A prototype system for economic, environmental and sustainable optimization of a chemical complex

Abstract

A prototype of a chemical complex analysis system has been developed and used to demonstrate optimization of a chemical complex. The system incorporates economic, environmental and sustainable costs, and solves a MINLP for the best configuration of plants. It was applied to expanding production of sulfuric and phosphoric acid capacities and to evaluating heat recovery options at a major chemical company, and the results were compared to the company's case study. The system selected the better of two sites for required new phosphoric and sulfuric acids production capacities and selected, sited, and sized the optional heat-recovery and power-generation facilities. System capability was demonstrated by duplicating and expanding the industrial case study. A second application of the prototype was based on an agricultural chemical complex with ten multiple plant production units as found in the Baton Rouge–New Orleans, Mississippi river corridor. The optimal configuration of units was determined based on economic, environmental and sustainable costs. A comparison of the current configuration with the optimal one was made, and sensitivity to cost and prices was analyzed. The profit increased about 7.8% from the base case to the optimal solution. Also, environmental cost declined about 17%, and sustainability costs increased about 1.5%. These results illustrated the capability of the system to select an optimum configuration of plants in an agricultural chemical complex and to incorporate economic, environmental and sustainable costs. A brief sensitivity study gave predictable results and demonstrated additional capabilities of the system.