Control and Safety Analysis of Intensified Chemical Processes covers the basic principles of and recent developments in control and safety analysis of intensified chemical processes, ranging from dynamic simulations and safety analysis to the design and control of important processes. The text discusses general methods and tools such as dynamic simulation, control and safety analysis as well as design aspects and analysis of important applications in order to provide scientists and engineers with an understanding of the design, control and safety considerations involved in intensified chemical processes.
Sample topics covered in Control and Safety Analysis of Intensified Chemical Processes include: - Simulation and optimization methods, common programs and simulators for simulation and optimization, and interfacing of simulators and optimizers - Programs/simulators for dynamic simulation and control, tuning of controllers, and popular criteria for control assessment - Control of a hybrid reactive-extractive distillation systems for ternary azeotropic mixtures, reactive distillation in recycle systems, and middle vessel batch distillation with vapor recompression - Safety analysis of intensified processes (e.g. extractive distillation, dividing wall column, dividing wall column with mechanical vapor recompression, and algal biodiesel process)
A comprehensive resource on the subject, Control and Safety Analysis of Intensified Chemical Processes is a highly valuable reference for researchers, students and practitioners interested in process intensification and their applications. The text can be adopted by instructors for use in advanced courses on process control and safety.
Table of Contents
Preface xv
Part I Overview and Background 1
1 Introduction 3
Dipesh Shikchand Patle and Gade Pandu Rangaiah
1.1 Process Intensification 3
1.2 Need for Control and Safety Analysis of Intensified Chemical Processes 5
1.3 Studies on Control and Safety Analysis of Intensified Chemical Processes 7
1.4 Scope and Organization of the Book 9
1.5 Conclusions 12
References 13
2 Applications and Potential of Process Intensification in Chemical Process Industries 15
Chirla C.S. Reddy
2.1 Introduction 15
2.2 Benefits of Process Intensification Techniques 16
2.3 Static Mixers 17
2.4 Process Intensification for Separation Vessels 18
2.5 Process Intensification for Distillation 21
2.6 Process Intensification for Heating 24
2.6.1 Steam Injection Heater 24
2.6.2 Steam/Electric Heaters as a Replacement for Fired Heaters 25
2.6.3 Process Intensification for Flue Gas Heat Recovery 26
2.6.4 Process Heat Exchangers 26
2.6.5 Sonic Horn 27
2.7 Steam Compression 27
2.8 Process Intensification for Carbon Capture 30
2.9 Process Intensification for Vacuum Systems 31
2.10 Process Intensification for Water Deaeration 33
2.11 Process Intensification for Development of Inherently Safer Design (isd) 33
2.12 Process Intensification for Reducing Pressure Relief and Handling Requirements 35
2.12.1 Non-safety Instrumented Solutions for Pressure Relief Systems 37
2.12.2 Safety Instrumented System (SIS) Solutions for Reducing Pressure Relief Requirements 39
2.13 Process Intensification for Wastewater Recovery 41
2.14 Challenges of Process Intensification Techniques 43
2.15 Conclusions 44
References 45
Part II Procedures and Software for Simulation, Control and Safety Analysis 47
3 Simulation and Optimization of Intensified Chemical Processes 49
Zemin Feng and Gade Pandu Rangaiah
3.1 Introduction 49
3.2 Simulation of Chemical Processes 50
3.2.1 Usefulness of Process Simulation 50
3.2.2 Commercial Process Simulators 52
3.2.3 Free Process Simulators 53
3.2.4 Computational Methods for Process Simulation 53
3.3 Procedure for Simulation of (Intensified) Chemical Processes 56
3.3.1 Problem Analysis 56
3.3.2 Basic Process Flow Design 57
3.3.3 Process Intensification and Integration 57
3.3.4 Model Construction 57
3.3.5 Simulation and Convergence 59
3.3.6 Results Analysis 59
3.4 Optimization of (Intensified) Chemical Processes 59
3.4.1 Mathematical Optimization Methods 59
3.4.2 Optimization of Chemical Processes with a Process Simulator 62
3.4.2.1 Optimization Using MATLAB 62
3.4.2.2 Optimization Using Python 63
