Control and Safety Analysis of Intensified Chemical Processes

Dr. Dipesh Shikchand Patle is associated with the Motilal Nehru National Institute of Technology Allahabad (India). His research interests include Biodiesel Synthesis, Process Intensification, Simulation, Plantwide Control, and Operator Training Simulator development. Dr. Gade Pandu Rangaiah has been with the National University of Singapore since 1982. His extensive research covers Modeling, Design, Optimization, and Control of (Intensified) Chemical and related Processes. Currently, it is focused on Multi-Objective Optimization and Multi-Criteria Decision Making, and their Applications.

• Preface xvPart I Overview and Background 11 Introduction 3Dipesh Shikchand Patle and Gade Pandu Rangaiah1.1 Process Intensification 31.2 Need for Control and Safety Analysis of Intensified Chemical Processes 51.3 Studies on Control and Safety Analysis of Intensified Chemical Processes 71.4 Scope and Organization of the Book 91.5 Conclusions 12References 132 Applications and Potential of Process Intensification in Chemical Process Industries 15Chirla C.S. Reddy2.1 Introduction 152.2 Benefits of Process Intensification Techniques 162.3 Static Mixers 172.4 Process Intensification for Separation Vessels 182.5 Process Intensification for Distillation 212.6 Process Intensification for Heating 242.6.1 Steam Injection Heater 242.6.2 Steam/Electric Heaters as a Replacement for Fired Heaters 252.6.3 Process Intensification for Flue Gas Heat Recovery 262.6.4 Process Heat Exchangers 262.6.5 Sonic Horn 272.7 Steam Compression 272.8 Process Intensification for Carbon Capture 302.9 Process Intensification for Vacuum Systems 312.10 Process Intensification for Water Deaeration 332.11 Process Intensification for Development of Inherently Safer Design (isd) 332.12 Process Intensification for Reducing Pressure Relief and Handling Requirements 352.12.1 Non-safety Instrumented Solutions for Pressure Relief Systems 372.12.2 Safety Instrumented System (SIS) Solutions for Reducing Pressure Relief Requirements 392.13 Process Intensification for Wastewater Recovery 412.14 Challenges of Process Intensification Techniques 432.15 Conclusions 44References 45Part II Procedures and Software for Simulation, Control and Safety Analysis 473 Simulation and Optimization of Intensified Chemical Processes 49Zemin Feng and Gade Pandu Rangaiah3.1 Introduction 493.2 Simulation of Chemical Processes 503.2.1 Usefulness of Process Simulation 503.2.2 Commercial Process Simulators 523.2.3 Free Process Simulators 533.2.4 Computational Methods for Process Simulation 533.3 Procedure for Simulation of (Intensified) Chemical Processes 563.3.1 Problem Analysis 563.3.2 Basic Process Flow Design 573.3.3 Process Intensification and Integration 573.3.4 Model Construction 573.3.5 Simulation and Convergence 593.3.6 Results Analysis 593.4 Optimization of (Intensified) Chemical Processes 593.4.1 Mathematical Optimization Methods 593.4.2 Optimization of Chemical Processes with a Process Simulator 623.4.2.1 Optimization Using MATLAB 623.4.2.2 Optimization Using Python 633.5 Challenges in the Simulation/Optimization of Intensified Chemical Processes 653.6 Case Study 663.6.1 Problem Analysis 663.6.2 Process Flow Design 673.6.3 Model Construction 693.6.4 Simulation and Convergence 703.6.4.1 Process Simulation 703.6.4.2 Economic Evaluation Criterion 713.6.4.3 Process Optimization 733.6.5 Results and Analysis 753.7 Conclusions 78References 794 Dynamic Simulation and Control of Intensified Chemical Processes 83Zemin Feng and Gade Pandu Rangaiah4.1 Introduction 834.2 Dynamic Simulation of Chemical Processes 844.2.1 Understanding Dynamic Simulation 844.2.2 Applications of Dynamic Simulation 874.2.3 Dynamic Simulation Software 884.3 Dynamic Simulation