A Systematic Framework for the synthesis of operable process intensification systems – Reactive separation systems

In this work, we propose a systematic framework to synthesize process intensification systems with guaranteed operability, safety, and control performances accounting for both steady-state design and dynamic operation. A step-wise procedure is outlined which synergizes: (i) phenomena-based process synthesis with the Generalized Modular Representation Framework to derive novel intensified design configurations, (ii) flexibility and risk analysis for evaluation of operability and inherent safety performances at conceptual design stage, (iii) explicit/multi-parametric model predictive control following the PAROC (PARametric Optimisation and Control) framework to ensure dynamic operation under uncertainty, and (iv) simultaneous design and control via dynamic optimization to close the loop for the design of verifiable, operable, and optimal intensified systems. The proposed framework is demonstrated through a reactive separation case study for methyl tert-butyl ether production. Multiple process solutions are generated to showcase the trade-offs between economic and operational performances.