Novel Natural Gas to Liquids Processes: Process Synthesis and Global Optimization Strategies

An optimization‐based process synthesis framework is proposed for the conversion of natural gas to liquid transportation fuels. Natural gas conversion technologies including steam reforming, autothermal reforming, partial oxidation to methanol, and oxidative coupling to olefins are compared to determine the most economic processing pathway. Hydrocarbons are produced from Fischer–Tropsch (FT) conversion of syngas, ZSM‐5 catalytic conversion of methanol, or direct natural gas conversion. Multiple FT units with different temperatures, catalyst types, and hydrocarbon effluent compositions are investigated. Gasoline, diesel, and kerosene are generated through upgrading units involving carbon‐number fractionation or ZSM‐5 catalytic conversion. A powerful deterministic global optimization method is introduced to solve the mixed‐integer nonlinear optimization model that includes simultaneous heat, power, and water integration. Twenty‐four case studies are analyzed to determine the effect of refinery capacity, liquid fuel composition, and natural gas conversion technology on the overall system cost, the process material/energy balances, and the life cycle greenhouse gas emissions. © 2013 American Institute of Chemical Engineers AIChE J, 59: 505–531, 2013     

Separation of C6H6 and C6H12 from H2 using ionic liquid/PVDF composite membrane

Ionic liquid/polyvinylidene fluoride composite membrane was successfully prepared by impregnation method and used for the separation on organic chemical hydride process. The separation factors of C₆H₆/H₂ and C₆H₁₂/H₂ in the ternary mixture system were 7500 and 300, respectively. The ionic liquid membrane showed an excellent possibility as a technology of H₂ purification in the organic chemical hydride process by removing aromatic hydrocarbon and cycloalkane simultaneously from the ternary system. © 2015 American Institute of Chemical Engineers AIChE J, 62: 624–628, 2016     

n‐butane carbonylation to n‐pentanal using a cascade reaction of dehydrogenation and SILP‐catalyzed hydroformylation

A novel gas‐phase process has been developed that allows direct two‐step conversion of butane into pentanals with high activity and selectivity. The process consists of alkane dehydrogenation over a heterogeneous Cr/Al₂O₃ catalyst followed by direct gas‐phase hydroformylation using advanced supported ionic liquid phase (SILP) catalysis. The latter step uses rhodium complexes modified with the diphosphite ligands biphephos (BP) and benzopinacol to convert the butane/butene mixture from the dehydrogenation step efficiently into aldehydes. The use of the BP ligand results in improved yields of linear pentanal because SILP systems with this ligand are active for both isomerization and hydroformylation. © 2014 American Institute of Chemical Engineers AIChE J, 61: 893–897, 2015     

Superstructure optimization of integrated fast pyrolysis‐gasification for production of liquid fuels and propylene

Motivated by the apparent advantages of fast pyrolysis and gasification, a novel integrated biorefinery plant is systematically synthesized for coproducing premium quality liquid fuels and propylene. The required heat and fluidization promotion of the fast pyrolyzer are provided by hot syngas from the gasifier. Light gas and syngas from the fast pyrolyzer are finally converted to hydrocarbons via Fischer‐Tropsch synthesis. Multiple syngas production technologies, hydrocarbon production and downstream upgrading routes are incorporated within a superstructure optimization based process synthesis framework. This is the first article to investigate the benefits associated with the introduction of conventional catalytic cracking and dewaxing from a systems engineering perspective. Surrogate models describing the gasifiers and rigorous equations for Fischer‐Tropsch effluents validated by our experimental collaborator are introduced. Through investigation of five scenarios the primary parameters affecting overall economic performance are identified through ranking of the relevant candidates. Comparisons of the hybrid conversion route and stand‐alone routes are made. © 2016 American Institute of Chemical Engineers AIChE J, 62: 3155–3176, 2016     

Dew‐point measurements for water in compressed carbon dioxide

When transporting CO₂ for sequestration, it is important to know the water dew point in order to avoid condensation that can lead to corrosion. A flow apparatus to measure the water content at saturation in a compressed gas has been constructed. A saturator humidifies the flowing gas by equilibrating it with liquid water. Then, a gravimetric hygrometer measures the water mole fraction of the humid gas. Dew‐point data for H₂O in CO₂ on six isotherms between 10 and 80 °C at pressures from 0.5 to 5 MPa are reported. The uncertainties in water content at the dew point (expanded uncertainty with coverage factor k = 2) are on average 0.3%, significantly smaller than in any previous work. The data have been analyzed to extract the interaction second virial coefficient; the values are consistent with the theoretical estimates of Wheatley and Harvey but have a much smaller uncertainty. Published 2015 American Institute of Chemical Engineers AIChE J, 2015 © 2015 American Institute of Chemical Engineers AIChE J, 61: 2913–2925, 2015     