and Control Procedure 914.4 Dynamic Simulation and Control of Intensified Chemical Processes 984.4.1 Challenges Due to Process Intensification 1004.5 Process Control 1004.5.1 Controlled, Manipulated, and Disturbance Variables 1014.5.2 Typical Control Loop 1014.5.3 Control Degrees of Freedom 1014.6 Case Study 1024.6.1 Steady-state Simulation and Optimization 1034.6.2 Preparation/Initialization for Dynamic Simulation 1034.6.3 Control Structure Design 1074.6.3.1 Composition Control Scheme 1084.6.3.2 Temperature Control Scheme 1104.6.4 Tuning of Controller Parameters 1124.6.5 Analysis of Dynamic Simulation Results 1124.7 Conclusions 120References 1215 Safety Analysis of Intensified Chemical Processes 125Masrina Mohd Nadzir, Zainal Ahmad, and Syamsul Rizal Abd Shukor5.1 Introduction 1255.2 Safety Analysis in Chemical Process Industry 1265.2.1 Safety Analysis Tools 1285.2.1.1 Hazard Identification 1285.2.1.2 Risk Assessment 1305.2.1.3 Inherently Safer Design (ISD) 1315.2.1.4 Safety Instrumented Systems 1325.2.1.5 Human Factors and Safety Culture 1325.2.1.6 Regulatory Framework and Compliance 1345.2.1.7 Monitoring and Continuous Improvement 1355.3 Process Intensification and Safety Analysis 1365.3.1 Impacts of Process Intensification on Safety 1365.3.2 Safety Analysis in Intensified Process Design 1375.3.2.1 Hazard Identification Techniques for Process Intensification Technologies 1385.3.2.2 Risk Assessment for Process Intensification Technologies 1405.3.3 Inherently Safer Design Principles Intensified Processes 1415.4 Safety Management Systems for Intensified Processes 1445.5 Safety Training and Competency for Intensified Processes 1465.5.1 Importance of Safety Training and Competency 1465.5.2 Developing Safety Training and Competency Programs 1475.5.3 Utilizing a Blended Learning Approach 1485.5.4 Assessing Training Effectiveness and Continual Improvement 1485.5.5 Benefits of Effective Safety Training and Competency Management 1485.6 Case Studies of Safety Analysis in Intensified Processes 1495.7 Conclusions 151References 151Part III Control and Safety Analysis of Intensified Chemical Processes 1556 Control of Hybrid Reactive–Extractive Distillation Systems for Ternary Azeotropic Mixtures 157Zong Yang Kong and Hao-Yeh Lee6.1 Introduction 1576.2 Steady-state Design of the RED 1606.3 Dynamic Simulation Setup 1616.4 Inventory Control Setup 1626.5 Sensitivity Analysis 1636.6 Quality Control Structures 1656.6.1 Control Structure 1 (CS 1) – Simple Temperature Control 1656.6.2 Control Structure 2 (CS 2) – Triple Point Temperature Control 1686.6.3 Control Structure 3 (CS 3) – Triple Point Temperature Control Using SVD Analysis 1706.6.4 Feedforward Control Structure 3 (FF-CS 3) 1726.7 Control Performance Evaluation 1776.8 Conclusions 178Acknowledgements 179Acronyms 179Nomenclature 180References 1807 Process Design and Control of Reactive Distillation in Recycle Systems 183Mihai Daniel Moraru, Costin Sorin Bildea, and Anton Alexandru Kiss7.1 Introduction 1837.2 Design of Reactive Distillation Processes 1847.3 Control of Reactive Distillation Processes 1887.4 Case Study: RD Coupled with a Distillation–Reactor System and Recycle 1927.4.1 Basis of Design and Basic Data 1927.4.2 Process Design 1987.4.3 Process Control 2017.4.4 Discussion 2047.5 Conclusions 204References 2058 Dynamics and Control of Middle-vessel Batch Distillation with Vapor Recompression 209Radhika Gandu, Akash Burolia, Dipesh Shikchand Patle, and Gara Uday Bhaskar Babu8.1 Introduction 2098.2 Conventional Middle-vessel Batch Distillation 2118.2.1 A Systematic Simulation Approach of CMVBD 2128.2.1.1 Model Equations 2138.2.2 Constant Composition Control 2168.3 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 2168.3.1 A Systematic Simulation Approach of SiVRMVBD 2168.4 