过程系统工程面临的挑战和发展趋势

分析了21世纪过程工业的发展趋势及面临的挑战;指出了过程系统工程的研究对象正在由传统的中观向微观和宏观两个方向延伸,小到以分子模拟为手段的产品设计,大到供应链管理的优化和生态系统,均已成为研究的热点;提出了绿色过程系统工程、动态过程和批处理过程系统工程必将成为21世纪初的新增长点,系统集成是当前最受到重视的领域之一。     

过程系统工程的发展和面临的挑战

过程系统工程是一门蓬勃发展中的重要学科。对这门学科的发展沿革做了简略回顾,然后对这门学科所做出的贡献和差距、存在的问题进行了探讨,最后指出过程系统工程在21世纪所面临的挑战及发展机遇。     

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.     

A systems engineering perspective on process integration in industrial biotechnology

Biotechnology has many applications in health care, agriculture, industry and the environment. By using renewable raw materials, biotechnology contributes to lowering greenhouse gas emissions and moving away from a petro‐based towards a circular sustainable economy. However, major developments are still needed to make industrial biotechnology an economic alternative to conventional processes for fuels, specialty and/or bulk chemicals production. Process integration is a holistic approach to process design, which emphasizes the unity of the process and considers the interactions between different unit operations from the outset, rather than optimizing them separately. Furthermore, it also involves the substitution of two or more unit operations by one single novel unit capable of achieving the same process goal. Conversely, process systems engineering (PSE) deals with the analysis, design, optimization, operation and control of complex process systems, as well as the development of model‐based methods and tools that allow the systematic development of processes and products across a wide range of systems involving physical and chemical change. Mature tools and applications are available for chemical technology and steps have been taken to apply PSE principles also to bioprocess technology. This perspective paper argues that an interdisciplinary approach is needed towards integrated bio‐processing in order to link basic developments in biosciences with possible industrial applications. PSE can foster the application of existing and the development of new methods and tools for bioprocess integration that could promote the sustainable production of bio‐/chemical products. The inclusion of PSE principles and methods in biochemical engineering curricula and research is essential to achieve such goals. © 2014 Society of Chemical Industry     

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。     

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.     

绿色过程系统工程进展

介绍了由于可持续发展的要求、绿色壁垒的出现及企业形象认证等因素促使绿色过程系统工程作为一门学科分枝应运而生。与传统过程系统工程集中研究人为系统而把环境要求作为约束条件不同,绿色过程系统工程强调过程系统和自然系统之间关系,目的在于把人为系统放回到自然系统中去以形成经济一技术一社会和谐发展的统一体。评述了近20年来在该领域的工作进展。提出了绿色过程系统应成为一门大学教育课程。     

Intensification of chemical separation engineering by nanostructured channels and nanofluidics: From theories to applications

With the development of manufacturing technology on the nanoscale, the precision of nano-devices is rapidly increasing with lower cost. Different from macroscale or microscale fluids, many specific phenomena and advantages are observed in nanofluidics. Devices and process involving and utilizing these phenomena play an important role in many fields in chemical engineering including separation, chemical analysis and transmission.In this article, we summarize the state-of-the-art progress in theoretical studies and manufacturing technologies on nanofluidics. Then we discuss practical applications of nanofluidics in many chemical engineering fields,especially in separation and encountering problems. Finally, we are looking forward to the future of nanofluidics and believe it will be more important in the separation process and the modern chemical industry.     

中国过程系统工程30年：回顾与展望

中国系统工程学会过程系统工程专业委员会至今已成立了30年，本文是一篇纪念文章，全文分为四个部分。首先就过程系统工程（process systems engineering, PSE）作为一个学科在中国的缘起做一个简要回顾；其次，介绍了30年来PSE的发展贡献和问题，简要回顾30年来（特别是近10年来）PSE领域的重要成果及其对于过程工业的贡献，并对当前工作中存在的问题提出一些看法；再次，介绍了PSE面临的挑战和机遇，主要从全球和我国角度简要评述今后发展面临的问题，针对发展形势的要求，进一步指出了PSE学科将会有哪一些发挥作用的机会；最后展望未来，主要是对PSE今后工作提出了一些建议。     

Process systems opportunities in power generation,storage and distribution

This paper presents an overview of the current process systems opportunities in power generation, storage and distribution. It puts in perspective how process systems engineering (PSE) has contributed to the area and explores the current technical problems that PSE can contribute to. Fuel cells, solar cells, wind turbines, flow batteries and rechargeable batteries as well as their interactions with the smart grid are considered. PSE has contributed and will contribute to the design as well as optimal integration and operation of power generators, storage systems and power grids, through mathematical modeling, control and optimization.     

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。     

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.     

From PSE to PSE—Decision support for resilient enterprises

In recent years, the process systems engineering (PSE) community has recognized the need to address chemical enterprises comprising globally distributed, but strongly interacting, facilities. We examine this extension of PSE, which we call the PSE of enterprise (PSE²), as it relates to the five traditional PSE areas of system representation, modeling and simulation, synthesis and design, planning and scheduling, and control and supervision. We illustrate the strong structural, operational, and methodological parallels between PSE and PSE² in this study.     

Magnetic separations: From steel plants to biotechnology

Magnetic separations have for decades been essential processes in diverse industries ranging from steel production to coal desulfurization. In such settings magnetic fields are used in continuous flow processes as filters to remove magnetic impurities. High gradient magnetic separation (HGMS) has found even broader use in wastewater treatment and food processing. Batch scale magnetic separations are also relevant in industry, particularly biotechnology where fixed magnetic separators are used to purify complex mixtures for protein isolation, cell separation, drug delivery, and biocatalysis. In this review, we introduce the basic concepts behind magnetic separations and summarize a few examples of its large scale application. HGMS systems and batch systems for magnetic separations have been developed largely in parallel by different communities. However, in this work we compare and contrast each approach so that investigators can approach both key areas. Finally, we discuss how new advances in magnetic materials, particularly on the nanoscale, as well as magnetic filter design offer new opportunities for industries that have challenging separation problems.     

