Editorial Cite This: Ind. Eng. Chem. Res. 2019, 58, 5747−5749
pubs.acs.org/IECR
Preface for Special Issue on Frameworks for Process Intensification and Modularization
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rocess intensification (PI) focuses on “doing more with less”, and the application of intensification concepts promises reducing plant size and increasing energy efficiency, compared to a conventional facility of comparable capacity. So far, intensification has been largely regarded as an Edisonian effort, whereby brilliant engineering thinking is, in many ways, ahead of theory and rigorous understanding. In this Special Issue, we strive to address the need for more-systematic frameworks for achieving intensification. The Issue presents 33 papers from leading global contributors and addresses a gamut of issues running from basic science geared toward intensification, to optimal synthesis, to design and operational optimization of intensified plants. The contributions are categorized and summarized below.
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MODULAR PRODUCTION Modular production can transform entire supply chains of many products through partial or complete replacement of conventional large-scale, fixed location production with smaller-scale and/or transportable modular systems. Mass production of modular plants can lead to significant cost savings and operational benefits due to the economy of numbers. However, this transition might not be appropriate for all products, locations, or markets. To assess the tradeoff between centralized large-scale production and modular production, mathematical programming can be used to solve complex supply chain, planning, scheduling, and design optimization problems. Three contributions in this Issue study this topic either by introducing novel optimization methods to solve simultaneous planning and design problems,11 or by analyzing the potential of modularization for specific markets, such as shale gas production12 and ammonia production.13 Specifically, Chen and Grossmann11 describe the use of Generalized Disjunctive Programming to solve large-scale multiperiod, multiproduct planning problems with embedded modular design decisions. They use their approach to quantify the tradeoffs between modularization and centralized manufacturing through a series of case studies, including bioethanol production and heat exchanger network synthesis. Palys et al.13 propose a supply chain optimization formulation that considers the number of modular chemical processes for wind-powered ammonia production as a decision variable. Through two case studies for Iowa and Minnesota, they show that adding modular ammonia production to the existing infrastructure can be financially beneficial in certain scenarios, while in other cases, the effects of economy of scale dominate. Finally, Allen et al.12 show that modular transportable shale-gas processing plants operated in parallel are more profitable than oversized spatially fixed facilities. In their study, they formulate the capacity planning and allocation problem of the uncertain future operation of gas fields as a multistage stochastic programming problem.
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ENABLING TECHNOLOGIES FOR PROCESS INTENSIFICATION Intensification is intrinsically related to progress at the molecular level, particularly in the development of new materials for supporting reaction and separation processes, as well in positing new equipment concepts and configurations for exploiting such novel materials. We refer to developments in this category as “enabling technologies,” and note that they are well-represented in this special issue. In the separations area, Realff et al. propose a new concept of structured adsorption bed, whereby structure is provided by hollow fibers.1 Furthermore, a thermal modulator for hollow fibers, consisting of a phase-change material, is proposed by Lively et al.2 Also in the separations realm, Zhou et al. concentrate on the design of solvents for extractive distillation,3 while Lin et al. review the impact and contribution of inorganic membranes to process intensification.4 In a different vein, Pandit et al., review the use of cavitation as a process intensification technology,5 while Subramaniam et al. investigate the use of millichannel systems in intensifying the synthesis of nanoparticles.6
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INTENSIFIED OPERATIONS The impact and implications of process operation strategies on process intensification has received increased attention recently. Here, Baldea et al. introduce the concept of dynamic intensification as an operational strategy to achieve intensification goals typically reached via process design changes.7 The concept is demonstrated by developing a dynamic intensification strategy for a binary distillation column. Karimi et al. also focus on operational optimization, presenting a framework that is tailored to multistream heat exchangers−a key operation in many processes, particularly those operating at low temperatures.8 Finally, Ierapetritou et al. investigate the switch from batch to continuous processing, focusing on a monoclonal antibody production test case,9 and Kumar et al. present a continuous process for manufacturing of polyaniline nanofibers, emphasizing its advantages over traditional batch production.10 © 2019 American Chemical Society
