Achieving the Promise of Process Integration & Intensification through Proper Controls Design

Process integration (mass and energy integration) is predominantly established as means for process and productivity improvement. Process Integration & Intensification (PII), while widely investigated in academia, has been implemented in industrial settings on a relatively limited basis. This is due to several factors, mostly revolving around the perceived (in)ability to control these processes robustly across the operating envelope. Thus, rather than taking advantage of the potential cost savings from an Integrated & Intensified Process (IIP), many industrial projects fall back on the security of more familiar, though higher cost, designs.

This paper reviews a number of IIPs, from “simple” to “complex” and assesses both the process and controls design considerations that allow for successful operational performance. It will be shown that a clear understanding of the process engineering fundamentals and process dynamics led to the design of better process control structures and/or unit operations designs. Based on this understanding, the solutions proved to be relatively simple. This important finding contrasts with solutions proposed by both industrial control engineers as well as control academics that tend to suggest complex solutions which are both difficult and expensive to implement and not robust. Additional conclusions are:

• Control of IIPs is not well-developed during design.
• Early consideration of control structures is necessary for success.
• Knowledge of dynamic process behavior is a prerequisite for success
• Simulation & visualization plays a vital role in successful operations.