A multiobjective optimization framework for design of integrated biorefineries under uncertainty

A systematic approach for development of a reliable optimization framework to address the optimal design of integrated biorefineries in the face of uncertainty is presented. In the current formulation, a distributed strategy which is composed of different layers including strategic optimization, risk management, detailed mechanistic modeling, and operational level optimization is applied. In the strategic model, a multiobjective stochastic optimization approach is utilized to incorporate the tradeoffs between the cost and the financial risk. Then, Aspen Plus models are built to provide detailed simulation of biorefineries. In the final layer, an evolutionary algorithm is employed to optimize the operating condition. To demonstrate the effectiveness of the framework, a hypothetical case study referring to a multiproduct lignocellulosic biorefinery is utilized. The numerical results reveal the efficacy of the proposed approach; it provides decision makers with a quantitative analysis to determine the optimum capacity plan and operating conditions of the biorefinery. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3208–3222, 2015     

Pinch‐based shortcut method for the conceptual design of adiabatic absorption columns

Shortcut methods are valuable tools for the fast evaluation of key performance indicators in the early phase of conceptual process design. For the design of absorption columns, operation at minimum solvent demand represents a thermodynamically sound indicator, which is, however, difficult to determine because an infinite number of separation stages need to be considered. Instead, the suggested shortcut model exploits the existence of the pinch point to identify operation at minimum solvent demand. Existing shortcut concepts, such as the well‐known equation of Kremser (Natl Pet News, 22, 43–49, 1930), are significantly outperformed by the novel shortcut model, which can be gradually refined to any desired accuracy. Integration into a stepwise procedure results in reliable solutions. The model covers rigorous thermodynamics; no simplifications regarding phase equilibrium, heat effects, or number of components are required. The performance of the method is illustrated by several case studies with up to seven components. © 2016 American Institute of Chemical Engineers AIChE J, 63: 1213–1225, 2017     

Pinch‐based shortcut method for the conceptual design of isothermal extraction columns

Shortcut methods are valuable tools for a comprehensive evaluation of key performance indicators in the early phase of conceptual process design. For the design of extraction columns, operation at minimum solvent demand represents a thermodynamically sound indicator, which is, however, difficult to determine. The suggested shortcut model therefore exploits the existence of the pinch point to directly identify operation at minimum solvent demand. It is solved quickly and reliably by a step‐by‐step procedure. The final step allows a reduction of the approximation error to any desired degree of accuracy. No simplifications regarding the number of components in the mixture or its thermodynamic behavior are introduced. Hence, arbitrary mixtures can be tackled. The performance of the method is highlighted by a fully automated screening of thousands of solvents for the recovery of fermentation products acetone, 1‐butanol, and ethanol from aqueous solution. © 2016 American Institute of Chemical Engineers AIChE J, 63: 1236–1245, 2017     

A hybrid optimisation model for the synthesis of sustainable gasification-based integrated biorefinery

Depletion of fossil fuels and increasing public awareness of environmental issues has stimulated the search for alternative energy sources. Biofuels are recognised as one of the most promising alternatives to fossil fuels, as they can be produced from various types of feedstock. The efficiency and sustainability of biomass-based production can be maximised by producing biofuels along with other valuable coproducts in a “biorefinery”. This concept was proposed to make the production of biofuels and biochemicals more economically viable by taking advantage of opportunities for process integration and waste recovery. In this work, a novel hybrid optimisation model that combines superstructure-based optimisation approach and insight-based automated targeting for the synthesis of a sustainable integrated biorefinery is presented. In addition, fuzzy optimisation is also adapted to synthesize such integrated facility with the simultaneous consideration of both economic and environmental performance. Note that the proposed approach is a generic synthesis strategy that can be applied even without detailed modelling of individual processes.     

