Model-based retrofit design and analysis of petrochemical processes

Abstract

This paper presents the development of a systematic methodology that can generate and screen feasible retrofit process alternatives, to produce the same products from the same raw materials and from them, to identify the more sustainable ones. The methodology is organized in three stages: 1. targeted process analysis; 2. reverse process synthesis and design; and 3. final selection and verification. In the first stage, the process flowsheet is analyzed in order to identify the design/operational weak points, indicating potential for improvement and thereby to set design targets that may improve the process. In the next stage, the identification of feasible process options are made based on thermodynamic insights. The process options are generated through an analysis of the physico-chemical properties of the particular mixture present in the system and based on the relationships between properties and separation technique, a list of feasible alternatives for the particular separation task is generated. A reverse approach is used to match the final design details for process options. In the third stage, performance of the identified feasible process alternatives are compared, for final selection, in terms of sustainability metrics. Application of the developed methodology is illustrated through the tert- amyl methyl ether (TAME) production process.