PROCESS INTENSIFICATION DEVICES Process intensification and modularization will undoubtedly require the development of novel and robust devices. These devices may range from units that integrate different phenomena in one process (e.g., reactive distillation), or devices that are much smaller in size than conventional processes. In this Issue, there are four contributions that primarily focus on PI devices. Kiss et al.14 present a comprehensive review of advancements in one of the most prominent PI success stories, namely reactive distillation (RD). Specifically, they compare the advantages, limitations, and challenges of a series of RD devices, such as Special Issue: Frameworks for Process Intensification and Modularization Published: April 17, 2019 5747
DOI: 10.1021/acs.iecr.9b01358 Ind. Eng. Chem. Res. 2019, 58, 5747−5749
Industrial & Engineering Chemistry Research
Editorial
important to ensure the operability, controllability, safety, and flexibility of these new designs. These encapsulate a broader scope of process systems engineering (PSE) methodologies toward realizing the full potential of intensified process systems. Pistikopoulos et al. propose a modular representation-based synthesis framework considering the steady-state operability and safety of intensified processes.25 Lima et al. present a two-tiered framework to identify operable intensification targets and discuss the size and process operability in the context of a membrane reactor.26 Jimenez-Gutierrez et al. propose a framework for inherently safer design of intensified process systems, while considering economics, sustainability, and process safety.27 Wilhite et al. study improvements in safety of intensified reaction conditions for 3-methylpyridine N-oxidation through a combination of experiments and surrogate modeling.28 Segovia-Hernãndez et al. illustrate the benefits of intensification toward inherently safer design of separation processes, taking furfural separation as a case study.29 Dai et al. introduce the production of ethyl lactate as an application and propose alternative solutions.30 Because of the novelty and complexity of intensified processes, the models that describe them can be multiscale, nonlinear distributed models, which poses several challenges during model development and model-based optimization. In addition, lack of data and uncertainty in the description of the phenomena governing intensified systems will require design frameworks that can handle uncertainty. There are three papers which discuss challenges in modeling and design of intensified systems in this Issue. Specifically, Chen et al. present a comprehensive multiscale design framework for intensified polymerization processes.31 Their framework integrates molecular weight distribution models (molecular level) with processlevel design models, in order to solve various optimization problems for design, synthesis, and control of polymer production. Their objective is to achieve target polymer molecular weight distributions by selecting the operating conditions, design superstructure, and dynamic operation of the polymerization processes. A process can be intensified by combining multiple phenomena, or by drastically enhancing a single phenomenon through using promising materials. To this end, Vlachos et al. have developed computationally efficient models for catalyst microstructure design and optimization.32 A different form of intensification is the design of highly integrated and efficient processes that minimize waste production and energy consumption. Manteca et al. propose and optimize a new integrated process that utilizes gypsum (a solid residue from coal power plants that is currently considered as waste) for the production of sodium sulfate.33 Their integrated design incorporates a variety of process models (i.e., milling, mixing, evaporation, and dehydration) that are simultaneously optimized to show that this process has a competitive cost and leads to significant energy and waste reduction. The editors are indebted to all the authors for submitting these excellent contributions, to the reviewers who have diligently provided constructive feedback, and to the Editorin-Chief of the journal for affording them the opportunity to guest edit this Special Issue.
reactive dividing wall columns, catalytic cyclic distillation, reactive heat-integrated distillation, reactive high gravity distillation, membrane-assisted RD, microwave-assisted RD, and ultrasound-assisted RD. The remaining contributions in this area present experimental results of novel intensified reactors. Wenzel et al.15 study rotating packed bed reactors (RPBs), which allow for micromixing and enhanced multiphase contact and mass transfer, because of the increased centrifugal forces that are achieved. Through a series of experiments and first-principle modeling, they show the large potential of RPBs to achieve fast mixing at high flow rates and low pressure drop. Scale-up studies for oscillatory multiorifice baffled reactor (OMBR) microreactors is studied by Ahmed et al.16 OMBRs are continuous tubular reactors with periodically spaced baffles, which have been observed to have up to 10-fold higher mass-transfer coefficients than conventional bubble column reactors. In this contribution, the authors propose and experimentally validate a mass-transfer coefficient correlation for scaling up OMBRs. Finally, EkinsCoward et al. have developed a technique for the production of photoreactive porous paper biocomposites embedded with C. vulgaris microalgae.17 These materials were, for the first time, successfully used in a microbial spinning disk gas absorber that achieves enhanced absorption.