An integrated mathematical programming approach for the design and optimisation of offshore fields

The paper presents a systematic methodology for the optimal design and operational management of offshore oil fields. It is comprised of two stages. At the design stage, the optimal production capacity of a main field is determined with an adjacent satellite field and a well drilling schedule. The problem is formulated as a mixed-integer linear programming formulation. Continuous variables represent individual well, jacket and topsides costs. Binary variables are used to select individual wells within a defined field grid. The mathematical formulation is concise and efficient. An MINLP model is proposed for the operational management optimisation of the offshore oilfields. In the latter model, non-linear equations are extensively used to model the pressure drops in pipes and wells for multiphase flow. Non-linear cost equations have been derived for the production costs of each well accounting for the length, the production rate and their maintenance. Operational decisions determine the oil flowrates, the operation/shut-in for each well and the pressures for each point in the piping network.     

Optimization of process synthesis and design problems: A modified differential evolution approach

A large number of process synthesis and design problems in chemical engineering can be modeled as mixed integer nonlinear programming (MINLP) problems. They involve continuous (floating point) and integer variables. A common feature of this class of mathematical problems is the potential existence of non-convexities due to the particular form of the objective function and/or the set of constraints. Due to their combinatorial nature, these problems are considered to be difficult. In recent years, evolutionary algorithms (EAs) are gaining popularity for finding the optimal solution of nonlinear multimodal problems encountered in many engineering disciplines. In the present study, a novel modified differential evolution [Angira, R., Babu, B.V., 2005a. Optimization of non-linear chemical processes using modified differential evolution (MDE). Proceedings of the Second Indian International Conference on Artificial Intelligence (IICAI-05), Pune, India, December 20-22, pp. 911-923. Also available at 〈http://discovery.bits-pilani.ac.in/discipline/chemical/bvb/publications.html〉], one of the evolutionary algorithms, is used for solving process synthesis and design problems. To illustrate the applicability and efficiency of modified differential evolution (MDE), seven test problems on process synthesis and design have been solved. These problems arise from the area of chemical engineering, and represent difficult nonconvex optimization problems, with continuous and discrete variables. The performance of MDE is compared with that of Genetic Algorithm, Evolution Strategy, and MINLP-Simplex Simulated Annealing (M-SIMPSA).     

A complete testing environment for the automated parallel performance characterization of biofuel cells: design,validation, and application

We present a complete testing environment for the parallel performance characterization of biofuel cells. Besides rapid-assembly electrode fixtures and an aseptic electrochemical reactor, it comprises a 24-channel electrical testing system that bridges the gap between simple load resistors and costly multi-channel potentiostats. The computer-controlled testing system features active current control to enable the forced operation of half-cell electrodes, whereas galvanic isolation between individual channels ensures interference-free operation of multiple fuel cells immersed in a common testing solution. Implemented into the control software is an automated procedure for the step-wise recording of polarization curves. This way, performance overestimation due to a too fast increase in load current can be circumvented. As an applicational example, three abiotically catalyzed glucose fuel cells are characterized simultaneously in a common testing solution. Complete disclosure of the electrical system (incl. printed circuit board layout, control software, and circuit diagrams) in the online supplementary material accompanying this paper allows researchers to replicate our setup in their lab and can serve as inspiration for the design of similar systems adapted to specific requirements. Electronic supplementary material  The online version of this article (doi:) contains supplementary material, which is available to authorized users.     

Optimal processing pathway for the production of biodiesel from microalgal biomass: A superstructure based approach

In this study, we propose a mixed integer nonlinear programming (MINLP) model for superstructure based optimization of biodiesel production from microalgal biomass. The proposed superstructure includes a number of major processing steps for the production of biodiesel from microalgal biomass, such as the harvesting of microalgal biomass, pretreatments including drying and cell disruption of harvested biomass, lipid extraction, transesterification, and post-transesterfication purification. The proposed model is used to find the optimal processing pathway among the large number of potential pathways that exist for the production of biodiesel from microalgae. The proposed methodology is tested by implementing on a specific case with different choices of objective functions. The MINLP model is implemented and solved in GAMS using a database built in Excel. The results from the optimization are analyzed and their significances are discussed.     

