Majozi Batch Chemical Process Integration

Analysis, Synthesis and Optimization
1. Auflage 2009
ISBN: 978-90-481-2588-3
Verlag: Springer Netherlands
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 282 Seiten

'Batch Chemical Process Integration: Analysis, Synthesis and Optimization' is an excellent source of information on state-of-the-art mathematical and graphical techniques for analysis, synthesis and optimization of batch chemical plants. It covers recent techniques in batch process integration with a particular focus on the capabilities of the mathematical techniques. There is a section on graphical techniques as well as performance comparison between graphical and mathematical techniques. Prior to delving into the intricacies of wastewater minimisation and heat integration in batch processes, the book introduces the reader to the basics of scheduling which is aimed at capturing the essence of time. A chapter on the synthesis of batch plants to highlight the importance of time in design of batch plants is also presented through a real-life case study. The book is targeted at undergraduates and postgraduate students, researchers in batch process integration, practising engineers and technical managers.

Autoren/Hrsg.

Majozi, Thokozani

Inhaltsverzeichnis

1;Foreword;5
2;Preface;7
3;Acknowledgments;10
4;1 Introduction to Batch Chemical Processes;17
4.1;1.1 Definition of a Batch Process;17
4.2;1.2 Operational Philosophies;19
4.3;1.3 Types of Batch Plants;21
4.4;1.4 Capturing the Essence of Time;22
4.5;1.5 Recipe Representations;24
4.6;1.6 Batch Chemical Process Integration: Why Is It Necessary?;25
5;References;26
6;2 Short-Term Scheduling;28
6.1;2.1 Problem Statement;28
6.2;2.2 State Sequence Network;29
6.3;2.3 Mathematical Model;31
6.3.1;2.3.0 Sets;32
6.3.2;2.3.0 Variables;32
6.3.3;2.3.0 Parameters;32
6.3.4;2.3.0 Capacity Constraints;33
6.3.5;2.3.0 Material Balances;33
6.3.6;2.3.0 Duration Constraints (Batch Time as a Function of Variable Batch Size);34
6.3.7;2.3.0 Duration Constraints (Batch Time Independent of Batch Size);34
6.3.8;2.3.0 Sequence Constraints;35
6.3.9;2.3.0 Assignment Constraint;35
6.3.10;2.3.0 Time Horizon Constraints;36
6.3.11;2.3.0 Storage Constraints;36
6.3.12;2.3.0 Objective Function;36
6.4;2.4 Literature Examples;36
6.4.1;2.4.1 First Literature Example;36
6.4.2;2.4.1 Capacity Constraints;36
6.4.3;2.4.1 Material Balances;37
6.4.4;2.4.1 Duration Constraints (Batch Time as a Function of Batch Size);38
6.4.5;2.4.1 Sequence Constraints;38
6.4.6;2.4.1 Time Horizon Constraints;38
6.4.7;2.4.1 Storage Constraints;39
6.4.8;2.4.1 Objective Function;39
6.4.9;2.4.1 Computational Results;39
6.4.10;2.4.2 Second Literature Example;41
6.4.10.1;2.4.2.0 Choice of Effective States;41
6.4.11;2.4.2 Capacity Constraints;43
6.4.12;2.4.2 Material Balances;44
6.4.13;2.4.2 Sequence Constraints;45
6.4.14;2.4.2 Assignment Constraint;46
6.4.15;2.4.2 Computational Results;46
6.5;2.5 Application of Aggregation Models in Reducing the Binary Dimension;48
6.5.1;2.5.1 Second Literature Example Revisited;48
6.5.1.1;2.5.1.0 Capacity Constraints;48
6.5.2;2.5.1 Material Balances;49
6.5.2.1;2.5.1.0 Computational Results;49
6.6;2.6 Summary and Conclusions;51
6.7;2.7 Exercise;51
7;References;54
8;3 Process Intermediate Storage Operational Philosophy: The New Operational Philosophy;55
8.1;3.1 The PIS Operational Philosophy;55
8.2;3.2 Problem Statement;57
8.3;3.3 Mathematical Formulation;58
8.3.1;3.3.0 Sets;58
8.3.2;3.3.0 Binary Variables;58
8.3.3;3.3.0 Continuous Variables;59
8.3.4;3.3.0 Parameters;59
8.3.5;3.3.0 Capacity Constraints;60
