Mass Integration for Process Design

1
Mass Integration for Process Design

• Vasilios Manousiouthakis
• Chemical Engineering Department
• UCLA
• United Engineering Foundation
• November 18, 1999
• Lake Arrowhead, CA

2
Mass Integration

• Tool Minimum Mass Utility Cost for Mass
  Exchanger Networks
• with Fixed or Variable, Single Component Targets
  
• Objective
• Unit Operations Mass Exchangers
• Framework Conservation of Mass
• 1st and 2nd Laws of Thermodynamics
• Mass cascades from high to low chemical
  potential
• Concepts Mass Pinch Analysis, Composition
  Interval Diagrams,
• Mass Exchange Diagram

3
Waste Minimization
Energy Conservation
Mass Integration
Heat Integration
MEN
Hot
Rich
HEN
Lean
Cold
Mass Load
4
Minimum Mass Utility 1
V , yi
V , yo yu
L , xi
L , xo xu
x
yi
yu
xu
xo
yo
xi
y
0
M
5
Minimum Mass Utility 2
V , yi
V , yo yu
L , xi
L , xo xu
yi
yu
-m
yo
y
xi
x
xu
xo
6
Mass Integration Zinc Recovery - Metal Finishing
Plant
Pickle Solution Makeup
Pickle Solution
Spent Pickle Liquor
Pickling Bath
Pickled Metal
Rinse Bath
Water
To Regeneration
Metal Workpieces
Rinse Water
R1
R2
Rinse Water Makeup
S2
2
S1
1
Treated Rinse Water
HCl
Spray Roaster
Absorber
Hydrochloric Acid
Zinc-Free Spent Solution
FeO, Fe2O3
Cost 0.4159 /s
7
Mass Integration Zinc Recovery - Metal Finishing
Plant
Pickle Solution Makeup
Pickle Solution
Spent Pickle Liquor
Pickling Bath
Pickled Metal
Rinse Bath
Water
Metal Workpieces
To Regeneration
Rinse Water
R1
R2
S2
S2
Mass Exchange Network
Rinse Water Makeup
S1
S1
R1
R2
Treated Rinse Water
HCl
Spray Roaster
Absorber
Hydrochloric Acid
Zinc-Free Spent Solution
FeO, Fe2O3
8
Mass Integration System Data
Equilibrium Data
Zinc Chloride
R (water) - S1 (Resin) y 0.376 (xe)
0.0001, e 10 - 4 R (water) - S2 (Phosphate) y
0.845 (xe), e 10 - 4
Input Output Data
Rich Streams
Lean Streams
V yi yu xi xu
c kg/s kg/kg kg/kg kg/kg kg/kg /kg
R1 0.1 0.045 0.02 S1 0.0015 0.075
0.7 R2 1.5 0.03 0.001 S2 0.004
0.05 0.03
9
Mass Integration Composition Interval Diagram
10
Mass Integration Optimal Design
Pickle Solution Makeup
Pickle Solution
Spent Pickle Liquor
Pickling Bath
Pickled Metal
Rinse Bath
Water
To Regeneration
Metal Workpieces
Rinse Water
R1
R2
S2
S2
Rinse Water Makeup
1
2
S1
S1
3
R1
R2
Treated Rinse Water
HCl
Spray Roaster
Absorber
Hydrochloric Acid
Zinc-Free Spent Solution
FeO, Fe2O3
11
Multicomponent Mass Integration

• Tool Minimum Mass Utility Cost for Mass
  Exchanger Networks
• with Multicomponent Targets
• Objective
• Unit Operations Mass Exchangers
• Framework 1st and 2nd Laws of Thermodynamics
• Infinite DimEnsional State Space (IDEAS)
• Conservation of Mass
• Mass cascades from high to low chemical
• potential for each component
• Concepts Composition Interval Diagrams, Mass
  Exchange
• Diagrams for Each Component

12
Multicomponent Mass Integration Infinite
DimEnsionAl State-Space (IDEAS)
Outlets
. . . . . . . .
DN
Inlets
. . . .
. . . . .
. . . . . . . .
MEN
13
Multicomponent Mass Integration Example
Input-Output Data
y1i 0.040 0.024 0.024 x1i 0.00
y1o 0.016 0.016 0.016 x1o 0.008
y2i 0.042 0.042 0.074 x2i 0.000
y2o 0.002 0.010 0.010 x2o 0.025
Flow 0.125 0.375 0.125 Cost 1.0
Stream R1 R2 R3 L
Equilibrium Data
y1 4.0 x1 , y2 2.0 x2
14
Multicomponent Mass Integration Network Design

