A Computer-Aided Platform for Simultaneous Process Synthesis and Intensification

Recent advances in gas-to-liquids process intensification with emphasis on reactive distillation

Integrated Process and Controller Design Software Tool – ProCACD

Integration of life cycle assessment software with tools for economic and sustainability analyses and process simulation for sustainable process design

Computer tool supported process design methodology

The objective of this research project is the development of a second generation in-duct sorbent injection technology as a cost-effective compliance option for the 1990 Clean Air Act Amendments. Research focused on the Advanced Coolside Process, which has shown the potential of exceeding the performance targets of 90% SO{sub 2} removal and 60% sorbent utilization. In Task 5, Conceptual Process Design and Economic Evaluation, the economics of the CONSOL Advanced Coolside Process as a Clean Air Act compliance option were evaluated. A conceptual process design for full-scale, coal-fired applications is described. Advanced Coolside is compared to conventional Limestone Forced Oxidation (LSFO) wet FGD technology. The process economics for coal sulfur levels ranging from 1.0% to 3.5% (as-received) and plant sizes ranging from 160 to 512 gross MW were investigated, In addition, the economics of on-site versus off-site lime hydration and the cost sensitivity to delivered pebble lime and hydrate prices are investigated, Advanced in-duct sorbent injection enjoys a capital and levelized cost advantage relative to LSFO in all cases examined in this study. As a result of this study and others made during this contract, the following conclusions can be made: (1) The capital cost of Advanced Coolside is 55% to 60% less than that of LSFO and varies slightly depending on coal sulfur content and plant size. (2) The total levelized SO{sub 2} control cost advantage relative to LSFO varies from 15% to 35% over the range of coal sulfur contents and plant sizes evaluated. This cost advantage is sensitive to sorbent transportation charges. As a result, the economics are site-specific. (3) The experimental optimizations based on interim economic analyses were the key to capital and levelized cost reductions.

In industrial practice, conceptual process design is typically conducted by repetitive simulation studies, which require detailed design specifications in an early design phase. Guided by heuristics, these iterative solution procedures result in high manual effort and, in addition, no guarantee concerning the quality of the solution can be given. Optimization-based design methods provide a tremendous potential to accelerate and improve conceptual process design. For this purpose, a synthesis framework for the optimization-based design of chemical processes is presented in this thesis. Powerful shortcut and rigorous evaluation methods for reaction and distillation are presented. These methods are computationally efficient in order to allow an optimization-based design of large-scale chemical processes. Various industrial case studies illustrate the application of the novel approaches and highlight their benefits. ...

This paper presents the design of multi-stage drawing process and tooling aided by finite element analysis (FEA) for fabrication of a miniature sheet metal component, made of a cold-reduced carbon steel material (SPCC). To design such a tooling, it is essential to figure out how many intermediate drawing steps are needed to produce the final part without deformation defect. First of all, a four-stage drawing process and a set of four-station tooling are designed. This pre-designed process is then analyzed by simulation, and the deformation behavior and formability in each stage is revealed. Based on the revealed deformation behavior and formability, the design of the process and tooling is confirmed. The reasonable drawing ratio and drawing depth in each drawing operation are determined. The size, clearance, and the corner radii of punch and die in each stage are also identified. The designed process and tooling are finally implemented. Through experiment, the “right design in the first time” is realized, and the simulation and experiment are found to have a good agreement. The research further demonstrates that the FEA simulation can be used as an effective tool to aid the design of metal-formed component, tooling, and process in upfront design process.

Process synthesis and design methods for process intensification

Process synthesis and simulation strategies for integrated biochemical process design

With the extensive development of new technologies and the application of information in the manufacturing industry, immense volumes of distinct data are being generated and collected daily. However, this data is largely unusable as its not meticulously cleaned and processed. The effective utilization of such complex data is the cornerstone of data analytics, as successful analysis leads to useful, relevant, and actionable knowledge, which in the long run can prove to be revolutionary for any field and open new avenues. Although the application of data analytics in areas such as sales & marketing, healthcare, cybersecurity, and climate change is largely prevalent, the implementation of data analysis and its tools for efficient product & process design is an unexplored opportunity with large volumes of data generated by major stakeholders throughout the manufacturing and product-process design activity remaining underutilized. This paper, therefore, defines a novel conceptual framework that applies data analysis to integrated product-process design (IPPD) for weighted data-driven IPPD that amalgamates data generated from multiple streams. Primarily from the user perspective, supply chain network, current & upcoming technological processes, and competitor process and product designs, will be utilized. The proposed framework can be further used to create new products better aligned with customer requirements, enhance the overall quality of the product, improve production efficiency through new technological advancements, support the supply chain network, and give the applicant industry a competitive advantage against its competitors.

This paper proposes a conceptual design tool, based upon inferential design theory. It has been specifically developed for the design of production and operations systems, but its use can be extended to other engineering areas, such as mechanical and structural systems. Inferential design theory and its foundation in the inferential theory of learning are briefly outlined. Both theories are based on the idea of using specialised knowledge operators in learning and design, termed knowledge transmutations and design knowledge transmutations respectively. The 24 transmutations existing in the two theories are outlined, and a further 12 design-specific transmutations are proposed. These have been developed as a result of our research. A conceptual design process is proposed, in which design knowledge transmutations are used. A software tool for design, CREDO, is also described and an example of its use in the generation of design concepts for an after-sales service facility is presented. The conclusions discuss the initial methodological experience of using CREDO to generate design concepts. They are based on the introductory use of CREDO at Technion in Israel for teaching purposes. Directions for further research are also provided.

Towards further internal heat integration in design of reactive distillation columns—Part IV: Application to a high-purity ethylene glycol reactive distillation column

We report on a consultation with a panel of senior technical managers within the European process industries. The outcome of the consultation is that, with known and foreseeable technology, the European industry could remain profitable, and reduce pollution by over 20% within 10 years. This paper reports the tools and technologies that are perceived to be important in achieving low pollution levels economically. Alongside established tools such as process simulation, the study gives priority to less established tools including Computer-Aided Molecular Design (CAMD) and process synthesis. The study places a high priority on a range of established and emerging technologies. These include highly selective catalysts, fuel cells, process intensification, supercritical separation and reaction, solar cells, bulk chemicals from renewables, novel chemicals, design for recycle and processes that are economic on smaller scales.

The synthesis, design, and control of a reactive distillation column for decomposing methyl tertiary butyl ether into isobutylene and methanol are reported in this work. Because the reaction is highly endothermic, it is advantageous to consider cautiously internal heat integration between the reaction and separation operations during process synthesis the and design, thereby necessitating deliberate determination of the feed location and judicious distribution of reactive section along the height of the process (Huang et al. AIChE J. 2006, 52, 2518). Through extensive comparison with a simple process design in which the reactive section is located between the rectifying section and the stripping section, it is demonstrated that a substantial reduction of capital investment and energy consumption can be achieved with this strategy of process development. Process dynamics and operation of the resultant process design were further investigated, and a noticeable improvement was gained in process controllability. The major reason for this improvement can be attributed to the fact that a more synergistic relationship has been evolved between the reaction and separation operations in the pursuit of further internal heat integration during process synthesis and design.

Modeling of ammonium lactate recovery and impurity removal from simulated fermentation broth by nanofiltration