A numerical method of cascade analysis and design for multi-component isotope separation

A numerical method is presented for cascade analysis and design for multi-component isotope separations. A fundamental issue of interest in cascade analysis and design is the solution of the nonlinear algebraic equation system. This system describes the mass conservation and the separation property of a cascade, which provides the hydraulic state and the component distributions in the cascade. Analytical solutions for the system are only available in a few special cases. Numerical methods are preferred for many of the complicated separation situations; however, the solution process in a numerical method is carried out through iterations and is very sensitive to initial values, which often leads to the failure of the method. Continuation techniques satisfactorily resolve the problem of sensitivity. This paper presents computer algorithms in detail to show how the techniques were implemented in order to tackle the problems in constructing different cascades. Various cascades were employed as test problems, including the well-known matched-R cascade, the quasi-ideal cascade, the less-known matched-X cascade and a newly invented pseudo-binary cascade. Numerical experiments on these cascades demonstrated that these cascades are readily solved with the required properties and that the proposed method is a powerful technique for analyzing and designing isotope separation cascades.     

A generalized method for the synthesis and design of reactive distillation columns

Owing to the combination between the reaction operation and the separation operation involved, it is extremely difficult to determine in advance the optimum configuration of a reactive distillation column and this makes process synthesis and design a great challenging task. Currently, no easy-to-use and yet effective methods are available to guide process synthesis and design, restricting considerably the applications and therefore the impacts of reactive distillation columns to the chemical process industry. In this paper, a generalized method is proposed for the synthesis and design of reactive distillation columns in terms of the insights from process intensification. The method is initiated from a simple process design with all feeds of reactants at the middle of the process and all stages as reactive ones. In terms of an economical objective function, it can be evolved into the optimum process design via sequential structure adjustments, including reactive section arrangement, feed stage relocation, feed splitting, and catalyst redistribution. The generalized method proposed is characterized by great simplicity in principle, the capability to tap the full potentials of process intensification, and the high robustness to the initial guess of process configuration as well as the thermodynamic properties of the reacting mixtures separated. Four example systems are employed to evaluate the generalized method proposed and the obtained outcomes demonstrate its effectiveness and applicability to the synthesis and design of various reactive distillation columns.     

Synthesis of sustainable integrated biorefinery via reaction pathway synthesis: Economic,incremental enviromental burden and energy assessment with multiobjective optimization

With the increasing attention toward sustainable development, biomass has been identified as one of the most promising sources of renewable energy. To convert biomass into value‐added products and energy, an integrated processing facility, known as an integrated biorefinery is needed. To date, various biomass conversion systems such as gasification, pyrolysis, anaerobic digestion and fermentation are well established. Due to a large number of technologies available, systematic synthesis of a sustainable integrated biorefinery which simultaneously considers economic performance, environmental impact, and energy requirement is a challenging task. To address this issue, multiobjective optimization approaches are used in this work to synthesize a sustainable integrated biorefinery. In addition, a novel approach (incremental environmental burden) to assess the environmental impact for an integrated biorefinery is presented. To illustrate the proposed approach, a palm‐based biomass case study is solved. © 2014 American Institute of Chemical Engineers AIChE J, 61: 132–146, 2015     

一种通用的反应蒸馏塔综合与设计方法

反应精馏是反应过程和分离过程耦合为一体的单元操作,已成为当今研究的重要领域。然而,到目前为止并没有一套通用简便的方法去指导反应精馏过程的综合与设计,严重限制了它的广泛应用。本文在过程强化原理的基础上提出了一种反应蒸馏塔通用的综合与设计方法,并利用2种反应蒸馏系统来评价所提出的设计策略。结果表明,该综合设计方法可以简便高效地搜索出反应蒸馏塔的最优结构,适用于不同类型的反应蒸馏塔的综合与设计。     

Identification of critical points for the design and synthesis of flexible processes

