Towards a Framework for Systematic Innovation of Catalytic Gas Conversion Processes

Abstract

The recent past has seen increased research efforts into how optimal process designs can be systematically achieved for a given chemistry using mathematical optimization of process network superstructures. Such methods have been highlighted as key technologies that promise to deliver major improvements in process efficiencies. However, the methods are rarely applied in industry, mainly as a result of their inability to handle practical process constraints, to robustly process complex kinetic models and to support the design-decision making process. This chapter presents the development of advanced optimal process synthesis framework that enables the identification of optimal process structures. The framework enables the exploration of design trends and key design features that maximize process performance in terms of profit for catalytic gas phase reaction systems, taking into account various design options for the reactor, the separation system, and the energy systems. The process synthesis strategy consists of multiple levels to generate maximum design insight and understanding. Initial screening stages enable the development of conceptual design candidates that can be evolved and investigated in detail in the design evolution stages. The developments are illustrated with an application to styrene production.