联合循环发电(IGCC)和化学工程的挑战

联合循环发电（IGCC）过程是很有发展前途的高效清洁发电过程,高温气体净化是实现IGCC高效节能的关键,也是将来化工过程发展的重要方向．高温气体净化的实现必将大幅度提高能源利用率,并可能导致合成氨、硫酸、甲醇等传统化学工业的革命,改变化学工业中存在的不合理鞍马型温度分布,是将来化学工业节能的发展趋势．IGCC中涉及的脱氮问题、低阻力气体处理,都是化学工业中碰到的普遍问题,也将是21世纪化学工程学科的研究热点．     

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。     

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     

Exergy analysis in ProSimPlus® simulation software: A focus on exergy efficiency evaluation

On industrial sites, the promotion of best practices to enable an efficient utilization of energy has emerged as one of the major point of focus. Among the different approaches existing to improve industrial processes, the exergy analysis, although limited to the academic world, has been shown to be a powerful tool for improving energy efficiency of thermal and chemical systems. The purpose of this paper is then to present the use of the ProSimPlus^® modelling and simulation environment as an exergy analysis computer-aided tool. Expressions implemented in the simulator for computing exergies in its various forms are presented. The adopted approach for calculating exergy efficiency in a systematic way is also exposed; it combines the fuel-product concepts to the transit exergy concept. ProsimPlus^® exergy module's capabilities are illustrated through the example of an ammonia production plant.     

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.     

Among the trends for a modern chemical engineering,the third paradigm: The time and length multiscale approach as an efficient tool for process intensification and product design and engineering

To respond to the changing needs of the chemical and related industries in order both to meet today's economy demands and to remain competitive in global trade, a modern chemical engineering is vital to satisfy both the market requirements for specific nano and microscale end-use properties of products, and the social and environmental constraints of industrial meso and macroscale processes. Thus an integrated system approach of complex multidisciplinary, non-linear, non-equilibrium processes and phenomena occurring on different length and time scales of the supply chain is required. That is, a good understanding of how phenomena at a smaller length-scale relates to properties and behaviour at a longer length-scale is necessary (from the molecular-scale to the production-scales). This has been defined as the triplet “molecular Processes-Product-Process (3PE)” integrated multiscale approach of chemical engineering. Indeed a modern chemical engineering can be summarized by four main objectives: (1) Increase productivity and selectivity through intensification of intelligent operations and a multiscale approach to processes control: nano and micro-tailoring of materials with controlled structure. (2) Design novel equipment based on scientific principles and new production methods: process intensification using multifunctional reactors and micro-engineering for micro structured equipment. (3) Manufacturing end-use properties to synthesize structured products, combining several functions required by the customer with a special emphasis on complex fluids and solid technology, necessating molecular modeling, polymorph prediction and sensor development. (4) Implement multiscale application of computational chemical engineering modeling and simulation to real-life situations from the molecular-scale to the production-scale, e.g., in order to understand how phenomena at a smaller length-scale relate to properties and behaviour at a longer length-scale. The presentation will emphasize the 3PE multiscale approach of chemical engineering for investigations in the previous objectives and on its success due to the today's considerable progress in the use of scientific instrumentation, in modeling, simulation and computer-aided tools, and in the systematic design methods.     

Microscale and Nanoscale Process Systems Engineering: Challenge and Progress

This is an overview of the development of process systems engineering (PSE) in a smaller world. Two different spatio-temporal scopes are identified for microscale and nanoscale process systems. The features and challenges for each scale are reviewed, and different methodologies used by them discussed. Comparison of these two new areas with traditional process systems engineering is described. If microscale PSE could be considered as an extension of traditional PSE, nanoscale PSE should be accepted as a new discipline which has looser connection with the extant core of chemical engineering. Since "molecular factories" is the next frontier of processing scale, nanoscale PSE will be the new theory to handle the design, simulation and operation of those active processing systems.     

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。     

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.     

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.     

Challenges and opportunities in integration of design and control

Process synthesis and design of plant operation are related topics but current industrial practice solves these problems sequentially. The implication of this sequential strategy may result in design of processing systems which are very hard to control. This paper presents a discussion on drivers for an integrated approach and outlines the challenges in formulation of such a multi-objective synthesis problem. This discussion is viewed in relation to some of the changing trends in the industry. Significant results have been published which in different ways seek to handle the integrated problem. Further, advancements in control algorithms and software have widened the range of feasible operation and control for strongly interconnected production systems. In light of these advances in different areas of the field, recommendations for further research and initiatives for development of an integrated approach are given with focus on how new results on the short term can improve industrial practice.     