Optimization problems for the design and synthesis of flexible chemical processes are often associated with highly discretized models. The ultimate goal of this work is to significantly reduce the set of uncertain parameter points used in these problems. To accomplish the task, an approach was developed for identifying the minimum set of critical points needed for flexible design. Critical points in this work represent those values of uncertain parameters that determine optimal overdesign of process, so that feasible operation is assured within the specified domain of uncertain parameters. The proposed approach identifies critical values of uncertain parameters a-priori by the separate maximization of each design variable, together with simultaneous optimization of the economic objective function. During this procedure, uncertain parameters are transformed into continuous variables. Three alternative methods are proposed within this approach: the formulation based on Karush–Kuhn–Tucker (KKT) optimality conditions, the iterative two-level method, and the approximate one-level method. The identified critical points are then used for the discretization of infinite uncertain problems, in order to obtain the design with the optimum objective function and flexibility index at unity. All three methods can identify vertex or even nonvertex critical points, whose total number is less than or equal to the number of design variables, which represents a significant reduction in the problem's dimensionality. Some examples are presented illustrating the applicability and efficiency of the proposed approach, as well as the role of the critical points in the optimization of design problems under uncertainty.     

A new superstructure optimization paradigm for process synthesis with product distribution optimization: Application to an integrated shale gas processing and chemical manufacturing process

We propose a novel process synthesis framework that combines product distribution optimization of chemical reactions and superstructure optimization of the process flowsheet. A superstructure with a set of technology/process alternatives is first developed. Next, the product distributions of the involved chemical reactions are optimized to maximize the profits of the effluent products. Extensive process simulations are then performed to collect high‐fidelity process data tailored to the optimal product distributions. Based on the simulation results, a superstructure optimization model is formulated as a mixed‐integer nonlinear program (MINLP) to determine the optimal process design. A tailored global optimization algorithm is used to efficiently solve the large‐scale nonconvex MINLP problem. The resulting optimal process design is further validated by a whole‐process simulation. The proposed framework is applied to a comprehensive superstructure of an integrated shale gas processing and chemical manufacturing process, which involves steam cracking of ethane, propane, n‐butane, and i‐butane. © 2017 American Institute of Chemical Engineers AIChE J, 63: 123–143, 2018     

A systematic approach to the synthesis and design of flexible site utility systems

The paper presents a systematic approach for the synthesis of flexible utility systems satisfying varying energy demands. The approach combines benefits of total site analysis, thermodynamic analysis and mathematical optimisation. A thermodynamic efficiency curve (TEC) is developed, which gives an overview of the maximum thermodynamic efficiencies of all possible design alternatives. TEC and hardware composites guide the selection of candidate structures in the superstructure, excluding uneconomic options from the synthesis model. The integration of thermodynamics yields significant reduction in the synthesis model, addresses the impact of variable loads on the unit efficiencies, and enables a compact formulation of the design problem over long horizons of operation. The optimisation is formulated as a multi-period MILP problem that relies on new target models to describe the performance of steam turbines, condensing turbines, gas turbines and boilers. Target models account for the variation of efficiency with unit size, load and operating conditions in a simple, yet accurate way. As a result, these models are capable of accounting for the efficiency trends of realistic units.     

A bi‐criterion optimization approach for the design and planning of hydrogen supply chains for vehicle use

In this article, we address the design of hydrogen supply chains for vehicle use with economic and environmental concerns. Given a set of available technologies to produce, store, and deliver hydrogen, the problem consists of determining the optimal design of the production‐distribution network capable of satisfying a predefined hydrogen demand. The design task is formulated as a bi‐criterion mixed‐integer linear programming (MILP) problem, which simultaneously accounts for the minimization of cost and environmental impact. The environmental impact is measured through the contribution to climate change made by the hydrogen network operation. The emissions considered in the analysis are those associated with the entire life cycle of the process, and are quantified according to the principles of Life Cycle Assessment (LCA). To expedite the search of the Pareto solutions of the problem, we introduce a bi‐level algorithm that exploits its specific structure. A case study that addresses the optimal design of the hydrogen infrastructure needed to fulfill the expected hydrogen demand in Great Britain is introduced to illustrate the capabilities of the proposed approach. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

