Control and Safety Analysis of Intensified Chemical Processes

Cover
Half Title
Control and Safety Analysis of Intensified Chemical Processes
Copyright
Dedication
Contents
Preface
Part I. Overview and Background
	1. Introduction
		1.1 Process Intensification
		1.2 Need for Control and Safety Analysis of Intensified Chemical Processes
		1.3 Studies on Control and Safety Analysis of Intensified Chemical Processes
		1.4 Scope and Organization of the Book
		1.5 Conclusions
		References
	2. Applications and Potential of Process Intensification in Chemical Process Industries
		2.1 Introduction
		2.2 Benefits of Process Intensification Techniques
		2.3 Static Mixers
		2.4 Process Intensification for Separation Vessels
		2.5 Process Intensification for Distillation
		2.6 Process Intensification for Heating
			2.6.1 Steam Injection Heater
			2.6.2 Steam/Electric Heaters as a Replacement for Fired Heaters
			2.6.3 Process Intensification for Flue Gas Heat Recovery
			2.6.4 Process Heat Exchangers
			2.6.5 Sonic Horn
		2.7 Steam Compression
		2.8 Process Intensification for Carbon Capture
		2.9 Process Intensification for Vacuum Systems
		2.10 Process Intensification for Water Deaeration
		2.11 Process Intensification for Development of Inherently Safer Design (ISD)
		2.12 Process Intensification for Reducing Pressure Relief and Handling Requirements
			2.12.1 Non-safety Instrumented Solutions for Pressure Relief Systems
			2.12.2 Safety Instrumented System (SIS) Solutions for Reducing Pressure Relief Requirements
		2.13 Process Intensification for Wastewater Recovery
		2.14 Challenges of Process Intensification Techniques
		2.15 Conclusions
		Acronyms
		References
Part II. Procedures and Software for Simulation, Control and Safety Analysis
	3. Simulation and Optimization of Intensified Chemical Processes
		3.1 Introduction
		3.2 Simulation of Chemical Processes
			3.2.1 Usefulness of Process Simulation
			3.2.2 Commercial Process Simulators
			3.2.3 Free Process Simulators
			3.2.4 Computational Methods for Process Simulation
		3.3 Procedure for Simulation of (Intensified) Chemical Processes
			3.3.1 Problem Analysis
			3.3.2 Basic Process Flow Design
			3.3.3 Process Intensification and Integration
			3.3.4 Model Construction
			3.3.5 Simulation and Convergence
			3.3.6 Results Analysis
		3.4 Optimization of (Intensified) Chemical Processes
			3.4.1 Mathematical Optimization Methods
			3.4.2 Optimization of Chemical Processes with a Process Simulator
				3.4.2.1 Optimization Using MATLAB
				3.4.2.2 Optimization Using Python
		3.5 Challenges in the Simulation/Optimization of Intensified Chemical Processes
		3.6 Case Study
			3.6.1 Problem Analysis
			3.6.2 Process Flow Design
			3.6.3 Model Construction
			3.6.4 Simulation and Convergence
				3.6.4.1 Process Simulation
				3.6.4.2 Economic Evaluation Criterion
				3.6.4.3 Process Optimization
			3.6.5 Results and Analysis
		3.7 Conclusions
		Acronyms
		References
	4. Dynamic Simulation and Control of Intensified Chemical Processes
		4.1 Introduction
		4.2 Dynamic Simulation of Chemical Processes
			4.2.1 Understanding Dynamic Simulation
			4.2.2 Applications of Dynamic Simulation
			4.2.3 Dynamic Simulation Software
		4.3 Dynamic Simulation and Control Procedure
		4.4 Dynamic Simulation and Control of Intensified Chemical Processes
			4.4.1 Challenges Due to Process Intensification
		4.5 Process Control
