<p>Preface xv</p> <p><b>Part I Overview and Background 1</b></p> <p><b>1 Introduction 3<br /> </b><i>Dipesh Shikchand Patle and Gade Pandu Rangaiah</i></p> <p>1.1 Process Intensification 3</p> <p>1.2 Need for Control and Safety Analysis of Intensified Chemical Processes 5</p> <p>1.3 Studies on Control and Safety Analysis of Intensified Chemical Processes 7</p> <p>1.4 Scope and Organization of the Book 9</p> <p>1.5 Conclusions 12</p> <p>References 13</p> <p><b>2 Applications and Potential of Process Intensification in Chemical Process Industries 15<br /> </b><i>Chirla C.S. Reddy</i></p> <p>2.1 Introduction 15</p> <p>2.2 Benefits of Process Intensification Techniques 16</p> <p>2.3 Static Mixers 17</p> <p>2.4 Process Intensification for Separation Vessels 18</p> <p>2.5 Process Intensification for Distillation 21</p> <p>2.6 Process Intensification for Heating 24</p> <p>2.6.1 Steam Injection Heater 24</p> <p>2.6.2 Steam/Electric Heaters as a Replacement for Fired Heaters 25</p> <p>2.6.3 Process Intensification for Flue Gas Heat Recovery 26</p> <p>2.6.4 Process Heat Exchangers 26</p> <p>2.6.5 Sonic Horn 27</p> <p>2.7 Steam Compression 27</p> <p>2.8 Process Intensification for Carbon Capture 30</p> <p>2.9 Process Intensification for Vacuum Systems 31</p> <p>2.10 Process Intensification for Water Deaeration 33</p> <p>2.11 Process Intensification for Development of Inherently Safer Design (isd) 33</p> <p>2.12 Process Intensification for Reducing Pressure Relief and Handling Requirements 35</p> <p>2.12.1 Non-safety Instrumented Solutions for Pressure Relief Systems 37</p> <p>2.12.2 Safety Instrumented System (SIS) Solutions for Reducing Pressure Relief Requirements 39</p> <p>2.13 Process Intensification for Wastewater Recovery 41</p> <p>2.14 Challenges of Process Intensification Techniques 43</p> <p>2.15 Conclusions 44</p> <p>References 45</p> <p><b>Part II Procedures and Software for Simulation, Control and Safety Analysis 47</b></p> <p><b>3 Simulation and Optimization of Intensified Chemical Processes 49<br /> </b><i>Zemin Feng and Gade Pandu Rangaiah</i></p> <p>3.1 Introduction 49</p> <p>3.2 Simulation of Chemical Processes 50</p> <p>3.2.1 Usefulness of Process Simulation 50</p> <p>3.2.2 Commercial Process Simulators 52</p> <p>3.2.3 Free Process Simulators 53</p> <p>3.2.4 Computational Methods for Process Simulation 53</p> <p>3.3 Procedure for Simulation of (Intensified) Chemical Processes 56</p> <p>3.3.1 Problem Analysis 56</p> <p>3.3.2 Basic Process Flow Design 57</p> <p>3.3.3 Process Intensification and Integration 57</p> <p>3.3.4 Model Construction 57</p> <p>3.3.5 Simulation and Convergence 59</p> <p>3.3.6 Results Analysis 59</p> <p>3.4 Optimization of (Intensified) Chemical Processes 59</p> <p>3.4.1 Mathematical Optimization Methods 59</p> <p>3.4.2 Optimization of Chemical Processes with a Process Simulator 62</p> <p>3.4.2.1 Optimization Using MATLAB 62</p> <p>3.4.2.2 Optimization Using Python 63</p> <p>3.5 Challenges in the Simulation/Optimization of Intensified Chemical Processes 65</p> <p>3.6 Case Study 66</p> <p>3.6.1 Problem Analysis 66</p> <p>3.6.2 Process Flow Design 67</p> <p>3.6.3 Model Construction 69</p> <p>3.6.4 Simulation and Convergence 70</p> <p>3.6.4.1 Process Simulation 