(3fl) A Modular Approach to Process Intensification - Modeling, Optimization and Control

Process intensification (PI) offers the potential to boost process and energy efficiency, enhance process profitability and safety, and reduce waste and emissions via the development of innovative and sustainable technology solutions[1,2]. A wide range of PI technologies have been developed, some of which are already successfully commercialized such as reverse flow reactor, reactive distillation, divided wall column. However, so far these progresses mostly rely on Edisonian effort driven by experimentation breakthrough while lack of theory and fundamental understanding. To address this challenge towards systematic process intensification, a rapidly emerging research theme is to leverage computer-aided tools for PI design and operation [3,4].

In this poster, we will present a modular approach for the synthesis of operable and sustainable process intensification systems (as part of the RAPID SYNOPSIS and COMPLETE projects) [5]. The proposed approach features: (i) phenomena-based process synthesis to derive novel intensified design configurations [6], (ii) flexibility and risk analysis for evaluation of operability and inherent safety performances at conceptual design stage [7], (iii) simultaneous design and control optimization via explicit/multi-parametric model predictive control to ensure dynamic operation under uncertainty [8]. Adapting this model-based step-wise procedure offers the following advantages: (i) to rapidly screen the PI design space to suggest promising and potentially innovative process solutions for further investigation and validation, (ii) to rigorously analyze process performance (e.g., cost, safety, sustainability) at early design stage, and (iii) to systematically deliver intensified process systems with guaranteed economic and operational performance. We will also highlight the integration of the above research advances into the teaching and course development for undergraduate/graduate students and industry professionals.

Research Interests

• Computer-aided process intensification - design, optimization, and control
• Resilient supply chain management with modular process manufacturing
• Multi-scale process synthesis framework for dual energy challenge
• Hybrid modeling framework for integrated process and product design

Teaching Interests

• I have been teaching assistant for multiple undergraduate/graduate courses, e.g. Numerical Analysis, Energy Systems Engineering, Chemical Engineering Thermodynamics, etc.
• I have contributed to several course development projects funded by AIChE RAPID Institute, e.g. Process Design for Process Intensification, Modeling and Simulation for Process Intensification
• I have actively participated in communities of TAMU Academy for Future faculty and Center for the Integration of Research, Teaching and Learning
• Teaching competency: Chemical Engineering Process Analysis, Chemical Engineering Thermodynamics, Chemical Engineer Heat/Mass Transfer Operations, Chemical Engineering Plant Design, Process Optimization, Process Dynamics and Control

References

1. Stankiewicz, A., & Moulijn, J. A. (2003). Re-engineering the chemical processing plant: process intensification. CRC Press.
2. Bielenberg, J., & Palou-Rivera, I. (2019). The RAPID Manufacturing Institute – Reenergizing US efforts in process intensification and modular chemical processing. Chem. Eng. Process., 138, 49-54.
3. Tula, A. K., Eden, M. R., & Gani, R. (2020). Computer‐aided process intensification: Challenges, trends and opportunities. AIChE J., 66(1), e16819.
4. Tian, Y., Demirel, S. E., Hasan, M. M. F., & Pistikopoulos, E. N (2018). An overview of process systems engineering approaches for process intensification: State of the art. Chem. Eng. Process., 133, 160-210.
5. Tian, Y., Pappas, I., Burnak, B., Katz, J., & Pistikopoulos, E. N. (2020). A systematic framework for the synthesis of operable process intensification systems – Reactive separation systems. Comput. Chem. Eng., 134, 106675.
6. Tian, Y., & Pistikopoulos, E. N. (2020). Towards an Envelope of Design Solutions for Combined/Intensified Reaction/Separation Systems. Ind. Eng. Chem. 59(24), 11350-11354.
7. Tian, Y., & Pistikopoulos, E. N. (2019). Synthesis of operable process intensification systems – Steady-state design with safety and operability considerations. Ind. Eng. Chem. Res., 58(15), 6049-6068.
8. Tian, Y., Pappas, I., Burnak, B., Katz, J., & Pistikopoulos, E. N. Simultaneous Design & Control of a Reactive Distillation System – A Parametric Optimization & Control Approach. Under Review.