Production of benzene,toluene, and xylenes from natural gas via methanol: Process synthesis and global optimization

A systematic global optimization‐based process synthesis framework is presented to determine the most profitable processes to produce aromatics from natural gas. Several novel, commercial, and/or competing technologies are modeled within the framework, including methanol‐to‐aromatics, toluene alkylation with methanol, selective toluene disproportionation, and toluene disproportionation and transalkylation with heavy aromatics, among others. We propose a stand‐alone chemicals facility: the main products are aromatics with allowable by‐products of gasoline, liquefied petroleum gas, and electricity. Several case studies are discussed that produce varying ratios of para‐, ortho‐, and meta‐xylene across multiple refinery capacities. The results indicate that utilizing natural gas for the production of aromatics is profitable with net present values as high as $3800 MM dollars and payback periods as low as 6 years. The required investment for these refineries represents as much as a 65% decrease compared to published estimates of similar coal‐based capacity plants. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1531–1556, 2016     

Phthalic anhydride production from hemicellulose solutions: Technoeconomic analysis and life cycle assessment

The process synthesis, technoeconomic analysis, and life cycle assessment (LCA) of a novel route for phthalic anhydride (PAN) production from hemicellulose solutions are presented. The production contains six steps including dehydration of xylose to furfural, reductive decarbonylation of furfural to furan, oxidation of furfural to maleic anhydride (MA), Diels‐Alder cycloaddition of furan, and MA to exo?4,10‐dioxa‐tricyclo[5.2.1.0]dec‐8‐ene‐3,5‐dione followed by dehydration to PAN in the presence of mixture of methanesulfonic acid and acetic anhydride (AAN) which is converted to acetyl methanesulfonate and acetic acid (AAD), and dehydration of AAD to AAN. The minimum selling price of PAN is determined to be $810/metric ton about half of oil‐based PAN. The coproduction of high‐value products is essential to improve the economics. Biomass feedstock contributes to the majority of cost. LCA results shows that biomass‐based PAN has advantages over oil‐based PAN to reduce climate change and fossil depletion however requires more water usage. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3708–3718, 2015     

Toward economical purification of styrene monomers: Eggshell Mo2C for front‐end hydrogenation of phenylacetylene

An eggshell Mo₂C catalyst which is designed from the rapid combination of molybdate with melamine is described. In contrast to Pd‐based catalysts, the eggshell Mo₂C operates effectively with a wide‐concentration window in high‐temperature gas phase hydrogenation of phenylacetylene, thus, an economical and energy‐efficient front‐end purification of styrene monomers might be possible. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2522–2531, 2015     

Gas absorption into a wavy two‐layer falling film

Absorption of a weakly soluble gas into a two‐layer film flowing down a vertical wall is studied in the framework of an approximate long‐wave model. It is shown that wavy regimes in the film strongly affect the absorption rate. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2058–2069, 2015     

New MINLP formulation for the multiperiod pooling problem

The modeling of blending tank operations in petroleum refineries for the most profitable production of liquid fuels in a context of time‐varying supply and demand is addressed. A new mixed‐integer nonlinear programming formulation is proposed that using individual flows and split fractions as key model variables leads to a different set of nonconvex bilinear terms compared with the original work of Kolodziej et al. These are better handled by decomposition algorithms that divide the problem into integer and nonlinear components as well as by commercial solvers. In fact, BARON and GloMIQO can solve to global optimality all problems resulting from the new formulation and test problems from the literature. A tailored global optimization algorithm working with a tight mixed‐integer linear relaxation from multiparametric disaggregation achieves a similar performance. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3728–3738, 2015     

Enantioseparation of chiral aromatic acids in process intensified liquid–liquid extraction columns