70</p> <p>3.6.4.2 Economic Evaluation Criterion 71</p> <p>3.6.4.3 Process Optimization 73</p> <p>3.6.5 Results and Analysis 75</p> <p>3.7 Conclusions 78</p> <p>References 79</p> <p><b>4 Dynamic Simulation and Control of Intensified Chemical Processes 83<br /> </b><i>Zemin Feng and Gade Pandu Rangaiah</i></p> <p>4.1 Introduction 83</p> <p>4.2 Dynamic Simulation of Chemical Processes 84</p> <p>4.2.1 Understanding Dynamic Simulation 84</p> <p>4.2.2 Applications of Dynamic Simulation 87</p> <p>4.2.3 Dynamic Simulation Software 88</p> <p>4.3 Dynamic Simulation and Control Procedure 91</p> <p>4.4 Dynamic Simulation and Control of Intensified Chemical Processes 98</p> <p>4.4.1 Challenges Due to Process Intensification 100</p> <p>4.5 Process Control 100</p> <p>4.5.1 Controlled, Manipulated, and Disturbance Variables 101</p> <p>4.5.2 Typical Control Loop 101</p> <p>4.5.3 Control Degrees of Freedom 101</p> <p>4.6 Case Study 102</p> <p>4.6.1 Steady-state Simulation and Optimization 103</p> <p>4.6.2 Preparation/Initialization for Dynamic Simulation 103</p> <p>4.6.3 Control Structure Design 107</p> <p>4.6.3.1 Composition Control Scheme 108</p> <p>4.6.3.2 Temperature Control Scheme 110</p> <p>4.6.4 Tuning of Controller Parameters 112</p> <p>4.6.5 Analysis of Dynamic Simulation Results 112</p> <p>4.7 Conclusions 120</p> <p>References 121</p> <p><b>5 Safety Analysis of Intensified Chemical Processes 125<br /> </b><i>Masrina Mohd Nadzir, Zainal Ahmad, and Syamsul Rizal Abd Shukor</i></p> <p>5.1 Introduction 125</p> <p>5.2 Safety Analysis in Chemical Process Industry 126</p> <p>5.2.1 Safety Analysis Tools 128</p> <p>5.2.1.1 Hazard Identification 128</p> <p>5.2.1.2 Risk Assessment 130</p> <p>5.2.1.3 Inherently Safer Design (ISD) 131</p> <p>5.2.1.4 Safety Instrumented Systems 132</p> <p>5.2.1.5 Human Factors and Safety Culture 132</p> <p>5.2.1.6 Regulatory Framework and Compliance 134</p> <p>5.2.1.7 Monitoring and Continuous Improvement 135</p> <p>5.3 Process Intensification and Safety Analysis 136</p> <p>5.3.1 Impacts of Process Intensification on Safety 136</p> <p>5.3.2 Safety Analysis in Intensified Process Design 137</p> <p>5.3.2.1 Hazard Identification Techniques for Process Intensification Technologies 138</p> <p>5.3.2.2 Risk Assessment for Process Intensification Technologies 140</p> <p>5.3.3 Inherently Safer Design Principles Intensified Processes 141</p> <p>5.4 Safety Management Systems for Intensified Processes 144</p> <p>5.5 Safety Training and Competency for Intensified Processes 146</p> <p>5.5.1 Importance of Safety Training and Competency 146</p> <p>5.5.2 Developing Safety Training and Competency Programs 147</p> <p>5.5.3 Utilizing a Blended Learning Approach 148</p> <p>5.5.4 Assessing Training Effectiveness and Continual Improvement 148</p> <p>5.5.5 Benefits of Effective Safety Training and Competency Management 148</p> <p>5.6 Case Studies of Safety Analysis in Intensified Processes 149</p> <p>5.7 Conclusions 151</p> <p>References 151</p> <p><b>Part III Control and Safety Analysis of Intensified Chemical Processes 155</b></p> <p><b>6 Control of Hybrid Reactive–Extractive Distillation Systems for Ternary Azeotropic Mixtures 157<br /> </b><i>Zong Yang Kong and Hao-Yeh Lee</i></p> <p>6.1 