Computer-aided design and scale-up of crystallization processes: Integrating approaches and case studies

Scaling up a crystallization process often results in significant changes to crystal size distribution (CSD), purity and morphology, which are key determinants of product quality and has implications for downstream operations such as filtration. This unwelcome observation results from the interplay between hydrodynamics and crystallization kinetics that scale in different ways. Computer-aided tools, such as process system engineering (PSE) software and computational fluid dynamics (CFD) simulations, offer a means to understand these interactions within system constraints and to use the insight thus gained to guide scale-up strategies. This article outlines approaches to scaling up crystallizers and how to develop new processes, showing how numerical simulations and other software tools can be used to address typical issues arising in each case.     

Interfacial microdroplet evaporative crystallization on 3D printed regular matrix platform

Droplet evaporative crystallization on microscale heterogeneous surface is a vivid topic in chemical engineering, bioengineering, nanomaterials, and so on. Here, 3D printed interfacial matrix platform with regular pillar convexity and tunnel structure is fabricated to reveal the mechanism of the interfacial micro droplet crystallization. Element-based rotation volume model is established to simulate the concentration and nucleation barrier distribution during the microscale process. Sodium urate monohydrate and NaCl crystallization on the pillar convex structure both confirm that confined capillary flow in the micro droplet and initial nucleation condition dominate the nucleation, growth control and particle distribution. Droplet crystallization stretches over the tunnel structure reveal an interesting phenomenon that two regions possessing distinct-different nucleation barriers can isolated obtain the crystal particles from nanoscale to even millimeter scale. The fabricated platform and the capillary circulation transfer theory unfold a potential approach to harvest high value-added crystals with specific morphology and desire sizes distribution.     

溶液结晶中的介尺度成核过程研究进展

成核作为溶液结晶的第一步,是决定晶体产品质量的关键因素。目前,成核理论主要包括经典成核理论和非经典成核理论。相比于仅以原子、离子或分子等均匀稳定结构为单元的经典成核理论,非经典成核理论以纳米级前聚体为单元,这类单元涵盖了聚集体、纳米粒子等介尺度非均匀动态结构,导致形成的非经典成核过程更为复杂,需在传统的化学、化学工程和过程系统工程研究方法的基础上,充分利用介尺度科学研究方法完成其核心规律的探究。为此,总结了二步成核理论、预成核团簇理论、粒子附着晶化理论以及其他新提出的非经典成核理论,分析了其中的介尺度结构及其时空动态行为,并探讨了利用介尺度数学模型对现有成核数学模型的修正和优化的思路,最后对溶液结晶中晶体成核的介尺度研究范式及理论发展进行了展望。     

An inverse mapping approach for process systems engineering using automatic differentiation and the implicit function theorem

The objective in this work is to propose a novel approach for solving inverse problems from the output space to the input space using automatic differentiation coupled with the implicit function theorem and a path integration scheme. A common way of solving inverse problems in process systems engineering (PSE) and in science, technology, engineering and mathematics (STEM) in general is using nonlinear programming (NLP) tools, which may become computationally expensive when both the underlying process model complexity and dimensionality increase. The proposed approach takes advantage of recent advances in robust automatic differentiation packages to calculate the input space region by integration of governing differential equations of a given process. Such calculations are performed based on an initial starting point from the output space and are capable of maintaining accuracy and reducing computational time when compared to using NLP-based approaches to obtain the inverse mapping. Two nonlinear case studies, namely a continuous stirred tank reactor (CSTR) and a membrane reactor for conversion of natural gas to value-added chemicals are addressed using the proposed approach and compared against: (i) extensive (brute-force) search for forward mapping and (ii) using NLP solvers for obtaining the inverse mapping. The obtained results show that the novel approach is in agreement with the typical approaches, while computational time and complexity are considerably reduced, indicating that a new direction for solving inverse problems is developed in this work.     

A New Era for Chemical Apparatus Engineering?

The ACHEMA conference is an impressive exhibition on chemical apparatus engineering, closely connected with the epoch‐making developments of chemical and process engineering. It is most timely to think about new opportunities of development. Large‐scale plant engineering and general plant construction has experienced considerable improvement during the past decades. The effects of these changes are particularly perceptible in the economic sector of German apparatus engineering. Economic pressures have given an additional impetus to a considerable shrinking process. Chemical apparatus engineering will have to focus on two main pillars in the near future: highly qualified standard and innovative products. The latter must be developed in close cooperation with the economic sector of chemical engineering in order to put the hardware required for new technologies and process strategies on the market. This article names fields of manifestation of the general technical progress. The thrust is directed toward an elevated level of product quality that can be achieved from the point of view of apparatus engineering. These are properties that will finally lead to higher profitability. The signs for a new start of apparatus engineering are quite favorable, and this opportunity has to be seized. The ACHEMA conference as a location of exchange of experiences and an opportunity of critical assessment could be a source of ideas for future work.     

化学工程科学发展的回顾与思考

简述了化学工程科学发展的主要成果,重点介绍了近期发展的“产品工程”,化学工程中的尺度问题及化工过程“场”和“流”分析等方面的进展及其对化学工程科学内容的贡献;提出以“质量传递与转化”,“能量传递与转化”及“信息传递与转化”来描述现代化学工程学科体系。本文还对我国化工科学及产业发展进行了展望。