Here, the results indicate that safety and operability considerations can result in significant changes in the structural and operating parameters of the optimal intensified design configuration.},

  doi          = {10.1021/acs.iecr.8b04389},

  journal      = {Industrial and Engineering Chemistry Research},

  number       = 15,

  volume       = 58,

  place        = {United States},

  year         = {Fri Dec 21 00:00:00 EST 2018},

  month        = {Fri Dec 21 00:00:00 EST 2018}

}

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https://doi.org/10.1021/acs.iecr.8b04389

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Cited by: 26 works

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Table 1: Synthesis approaches for process intensification: an indicative list

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Works referenced in this record:

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Demirel, Salih Emre; Li, Jianping; Hasan, M. M. Faruque
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Works referencing / citing this record:

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

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Similar Records

Title: Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations

Abstract

Citation Formats

Figures / Tables:

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

An overview of process systems engineering approaches for process intensification: State of the art journal, November 2018

From process integration to process intensification journal, October 2015

Attainable regions for reaction with separation journal, February 1997

Recent Developments and Challenges in Optimization-Based Process Synthesis journal, June 2017

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

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

Generalized modular representation framework for process synthesis journal, April 1996

Modular representation synthesis framework for homogeneous azeotropic separation journal, August 1999

Modular synthesis framework for combined separation/reaction systems journal, March 2001

Generalized Modular Framework for the Representation and Synthesis of Complex Distillation Column Sequences journal, June 2005

Generalized modular framework for the synthesis of heat integrated distillation column sequences journal, September 2005

Hybrid generalized modular/collocation framework for distillation column synthesis journal, January 2006

A framework for the synthesis of reactive absorption columns journal, April 2006

Infinite DimEnsionAl State-space approach to reactor network synthesis: application to attainable region construction journal, June 2002

IDEAS approach to process network synthesis: Application to multicomponent MEN journal, December 2000

Infinite-Dimensional State-Space (IDEAS) Approach to Globally Optimal Design of Distillation Networks Featuring Heat and Power Integration journal, October 2004

Non-ideal reactor network synthesis through IDEAS: Attainable region construction journal, November 2006

Globally Optimal Networks for Multipressure Distillation of Homogeneous Azeotropic Mixtures journal, August 2012

Infinite DimEnsionAl State-space as a systematic process intensification tool: Energetic intensification of hydrogen production journal, April 2017

Process intensification of reactive separator networks through the IDEAS conceptual framework journal, October 2017

Phenomena Based Methodology for Process Synthesis Incorporating Process Intensification journal, February 2013

A process synthesis-intensification framework for the development of sustainable membrane-based operations journal, December 2014

Sustainable process synthesis–intensification journal, October 2015

Process synthesis, design and analysis using a process-group contribution method journal, October 2015

A computer-aided software-tool for sustainable process synthesis-intensification journal, October 2017

Systematic process intensification using building blocks journal, October 2017

Fuel Gas Network Synthesis Using Block Superstructure journal, March 2018

Process synthesis using block superstructure with automated flowsheet generation and optimization journal, July 2018

Process Integration Using Block Superstructure journal, March 2018

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

Methodology for the Design of Optimal Chemical Reactors Based on the Concept of Elementary Process Functions journal, November 2010

Analysis and optimal design of an ethylene oxide reactor journal, December 2011

Probabilistic reactor design in the framework of elementary process functions journal, November 2016

Reactor-network synthesis via flux profile analysis journal, March 2018

Novel operability-based approach for process design and intensification: Application to a membrane reactor for direct methane aromatization journal, August 2016

An optimization-based operability framework for process design and intensification of modular natural gas utilization systems journal, October 2017

Safety Analysis Embedded in Heat Exchanger Network Synthesis journal, December 2017

Process operational safety using model predictive control based on a process Safeness Index journal, September 2017

Process operational safety via model predictive control: Recent results and future research directions journal, June 2018

Separation of Nonideal Mixtures based on Mass/Heat Exchange Principles. The Entrainer Selection and Sequencing Problem journal, January 1997

Generalized Benders decomposition journal, October 1972

An outer-approximation algorithm for a class of mixed-integer nonlinear programs journal, October 1986

Optimal process design under uncertainty journal, May 1983

An MINLP retrofit approach for improving the flexibility of heat exchanger networks journal, December 1993

Synthesis and Retrofit Design of Operable Heat Exchanger Networks. 1. Flexibility and Structural Controllability Aspects journal, July 1994

A multiperiod MINLP model for the synthesis of flexible heat and mass exchange networks journal, November 1994

Evolution of concepts and models for quantifying resiliency and flexibility of chemical processes journal, November 2014

CCPS guidelines for chemical process quantitative risk analysis journal, October 1990

An Approach for Solvent Selection in Extractive Distillation Systems Including Safety Considerations journal, July 2014

Kinetics of methyl tertiary butyl ether liquid phase synthesis catalyzed by ion exchange resin—I. Intrinsic rate expression in liquid phase activities journal, January 1990

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Why Methyl tert-Butyl Ether Production by Reactive Distillation May Yield Multiple Solutions
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A Hybrid Modelling Approach for Separation Systems Involving Distillation
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Multiple solutions in reactive distillation for methyl tert-butyl ether synthesis
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Methyl-Tert-Butyl-Ether Catalytic Distillation Column
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Process design and control optimization: A simultaneous approach by multi-parametric programming
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The interactions of design control and operability in reactive distillation systems
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Dynamic Disadvantages of Intensification in Inherently Safer Process Design
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