			4.5.1 Controlled, Manipulated, and Disturbance Variables
			4.5.2 Typical Control Loop
			4.5.3 Control Degrees of Freedom
		4.6 Case Study
			4.6.1 Steady-state Simulation and Optimization
			4.6.2 Preparation/Initialization for Dynamic Simulation
			4.6.3 Control Structure Design
				4.6.3.1 Composition Control Scheme
				4.6.3.2 Temperature Control Scheme
			4.6.4 Tuning of Controller Parameters
			4.6.5 Analysis of Dynamic Simulation Results
		4.7 Conclusions
		Acronyms
		References
	5. Safety Analysis of Intensified Chemical Processes
		5.1 Introduction
		5.2 Safety Analysis in Chemical Process Industry
			5.2.1 Safety Analysis Tools
				5.2.1.1 Hazard Identification
				5.2.1.2 Risk Assessment
				5.2.1.3 Inherently Safer Design (ISD)
				5.2.1.4 Safety Instrumented Systems
				5.2.1.5 Human Factors and Safety Culture
				5.2.1.6 Regulatory Framework and Compliance
				5.2.1.7 Monitoring and Continuous Improvement
		5.3 Process Intensification and Safety Analysis
			5.3.1 Impacts of Process Intensification on Safety
			5.3.2 Safety Analysis in Intensified Process Design
				5.3.2.1 Hazard Identification Techniques for Process Intensification Technologies
				5.3.2.2 Risk Assessment for Process Intensification Technologies
			5.3.3 Inherently Safer Design Principles Intensified Processes
		5.4 Safety Management Systems for Intensified Processes
		5.5 Safety Training and Competency for Intensified Processes
			5.5.1 Importance of Safety Training and Competency
			5.5.2 Developing Safety Training and Competency Programs
			5.5.3 Utilizing a Blended Learning Approach
			5.5.4 Assessing Training Effectiveness and Continual Improvement
			5.5.5 Benefits of Effective Safety Training and Competency Management
		5.6 Case Studies of Safety Analysis in Intensified Processes
		5.7 Conclusions
		References
Part III. Control and Safety Analysis of Intensified Chemical Processes
	6. Control of Hybrid Reactive–Extractive Distillation Systems for Ternary
		6.1 Introduction
		6.2 Steady-state Design of the RED
		6.3 Dynamic Simulation Setup
		6.4 Inventory Control Setup
		6.5 Sensitivity Analysis
		6.6 Quality Control Structures
			6.6.1 Control Structure 1 (CS 1) – Simple Temperature Control
			6.6.2 Control Structure 2 (CS 2) – Triple Point Temperature Control
			6.6.3 Control Structure 3 (CS 3) – Triple Point Temperature Control Using SVD Analysis
			6.6.4 Feedforward Control Structure 3 (FF-CS 3)
		6.7 Control Performance Evaluation
		Acknowledgements
		Acronyms
		Nomenclature
		References
	7. Process Design and Control of Reactive Distillation in Recycle Systems
		7.1 Introduction
		7.2 Design of Reactive Distillation Processes
		7.3 Control of Reactive Distillation Processes
		7.4 Case Study: RD Coupled with a Distillation–Reactor System and Recycle
			7.4.1 Basis of Design and Basic Data
			7.4.2 Process Design
			7.4.3 Process Control
			7.4.4 Discussion
		References
	8. Dynamics and Control of Middle-vessel Batch Distillation with Vapor Recompression
		8.1 Introduction
		8.2 Conventional Middle-vessel Batch Distillation
			8.2.1 A Systematic Simulation Approach of CMVBD
				8.2.1.1 Model Equations
			8.2.2 Constant Composition Control
		8.3 Single-stage Vapor Recompression in Middle-vessel Batch Distillation
			8.3.1 A Systematic Simulation Approach of SiVRMVBD
		8.4 Performance Specifications
			8.4.1 Energy Savings
			8.4.2 Total Annual Cost