3.5 Challenges in the Simulation/Optimization of Intensified Chemical Processes 65
3.6 Case Study 66
3.6.1 Problem Analysis 66
3.6.2 Process Flow Design 67
3.6.3 Model Construction 69
3.6.4 Simulation and Convergence 70
3.6.4.1 Process Simulation 70
3.6.4.2 Economic Evaluation Criterion 71
3.6.4.3 Process Optimization 73
3.6.5 Results and Analysis 75
3.7 Conclusions 78
References 79
4 Dynamic Simulation and Control of Intensified Chemical Processes 83
Zemin Feng and Gade Pandu Rangaiah
4.1 Introduction 83
4.2 Dynamic Simulation of Chemical Processes 84
4.2.1 Understanding Dynamic Simulation 84
4.2.2 Applications of Dynamic Simulation 87
4.2.3 Dynamic Simulation Software 88
4.3 Dynamic Simulation and Control Procedure 91
4.4 Dynamic Simulation and Control of Intensified Chemical Processes 98
4.4.1 Challenges Due to Process Intensification 100
4.5 Process Control 100
4.5.1 Controlled, Manipulated, and Disturbance Variables 101
4.5.2 Typical Control Loop 101
4.5.3 Control Degrees of Freedom 101
4.6 Case Study 102
4.6.1 Steady-state Simulation and Optimization 103
4.6.2 Preparation/Initialization for Dynamic Simulation 103
4.6.3 Control Structure Design 107
4.6.3.1 Composition Control Scheme 108
4.6.3.2 Temperature Control Scheme 110
4.6.4 Tuning of Controller Parameters 112
4.6.5 Analysis of Dynamic Simulation Results 112
4.7 Conclusions 120
References 121
5 Safety Analysis of Intensified Chemical Processes 125
Masrina Mohd Nadzir, Zainal Ahmad, and Syamsul Rizal Abd Shukor
5.1 Introduction 125
5.2 Safety Analysis in Chemical Process Industry 126
5.2.1 Safety Analysis Tools 128
5.2.1.1 Hazard Identification 128
5.2.1.2 Risk Assessment 130
5.2.1.3 Inherently Safer Design (ISD) 131
5.2.1.4 Safety Instrumented Systems 132
5.2.1.5 Human Factors and Safety Culture 132
5.2.1.6 Regulatory Framework and Compliance 134
5.2.1.7 Monitoring and Continuous Improvement 135
5.3 Process Intensification and Safety Analysis 136
5.3.1 Impacts of Process Intensification on Safety 136
5.3.2 Safety Analysis in Intensified Process Design 137
5.3.2.1 Hazard Identification Techniques for Process Intensification Technologies 138
5.3.2.2 Risk Assessment for Process Intensification Technologies 140
5.3.3 Inherently Safer Design Principles Intensified Processes 141
5.4 Safety Management Systems for Intensified Processes 144
5.5 Safety Training and Competency for Intensified Processes 146
5.5.1 Importance of Safety Training and Competency 146
5.5.2 Developing Safety Training and Competency Programs 147
5.5.3 Utilizing a Blended Learning Approach 148
5.5.4 Assessing Training Effectiveness and Continual Improvement 148
5.5.5 Benefits of Effective Safety Training and Competency Management 148
5.6 Case Studies of Safety Analysis in Intensified Processes 149
5.7 Conclusions 151
References 151
Part III Control and Safety Analysis of Intensified Chemical Processes 155
6 Control of Hybrid Reactive-Extractive Distillation Systems for Ternary Azeotropic Mixtures 157
Zong Yang Kong and Hao-Yeh Lee
6.1 Introduction 157
6.2 Steady-state Design of the RED 160
6.3 Dynamic Simulation Setup 161
6.4 Inventory Control Setup 162
6.5 Sensitivity Analysis 163
6.6 Quality Control Structures 165
6.6.1 Control Structure 1 (CS 1) - Simple Temperature Control 165
6.6.2 Control Structure 2 (CS 2) - Triple Point Temperature Control 168
6.6.3 Control Structure 3 (CS 3) - Triple Point Temperature Control Using SVD Analysis 170
6.6.4 Feedforward Control Structure 3 (FF-CS 3) 172
6.7 Control Performance Evaluation 177
6.8 Conclusions 178
Acknowledgements 179
Acronyms 179
Nomenclature 180
References 180
7 Process Design and Control of Reactive Distillation in Recycle Systems 183
Mihai Daniel Moraru, Costin Sorin Bildea, and Anton Alexandru Kiss
7.1 Introduction 183
7.2 Design of Reactive Distillation Processes 184
7.3 Control of Reactive Distillation Processes 188
7.4 Case Study: RD Coupled with a Distillation-Reactor System and Recycle 192
7.4.1 Basis of Design and Basic Data 192
7.4.2 Process Design 198
7.4.3 Process Control 201
7.4.4 Discussion 204
7.5 Conclusions 204
References 205
8 Dynamics and Control of Middle-vessel Batch Distillation with Vapor Recompression 209
Radhika Gandu, Akash Burolia, Dipesh Shikchand Patle, and Gara Uday Bhaskar Babu