A note on an extended short-cut method for the design of multicomponent reactive distillation columns

Until now, few studies have proposed analytical short-cut methods for reliably designing multicomponent reactive distillation columns. Therefore, in this study we have improved and extended a design methodology for the design of RD columns of multicomponent systems. We have developed a graphical design method, based on distillation lines and tray-by-tray calculations defined in terms of reaction-invariant composition variables, to determine RD design parameters such as the number of theoretical stages, operating reflux ratio, the feed tray location and the top or bottom flow. In this note, we report our extended and improved method, which is analytical and useful for reliably determining the design parameters of multicomponent RD systems. We study the synthesis of TAME with inert components (with different feed thermal conditions) as case of study to show the effectiveness of the proposed strategy. Results obtained with our strategy show a significant agreement with those obtained using a rigorous model of commercial simulator AspenONE Aspen Plus^®.     

Wicking and evaporation of liquids in porous wicks: A simple analytical approach to optimization of wick design

Wicking and evaporation of volatile liquids in porous, cylindrical wicks is investigated where the goal is to model, using simple analytical expressions, the effects of variation in geometrical parameters of a wick, such as porosity, height and bead‐size, on the wicking and evaporation processes, and find optimum design conditions. An analytical sharp‐front flow model involving the single‐phase Darcy's law is combined with analytical expressions for the capillary suction pressure and wick permeability to yield a novel analytical approach for optimizing wick parameters. First, the optimum bead‐radius and porosity maximizing the wicking flow‐rate are estimated. Later, after combining the wicking model with evaporation from the wick‐top, the allowable ranges of bead‐radius, height and porosity for ensuring full saturation of the wick are calculated. The analytical results are demonstrated using some highly volatile alkanes in a polycarbonate sintered wick. © 2014 American Institute of Chemical Engineers AIChE J, 60: 1930–1940, 2014     

Bi-objective optimization approach to the design and planning of supply chains: Economic versus environmental performances

Traditionally the design of supply chains has been based on economic objectives. However, as societal environment concerns grows, environmental aspects are also emerging at academic and industry levels as decisive factors within the supply chain management context. The investment towards logistics structures that considers both economic and environmental performances is nowadays an important and current research topic.This paper addresses the planning and design of supply chain structures for annual profit maximization, while considering environmental aspects. The latter are accounted for through the Eco-indicator methodology. Profit and environmental impacts are balanced using an optimization approach adapted from symmetric fuzzy linear programming (SFLP), while the supply chain is modelled as a mixed integer linear programming (MILP) optimization problem using the Resource-Task-Network (RTN) methodology. The obtained model applicability is validated through the solution of a set of supply chain problems.     

Multivariate optimization of the synthesis of titania biomorphic ceramics and development of a FT-IR method for quantification synthesis yield

Titania biomorphic ceramics were manufactured from wood preforms by a two steps process, i.e. infiltration and then pyrolysis in an inert atmosphere to produce porous TiC ceramics, followed by infiltration and pyrolysis in an air atmosphere where TiC was oxidized to TiO₂. This technology provides a cost effective and eco-friendly route to advanced ceramic materials. The properties of biomorphic ceramics depend decisively on the synthesis parameters, that were optimized using a multivariate methodology for the design of experiments. Four variables (infiltration time, titanium isopropoxide and acetic acid proportion, and number of infiltrations before and after pyrolysis) were considered as factors in the synthesis optimization process. Interactions between these factors and their optimal levels were investigated using a two level factorial design. For evaluating the yields, a new method by Fourier transform infrared spectrometry (FTIR) has been developed for the direct determination of TiO₂ by absorbance measurements in KBr pellets. The procedure is based on the use of the ratio between the absorbance of the characteristic band of titania and those of a nitrate internal standard added to samples. A multivariate calibration strategy based on inverse least squares approach was employed for quantification.