• Our recent results can identify minimum utility
  cost for the multicomponent MEN problem

R1
R1
R2
R2
1
R3
R3
L

• Multicomponent Minimum Utility Cost 1.0/min

15
Multicomponent Mass Integration Network Data
16
Multicomponent Mass Integration Mass Exchange
Diagrams
Component 1
Component 2
y1
x2
x1
y2
0.040
0.032
0.008
0.08
0.038
3
123
0.024
0.06
0.025
123
0.016
0.004
0.04
0.013
3
0.008
0.02
1
2
3
4
5
6
7
8
5
10
15
20
25
Mass Load (x10-3)
Mass Load (x10-3)
Minimum Utility Cost 1.0/min
Minimum Utility Cost 1.0/min
17
Multicomponent Mass IntegrationFirst Component
based Network Design
0.0240.050
0.125/0.0400.042
0.0160.012
R1
R1
1
2
0.375/0.0240.042
0.0160.011
R2
R2
3
0.125/0.0240.074
0.0160.017
0.0080.006
R3
R3
5
4
0.0060.025
0.0080.024
0.0010.001
1.0/0.00.0
L
L
Pinch

• Above network does not meet second component
  specifications for R1, R2
• Above network requires utility cost gt 1.21/min
  to meet second component specifications

18
Globally Optimal Distillation
Networks Minimum Utility
19
A
Petlyuk Column
III
IV
I
B
II
ABC
V
VI
C
20
IDEAS Representation of Petlyuk Column
21
(No Transcript)
22
(No Transcript)
23
(No Transcript)
24
(No Transcript)
25
(No Transcript)
26
(No Transcript)
27
(No Transcript)
28
(No Transcript)
29
(No Transcript)
30
(No Transcript)
31
(No Transcript)
32
(No Transcript)
33
(No Transcript)
34
(No Transcript)
35
(No Transcript)
36
(No Transcript)
37
Globally Optimal Distillation
Networks Minimum Plate Area for
Fixed Utility Cost
38
(No Transcript)
39
(No Transcript)
40
(No Transcript)
41
(No Transcript)
42
(No Transcript)
43
(No Transcript)
44
Globally Optimal Reaction/Distillation
Networks
45
Motivation

• Reactor and Distillation networks impact waste
  generation at two levels Processing and
  Recycling
• Design of such networks typically pursued through
  convex and/or mixed integer programs which do not
  guarantee global optimality.

46
Infinite DimEnsionAl State-space (IDEAS)
States Composition, Enthalpy Infinite number
of states Distribution Network (DN) allows for
stream mixing Process Blocks (RXN, MEN, HEN)
external to DN Includes ALL possible
designs Convex Programs Local optima are global
47
IDEAS Representation of a Reaction/Distillation
Network
48
Reactor/Distillation Network Synthesis
?
250K
250K
10 kg-moles/hr
10 kg-moles/hr
0.95 A
0.10 A
0.05 B
0.90 B
Determine the globally minimum utility cost over
any
complex reactor/distillation network
49
(No Transcript)
50
Reverse Exchangers
51
Reactor/Distillation Conventional Design Minimum
Utility Design
Utility Cost 0.773/hr
52
State-space representation of conventional
optimal design
53
Temperature-Heat Exchanged Diagram Minimum
Utility Conventional Design
54
IDEAS Optimal Design Minimum Utility
Utility Cost 0.365/hr
55
IDEAS Convergence Characteristics
56
Temperature-Heat Exchanged Diagram Minimum
Utility IDEAS Design
57
(No Transcript)
58
(No Transcript)
59
Reactor/Distillation Conventional Design Minimum
TAC Solution
LTAC 10,358
60
IDEAS Optimal Design LTAC
LTAC 6,487/yr
61
Conclusions Infinite DimEnsionAl State-space
(IDEAS) process representation includes all
possible processes Resulting problem
formulations are convex IDEAS designs are
flexible and may be used to represent a wide
variety of processes For reaction/distillation
networks, IDEAS designs have lower utility cost
and TAC than conventional designs
62
ACKNOWLEDGEMENTS
Mahmoud El-Halwagi Ashish Gupta Stevan
Wilson James Drake