8.1 Introduction 209
8.2 Conventional Middle-vessel Batch Distillation 211
8.2.1 A Systematic Simulation Approach of CMVBD 212
8.2.1.1 Model Equations 213
8.2.2 Constant Composition Control 216
8.3 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 216
8.3.1 A Systematic Simulation Approach of SiVRMVBD 216
8.4 Performance Specifications 218
8.4.1 Energy Savings 218
8.4.2 Total Annual Cost 218
8.4.3 Greenhouse Gas Emissions 219
8.5 Results and Discussion 219
8.5.1 Conventional Middle-vessel Batch Distillation Column 219
8.5.1.1 Dynamic Composition Profiles 219
8.5.2 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 222
8.5.3 Energetic, Economic, and Environmental Performance: CMVBD vs. SiVRMVBD 225
8.5.4 Constant Composition Control 226
8.5.4.1 SiVRMVBD-GSPI 229
8.5.5 Energetic, Economic, and Environmental Performance: CMVBD vs. Controlled CMVBD and SiVRMVBD 232
8.6 Conclusions 234
References 234
9 Safety Analysis of Intensified Distillation Processes Using Existing and Modified Safety Indices 237
Savyasachi Shrikhande, Gunawant K. Deshpande, Gade Pandu Rangaiah, andDipeshShikchandPatle
9.1 Introduction 237
9.2 Safety Indices for Process Safety Assessment 239
9.3 Description of Distillation Systems 241
9.3.1 Conventional Sequence of Columns 241
9.3.2 Dividing-Wall Column 241
9.3.3 Dividing-Wall Column with Mechanical Vapor Recompression 243
9.4 Selection of Safety Indices 244
9.5 Results and Discussion 245
9.5.1 Conventional Sequence of Columns 245
9.5.2 Dividing-Wall Column 251
9.5.3 Dividing-Wall Column with Mechanical Vapor Recompression 253
9.5.4 Comparative Analysis 255
9.6 Survey of Engineers and Discussion of their Responses 257
9.7 Improved PRI 262
9.8 Conclusions 263
Acknowledgments 263
References 264
10 Dynamic Safety Analysis of Intensified Extractive Distillation Processes with Independent Protection Layers 269
Chengtian Cui and Meng Qi
10.1 Introduction 269
10.2 Preliminary 271
10.3 Process Studied 272
10.3.1 Process Intensification Measures 272
10.3.2 Steady-state Process Design 273
10.3.3 Process Intensification Analysis 274
10.4 Dynamics and Control 276
10.4.1 Control Basis 276
10.4.2 Bpcs # 1 279
10.4.3 Bpcs # 2 279
10.4.4 Bpcs # 3 282
10.5 Safety Analysis 284
10.5.1 Process #1 Safety Analysis 285
10.5.2 Process #2 Safety Analysis 286
10.5.3 Process #3 Safety Analysis 288
10.5.4 Dynamic Safety Analysis of Process #3 with IPLs 289
10.6 Conclusions 292
Acknowledgments 293
References 293
11 Operability and Safety Considerations in Intensified Structures for Purification of Bioproducts 295
Juan G. Segovia-Hernández, César Ramírez-Márquez, Gabriel Contreras-Zarazúa, Eduardo Sánchez-Ramírez, and Juan J. Quiroz-Ramírez
11.1 Introduction 295
11.2 Methodology 302
11.2.1 Control Behavior Analysis 306
11.2.1.1 Singular Value Decomposition 306
11.3 Methyl Ethyl Ketone 307
11.3.1 Methyl Ethyl Ketone Production Through a Conventional Process 308
11.3.1.1 MEK Production from Non-renewable Sources 308
11.3.2 Purification of MEK Through Process-Intensified Schemes 308
11.4 Intensification of Alcohol-to-Jet Fuel Process 313
11.4.1 Process Modeling and Optimization 314
11.4.2 Results 316
11.5 New Processes for Furfural and Co-products 318
11.5.1 Results 321
11.6 Lactic Acid 324
11.6.1 Lactic Acid Production by Reactive Distillation 325
11.6.2 Design and Synthesis of Intensified Processes 326
11.6.3 Optimization 326
11.6.4 Results and Discussion 327
11.7 Future and Perspectives 329
11.8 Conclusions 329
Acknowledgments 330
References 330
12 Analysis of Safety and Economic Objectives for Intensified Algal Biodiesel Process 335
Gunavant Deshpande, Ashish N. Sawarkar, and Dipesh Shikchand Patle
12.1 Introduction 335
12.2 Process Development 337
12.2.1 Process Development of Alternative 1 337
12.2.2 Process Development of Alternative 2 340
12.3 Multi-Objective Optimization 342
12.3.1 Objective Functions 344
12.3.1.1 Break-Even Cost 344
12.3.1.2 Individual Risk (IR) 345
12.3.2 Simple Additive Weighting (SAW) Method 347
12.4 Results and Discussion 347
12.4.1 Minimization of BEC and IR for Alternative 1 348
12.4.2 Minimization of BEC and IR for Alternative 2 350
12.5 Comparative Analysis 352
12.6 Conclusions 353
References 354
Index 359