8.3.6;3.3.0 Material Balances;60
8.3.7;3.3.0 Duration Constraints;61
8.3.8;3.3.0 Sequence Constraints;61
8.3.9;3.3.1 Feasibility Constraints;62
8.3.10;3.3.1 Time Horizon Constraints;62
8.3.11;3.3.1 Storage Constraints;62
8.3.11.1;3.3.1.0 Extension to PIS Philosophy;62
8.3.12;3.3.1 Capacity Constraints;63
8.3.13;3.3.1 Material Balances;63
8.3.14;3.3.1 Duration Constraints;63
8.3.15;3.3.1 Sequence Constraints;64
8.3.16;3.3.1 Time Horizon Constraints;65
8.3.17;3.3.1 Feasibility Constraints;65
8.3.17.1;3.3.1.0 Necessary Modifications to the Basic Scheduling Model;65
8.3.17.2;3.3.1.0 Possible Performance Indices (Objective Functions);66
8.4;3.4 Illustrative Examples;67
8.4.1;3.4.1 First Illustrative Example;67
8.4.1.1;3.4.1.0 Case 1;68
8.4.1.2;3.4.1.0 Case 2;69
8.4.2;3.4.1 Design Implications;71
8.4.2.1;3.4.1.0 Problem Statement;71
8.4.2.2;3.4.1.0 Necessary Modifications to Case 1;71
8.4.3;3.4.1 Capacity Constraints;71
8.4.4;3.4.1 Feasibility Constraint;72
8.4.5;3.4.2 Second Illustrative Example;72
8.4.5.1;3.4.2.0 Results;72
8.4.6;3.4.2 Conclusions on the Results for the Illustrative Examples;74
8.5;3.5 Industrial Application;74
8.5.1;3.5.1 Computational Results;77
8.5.2;3.5.2 Conclusions and Discussion on the Industrial Application;79
8.6;3.6 Conclusions;79
8.7;3.7 Exercise;81
9;References;81
10;4 Wastewater Minimisation in Multiproduct Batch Plants: Single Contaminants;82
10.1;4.1 Problem Statement;82
10.2;4.2 Problem Superstructure;83
10.3;4.3 Mathematical Model;84
10.3.1;4.3.0 Sets;85
10.3.2;4.3.0 Variables;86
10.3.3;4.3.0 Parameters;86
10.3.4;4.3.1 Water Reuse/Recycle Module;87
10.3.5;4.3.2 Sequencing/Scheduling Module;93
10.3.5.1;4.3.2.0 Sequencing in the Absence of Reusable Water Storage;94
10.3.5.2;4.3.2.0 Sequencing in the Presence of Reusable Water Storage;95
10.4;4.4 Objective Function;97
10.5;4.5 Literature Example;98
10.5.1;4.5.0 Objective Function;98
10.5.2;4.5.0 Computational Results;98
10.6;4.6 First Case Study;101
10.6.1;4.6.0 Water Reuse/Recycle Module;102
10.6.2;4.6.0 Sequencing/Scheduling Module;103
10.6.3;4.6.0 Computational Results;103
10.7;4.7 Second Case Study;106
10.7.1;4.7.0 Capacity Constraints;107
10.7.2;4.7.0 Mass Ratio Constraints;108
10.7.3;4.7.0 Computational Results;108
10.8;4.8 Concluding Remarks;109
10.9;4.9 Exercise;111
11;References;111
12;5 Storage Design for Maximum Wastewater Reuse in Batch Plants;112
12.1;5.1 The Essence of the Problem;112
12.2;5.2 Problem Statement;113
12.3;5.3 Mathematical Model;114
12.3.1;5.3.0 Sets;114
12.3.2;5.3.0 Variables;115
12.3.3;5.3.0 Parameters;115
12.3.4;5.3.1 Water Reuse/Recycle Constraints;117
12.3.5;5.3.2 Sequencing/Scheduling Constraints;120
12.3.6;5.3.3 Additional Constraints;123
12.3.7;5.3.4 Objective Function;124
12.4;5.4 Solution Procedure;124
12.4.1;5.4.1 Two-Stage Optimisation Algorithm for Freshwater and Reusable Water Storage Minimisation;124
12.5;5.5 Case Study;124
12.5.1;5.5.1 Computational Results;126
12.6;5.6 Concluding Remarks;127
12.7;5.7 Exercise;129
13;References;130
14;6 Wastewater Minimisation in Multipurpose Batch Plants: Multiple Contaminants;131
14.1;6.1 Multiple Contaminant Wastewater Minimisation Background;131
14.2;6.2 Problem Statement;132
14.3;6.3 Mathematical Formulation;132
14.3.1;6.3.0 Sets;133
14.3.2;6.3.0 Variables Associated with Wastewater Minimization;133
14.3.3;6.3.0 Variables Associated with Production Scheduling;134
14.3.4;6.3.0 Parameters Associated with Wastewater Minimization;134
14.3.5;6.3.0 Parameters Associated with Production Scheduling;134
14.3.6;6.3.1 Mass Balance Constraints;135