			8.4.3 Greenhouse Gas Emissions
		8.5 Results and Discussion
			8.5.1 Conventional Middle-vessel Batch Distillation Column
				8.5.1.1 Dynamic Composition Profiles
			8.5.2 Single-stage Vapor Recompression in Middle-vessel Batch Distillation
			8.5.3 Energetic, Economic, and Environmental Performance: CMVBD vs. SiVRMVBD
			8.5.4 Constant Composition Control
				8.5.4.1 SiVRMVBD-GSPI
			8.5.5 Energetic, Economic, and Environmental Performance: CMVBD vs. Controlled CMVBD and SiVRMVBD
		8.6 Conclusions
		References
	9. Safety Analysis of Intensified Distillation Processes Using Existing and Modified Safety Indices
		9.1 Introduction
		9.2 Safety Indices for Process Safety Assessment
		9.3 Description of Distillation Systems
			9.3.1 Conventional Sequence of Columns
			9.3.2 Dividing-Wall Column
			9.3.3 Dividing-Wall Column with Mechanical Vapor Recompression
		9.4 Selection of Safety Indices
		9.5 Results and Discussion
			9.5.1 Conventional Sequence of Columns
			9.5.2 Dividing-Wall Column
			9.5.3 Dividing-Wall Column with Mechanical Vapor Recompression
			9.5.4 Comparative Analysis
		9.6 Survey of Engineers and Discussion of their Responses
		9.7 Improved PRI
		9.8 Conclusions
		Acknowledgments
		References
	10. Dynamic Safety Analysis of Intensified Extractive Distillation Processes with Independent Protection Layers
		10.1 Introduction
		10.2 Preliminary
		10.3 Process Studied
			10.3.1 Process Intensification Measures
			10.3.2 Steady-state Process Design
			10.3.3 Process Intensification Analysis
		10.4 Dynamics and Control
			10.4.1 Control Basis
			10.4.2 BPCS #1
			10.4.3 BPCS #2
			10.4.4 BPCS #3
		10.5 Safety Analysis
			10.5.1 Process #1 Safety Analysis
			10.5.2 Process #2 Safety Analysis
			10.5.3 Process #3 Safety Analysis
			10.5.4 Dynamic Safety Analysis of Process #3 with IPLs
		10.6 Conclusions
		Acknowledgments
		References
	11. Operability and Safety Considerations in Intensified Structures for Purification of Bioproducts
		11.1 Introduction
		11.2 Methodology
			11.2.1 Control Behavior Analysis
				11.2.1.1 Singular Value Decomposition
		11.3 Methyl Ethyl Ketone
			11.3.1 Methyl Ethyl Ketone Production Through a Conventional Process
				11.3.1.1 MEK Production from Non-renewable Sources
			11.3.2 Purification of MEK Through Process-Intensified Schemes
		11.4 Intensification of Alcohol-to-Jet Fuel Process
			11.4.1 Process Modeling and Optimization
			11.4.2 Results
		11.5 New Processes for Furfural and Co-products
			11.5.1 Results
		11.6 Lactic Acid
			11.6.1 Lactic Acid Production by Reactive Distillation
			11.6.2 Design and Synthesis of Intensified Processes
			11.6.3 Optimization
			11.6.4 Results and Discussion
		11.7 Future and Perspectives
		11.8 Conclusions
		Acknowledgments
		Acronyms
		Nomenclature
		References
	12. Analysis of Safety and Economic Objectives for Intensified Algal Biodiesel Process
		12.1 Introduction
		12.2 Process Development
			12.2.1 Process Development of Alternative 1
			12.2.2 Process Development of Alternative 2
		12.3 Multi-Objective Optimization
			12.3.1 Objective Functions
				12.3.1.1 Break-Even Cost
				12.3.1.2 Individual Risk (IR)
			12.3.2 Simple Additive Weighting (SAW) Method
		12.4 Results and Discussion
			12.4.1 Minimization of BEC and IR for Alternative 1
			12.4.2 Minimization of BEC and IR for Alternative 2
		12.5 Comparative Analysis
		12.6 Conclusions
		References
Index