Erfahrungen mit der Auswahl,Einführung und Anwendung von CAD-Systemen in der Anlagenplanung

Experience gained in the choice, introduction, and application of CAD systems in plant engineering. Computer-aided design in plant engineering is not restricted to technical or chemical engineering calculations but is also used for the creation of graphic design documents. A standing working party ?Computer-aided plant design”? of DECHEMA covered the topic of computer-aided design systems in its sessions of 1982. The presentations are reported here in short form. After an introduction to the problems concerned, the selection, preparation, and use of computer-aided design systems are discussed.     

化学工业多尺度融合的智能制造模式——互联化工

化工过程通过物质和能量的可控转化和传递来实现化工产品制备,具有多相性、非线性、非平衡、多尺度和多时空域等特性,化工行业智能制造发展的关键是实现多尺度条件下的互联协同与过程高效。一方面,化工过程多尺度互联机制的认识和调控是化工过程系统的安全可靠运行的关键;另一方面,实现化工过程多尺度下的互联、融合与协同是化工产业绿色发展的路径。鉴于此,本文提出了化学工业面向多尺度融合的智能制造模式——互联化工,给出了“互联化工”的概念、目标、特点和架构,并讨论了互联化工的相关关键技术,包括化学工业多层级的信息物理系统、云制造,以及全生命周期的安全管理技术、耦合互锁机制下的动态安全监控与决策模型、基于区块链的互联化工数据安全技术。     

Integrated design of power- and resource-saving chemical processes and process control systems: Strategy,methods, and application

A strategy for the integrated design of power-and resource-saving chemical processes and the systems controlling their operating conditions with uncertain input data on physicochemical and process parameters is formulated. A multistep iterative procedure for solving integrated design problems is developed. The procedure includes the generation of alternative chemical processes meeting the “rigid” and/or “soft” flexibility constraints and the choice of operating (control) actions, the synthesis of alternative systems for the automatic control of the operating conditions of the chemical process and the choice of the best control system, the pairwise comparison of feasible automated integrated systems consisting of the chemical engineering process and its control system and the choice of the best integrated system using the criterion based on the power and resource savings and control quality by solving one-and/or two-stage stochastic optimization problems with rigid and/or soft constraints. An example integrated design of the flexible continuous synthesis of azo pigments with an automatic-control system for stabilizing the optimal static conditions is discussed.     

A knowledge-based simulation-optimization framework and system for sustainable process operations

Design and operation of chemical plants involves a combination of synthesis, analysis and evaluation of alternatives. Such activities have traditionally been driven by economic factors first, followed by engineering, safety and environmental considerations. Recently, chemical companies have embraced the concept of sustainable development, entailing renewable feed materials and energy, non-toxic and biodegradable products, and waste minimization or even elimination at source. In this paper, we introduce a knowledge-based simulation-optimization framework for generating sustainable alternatives to chemical processes. The framework has been developed by combining different process systems engineering methodologies - the knowledge-based approach for identifying the root cause of waste generation, the hierarchical design method for generating alternative designs, sustainability metrics, and multi-objective optimization - into one coherent simulation-optimization framework. This is implemented as a decision-support system using Gensym's G2 and the HYSYS process simulator. We illustrate the framework and system using the HDA and biodiesel production case studies.     

PGS-COM: A hybrid method for constrained non-smooth black-box optimization problems: Brief review,novel algorithm and comparative evaluation

In the areas of chemical processes and energy systems, the relevance of black-box optimization problems is growing because they arise not only in the optimization of processes with modular/sequential simulation codes but also when decomposing complex optimization problems into bilevel programs. The objective function is typically discontinuous, non-differentiable, not defined in some points, noisy, and subject to linear and nonlinear relaxable and unrelaxable constraints. In this work, after briefly reviewing the main available direct-search methods applicable to this class of problems, we propose a new hybrid algorithm, referred to as PGS-COM, which combines the positive features of Constrained Particle Swarm, Generating Set Search, and Complex. The remarkable performance and reliability of PGS-COM are assessed and compared with those of eleven main alternative methods on twenty five test problems as well as two challenging process engineering applications related to the optimization of a heat recovery steam cycle and a styrene production process.     

