Software tools overview: Process integration, modelling and optimisation for energy saving and pollution reduction

This paper provides an overview of software tools based on long experience and applications in the area of process integration, modelling and optimisation. The first part reviews the current design practice and the development of supporting software tools. Those are categorised as: (1) process integration and retrofit analysis tools, (2) general mathematical modelling suites with optimisation libraries, (3) flowsheeting simulation and (4) graph-based process optimisation tools. The second part covers an assessment of tools which enable the generation of new sustainable alternatives to adapt to the future needs. They deal with waste, environment, energy consumption, resources depletion and production cost constrains. The emphasis of the sustainable process design tools is largely on the evaluation of process viability under sustainable economic conditions, synthesis of sustainable process and supply chain process maintenance and life cycle analysis. Major software tools development and the potential of the research-based tools for sustainable process design task are overviewed in the concluding part. Copyright © 2010 Curtin University of Technology and John Wiley & Sons, Ltd.

[1]  L. T. Fan,et al.  Combinatorially Accelerated Branch-and-Bound Method for Solving the MIP Model of Process Network Synthesis , 1996 .

[2]  Mariano Asteasuain,et al.  Modeling and optimization of a high-pressure ethylene polymerization reactor using gPROMS , 2008, Comput. Chem. Eng..

[3]  George B. Dantzig,et al.  Linear programming and extensions , 1965 .

[4]  Cheng-Liang Chen,et al.  Superstructure-Based MINLP Formulation for Synthesis of Semicontinuous Mass Exchanger Networks , 2006 .

[5]  Michael Narodoslawsky,et al.  SPIonExcel—Fast and easy calculation of the Sustainable Process Index via computer , 2007 .

[6]  Jiři Klemeš,et al.  Computer-aided availability analysis on chemical plants , 1985 .

[7]  Simon Perry,et al.  Heat integration retrofit analysis of a heat exchanger network of a fluid catalytic cracking plant , 2001 .

[8]  Zdravko Kravanja,et al.  MINLP Synthesis of Processes for the Production of Biogas from Organic and Animal Waste , 2009 .

[9]  L. T. Fan,et al.  Decision-mapping: A tool for consistent and complete decisions in process synthesis , 1995 .

[10]  Igor Bulatov,et al.  Novel energy saving technologies evaluation tool , 2009, Comput. Chem. Eng..

[11]  Jane C. Bare,et al.  Pollution prevention with chemical process simulators: the generalized waste reduction (WAR) algorithm—full version , 1999 .

[12]  Cheng-Liang Chen,et al.  Synthesis of a Continuously Operated Mass-Exchanger Network for a Semiconsecutive Process , 2007 .

[13]  Ferenc Friedler,et al.  Incorporating heat integration in batch process scheduling , 2003 .

[14]  Nidal Hilal,et al.  Simulation and optimisation of extractive distillation with water as solvent , 2005 .

[15]  L. T. Fan,et al.  Integrated synthesis of process and heat exchanger networks: algorithmic approach , 2001 .

[16]  N. Mahinpey,et al.  Simulation of biomass gasification in fluidized bed reactor using ASPEN PLUS. , 2008 .

[17]  Raymond P. Côté,et al.  Using chemical process simulation to design industrial ecosystems , 2004 .

[18]  Peter Glavič,et al.  Process integration of a steam turbine , 2003 .

[19]  László Sikos,et al.  RAMS contribution to efficient waste minimisation and management , 2009 .

[20]  Jirí Jaromír Klemes,et al.  Water and wastewater minimisation study of a citrus plant , 2003 .

[21]  Dominic C.Y. Foo,et al.  Automated targeting for inter-plant water integration , 2009 .

[22]  R. Tan,et al.  Environmental performance optimization using process water integration and Sustainable Process Index , 2006 .

[23]  Henrique A. Matos,et al.  Dynamic modelling and simulation of a cogeneration system integrated with a salt recrystallization process , 2005, Comput. Chem. Eng..

[24]  C. Cormos,et al.  Innovative Concepts for Hydrogen Production Processes Based on Coal Gasification with CO2 Capture , 2008 .

[25]  Krist V. Gernaey,et al.  Model-based computer-aided framework for design of process monitoring and analysis systems , 2009, Comput. Chem. Eng..

[26]  Richard Loulou,et al.  Energy Technology Systems Analysis Programme , 2005 .

[27]  Rafiqul Gani,et al.  Computer-Aided Model Based Analysis for Design and Operation of a Copolymerization Process , 2006 .

[28]  S. Kravanja,et al.  The multilevel MINLP optimization approach to structural synthesis: the simultaneous topology, material, standard and rounded dimension optimization , 2005, Adv. Eng. Softw..

[29]  Denny K. S. Ng,et al.  A superstructure model for the synthesis of single-contaminant water networks with partitioning regenerators , 2009 .

[30]  Peter J.T. Verheijen,et al.  Modelling and simulation of the operation of an industrial batch plant using gPROMS , 1995 .

[31]  Ingwald Obernberger,et al.  Ecological Assessment of Integrated Bioenergy Systems using the Sustainable Process Index , 2000 .

[32]  S. Kravanja,et al.  THE MINLP OPTIMIZATION APPROACH TO STRUCTURAL SYNTHESIS. PART II : SIMULTANEOUS TOPOLOGY, PARAMETER AND STANDARD DIMENSION OPTIMIZATION BY THE USE OF THE LINKED TWO-PHASE MINLP STRATEGY , 1998 .

[33]  Jiří Jaromír Klemeš,et al.  Minimising carbon footprint of regional biomass supply chains , 2010 .

[34]  Ferenc Friedler,et al.  Process integration, modelling and optimisation for energy saving and pollution reduction , 2009 .

