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Synthesis of Intensified Processes for the Production of Valuable Chemicals

Abstract

Process Intensification (PI) was borne out of a desire to meet ever stringent demands placed on the chemical process industry. These demands, expressed in terms of process objectives, include but are not limited to, reductions in waste generation, carbon emissions, utility consumption and capital and operating costs. PI also encompasses increases in energy efficiency and transition to green and sustainable chemical production. Meeting these objectives requires the application of unique techniques to identify and incorporate possible PI improvements in process design.

This dissertation features the application of several PI tools to various processes in the chemical process industry. In Chapter 1, the Energetic Self Sufficiency (ESS) tool is applied to the coproduction of Acetic acid and Hydrogen with no CO2 emissions. This PI tool is employed to other coproduction targets: Formic acid and Hydrogen (Chapter 2) and Dimethyl Ether and Hydrogen (Chapter 3). Next, the Atom Species Attainable Region (ASAR) concept is formally defined and applied to an equilibrium mixture of carbon monoxide, CO, carbon dioxide, CO2, hydrogen, H2, methanol, CH3OH, dimethyl ether, DME and water, H2O. In this chapter (Chapter 4), the atom-mol fraction space is explored for regions that maximize DME production while minimizing CH3OH formation. In Chapter 5, an updated technoeconomic analysis (TEA) of a commercial scale Integrated Gasification Combined Cycle (IGCC) power plant featuring intensified equipment, in the form of Membrane Reactors (MRs) and Adsorptive Reactors (ARs), is presented showing the benefits of the technology. In Chapter 6, the Infinite Dimensional State Space (IDEAS) conceptual framework is applied to an isobaric reactive distillation network featuring Vapor-Liquid Equilibrium (VLE), Vapor-Liquid-Liquid Equilibrium (VLLE), and Liquid-Liquid Equilibrium (LLE) flashes for the synthesis of Isopropyl Acetate.

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