Design of Sustainable Chemical Processes:Systematic Retrofit Analysis and Generation & evaluation of alternatives
Multi-scale and/or multi-disciplinary approach to process-product innovation
Integrated Methodologies for Process Development (T3-7)
Keywords: indicators,sustainability,safety,retrofit
The objective of this paper is to present a new generic and systematic methodology for identifying and evaluating the potential design (retrofit) alternatives of chemical processes operating in continuous and/or batch modes. This methodology uses three general indices to measure parameters in a specific chemical process that allow the identification of operational difficulties, process sensitivities and/or unused resources, and, through their analysis, identifies opportunities for targeted process/operation improvements. These indices (or indicators) give us general information about the costs, benefits and accumulation problems present across the process. In addition; a set of sustainability metrics are employed to evaluate the impact of the process on its surroundings (environmental, social and economic impact); and a set of safety indices are employed to measure the inherent safety of the process. Assigned values for the indicators are used as improvement targets, while the sustainability and safety indices are used as performance criteria to identify the best alternative. A software (Sustain Pro) has been developed to calculate the indicators, the sustainability metrics as well as the safety indices of a given process. Using data from plant data or from results of a simulation of the process at a reference design, it is possible to make an analysis of the process based on the calculated indicators. The critical points of the process are pointed out by the indicators and the impact of the process to its surroundings is also showed by the sustainability metrics and the safety indices. This software decreases the time spent in generating and evaluating alternatives by concentrating on the calculations that lead to identifying the most promising alternatives. Also the Sustain Pro software integrates different tools by providing efficient data transfer between them. It also extends the application of this methodology to any processes, with multiple reactors, and large and/or complex flowsheets.
The main features of the indicator based methodology has been highlighted through different case studies, for example, the well known HDA process the production of Methyl Tertiary Butyl Ether (MTBE). With the SustainPro software it was also possible to apply this methodology to more complex processes such as VCM production and Ammonia production. Through these case studies, the main features of the algorithm, such as the determination of the indicators, and the generation of targeted retrofit alternatives, which will improve the process, will be illustrated making these processes more competitive and sustainable.
Another important feature of this methodology is its applicability in real plant. To highlight this feature, a case study for an industrial process will be highlighted. This case study was jointly developed as a trial of the methodology and the SustainPro software.
Presented Thursday 20, 15:40 to 16:00, in session Integrated Methodologies for Process Development (T3-7).