[35]  László Sikos,et al.  Reliability, availability and maintenance optimisation of heat exchanger networks , 2010 .

[36]  I. Heckl,et al.  Integrated Synthesis of Optimal Separation and Heat Exchanger Networks Involving Separations Based on Various Properties , 2005 .

[37]  Diego Barba,et al.  Simulation of a waste incineration process with flue-gas cleaning and heat recovery sections using Aspen Plus. , 2005, Waste management.

[38]  S. Kravanja,et al.  The MINLP optimization approach to structural synthesis. Part I: A general view on simultaneous topology and parameter optimization , 1998 .

[39]  Petar Sabev Varbanov,et al.  Optimisation of regional energy supply chains utilising renewables: P-graph approach , 2010, Comput. Chem. Eng..

[40]  Rafiqul Gani,et al.  Use of CAPE-OPEN standards in the interoperability between modelling tools (MoT) and process simulators (Simulis® Thermodynamics and ProSimPlus) , 2008 .

[41]  Zdravko Kravanja The Development of an Advanced Systems Synthesis Environment: Integration of MI(NL)P Methods and Tools for Sustainable Applications , 2009 .

[42]  R. Tan,et al.  Automated Targeting Technique for Single-Impurity Resource Conservation Networks. Part 1: Direct Reuse/Recycle , 2009 .

[43]  Zdravko Kravanja,et al.  MINLP retrofit of heat exchanger networks comprising different exchanger types , 2004, Comput. Chem. Eng..

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

[45]  L. T. Fan,et al.  Graph-theoretic approach to process synthesis: axioms and theorems , 1992 .

[46]  Zdravko Kravanja,et al.  MINLP synthesis of reactor networks in overall process schemes based on a concept of time-dependent economic regions , 2007, Comput. Chem. Eng..

[47]  Jing Chen,et al.  An object-oriented framework for modular chemical process simulation with semiconductor processing applications , 2006, Comput. Chem. Eng..

[48]  Ligang Zheng,et al.  ASPEN simulation of cogeneration plants , 2003 .

[49]  Ignacio E. Grossmann,et al.  Prosyn—an MINLP process synthesizer , 1990 .

[50]  Stanislaw Sieniutycz,et al.  Energy Optimization in Process Systems , 2009 .

[51]  Denny K. S. Ng,et al.  Automated Targeting Technique for Single-Impurity Resource Conservation Networks. Part 2: Single-Pass and Partitioning Waste-Interception Systems , 2009 .

[52]  Michael Narodoslawsky,et al.  The sustainable process index (SPI): evaluating processes according to environmental compatibility , 1995 .

[53]  Petar Sabev Varbanov,et al.  P-graph methodology for cost-effective reduction of carbon emissions involving fuel cell combined cycles , 2008, 2011 Fourth International Conference on Modeling, Simulation and Applied Optimization.

[54]  Denny K. S. Ng,et al.  Synthesis of Direct and Indirect Interplant Water Network , 2008 .

[55]  Zorka Novak Pintarič,et al.  Synthesis of batch water network for a brewery plant. , 2009 .

[56]  Zdravko Kravanja,et al.  Translation of variables and implementation of efficient logic‐based techniques in the MINLP process synthesizer MIPSYN , 2009 .

[57]  J. A. Bandoni,et al.  Dynamic simulation and optimisation of tubular polymerisation reactors in gPROMS , 2001 .

[58]  Haralambos Sarimveis,et al.  Model predictive temperature control in long ducts by means of a neural network approximation tool , 2007 .

[59]  Zhigang Lei,et al.  New process for separating propylene and propane by extractive distillation with aqueous acetonitrile , 2001 .

[60]  Ferenc Friedler,et al.  Maximization of Throughput in a Multipurpose Batch Plant under a Fixed Time Horizon: S-graph Approach , 2006 .

[61]  Michael Narodoslawsky,et al.  What can we learn from ecological valuation of processes with the sustainable process index (SPI) — the case study of energy production systems , 2004 .

[62]  Rafiqul Gani,et al.  Computer-Aided Methods and Tools for Chemical Product Design , 2004 .

[63]  Zdravko Kravanja,et al.  Simultaneous MINLP synthesis of heat exchanger networks comprising different exchanger types , 2002 .

[64]  Valentin Plesu,et al.  Thermal coupling between crude distillation and delayed coking units , 2003 .

[65]  László Sikos,et al.  Evaluation and assessment of reliability and availability software for securing an uninterrupted energy supply , 2010 .

[66]  Petr Stehlík,et al.  WASTE-TO-ENERGY (W2E) SOFTWARE – A SUPPORT TOOL FOR DECISION MAKING PROCESS , 2009 .

[67]  Ignacio E. Grossmann,et al.  Prosyn — An automated topology and parameter process synthesizer , 1994 .

[68]  Krist V. Gernaey,et al.  Biorefining: Computer aided tools for sustainable design and analysis of bioethanol production , 2009 .

[69]  Naoko Ellis,et al.  Assessment of four biodiesel production processes using HYSYS.Plant. , 2008, Bioresource technology.

[70]  Ignacio E. Grossmann,et al.  New trends in optimization-based approaches to process synthesis , 1996 .

[71]  A. VasickaninovÃ,et al.  Fuzzy Model-based Neural Network Predictive Control of a Heat Exchanger , 2010 .

[72]  Rafiqul Gani,et al.  Modelling and simulation of vegetable oil processes , 2008 .

[73]  Brian Vad Mathiesen,et al.  A review of computer tools for analysing the integration of renewable energy into various energy systems , 2010 .

[74]  T. Gundersen,et al.  Optimal operation of heat exchanger networks based on structural information , 1996 .