Performance Specifications 2188.4.1 Energy Savings 2188.4.2 Total Annual Cost 2188.4.3 Greenhouse Gas Emissions 2198.5 Results and Discussion 2198.5.1 Conventional Middle-vessel Batch Distillation Column 2198.5.1.1 Dynamic Composition Profiles 2198.5.2 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 2228.5.3 Energetic, Economic, and Environmental Performance: CMVBD vs. SiVRMVBD 2258.5.4 Constant Composition Control 2268.5.4.1 SiVRMVBD-GSPI 2298.5.5 Energetic, Economic, and Environmental Performance: CMVBD vs. Controlled CMVBD and SiVRMVBD 2328.6 Conclusions 234References 2349 Safety Analysis of Intensified Distillation Processes Using Existing and Modified Safety Indices 237Savyasachi Shrikhande, Gunawant K. Deshpande, Gade Pandu Rangaiah, andDipeshShikchandPatle9.1 Introduction 2379.2 Safety Indices for Process Safety Assessment 2399.3 Description of Distillation Systems 2419.3.1 Conventional Sequence of Columns 2419.3.2 Dividing-Wall Column 2419.3.3 Dividing-Wall Column with Mechanical Vapor Recompression 2439.4 Selection of Safety Indices 2449.5 Results and Discussion 2459.5.1 Conventional Sequence of Columns 2459.5.2 Dividing-Wall Column 2519.5.3 Dividing-Wall Column with Mechanical Vapor Recompression 2539.5.4 Comparative Analysis 2559.6 Survey of Engineers and Discussion of their Responses 2579.7 Improved PRI 2629.8 Conclusions 263Acknowledgments 263References 26410 Dynamic Safety Analysis of Intensified Extractive Distillation Processes with Independent Protection Layers 269Chengtian Cui and Meng Qi10.1 Introduction 26910.2 Preliminary 27110.3 Process Studied 27210.3.1 Process Intensification Measures 27210.3.2 Steady-state Process Design 27310.3.3 Process Intensification Analysis 27410.4 Dynamics and Control 27610.4.1 Control Basis 27610.4.2 Bpcs # 1 27910.4.3 Bpcs # 2 27910.4.4 Bpcs # 3 28210.5 Safety Analysis 28410.5.1 Process #1 Safety Analysis 28510.5.2 Process #2 Safety Analysis 28610.5.3 Process #3 Safety Analysis 28810.5.4 Dynamic Safety Analysis of Process #3 with IPLs 28910.6 Conclusions 292Acknowledgments 293References 29311 Operability and Safety Considerations in Intensified Structures for Purification of Bioproducts 295Juan G. Segovia-Hernández, César Ramírez-Márquez, Gabriel Contreras-Zarazúa, Eduardo Sánchez-Ramírez, and Juan J. Quiroz-Ramírez11.1 Introduction 29511.2 Methodology 30211.2.1 Control Behavior Analysis 30611.2.1.1 Singular Value Decomposition 30611.3 Methyl Ethyl Ketone 30711.3.1 Methyl Ethyl Ketone Production Through a Conventional Process 30811.3.1.1 MEK Production from Non-renewable Sources 30811.3.2 Purification of MEK Through Process-Intensified Schemes 30811.4 Intensification of Alcohol-to-Jet Fuel Process 31311.4.1 Process Modeling and Optimization 31411.4.2 Results 31611.5 New Processes for Furfural and Co-products 31811.5.1 Results 32111.6 Lactic Acid 32411.6.1 Lactic Acid Production by Reactive Distillation 32511.6.2 Design and Synthesis of Intensified Processes 32611.6.3 Optimization 32611.6.4 Results and Discussion 32711.7 Future and Perspectives 32911.8 Conclusions 329Acknowledgments 330References 33012 Analysis of Safety and Economic Objectives for Intensified Algal Biodiesel Process 335Gunavant Deshpande, Ashish N. Sawarkar, and Dipesh Shikchand Patle12.1 Introduction 33512.2 Process Development 33712.2.1 Process Development of Alternative 1 33712.2.2 Process Development of Alternative 2 34012.3 Multi-Objective Optimization 34212.3.1 Objective Functions 34412.3.1.1 Break-Even Cost 34412.3.1.2 Individual Risk (IR) 34512.3.2 Simple Additive Weighting (SAW) Method 34712.4 Results and Discussion 34712.4.1 Minimization of BEC and IR for Alternative 1 34812.4.2 Minimization of BEC and IR for Alternative 2 35012.5 Comparative Analysis 35212.6 Conclusions 353References 354Index 359