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Subject3.OverviewofProcessSynthesis
JavierR.ViguriFuente
CHEMICALENGINEERINGANDINORGANIC
CHEMISTRYDEPARTMENT
UNIVERSITYOFCANTABRIA
javier.viguri@unican.es
License:
CreaNveCommonsBYNCSA3.0
INDEX
1.- Preliminary Process Synthesis
2.- Basic Steps in flowsheet synthesis
- Gathering Information
- Representing Alternatives
- Criteria for Assessing preliminary design
3.- Generation of flowsheets
- Hierarchical decomposition
- Process Integration and Intensification
Case Study: application of hierarchical decomposition
- Superstructure optimization
* Examples: HEN, Distillation, Waste treatment network
Raw materials
PROCESS
FLOWSHEET ?
Desired Product
- Process
Operations:
task
- Eliminate differences
In molecular types
- Chemical reaction
- Mixing
-Eliminate differences in
composition
- Separation
- Eliminate differences in
T, P and phase
- T, P, phase change
- Integrate task
- Unit operations
Feasible
Solutions
(Suboptimal)
Li, H., Marechal, F., Burer,
M., Favrat, D., 2006, Multiobjective optimization of an
advanced combined cycle
power plant including CO2
separation options. Energy
31, 31173134
Unfeasible
Solutions
(Impossible)
Pareto
Optimal
Frontier
- Hierarchical Decomposition:
- Successive Refinement.
- Tends to ignore some strong interactions between the
levels
- Obtaining flowsheets to apply optimization
- Superstructure optimization:
- Optimize superflowsheet that contains all alternatives
- Interactions between levels can be considered
systematically (with more powerful strategies).
9
10
Level 1
Level 2
Level 3
Level 4
Level 5
BatchContinuous
Input-output
structure
Recycle
structure
Separation
Synthesis
Heat Recovery
Product
* Due to he interaction of several process steps in one apparatus (system), the steadystate and the dynamic operating behavior of integrated process unit (system) is much
more complex than the behahvior of single, non-integrated units (systems).
Examples:
- Heat and Power Integration;
F
e
e
d
Level 1
BatchContinuo
us
Level 2
Inputoutput
structure
Level 3
Recycle
structure
Level 4
Separatio
n
Synthesis
Level 5
Produc
t
Heat
Recovery
Examples:
- Equipments: heat exchanger in the form of the printed circuit/diffusion bonded unit; microchannel heat
exchangers; structured packed columns; heat exchange reactor; supersonic gas liquid reactor.
- Methodologies: reactive distillation, reactive extraction, membrane separations, oscillating flows in reactors,
membrane reactions, fuel cells. Use of ultrasound, microwave, centrifugal fields, supercritical fluids.
- Industrial applications: Small intensely stirred reactors and microchannel reactors in Organic Nitration
(nitroglycerine); isothermal reactor crystallizer in Phosphoric acid; single equipment to coagulation of latex,
washing, extrusion, dewatering and drying in styrene-butadiene rubber. Methyl isocyanate (MIC-Bhopal
accident) generated and immediately converted to final pesticide in process with a total inventory <10 kg MIC.
12
13
Example 1: Heat exchange of H1 with C1, C2, C3 and H1, H2 with C1, C2
Superstructure
(Floudas et al.,1986)
STAGE 1
STAGE 2
H1-C1
H1-C1
H1-CU
H1
C1-HU
Superstructure
H1-C2
H1-C2
C1
C2
H2-C1
H2-C1
C2-HU
H2-CU
H2
H2-C2
H2-C2
15
Sp
S
MbI
MbO
MbB
Wastewater 1
Sw1
MbH
SpH
HM.
BATs
MbB
MbI
Wastewater 2
MbI
MbO
Sw2
Inorg.
BATs
SpI
MbO
Final
wasterwater
to discharge
MbB
Final Mixer
MbO
Wastewater 3
Org.
BATs
Sw3
SpO
MbB
Biorg.
BATs
MbB
SpB
16
Sw1
MbS
Solid
BATs
Sp
S
MbH
SpH
HM.
BATs
Sw2
Final
Mixer
MbI
Sw3
Inorg.
BATs
Sp
I
17
Superstructure
(Biegler et al.,1997)
18