Table of Contents
Foreword vii
Part I Process Design
1 Introduction 3
1.1 The current setting of process industry 3
1.2 The development of the PDPS approach 4
1.3 Structure of the book 5
2 Performance products in a challenging environment 9
2.1 A challenging environment for the process industry 9
2.1.1 Environmental and energy challenges 9
2.1.2 Changes in consumer needs and requirements 13
2.1.3 Changes in the network of raw materials and their availability 16
2.1.4 Technological and operational changes 18
2.2 Product-centered process design 39
2.2.1 Product life cycle 43
2.2.2 Structured products and fast-moving consumer goods 46
2.3 New product development 48
2.3.1 Stage-gate innovation process 49
2.3.2 Management toots to support NPD 54
2.3.3 Competitive advantage 58
2.4 Design is not a trivial task 61
2.5 The challenges of the FMCG sector 62
2.5.1 Challenge #1: product profile improvement by microstructure creation 65
2.5.2 Challenge #2: product naturalness by mild processing 68
2.5.3 Challenge #3: benign products by improved sustainability practices 72
2.5.4 Challenge #4: on-shelf availability by supply chain optimization 75
2.6 A novel approach for product design and process synthesis 76
2.7 Take-away message 77
3 A structured approach for product-driven process design of consumer products 89
3.1 Introduction 89
3.2 Conceptual process design in the context of process systems engineering 93
3.2.1 Developments in new processes and retrofits 95
3.2.2 Interactions between process development and process design 96
3.2.3 Structure of the design activity 97
3.2.4 Life span performance criteria 99
3.3 Process synthesis in the industry of consumer products 100
3.4 A Product-driven Process Synthesis approach 102
3.4.1 Generalities 102
3.4.2 Structure of the methodology 104
3.5 Take-away message 109
4 Formulation of design problems and identification of consumer wants 119
4.1 Introduction 119
4.2 Level 0: formulation of design problem 119
4.3 Level 1: Identifying consumer wants 123
4.3.1 The perception and creation of value 124
4.3.2 Consumer focus: the consumer is king 126
4.3.3 Consumer wants and needs, product specifications 129
4.3.4 Quality Function Deployment 133
4.3.5 The QFD House of Quality 135
4.3.6 The BROC decision making method 137
4.4 Take-away message 141
5 Product function and generation of ideas 145
5.1 Level 2: product function 145
5.1.1 Building the HoQ-2 148
5.1.2 Generation of ideas 151
5.2 Level 3: input-output 157
5.2.1 Economic evaluation 159
5.3 Take-away message 161
6 Network of tasks, mechanisms and operational window 165
6.1 Level 4: fundamental tasks and task network 165
6.2 Level 5: mechanism and operational window 171
6.3 Take-away message 181
7 Equipment selection and design 185
7.1 Level 7: equipment selection and design 185
7.1.1 Selection of operating units 186
7.1.2 Design of operating units 187
7.2 Take-away message 230
8 Multi-product and multi-product-equipment integration 233
8.1 Level 6: multi-product integration 233
8.2 Level 8: multi-product-equipment integration 234
8.2.1 Supply Chain Management 236
8.2.2 Supply Chain Modeling 238
8.3 Take-away message 241
9 Molecular product design 243
9.1 Introduction and motivation 243
9.2 CAMD methodology 244
9.3 Quantitative structure-property relationships 245
9.4 Optimization formulations for CAMD 247
9.5 Mathematical techniques for the solution of CAMD optimization problems 248
9.6 Example 249
9.6.1 Initial steps 250
9.6.2 Generation of QSPR models 251
9.6.3 Problem formulation 253
9.6.4 Example results 254
9.7 Take-away message 256
Part II Process Design Principles
10 Process synthesis 261
10.1 Introductory concepts 261
10.2 Collection of relevant information 263
10.3 The hierarchy of decisions 266
10.4 Data structures for the space of alternative designs 271
10.5 Evaluation of alternative designs 273
10.6 Take-away message 275
10.7 Further reading 276
11 Process simulation 277
11.1 Process simulators 277
11.2 Modular- and equation-oriented modes 277
11.3 Analysis, process and simulation flowsheets 279
11.4 Degrees of freedom analysis 280
11.5 Bidirectional information and design specs 282
11.6 Recycles and tear streams 282
11.7 Convergence algorithms 283
11.8 Open-loop simulation of an ammonia synthesis plant in UniSim 284
11.8.1 Background 284
11.8.2 UniSim Design solution 286
11.8.3 Creating a new unit set 287
11.8.4 Building the simulation 288
11.8.5 Defining Reaction Sets 292
11.8.6 Entering the simulation environment 298
11.8.7 Using the Workbook 299
11.8.8 Installing the feed streams 299
11.8.9 Installing unit operations 303
11.9 Review simulation results 315
11.10 Saving 316
11.11 Closed-loop simulation of an ammonia synthesis plant in UniSim 317