Introduction 157</p> <p>6.2 Steady-state Design of the RED 160</p> <p>6.3 Dynamic Simulation Setup 161</p> <p>6.4 Inventory Control Setup 162</p> <p>6.5 Sensitivity Analysis 163</p> <p>6.6 Quality Control Structures 165</p> <p>6.6.1 Control Structure 1 (CS 1) – Simple Temperature Control 165</p> <p>6.6.2 Control Structure 2 (CS 2) – Triple Point Temperature Control 168</p> <p>6.6.3 Control Structure 3 (CS 3) – Triple Point Temperature Control Using SVD Analysis 170</p> <p>6.6.4 Feedforward Control Structure 3 (FF-CS 3) 172</p> <p>6.7 Control Performance Evaluation 177</p> <p>6.8 Conclusions 178</p> <p>Acknowledgements 179</p> <p>Acronyms 179</p> <p>Nomenclature 180</p> <p>References 180</p> <p><b>7 Process Design and Control of Reactive Distillation in Recycle Systems 183<br /> </b><i>Mihai Daniel Moraru, Costin Sorin Bildea, and Anton Alexandru Kiss</i></p> <p>7.1 Introduction 183</p> <p>7.2 Design of Reactive Distillation Processes 184</p> <p>7.3 Control of Reactive Distillation Processes 188</p> <p>7.4 Case Study: RD Coupled with a Distillation–Reactor System and Recycle 192</p> <p>7.4.1 Basis of Design and Basic Data 192</p> <p>7.4.2 Process Design 198</p> <p>7.4.3 Process Control 201</p> <p>7.4.4 Discussion 204</p> <p>7.5 Conclusions 204</p> <p>References 205</p> <p><b>8 Dynamics and Control of Middle-vessel Batch Distillation with Vapor Recompression 209<br /> </b><i>Radhika Gandu, Akash Burolia, Dipesh Shikchand Patle, and Gara Uday Bhaskar Babu</i></p> <p>8.1 Introduction 209</p> <p>8.2 Conventional Middle-vessel Batch Distillation 211</p> <p>8.2.1 A Systematic Simulation Approach of CMVBD 212</p> <p>8.2.1.1 Model Equations 213</p> <p>8.2.2 Constant Composition Control 216</p> <p>8.3 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 216</p> <p>8.3.1 A Systematic Simulation Approach of SiVRMVBD 216</p> <p>8.4 Performance Specifications 218</p> <p>8.4.1 Energy Savings 218</p> <p>8.4.2 Total Annual Cost 218</p> <p>8.4.3 Greenhouse Gas Emissions 219</p> <p>8.5 Results and Discussion 219</p> <p>8.5.1 Conventional Middle-vessel Batch Distillation Column 219</p> <p>8.5.1.1 Dynamic Composition Profiles 219</p> <p>8.5.2 Single-stage Vapor Recompression in Middle-vessel Batch Distillation 222</p> <p>8.5.3 Energetic, Economic, and Environmental Performance: CMVBD vs. SiVRMVBD 225</p> <p>8.5.4 Constant Composition Control 226</p> <p>8.5.4.1 SiVRMVBD-GSPI 229</p> <p>8.5.5 Energetic, Economic, and Environmental Performance: CMVBD vs. Controlled CMVBD and SiVRMVBD 232</p> <p>8.6 Conclusions 234</p> <p>References 234</p> <p><b>9 Safety Analysis of Intensified Distillation Processes Using Existing and Modified Safety Indices 237<br /> </b><i>Savyasachi Shrikhande, Gunawant K. Deshpande, Gade Pandu Rangaiah, andDipeshShikchandPatle</i></p> <p>9.1 Introduction 237</p> <p>9.2 Safety Indices for Process Safety Assessment 239</p> <p>9.3 Description of Distillation Systems 241</p> <p>9.3.1 Conventional Sequence of Columns 241</p> <p>9.3.2 Dividing-Wall Column 241</p> <p>9.3.3 Dividing-Wall Column with Mechanical Vapor Recompression 243</p> <p>9.4 Selection of Safety Indices 244</p> <p>9.5 Results and Discussion 245</p> <p>9.5.1 Conventional Sequence of Columns 245</p> <p>9.5.2 Dividing-Wall