PSE for problem solving excellence in industrial R&D

PSE, process systems engineering, is about the development and application of systematic methods for process studies by the chemical engineer. By means of software tools, the application of these methods is facilitated. Over the last about half a century, CAPE (computer aided process engineering) tools have found their way into process engineering. For example it is unthinkable nowadays to design a plant without a simulation through a process simulator. But there are many more applications of PSE in industry.The aim of this paper is to provide a taste of the meaning of PSE within the industrial R&D environment. The intention is not to provide a complete overview but to give a flavour of what is perceived as the benefits of PSE during process development, and, in which areas PSE should be extended to render further benefits. The combined approach of experiments and modelling offers a very (cost-)effective strategy in industrial R&D. Further improvements are desired in the areas related to process intensification (PI) and (conceptual) product design. It is believed that the current methods would be more beneficial and have a stronger applicability in industry by inclusion of semi-predictive models and uncertainty considerations.     

Downstream of downstream processing: development of recycling strategies for biopharmaceutical processes

BACKGROUND: Downstream processing plays a crucial role in biotechnological production processes. Product concentration and purification require complex, multi‐step operations, using significant amounts of chemical and auxiliary material. Today, design and optimization is important because the process development of biotechnological products is becoming more and more expensive. It is of great importance to improve sustainable development of eco‐efficient products and processes. Integrated process and product development leads to more efficient use of raw materials. RESULTS: A new stepwise approach is proposed to develop recycling strategies for biopharmaceutical products, which can be implemented within an existing and approved process environment. This article describes the approach in detail and exemplifies the methodical procedure for characteristic reference processes. The theoretical recycling and separation tasks as well as possible strategies are defined and evaluated experimentally. An experimental model parameter determination in small scale is shown. In addition, concrete solutions are discussed due to solving regulatory constraints addressing comparability studies. CONCLUSION: It is shown that development with the aim of intensification and full integration of the individual steps of bioprocess production (modules, unit operations) leads to an improvement in every single step at the same time. It follows clearly that consistent implementation represents a meaningful contribution to next generation bioproduction design. Copyright © 2012 Society of Chemical Industry     

Integration of microbial and chemical processing for a sustainable metallurgy

Bioprocessing for the recovery of metal from divergent resources using the microbial strategy has emerged as a green technology in metallurgical operations. The limitations to maintain the ideal condition for bacterial growth with slow kinetics, however, have been considered as major obstacles to bioprocessing being implemented more widely. This can be overcome by integrating the microbes with a chemical processing route. The available reports on recent developments in hybrid bio‐chemical processing of both primary and secondary resources have presented promising results, exhibiting the potential for use in large‐scale metallurgy. In this context, reviewing the factors of the hybrid process would benefit from knowledge acquired in fundamental studies. The present review focuses on bio‐chemical process integration using eco‐friendly design tools for treating the difficult to extract resources and complex spent materials as well. Furthermore, the potential of hybrid technology has been evaluated by establishing an economic model as a case study which encompasses features of economic development, environmental consideration and societal matters to achieve process sustainability. © 2017 Society of Chemical Industry     

生物催化技术在化学工业中的应用（一）

化学工业在尝试使用可再生的原料以改善其持续性 ,促使化学品生产中生物加工的探索。生物系统吸引人的特征包括多样性、酶作用物选择性、区域选择性、化学选择性、对映体选择性以及在温和环境温度和压力下的催化作用。然而 ,生物加工的问题在于同化学加工的成本竞争 ,因为与现行的工业化生产过程对应的资产成本是很高的。化学工业可能会将生物技术运用于现有的原料和生产过程中 ,以从原料、加工副产物及废弃物中获取更多的好处。在今后的 10年间 ,能提供优于传统化学路线的生产过程或产品的生物加工将被更为广泛地应用。本文综述了环烷酮、烷基芳香烃、腈的生物转化 ,生物的芳香烃羧化作用和葡萄糖制 1,3 丙二醇     

化学工业"两化融合"发展与过程系统工程:挑战和前景(二)——"两化融合"发展对过程系统工程的挑战及前景

论述了化学工业"两化融合"发展,趋向精细化、服务化和可持续化,对过程系统工程(PSE)提出挑战.研究了过程系统工程应从产品工程/纳米过程系统工程、间歇过程系统工程、供应链的优化与协同、多尺度过程集成及绿色过程系统工程5个方面提供技术支撑的前景.     

