A process synthesis-intensification framework for the development of sustainable membrane-based operations

Abstract In this paper a multi-level, multi-scale framework for process synthesis-intensification that aims to make the process more sustainable than a base-case, which may represent a new process or an existing process, is presented. At the first level (operation-scale) a conceptual base case design is synthesized through the sequencing of unit operations and subsequently analyzed for identifying process hot-spots using economic, life cycle and sustainability metrics. These hot-spots are limitations/bottlenecks associated with tasks that may be targeted for overall process improvement. At the second level (task-scale) a task-based synthesis method is applied where one or more tasks representing unit operations are identified and analyzed in terms of means-ends for generating intensified flowsheet alternatives. At the third level (phenomena-scale) a phenomena-based synthesis method is applied, where the involved phenomena in various tasks are identified, manipulated and recombined to generate new and/or existing unit operations configured into flowsheet alternatives that target the tasks associated with hot-spots. Every lower-scale or higher-level, generates more alternatives than their corresponding larger-scale. Those alternatives that are able to address the identified hot-spots therefore give innovative and more sustainable process designs that otherwise could not be found from the larger-scales. In this paper, membrane-based operations identified through this framework are highlighted in terms of extension of the combined intensification-synthesis method and its application to generate membrane-based operations. Also, application of the framework is illustrated through a case study involving the production of methyl acetate where membrane-based intensified operations play a major role in determining more sustainable process design alternatives.

[1]  Rafiqul Gani,et al.  A New Decomposition-Based Computer-Aided Molecular/Mixture Design Methodology for the Design of Optimal Solvents and Solvent Mixtures , 2005 .

[2]  Rafiqul Gani,et al.  SEPARATION PROCESS DESIGN AND SYNTHESIS BASED ON THERMODYNAMIC INSIGHTS , 1995 .

[3]  V. Agreda,et al.  High-purity methyl acetate via reactive distillation , 1990 .

[4]  Jan Degrève,et al.  Pervaporation of water¿alcohol mixtures and acetic acid¿water mixtures , 2005 .

[5]  Colin Ramshaw,et al.  Evaluation of Spinning Disk Reactor Technology for the Manufacture of Pharmaceuticals , 2000 .

[6]  Jeffrey J. Siirola,et al.  Strategic process synthesis : Advances in the hierarchical approach , 1996 .

[7]  Michael F. Malone,et al.  Reactive distillation for methyl acetate production , 2003, Comput. Chem. Eng..

[8]  Rafiqul Gani,et al.  An integrated computer aided system for integrated design of chemical processes , 1997 .

[9]  Jorge A. Marrero,et al.  Group-contribution based estimation of pure component properties , 2001 .

[10]  Rafiqul Gani,et al.  SustainPro - A tool for systematic process analysis, generation and evaluation of sustainable design alternatives , 2013, Comput. Chem. Eng..

[11]  Rafiqul Gani,et al.  Phenomena Based Methodology for Process Synthesis Incorporating Process Intensification , 2013 .

[12]  Rafiqul Gani,et al.  Achieving More Sustainable Designs through a Process Synthesis-Intensification Framework , 2014 .

[13]  Fujio Mizukami,et al.  Stoichiometric Ester Condensation Reaction Processes by Pervaporative Water Removal via Acid-Tolerant Zeolite Membranes , 2007 .

[14]  Rafiqul Gani,et al.  Systematic Sustainable Process Design and Analysis of Biodiesel Processes , 2013 .

[15]  Jürgen Gmehling,et al.  Reaction Kinetics and Chemical Equilibrium of Homogeneously and Heterogeneously Catalyzed Acetic Acid Esterification with Methanol and Methyl Acetate Hydrolysis , 2000 .

[16]  James M. Douglas,et al.  A hierarchical decision procedure for process synthesis , 1985 .

[17]  Philip Lutze,et al.  An Innovative Synthesis Methodology for Process Intensification , 2011 .

[18]  Philip Lutze,et al.  Synthesis of dimethyl carbonate and propylene glycol in a membrane-assisted reactive distillation process: Pilot-scale experiments, modeling and process analysis , 2014 .

[19]  Sigurd Skogestad,et al.  Energy efficient distillation , 2011 .

[20]  Rafiqul Gani,et al.  Graphical and Stage-to-Stage Methods for Reactive Distillation Column Design , 2003 .

[21]  Rafiqul Gani,et al.  Process intensification: A perspective on process synthesis , 2010 .

[22]  Bart Van der Bruggen,et al.  Simulation of a hybrid pervaporation-distillation process , 2008, Comput. Chem. Eng..

[23]  Rafiqul Gani,et al.  A multi-step and multi-level approach for computer aided molecular design , 2000 .

[24]  Michael F. Malone,et al.  Measurement of Residue Curve Maps and Heterogeneous Kinetics in Methyl Acetate Synthesis , 1998 .

[25]  Suttichai Assabumrungrat,et al.  Theoretical study on the synthesis of methyl acetate from methanol and acetic acid in pervaporation membrane reactors: effect of continuous-flow modes , 2003 .

[26]  Philip Lutze,et al.  Reactive and membrane-assisted distillation: Recent developments and perspective , 2013 .

[27]  Rafiqul Gani,et al.  Integration of life cycle assessment software with tools for economic and sustainability analyses and process simulation for sustainable process design , 2014 .