Column 251</p> <p>9.5.3 Dividing-Wall Column with Mechanical Vapor Recompression 253</p> <p>9.5.4 Comparative Analysis 255</p> <p>9.6 Survey of Engineers and Discussion of their Responses 257</p> <p>9.7 Improved PRI 262</p> <p>9.8 Conclusions 263</p> <p>Acknowledgments 263</p> <p>References 264</p> <p><b>10 Dynamic Safety Analysis of Intensified Extractive Distillation Processes with Independent Protection Layers 269<br /> </b><i>Chengtian Cui and Meng Qi</i></p> <p>10.1 Introduction 269</p> <p>10.2 Preliminary 271</p> <p>10.3 Process Studied 272</p> <p>10.3.1 Process Intensification Measures 272</p> <p>10.3.2 Steady-state Process Design 273</p> <p>10.3.3 Process Intensification Analysis 274</p> <p>10.4 Dynamics and Control 276</p> <p>10.4.1 Control Basis 276</p> <p>10.4.2 Bpcs # 1 279</p> <p>10.4.3 Bpcs # 2 279</p> <p>10.4.4 Bpcs # 3 282</p> <p>10.5 Safety Analysis 284</p> <p>10.5.1 Process #1 Safety Analysis 285</p> <p>10.5.2 Process #2 Safety Analysis 286</p> <p>10.5.3 Process #3 Safety Analysis 288</p> <p>10.5.4 Dynamic Safety Analysis of Process #3 with IPLs 289</p> <p>10.6 Conclusions 292</p> <p>Acknowledgments 293</p> <p>References 293</p> <p><b>11 Operability and Safety Considerations in Intensified Structures for Purification of Bioproducts 295<br /> </b><i>Juan G. Segovia-Hernández, César Ramírez-Márquez, Gabriel Contreras-Zarazúa, Eduardo Sánchez-Ramírez, and Juan J. Quiroz-Ramírez</i></p> <p>11.1 Introduction 295</p> <p>11.2 Methodology 302</p> <p>11.2.1 Control Behavior Analysis 306</p> <p>11.2.1.1 Singular Value Decomposition 306</p> <p>11.3 Methyl Ethyl Ketone 307</p> <p>11.3.1 Methyl Ethyl Ketone Production Through a Conventional Process 308</p> <p>11.3.1.1 MEK Production from Non-renewable Sources 308</p> <p>11.3.2 Purification of MEK Through Process-Intensified Schemes 308</p> <p>11.4 Intensification of Alcohol-to-Jet Fuel Process 313</p> <p>11.4.1 Process Modeling and Optimization 314</p> <p>11.4.2 Results 316</p> <p>11.5 New Processes for Furfural and Co-products 318</p> <p>11.5.1 Results 321</p> <p>11.6 Lactic Acid 324</p> <p>11.6.1 Lactic Acid Production by Reactive Distillation 325</p> <p>11.6.2 Design and Synthesis of Intensified Processes 326</p> <p>11.6.3 Optimization 326</p> <p>11.6.4 Results and Discussion 327</p> <p>11.7 Future and Perspectives 329</p> <p>11.8 Conclusions 329</p> <p>Acknowledgments 330</p> <p>References 330</p> <p><b>12 Analysis of Safety and Economic Objectives for Intensified Algal Biodiesel Process 335<br /> </b><i>Gunavant Deshpande, Ashish N. Sawarkar, and Dipesh Shikchand Patle</i></p> <p>12.1 Introduction 335</p> <p>12.2 Process Development 337</p> <p>12.2.1 Process Development of Alternative 1 337</p> <p>12.2.2 Process Development of Alternative 2 340</p> <p>12.3 Multi-Objective Optimization 342</p> <p>12.3.1 Objective Functions 344</p> <p>12.3.1.1 Break-Even Cost 344</p> <p>12.3.1.2 Individual Risk (IR) 345</p> <p>12.3.2 Simple Additive Weighting (SAW) Method 347</p> <p>12.4 Results and Discussion 347</p> <p>12.4.1 Minimization of BEC and IR for Alternative 1 348</p> <p>12.4.2 Minimization of BEC and IR for Alternative 2 350</p> <p>12.5 Comparative Analysis 352</p> <p>12.6 Conclusions 353</p> <p>References 354</p> <p>Index 359</p>