PSE在石化科技创新中的应用

过程系统工程(process system engineering,简称PSE)的各项技术在石化科技创新的各个环节发挥着越来越重要的作用,本文介绍PSE的各项技术在石化工艺开发、催化材料研究和新产品设计、反应机理研究中的应用背景、应用过程和若干典型应用结果。针对科技创新与生产经营越来越紧密的趋势,讨论了PSE技术在促进过程控制与优化集成技术的开发、新仪器研发,并介绍了PSE技术在原油加工流程优化和生产调度优化等领域的应用前景。指出了PSE技术在石化科技创新中进一步应用的方向。     

可持续发展时代的过程集成

介绍了可持续性和过程系统工程的发展和定义,讨论了过程集成在可持续发展时代的企业内部和企业间的发展和应用。企业内的过程集成主要介绍了其集成方法以及多方面的应用实例,并提出了深度过程集成的概念;企业间的过程集成目前主要应用在多联产系统和生态工业园区。本文对一些典型的集成方法也简要进行了综述。     

Membrane Technology in Bioprocess Science

Membrane technology plays more and more a crucial role in the purification of biotechnological products. Integration of membrane based unit operations becomes a trend for ongoing process designs. By this, in addition to the well‐established membrane unit operations like microfiltration, ultrafiltration, nanofiltration and reverse osmosis, new membranes, modules and systems were developed in the last years. Herein, the efforts in the area of membrane chromatography should be mentioned as a major research topic. This paper focuses on the state of the art in membrane technology, especially in the field of biotechnology, and on innovative developments in the field of membrane chromatography as well as on process design methods, which are necessary to fulfill the challenges for competitive technologies for the future. To minimize the risk that is inherent in the design of any new process, it is essential to use unit operation models that describe the process behavior accurately. Modeling efforts, which were originally developed for other membrane unit operations, show a great potential for the adaption to new developed membrane technologies.     

中国过程系统工程20年——回顾与展望(上)

回顾了国际和国内过程系统工程(PSE)发展的历史。从模拟和优化技术对设计及运行优化的贡献、先进控制和实时监控优化、过程系统集成技术对节能减排的贡献、绿色PSE提高资源利用率、促进生态工业发展等几个方面了回顾了中国近20年PSE的发展。同时,探讨了发展中存在的问题,以及未来发展对PSE的挑战,展望了过程系统工程的未来。     

Process integration technology review: background and applications in the chemical process industry

Process integration is a holistic approach to process design and operation which emphasizes the unity of the process. Process integration design tools have been developed over the past two decades to achieve process improvement, productivity enhancement, conservation in mass and energy resources, and reductions in the operating and capital costs of chemical processes. The primary applications of these integrated tools have focused on resource conservation, pollution prevention and energy management. Specifically, the past two decades have seen the development and/or application of process integration design tools for heat exchange networks (HENs), wastewater reduction and water conservation networks, mass exchange networks (MENs), heat‐ and energy‐induced separation networks (HISENs and EISENs), waste interception networks (WINs) and heat‐ and energy‐induced waste minimization networks (HIWAMINs and EIWAMINs), to name a few. This paper provides an overview of some of these developments and outlines major driving forces and hurdles. The fundamental aspects of this approach along with their incorporation in an overall design methodology will be discussed. The paper also highlights several recent applications of process integration to industrial processes. Copyright © 2003 Society of Chemical Industry     

Integrating systems analysis and control for implementing process analytical technology in bioprocess development