Enantioselective liquid–liquid extraction (ELLE) is a powerful alternative to common technologies for separation of racemic mixtures. The first application of ELLE for aromatic acids in liquid–liquid extraction columns is described. The ELLE is investigated experimentally and theoretically for phenylsuccinic acid (PSA) as a representative for aromatic acids. A racemic mixture of (R/S)‐PSA is separated with hydroxypropyl‐β‐cyclodextrin as selector molecule. The ELLE obtained the highest operative selectivity (α_op = 1.8–2) for low pH‐values and temperatures. Because of the low operative selectivity, a countercurrent process is necessary to separate both enantiomers completely. The countercurrent process is investigated in process intensified extraction columns (Ø_in = 15 mm) with a high number of equilibrium stages. The experiments demonstrate a good symmetric separation with an enantiomeric excess of 60% and yields of 80% for both enantiomers. Finally, the back extraction is investigated to recycle the selector molecule and increase the efficiency. © 2014 American Institute of Chemical Engineers AIChE J, 61: 266–276, 2015     

A novel hybrid feedstock to liquids and electricity process: Process modeling and exergoeconomic life cycle optimization

This article proposes a novel hybrid low‐rank coal (LRC)/biomass/natural gas process for producing liquid fuels and electricity. The hybrid process highlights coexistence of indirect and direct liquefaction technologies, cogasification of char and biomass, and corefinery of LRC syncrude and Fischer–Tropsch syncrude. A process simulation based on detailed chemical kinetics is present to illustrate its feasibility. In addition, we propose an exergoeconomic life cycle optimization framework that seeks to maximize the primary exergy saving ratio, primary total overnight cost saving ratio, life cycle waste emissions avoidance ratio, and primary levelized cost saving ratio by comparing the proposed hybrid process to its reference stand‐alone subsystems. From the results, we can determine four optimal designs which yield competitive breakeven oil prices ranging from $1.87/GGE to $2.13/GGE. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3739–3753, 2014     

Dearomatization of pyrolysis gasoline with an ionic liquid mixture: Experimental study and process simulation

The pyrolysis gasoline is the main source of benzene, toluene, and xylenes. The dearomatization of this stream is currently performed by liquid – liquid extraction using sulfolane. However, the sulfolane process has high operating costs that could be minimized by employing ionic liquids as solvents because of their non‐volatile character. In this work, we proposed a novel process to perform the dearomatization of pyrolysis gasoline using a binary mixture of 1‐ethyl‐3‐methylimidazolium tricyanomethanide ([emim][TCM]) and 1‐ethyl‐4‐methylpyridinium bis(trifluoromethylsulfonyl)imide ([4empy][Tf₂N]) ILs. The composition in the IL mixture was optimized considering their extractive and thermophysical properties. The Kremser method was applied using the experimental data to determine the number of equilibrium stages in the liquid – liquid extractor which provides the same extraction yields of aromatics using the IL mixture that those of the sulfolane process. The recovery section was designed and simulated from the experimental vapor – liquid equilibrium between the hydrocarbons and the IL mixture. © 2017 American Institute of Chemical Engineers AIChE J, 63: 4054–4065, 2017     

Shear stability of inverse latexes during their polymerization process

The shear‐stability of inverse latexes (IL) during their polymerization process is studied. The IL is made of water droplets containing a copolymer of acrylamide and dimethyl‐aminoethyl‐methylenechloride emulsified in a paraffin oil. It is found for the first time that the shear stability of the ILs is a nonmonotonic function of the monomer conversion. At low conversions the shear stability increases as the conversion increases, but at a certain conversion value it reaches a local maximum and then decreases with conversion. Moreover, at the final stage of the conversion, the shear stability can increase again. A proper interpretation of this behavior is proposed and related to the combined effects of the polymer properties, fractal aggregation, and coalescence. © 2015 American Institute of Chemical Engineers AIChE J, 61: 1380–1384, 2015     

On the temperature control in a microstructured packed bed reactor for methanation of CO/CO2 mixtures

Microreactor technology is widely used for process intensification and is essential for fast and strongly exothermic reactions exhibiting mass and heat transfer limitations. In the scope of the MINERVE Power‐to‐Gas project, sponsored by KIC InnoEnergy from 2012 to 2015, a micro packed bed reactor was developed for conversion of syngas containing CO₂ into methane. This work focuses on heat removal and temperature control in a manufactured device using syngas throughputs less than 1.4 Nm³/h (10% CO, 7% CO₂, H₂/C = 4) while examining the cooling potential of different cooling fluids, e.g., air, steam and water. © 2016 American Institute of Chemical Engineers AIChE J, 63: 120–129, 2017     

Multiobjective optimization of product and process networks: General modeling framework,efficient global optimization algorithm,and case studies on bioconversion