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PROCESS DESIGN AND APPLICATIONS An integral part of the successful transition toward new intensified or modular technologies will be efficient process design through mathematical modeling, optimization, and validation. Specifically, innovative representations and synthesis approaches are expected to identify new intensification pathways at the equipment and flowsheet levels. A key question is obtaining optimal intensification pathways and out-of-the-box solutions systematically, without waiting for “eureka moments”. In this direction, Hasan et al. depart from the classic unit operation-based representation of chemical processes and introduce a new representation based on abstract building blocks (ABB), and incorporate the concept in a superstructurebased general framework for process synthesis, integration, and intensification.18 Such a framework is critical to reduce the risk of eliminating potential intensification pathways at the conceptual design stage. Within the realm of intensified schemes considering conventional unit operations, Da Cruz and Manousiouthakis propose a conceptual framework for globally optimal synthesis of reactive distillation networks.19 This Special Issue also features several contributions related to heat exchanger network synthesis (HENS). Karimi et al. revisit previous superstructure representations for HENS and offered ways to incorporate new possibilities.20 Maravelias et al. propose an optimization model for utility targeting that is able to provide optimal matching for heat integration without requiring classification of process streams beforehand.21 Feng and coworkers address the synthesis of a cooler network, which is also a part of heat integration.22 Du et al. incorporate process dynamics in HENS for improving the flexibility.23 Even before one embarks on designing intensified processes, it is important to know the extent to which intensification can help improve a process. A contribution in this direction comes from Doherty et al., who identify the limits of reaction selectivity that can be used as a target for process intensification using a reactor−separator.24 While synthesis-guided intensification provides promising intensification pathways and candidate flowsheets, it is also
Michael Baldea* The University of Texas at Austin
M. M. Faruque Hasan Texas A&M University 5748
DOI: 10.1021/acs.iecr.9b01358 Ind. Eng. Chem. Res. 2019, 58, 5747−5749
Industrial & Engineering Chemistry Research
Editorial
(16) Ahmed, S. M. R.; Phan, A. N.; Harvey, A. P. Scale-Up of GasLiquid Mass Transfer in Oscillatory Multiorifice Baffled Reactors (OMBRs). Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b04883. (17) Ekins-Coward, T.; Boodhoo, K. V. K.; Velasquez-Orta, S.; Caldwell, G.; Wallace, A.; Barton, R.; Flickinger, M. C. A Microalgae Biocomposite-Integrated Spinning Disk Bioreactor (SDBR): Toward a Scalable Engineering Approach for Bioprocess Intensification in LightDriven CO2 Absorption Applications. Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b05487. (18) Demirel, S. E.; Li, J.; Hasan, M. M. F. A General Framework for Process Synthesis, Integration, and Intensification. Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b05961. (19) Da Cruz, F. E.; Manousiouthakis, V. I. et al. Process Intensification of Multi-Pressure Reactive Distillation Networks Using IDEAS.Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b04262. (20) Nair, S. K.; Karimi, I. A. Unified Heat Exchanger Network Synthesis via a Stageless Superstructure. Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b04490. (21) Ryu, J.; Maravelias, C. T. Simultaneous Process and Heat Exchanger Network Synthesis Using a Discrete Temperature Grid.Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b04083. (22) Zhang, H.; Feng, X.; Wang, Y.; Zhang, Z. Optimization of Cooler Networks with Different Cooling Types in Series and Parallel Configuration. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/ acs.iecr.8b04059. (23) Gu, S.; Liu, L.; Zhang, L.; Bai, Y.; Du, J. Optimization-based Framework for Designing Dynamic Flexible Heat Exchanger Networks. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b04121. (24) Frumkin, J. A.; Fleitmann, L.; Doherty, M. F. Ultimate Reaction Selectivity Limits for Intensified Reactor-Separators. Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b04143. (25) Tian, Y.; Pistikopoulos, E. N. et al. Synthesis of Operable Process Intensification Systems - Steady-state Design with Safety and Operability Considerations.Ind. Eng. Chem. Res. 2019, DOI: 10.1021/acs.iecr.8b04389. (26) Gazzaneo, V.; Lima, F. V. A Multi-Layer Operability Framework for Process Design. Ind. Eng. Chem. Res. 2019, DOI: 10.1021/ acs.iecr.8b05482. (27) Castillo-Landero, A.; Ortiz-Espinoza, A. P.; Jimenez-Gutierrez, A. et al. A process intensification methodology including economic Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b04146. (28) Wang, J.; Huang, Y.; Wilhite, B. A.; Papadaki, M.; Mannan, M. S. Towards the Identification of Intensified Reaction Conditions using Response Surface Methodology: A Case Study on 3-Methylpyridine Noxide Synthesis.Ind. Eng. Chem. Res.2018, DOI: 10.1021/acs.iecr.8b03773. (29) Contreras-Zarazúa, G.; Sánchez-Ramı ́rez, E.; Vázquez-Castillo, J. A.; Ponce-Ortega, J. M.; Errico, M.; Kiss, A. A.; Segovia-Hernandez, J. G. et al. Inherently Safer Design and Optimization of Intensified Separation Processes for Furfural Production. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b03646. (30) Dai, S.-B.; Lee, H.-Y.; Chen, C.-L. et al. Design and Economic Evaluation for the Production of Ethyl Lactate via Reactive Distillation Combined with Various Separation Configurations. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b03343. (31) Chen, X.; Shao, Z.; Gu, X.; Feng, L.; Biegler, L. T. Process Intensification of Polymerization Processes with Embedded Molecular Weight Distributions Models: An Advanced Optimization Approach. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b04424. (32) Nunez, M.; Vlachos, D. G. Multiscale Modeling Combined with Active Learning for Microstructure Optimization of Bifunctional Catalysts.Ind. Eng. Chem. Res. 2018, DOI: 10.1021/acs.iecr.8b04801. (33) Manteca, P.; Martín, M. Integrated Facility for Power Plant Waste Processing. Ind. Eng. Chem. Res. 2018, DOI: 10.1021/ acs.iecr.8b04029.
Fani Boukouvala
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Georgia Institute of Technology
AUTHOR INFORMATION
Corresponding Author
*E-mail:
[email protected]. ORCID
Michael Baldea: 0000-0001-6400-0315 Notes
Views expressed in this editorial are those of the authors and not necessarily the views of the ACS.
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REFERENCES
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DOI: 10.1021/acs.iecr.9b01358 Ind. Eng. Chem. Res. 2019, 58, 5747−5749