14.3.6.1;6.3.1.0 Mass Balance Constraints Without Storage;135
14.3.6.2;6.3.1.0 Mass Balance Constraints Including Central Storage;137
14.3.7;6.3.2 Sequencing and Scheduling Constraints;140
14.3.7.1;6.3.2.0 Sequencing Constraints Associated with Production Scheduling;140
14.3.7.2;6.3.2.0 Capacity Constraints;140
14.3.7.3;6.3.2.0 Material Balances;141
14.3.7.4;6.3.2.0 Duration Constraints;141
14.3.7.5;6.3.2.0 Assignment Constraints;141
14.3.7.6;6.3.2.0 Storage Constraints;142
14.3.7.7;6.3.2.0 Sequencing Constraints for Recycle/Reuse in the Absence of Reusable Water Storage;142
14.3.7.8;6.3.2.0 Sequencing and Scheduling Constraints Associated with Storage;143
14.3.7.9;6.3.2.0 Sequencing Constraints that Associate Production Scheduling and Water Recycle/Reuse;145
14.3.8;6.3.3 Objective Function;146
14.4;6.4 Solution Procedure;146
14.5;6.5 Illustrative Examples;147
14.5.1;6.5.1 First Illustrative Example;147
14.5.1.1;6.5.1.0 Solution with No Central Storage Vessel;148
14.5.1.2;6.5.1.0 Solution with Central Storage;149
14.5.2;6.5.2 Second Illustrative Example;151
14.5.3;6.5.3 Literature Example;154
14.5.3.1;6.5.3.0 Results for the Literature Example;157
14.6;6.6 Conclusions;157
14.7;6.7 Exercise;158
14.7.1;6.7.1 A Typical Cleaning Procedure in the Toiletries Mixing Area;160
15;References;163
16;7 Wastewater Minimisation Using Multiple Storage Vessels;164
16.1;7.1 Multiple Storage Vessel Background;164
16.2;7.2 Problem Statement;165
16.3;7.3 Mathematical Formulation;165
16.3.1;7.3.0 Sets;166
16.3.2;7.3.0 Continuous Variables;166
16.3.3;7.3.0 Binary Variables;167
16.3.4;7.3.0 Parameters;167
16.3.5;7.3.1 Superstructure for the Multiple Storage Vessel Methodology;167
16.3.6;7.3.2 Mass Balance Constraints;168
16.3.7;7.3.3 Scheduling Constraints;172
16.3.7.1;7.3.3.0 Task Scheduling Constraints;172
16.3.7.2;7.3.3.0 Recycle/Reuse Scheduling;172
16.3.7.3;7.3.3.0 Storage Scheduling Constraints;173
16.3.7.4;7.3.3.0 Time Horizon Constraints;175
16.3.8;7.3.4 Objective Function;175
16.4;7.4 Illustrative Examples for the Multiple Storage Vessel Model;176
16.4.1;7.4.1 First Illustrative Example;176
16.4.2;7.4.2 Second Illustrative Example;178
16.4.3;7.4.3 Third Illustrative Example;181
16.5;7.5 Conclusions;182
16.6;7.6 Exercise;183
17;References;183
18;8 Zero Effluent Methodologies;184
18.1;8.1 Zero Effluent Operation;184
18.2;8.2 Superstructure Used in the Methodology;186
18.3;8.3 Zero Effluent Scheduling Model;187
18.3.1;8.3.0 Sets;187
18.3.2;8.3.0 Continuous Variables;187
18.3.3;8.3.0 Binary Variables;188
18.3.4;8.3.0 Parameters;188
18.3.5;8.3.1 Problem Statement for the Zero Effluent Scheduling Formulation;189
18.3.6;8.3.2 Mass Balance Constraints;190
18.3.6.1;8.3.2.0 Unit Mass Balances with Negligible Contaminant Mass in the Wastewater;190
18.3.6.2;8.3.2.0 Storage Mass Balances with Negligible Contaminant Mass in the Wastewater;191
18.3.7;8.3.3 Scheduling Constraints;192
18.3.7.1;8.3.3.0 Binary Variable Constraints for Wastewater Reuse;192
18.3.7.2;8.3.3.0 Unit Scheduling Constraints;193
18.3.7.3;8.3.3.0 Direct Recycle/Reuse Scheduling;194
18.3.7.4;8.3.3.0 Indirect Reuse Scheduling;194
18.3.7.5;8.3.3.0 Time Horizon Constraints;197
18.3.8;8.3.4 Additional Constraints for Significant Contaminant Mass in the Wastewater;197
18.3.9;8.3.5 Objective Function;198
18.4;8.4 Zero Effluent Plant Synthesis Formulation;198
18.4.1;8.4.1 Problem Statement for Synthesis Formulation;199
18.4.2;8.4.2 Constraints Considered in the Formulation;199
18.5;8.5 Illustrative Examples Using the Zero Effluent Mode of Operation;201
18.5.1;8.5.1 First Illustrative Example;201
18.5.2;8.5.2 Second Illustrative Example;204