A comprehensive optimization model that can determine the most cost‐effective and environmentally sustainable production pathways in an integrated processing network is needed, especially in the bioconversion space. We develop the most comprehensive bioconversion network to date with 193 technologies and 129 materials/compounds for fuels production. We consider the tradeoff between scaling capital and operating expenditures (CAPEX and OPEX) as well as life cycle environmental impacts. Additionally, we develop a general network‐based modeling framework with nonconvex terms for CAPEX. To globally optimize the nonlinear program with high computational efficiency, we develop a specialized branch‐and‐refine algorithm based on successive piecewise linear approximations. Two case studies are considered. The optimal pathways have profits from ?$12.9 to $99.2M/yr, and emit 791 ton CO₂‐eq/yr to 31,571 ton CO₂‐eq/yr. Utilized technologies vary from corn‐based fermentation to pyrolysis. The proposed algorithm reduces computational time by up to three orders of magnitude compared to general‐purpose global optimizers. © 2014 American Institute of Chemical Engineers AIChE J, 61: 530–554, 2015     

On the leakage flow around gas bubbles in slug flow in a microchannel

The leakage flow is that liquid does not push gas bubbles and leaks through the channel corners. This leakage flow was confirmed by tracking particles moving in the liquid film with a double light path method and was quantified by tracking the gas–liquid interface movement. The results show that leakage flow varies during bubble formation process. The average net leakage flow Q_net‐leak in a bubble formation cycle at T‐junction can be as large as 62.4% of the feeding liquid flow rate, depending on the liquid properties. Q_net‐leak for regular flow at main channel is much smaller, ranging from about 0 to 30% of the feeding liquid flow rate. The difference between the two leakage flows would lead to an increase in liquid slug length after generation. Finally, the effects of parameters such as phase flow rates, surface tension, and viscosity were investigated. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3964–3972, 2015     

A packed‐bed solar reactor for the carbothermal zinc production – dynamic modelling and experimental validation

Integration of concentrated solar energy into the pyrometallurgical Zn production process as clean source of high‐temperature process heat could significantly reduce fossil fuels consumption and its concomitant CO₂ emissions. The solar‐driven carbothermal reduction of ZnO is investigated using a 10‐kW_th solar reactor featuring two cavities, the upper one serving as the solar absorber and the lower one containing a packed‐bed of ZnO and beech charcoal as the biogenic reducing agent. Experimentation in a high‐flux solar simulator is carried out under radiative fluxes of 2300–2890 suns, yielding a peak solar‐to‐chemical energy conversion efficiency of 18.4%. The reactor performance under variable operating conditions is analyzed via a dynamic numerical model coupling heat transfer with chemical kinetics. The model is validated by comparison to the experimental data obtained with the 10‐kW_th packed‐bed solar reactor and further applied to predict the effect of incorporating semi‐continuous feeding of reactants on the process efficiency. © 2016 American Institute of Chemical Engineers AIChE J, 62: 4586–4594, 2016     

Process synthesis and optimization of a sustainable integrated biorefinery via fuzzy optimization

Over the last decade, utilization of biomasses is highly encouraged to conserve scarce resources, reduce dependency on energy imports as well as protect the environment. Integrated biorefinery emerged as noteworthy concept to integrate several conversion technologies to have more flexibility in product generation with energy self‐sustained and reduce the overall cost of the process. Integrated biorefinery is a processing facility that converts biomass feedstocks into a wide range of value added products via multiple technologies. In this work, a systematic approach for the synthesis and optimization of a sustainable integrated biorefinery which considers economic, environmental, inherent safety, and inherent occupational health performances is presented. Fuzzy optimization approach is adapted to solve four parameters simultaneously as they are often conflicting in process synthesis and optimization of an integrated biorefinery. An integrated palm oil‐based biorefinery case study is solved to demonstrate the proposed approach. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4212–4227, 2013     

Evaluation of pure‐component adsorption properties of silicalite based on the Langmuir and Sips models

The Langmuir and Sips models parameters were estimated for the adsorption of several light gases and hydrocarbons (H₂, CH₄, CO₂, CO, N₂, C₂H₆, C₃H₈, n‐C₄H₁₀) in silicalite along with their functionality with temperature. This is a scientific attempt to resume and reconcile the number of available experimental data and supply scientists and other operators with the adsorption properties of silicalite within a wider range of temperature and pressure. Furthermore, to provide readers with more detailed information on where each of the two models work better, the analysis is divided into three temperature ranges: low‐temperature, high‐temperature, and whole temperature range. As a result, it is found that the Langmuir model works well in the whole temperature range for the light gases considered but not for the other hydrocarbons, for which it is better to use the Sips model by splitting calculation over low‐ and high‐temperature range. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3911–3922, 2015