11.11.1 Review of UniSim Design convergence methods 317
11.11.2 UniSim Design solution 319
11.12 Add recycle loop to ammonia synthesis process 320
11.12.1 Adding a Tee 320
11.12.2 Adding a Compressor 320
11.12.3 Adding a Recycle 321
11.13 Optimize the purge rate to deliver desired product 325
11.13.1 Installing, connecting and defining the Adjust 326
11.13.2 Adjusting the target variable 327
11.14 Investigate the effects of flash feed temperature on product composition 329
11.14.1 Defining the key variables 329
11.14.2 Creating the case study 332
11.15 Take-away message 334
11.16 Further reading 335
12 Reactor design 337
12.1 Essence of reactors 337
12.2 Ideal reactors 337
12.2.1 Batch reactors 337
12.2.2 Plug flow reactor (PFR) 337
12.2.3 Continuously stirred tank reactor (CSTR) 338
12.3 General reactor design 338
12.4 Mixing in industrial reactors 346
12.4.1 Gas mixing 346
12.4.2 Liquid mixing 346
12.4.3 Gas-liquid mixing 347
12.4.4 Solid-liquid mixing 349
12.5 Types of reactors 350
12.5.1 Vapor-liquid reactors 350
12.5.2 Catalytic processes 351
12.5.3 Bioreactors 353
12.6 Heating and cooling of reacting systems 363
12.6.1 Stirred tank reactors 364
12.6.2 Catalytic reactors 364
12.7 Heat exchangers as reactors 365
12.7.1 Homogenous reactions 365
12.7.2 Heterogenous reactions 365
12.8 Safety considerations in reactor design 366
12.9 Capital cost of reactors 366
12.10 Take-away message 367
12.11 Further reading 368
13 Batch process design 369
13.1 Continuous versus batch-wise 369
13.2 Batch scheduling 370
13.3 Basics of batch scheduling 371
13.4 State-task networks 375
13.5 Mathematical formulations of scheduling problems 376
13.6 Example: scheduling of an ice cream factory 379
13.7 Implementation 381
13.8 AIMMS code for the scheduling model 384
13.9 Take-away message 387
13.10 Further reading 387
14 Separation train design 389
14.1 Separations in process development 389
14.2 Energy and separations 389
14.3 Selection of a suitable separation method 390
14.4 The sequencing of separations 391
14.5 The sequencing of ordinary distillation columns 392
14.6 Complex column configurations for ternary mixtures 395
14.7 Estimating the annualized costs for separation sequences 397
14.8 Distillation column design with a process simulator 399
14.8.1 Setting your session preferences 400
14.8.2 Building the simulation 401
14.8.3 Review simulation results 413
14.9 Take-away message 415
14.10 Further reading 415
15 Plant-wide control 417
15.1 Process control 417
15.2 Incentives for process control 417
15.3 Importance of modeling 419
15.4 Block diagrams 419
15.5 Control schemes 420
15.6 Dynamic model development and behavioral diagrams 422
15.7 Linearizations and Laplace transforms 424
15.8 Basic control loops 425
15.9 Sensors and valves 428
15.10 Process interlocks 429
15.11 Process control over the entire process 430
15.12 Take-away message 433
15.13 Further reading 434
16 Heat integration 435
16.1 Pinch analysis 435
16.2 Motivation for heat integration by pinch analysis 435
16.3 The pinch analysis approach 436
16.4 Take-away message 449
16.5 Further reading 449
17 Process economics and safety 451
17.1 Process safety 451
17.1.1 HAZOP analysis of a typical pipe section 452
17.2 Equipment sizing 454
17.2.1 Vessel geometry 455
17.2.2 Stresses and strains 456
17.2.3 Wall thickness 457
17.2.4 Head thickness 457
17.2.5 Corrosion allowance 458
17.3 Estimation of capital 458
17.3.1 Fixed capital investment 459
17.3.2 Project financing 459
17.3.3 Capital cost estimates 460
17.3.4 Estimation of production cost and revenues 461
17.3.5 Market effects 462
17.3.6 The gross (profit) margin 463
17.4 Engineering economic analysis 463
17.5 Computer tools for cost estimating 465
17.6 Take-away message 466
17.7 Further reading 467
18 Design for sustainability 469
18.1 Taking the long-term view 469
18.2 Metrics for sustainability 470
18.3 Including sustainability metrics within the design process 474
18.4 Retrofit for improved sustainability 475
18.5 Take-away message 477
18.6 Further reading 478
19 Optimization 479
19.1 Classification of optimization problems 479
19.2 Objectives and constraints 480
19.3 Specific formulations for process design and operations 482
19.4 Solution algorithms for optimization problems 485
19.5 Take-away message 489
19.6 Further reading 490
20 Enterprise-wide optimization 491
20.1 What is Enterprise-wide optimization? 491
20.2 Fast-moving consumer goods supply chains 491
20.3 Scheduling 492
20.4 Planning 494
20.5 Mixed-Integer programming 494
20.6 Optimization challenges 498
20.6.1 The challenge of flexibility 499
20.6.2 The challenge of sustainability 499
20.6.3 The challenge of complexity 502
20.6.4 Perspectives 502
20.7 Take-away message 504
20.8 Further reading 504
A Appendix 505
Index 507