18.6;8.6 Conclusions;206
18.7;8.7 Exercise;207
19;References;207
20;9 Wastewater Minimisation Using Inherent Storage;208
20.1;9.1 Inherent Storage Background;208
20.2;9.2 Problem Statement;209
20.3;9.3 Mathematical Formulation for Inherent Storage;210
20.3.1;9.3.0 Sets;210
20.3.2;9.3.1 Superstructure Used in the Mathematical Formulation;210
20.3.3;9.3.2 Mass Balance Constraints;211
20.3.3.1;9.3.2.0 Mass Balances Around a Unit Processing Raw Material;211
20.3.3.2;9.3.2.0 Mass Balance Constraints for a Processing Unit Operating in Inherent Storage Mode;213
20.3.3.3;9.3.2.0 Central Storage Mass Balances;214
20.3.4;9.3.3 Sequencing and Scheduling Constraints;215
20.3.4.1;9.3.3.0 Task Scheduling Constraints;215
20.3.4.2;9.3.3.0 Recycle/Reuse Sequencing Constraints;216
20.3.4.3;9.3.3.0 Inherent Storage Scheduling Through Inherent Storage;216
20.3.4.4;9.3.3.0 Scheduling Constraints Associated with Central Storage;219
20.3.4.5;9.3.3.0 Feasibility and Time Horizon Constraints;220
20.3.5;9.3.4 Inclusion of the Maximum Outlet Concentration Condition;221
20.4;9.4 Solution Procedures for the Problems Considered in the Inherent Storage Methodology;222
20.5;9.5 Illustrative Examples Using Inherent Storage;222
20.5.1;9.5.1 First Illustrative Example;223
20.5.2;9.5.2 Second Illustrative Example;225
20.5.2.1;9.5.2.0 Solution for Second Illustrative Example with Central Storage Only;225
20.5.2.2;9.5.2.0 Solution to Second Illustrative Example with Inherent Storage and Central Storage;227
20.6;9.6 Conclusions;228
20.7;9.7 Exercise;229
21;References;229
22;10 Heat Integration in Multipurpose Batch Plants: I. Direct Heat Integration;230
22.1;10.1 Some Background to Heat Integration of Batch Plants;230
22.2;10.2 Problem Statement;232
22.3;10.3 Mathematical Formulation;232
22.3.1;10.3.0 Sets;232
22.3.2;10.3.0 Variables;233
22.3.3;10.3.0 Glover Transformation Variables;233
22.3.4;10.3.0 Parameters;233
22.3.5;10.3.1 Case 1: Variable Batch Size;234
22.3.5.1;10.3.1.0 Linearization Using Glover Transformation;235
22.3.6;10.3.2 Case 2: Fixed Batch Size;236
22.4;10.4 Literature Example;238
22.4.1;10.4.1 Results and Discussion;238
22.5;10.5 Industrial Case Study;240
22.5.1;10.5.1 Results and Discussion;242
22.6;10.6 Conclusions;244
22.7;10.7 Exercise;244
23;References;245
24;11 Heat Integration in Multipurpose Batch Plants: II. Indirect Heat Integration;246
24.1;11.1 Problem Statement;246
24.2;11.2 Mathematical Model;247
24.2.1;11.2.0 Sets;247
24.2.2;11.2.0 Variables;248
24.2.3;11.2.0 Parameters;248
24.2.4;11.2.0 Constraints;248
24.3;11.3 Case Study;252
24.4;11.4 Results;253
24.5;11.5 Conclusions;254
24.6;11.6 Exercise;256
25;References;256
26;12 A Graphical Technique for Wastewater Minimisation in Batch Processes;257
26.1;12.1 Introduction;257
26.1.1;12.1.1 Wang and Smith Approach for Water Minimisation in Batch Processes;259
26.2;12.2 Graphical Analysis for Completely Batch Processes;264
26.2.1;12.2.1 Problem Statement;264
26.2.2;12.2.2 Time Taken as a Primary Constraints;264
26.2.2.1;12.2.2.0 Problem Specification for Graphical Analysis;265
26.2.2.2;12.2.2.0 Targeting (First Sequence);266
26.2.2.3;12.2.2.0 Targeting (Cyclic-State Operation);270
26.2.2.4;12.2.2.0 Assessment of Storage Potential for Process Vessels;271
26.2.3;12.2.3 Concentration Taken as a Primary Constraints;273
26.2.3.1;12.2.3.0 Targeting (First Sequence);274
26.2.3.2;12.2.3.0 Targeting (Cyclic-State);276
26.3;12.3 A Brief Comparison Between Graphical and Mathematical Approaches;279
26.4;12.4 Concluding Remarks;281
26.5;12.5 Exercise;282
27;References;282
28;Index;282