This paper provides a perspective on the increasingly critical role that systems analysis and process control play in bioprocess development today. This is of particular importance to the manufacturers of biotech therapeutics since the product quality is critical and depends on the process and its control. Because a large number of process variables and raw materials can influence the overall outcome of a bioprocess, the correct determination of the process trajectory is often an intensive exercise. A follow‐up involving design of a suitable process control strategy for implementation of process conditions would be logical. However, such an exercise can no longer consider each unit operation one at a time but rather requires holistic inclusion of all upstream and downstream unit operations for successfully meeting the global standards laid down by various regulatory agencies by exploring the potential of process analytical technology (PAT) to achieve bigger objectives. In this perspective, the focus is on the core issues associated with process integration and how these may influence future process development. © 2014 Society of Chemical Industry     

声发射技术在化工过程中的应用

在简要介绍声发射技术原理、测量手段与分析分析方法的基础上,系统回顾了被动声发射技术在化工过程中对于物理化学变化以及设备状态监控的广泛应用,对声发射技术在流程工业中各个单元操作以及设备监控等各个方面的应用进行了综述。总结表明,声发射技术适用于各种恶劣的工业环境,能够实时在线、准确地实现流程工业中关键过程参数的检测,具有广阔的工业应用前景;相比于传统的检测手段,声发射技术具有更为广阔的工业应用前景。     

Distillation technology – still young and full of breakthrough opportunities

Throughout history, distillation has been the most widespread separation method. However, despite its simplicity and flexibility, distillation still remains very energy inefficient. Novel distillation concepts based on process intensification, can deliver major benefits, not just in terms of significantly lower energy use, but also in reducing capital investment and improving eco‐efficiency. While very likely to remain the separation technology of choice for the next decades, there is no doubt that distillation technology needs to make radical changes in order to meet the demands of the energy‐conscious modern society. This article aims to show that in spite of its long age, distillation technology is still young and full of breakthrough opportunities. Moreover, it provides a broad overview of the recent developments in distillation based on process intensification principles, for example heat pump assisted distillation (e.g. vapor compression or compression–resorption), heat‐integrated distillation column, membrane distillation, HiGee distillation, cyclic distillation, thermally coupled distillation systems (Petlyuk), dividing‐wall column, and reactive distillation. These developments as well as the future perspectives of distillation are discussed in the context of changes towards a more energy efficient and sustainable chemical process industry. Several key examples are also included to illustrate the astonishing potential of these new distillation concepts to significantly reduce the capital and operating cost at industrial scale. © 2013 Society of Chemical Industry     

Potential innovations in separation technology by nature‐inspired membranes: beneath and beyond the Earth's crust

The understanding of complex bio‐mechanisms in nature is explored in this perspective as a way to effectively enable scientific advancements in membrane technology. The mechanisms of nature‐inspired technological improvements are first analyzed from macroscale to nanoscale. Separation methods using membranes can be related to natural separation mechanisms such as soil filtration, when the production of groundwater is considered. Innovative nature‐inspired mechanisms are presented, which include ideas in developing new methods for membrane synthesis in order to boost the vast range of applications of membrane separation processes. Future innovative applications discussed in this paper include nanoscale surface patterning, self‐organization, and the control of these processes. Improvements to existing membranes through the resemblance of natural mechanisms are also aimed towards realizing sustainable and cost‐effective systems. © 2013 Society of Chemical Industry     

Trends und Entwicklungstendenzen in der Mischtechnik – Eindrücke und Schlaglichter der ACHEMA 2022

This contribution shows an important excerpt of the trends, tendencies, further developments and innovations in mixing technology presented at ACHEMA 2022, which, as one of the most important chemical and process engineering unit operations, is particularly important against the background of one of the ACHEMAs main topics “sustainability”. In addition to process solutions for different viscosity ranges, examples of stirring technology for liquid-phase systems, static and solid-state mixers, as well as individual, novel mixing systems from the laboratory to industrial scale are dealt with.     