PROCESS CONTROL PERSPECTIVE FOR PROCESS ANALYTICAL TECHNOLOGY: INTEGRATION OF CHEMICAL ENGINEERING PRACTICE INTO SEMICONDUCTOR AND PHARMACEUTICAL INDUSTRIES

FDA's Process Analytical Technology (PAT) initiative provides an unprecedented opportunity for chemical engineers to play significant roles in the pharmaceutical industry. In this article, the authors provide their perspectives on (1) the need for chemical engineering principles in pharmaceutical development for a thorough process understanding; (2) applications of chemical engineering principles to meet the challenges from the semiconductor and pharmaceutical industries; and (3) the integration of chemical engineering practice into the semiconductor and pharmaceutical industries to achieve process understanding and the desired state of quality-by-design. A real-world case study from the semiconductor industry is presented to demonstrate how a classic chemical engineering concept, mixing homogeneity, can be implemented by inducing forced flow to ensure an excellent copper electrochemical plating process performance and to improve product quality substantially. Further, a case study of brake system design is discussed with the concept of Dr. Taguchi's robust engineering design to illustrate how quality-by-design can be achieved through appropriate experimental design, in conjunction with the discussion on the concept of quality-by-design in pharmaceuticals. Third, a case study of freeze-dried sodium ethacrynate is presented to demonstrate the vital importance of controlling the processing factors to achieve the desired product stability. Finally, the problems of the current pharmaceutical manufacturing mode, the opportunities and engineering challenges during implementation of PAT in the pharmaceutical industry, and the role of chemical engineering in implementation of PAT is discussed in detail.     

PROCESS CONTROL PERSPECTIVE FOR PROCESS ANALYTICAL TECHNOLOGY: INTEGRATION OF CHEMICAL ENGINEERING PRACTICE INTO SEMICONDUCTOR AND PHARMACEUTICAL INDUSTRIES

FDA's Process Analytical Technology (PAT) initiative provides an unprecedented opportunity for chemical engineers to play significant roles in the pharmaceutical industry. In this article, the authors provide their perspectives on (1) the need for chemical engineering principles in pharmaceutical development for a thorough process understanding; (2) applications of chemical engineering principles to meet the challenges from the semiconductor and pharmaceutical industries; and (3) the integration of chemical engineering practice into the semiconductor and pharmaceutical industries to achieve process understanding and the desired state of quality-by-design. A real-world case study from the semiconductor industry is presented to demonstrate how a classic chemical engineering concept, mixing homogeneity, can be implemented by inducing forced flow to ensure an excellent copper electrochemical plating process performance and to improve product quality substantially. Further, a case study of brake system design is discussed with the concept of Dr. Taguchi's robust engineering design to illustrate how quality-by-design can be achieved through appropriate experimental design, in conjunction with the discussion on the concept of quality-by-design in pharmaceuticals. Third, a case study of freeze-dried sodium ethacrynate is presented to demonstrate the vital importance of controlling the processing factors to achieve the desired product stability. Finally, the problems of the current pharmaceutical manufacturing mode, the opportunities and engineering challenges during implementation of PAT in the pharmaceutical industry, and the role of chemical engineering in implementation of PAT is discussed in detail.     

A future perspective on the role of industrial biotechnology for chemicals production

The development of recombinant DNA technology, the need for renewable raw materials and a green, sustainable profile for future chemical processes have been major drivers in the implementation of industrial biotechnology. The use of industrial biotechnology for the production of chemicals is well established in the pharmaceutical industry but is moving down the value chain toward bulk chemicals. Chemical engineers will have an essential role in the development of new processes where the need is for new design methods for effective implementation, just as much as new technology. Most interesting is that the design of these processes relies on an integrated approach of biocatalyst and process engineering.     

加强能源化学工程研究

能源产业是国民经济的支柱产业，能源科学技术水平强烈地制约着一个国家的经济发展与社会进步。从一次能源到次级能源转化的大多数过程实质上是工业化学过程。从发展能源技术的需要出发，进行高水平的化学工程研究，不仅加速新能源技术的开发具有十分重要的意义，而且也是化学工程作为一门独立学科自身发展的推动力。