低碳经济与工业生物技术

低碳经济以大幅度降低CO2排放量为主要手段,以提高能源利用率、实现经济可持续性发展为最终目标。低碳经济是经济转型的重点,是未来世界发展的方向。本文主要介绍了从低碳经济要求出发,当前工业生物产业的新局面,主要包括工业生物技术中的热点项目以及在生物材料领域备受关注的几种聚酯材料,同时也简介了当前工业生物技术发展中存在的问题与困难。     

工业园区生态化发展的挑战与过程系统工程的机遇

生态化成为过程工业园区可持续发展的必然选择。基于多要素、跨介质、多过程和多目标协同的园区内在特征,其生态化过程有赖于过程系统工程的研究范式和方法。在介绍过程工业园区生态化历程及特点的基础上,提出园区生态化趋势与研究需求;重点综述了在工业园区尺度上应用过程系统工程方法驱动其生态化发展的研究现状;分别就可持续性分析评价、节能、节水、碳管理、物质集成、多重网络集成优化及园区信息化等展开系统化评述。提出工业园区生态化给过程系统工程发展带来的挑战和机遇。     

Integrated Modelling of Process Operation Systems Using the Agent‐Oriented Approach

For the past years, several software and computer tools have been developed to aid the chemical process operations including real‐time simulation, on‐line optimization, fault diagnosis, process monitoring, and many other functions. These tools were designed separately and did not collaborate efficiently, making it difficult to integrate different engineering tasks for the optimal process operation. In this paper, an agent‐oriented modelling approach is presented to address this problem. Elements in the process operation systems are divided into two classes. One class consists of equipment, units and processes, while the other class consists of production operation tasks. The two classes of elements are modelled as objects and agents, respectively. Then, three strategies are presented to implement the integration of the whole process operation system, which are integration of object models, integration of agent models and supervision of operator. Also presented is a case study of integration of process operation decision optimization and abnormal situation management using the proposed agent oriented approach for TE challenge problem.     

Process systems engineering: From Solvay to modern bio- and nanotechnology.: A history of development, successes and prospects for the future

The term Process Systems Engineering (PSE) is relatively recent. It was coined about 50 years ago at the outset of the modern era of computer-aided engineering. However, the engineering of processing systems is almost as old as the beginning of the chemical industry, around the first half of the 19th century. Initially, the practice of PSE was qualitative and informal, but as time went on it was formalized in progressively increasing degrees. Today, it is solidly founded on engineering sciences and an array of systems-theoretical methodologies and computer-aided tools. This paper is not a review of the theoretical and methodological contributions by various researchers in the area of PSE. Its primary objective is to provide an overview of the history of PSE, i.e. its origin and evolution; a brief illustration of its tremendous impact in the development of modern chemical industry; its state at the turn of the 21st century; and an outline of the role it can play in addressing the societal problems that we face today such as; securing sustainable production of energy, chemicals and materials for the human wellbeing, alternative energy sources, and improving the quality of life and of our living environment. PSE has expanded significantly beyond its original scope, the continuous and batch chemical processes and their associated process engineering problems. Today, PSE activities encompass the creative design, operation, and control of: biological systems (prokaryotic and eukaryotic cells); complex networks of chemical reactions; free or guided self-assembly processes; micro- and nano-scale processes; and systems that integrate engineered processes with processes driven by humans, legal and regulatory institutions. Through its emphasis on synthesis problems, PSE provides the dialectic complement to the analytical bent of chemical engineering science, thus establishing the healthy tension between synthesis and analysis, the foundation of any thriving discipline. As a consequence, throughout this paper PSE emerges as the foundational underpinning of modern chemical engineering; the one that ensures the discipline's cohesiveness in the years to come.     

Cassava: Its polymer,fiber, composite,and application

Cassava is a type of plant which has different purposes of use. It is used to produce various foods, bio‐fibers, bio‐composites, and bio‐polymers. Besides, it is now used as renewable energy source of starch. The intention of the paper is to focus on the importance of cassava fibers, polymers, and composites as well as its potential applications, another focus point of this research is the biodegradable polymer development which is taken out from cassava starch. Moreover, this work gives a comprehensive review about surface treatments as well as the most recent developments of cassava polymer/fiber based bio‐composites and the summary of main result presented in the literature, focusing on properties of cassava composite and applications. These applications were related to various industrial application as well as others such as the production of xylenes, ethanol and bio‐fuel, food, food packaging and cassava foam . POLYM. COMPOS., 38:555–570, 2017. © 2015 Society of Plastics Engineers