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FRAMEWORK OF COMPUTER-AIDED SUSTAINABLE INTEGRATED
PROCESS DESIGN AND CONTROL FOR REACTOR SYSTEMS
SITI AMINAH BINTI ZAKARIA
UNIVERSITI TEKNOLOGI MALAYSIA
FRAMEWORK OF COMPUTER-AIDED SUSTAINABLE INTEGRATED
PROCESS DESIGN AND CONTROL FOR REACTOR SYSTEMS
SITI AMINAH BINTI ZAKARIA
A thesis submitted in fulfillment of the
requirements for the award of the degree of
Master of Engineering (Chemical)
Faculty of Chemical Engineering
Universiti Teknologi Malaysia
JUNE 2015
iii
To my beloved husband, little calliph, parents and family.
iv
ACKNOWLEDGEMENT
First of all, I would like to give a greatest thanks to Allah the Almighty when
lastly I finished this project. This project has been carried out at Process System
Engineering Centre (PROSPECT) at Department of Chemical Engineering from
August 2013 until January 2015, under the supervision of Dr Mohd Kamaruddin
Abd. Hamid. This work has been supported by Zamalah Universiti Teknologi
Malaysia (UTM).
I would like to give my sincerest thanks to my supervisor, Dr Mohd
Kamaruddin Abd. Hamid who has been provided all the support, help and guidance
whenever required. I am also grateful to him for this continuously guidance,
academic support and also weekly discussion that has been go through along the
journey in finishing this work.
A lot of thanks for my husband, Mohd Jufri bin Zakaria for his limitless
support and encouragement that he give to me. Futhermore, I also like to thanks my
little calliph, Muhammad Fateh Hizqil bin Mohd Jufri. Thank you for your love and
support. Importantly, I like to thanks my dad, mom, my mother in law and father in
law, Zakaria Awang, Sobil Yatu Aslamiah Junoh, Jora Kassim and Zakaria Husin for
their countless support, love and understanding during the work and thesis done. Not
to forget all of my family members for their support and doa’. Thank you.
v
ABSTRACT
An integrated process design and control (IPDC) methodology has been
developed which is able to identify and obtain an optimal solution for the IPDC
problem for chemical processes in an easy, simple and efficient way. However, the
developed IPDC methodology does not consider any sustainability aspect in the
analysis. This study aims to develop a framework of computer-aided sustainable
integrated process design and control (SustainIPDC) for reactor systems. This new
framework methodology was developed in order to ensure that the process is more
economical, controllable as well as sustainable to meet the product quality
specifications. The Sustain-IPDC problem for reactor systems, typically formulated
as a generic optimization problem was solved by decomposing it into six hierarchical
stages: (i) pre-analysis, (ii) design analysis, (iii) controller design analysis, (iv)
economic analysis, (v) sustainability analysis, and (vi) final selection and
verification. Using thermodynamics and process insights, a bounded search space
was first identified. This feasible solution space was further reduced to satisfy the
process design, controller design and economic constraints in stages 2, 3 and 4,
respectively. The sustainability aspect was then analyzed in stage 5 to satisfy the
sustainability constraints, until in the final stage all feasible solutions (candidates)
were ordered according to the defined performance criteria (objective function). The
final selected design was then verified through rigorous simulations or experiments.
In the first stage, the concept of the attainable region (AR) was used to locate the
optimal solution. The target for this optimal solution was defined and selected at the
maximum point of the AR diagram. It is expected that the solution target will show
higher value of the objective function, hence verifying the optimal solution for the
SustainIPDC problem for reactor systems. In addition, the sustainability calculator
(called SustainPlus©) was also developed in this study in which the simultaneous
calculation of three sustainability indices (one-dimensional, two-dimensional, and
three-dimensional) can be performed in one single analysis. Then, the developed
methodology were verified by using two different case studies; (i) production of
cyclohexanone in a continuous-stirred tank reactor system, and (ii) biomass
production in two continuous bioreactor system. Based on two different case studies
that have been performed, the results have shown that the optimal solution in terms
of design, controller design, economic and sustainability is the best at the highest
point of the AR diagram. It also shows that the proposed SustainIPDC methodology
is able to find the optimal solution that satisfies design, controller, economics and
sustainability criteria in an easy, efficient and systematic way.
vi
ABSTRAK
Kaedah proses rekabentuk dan kawalan bersepadu (IPDC) telah dihasilkan
yang mana ianya mampu mengenalpasti penyelesaian yang optimum untuk masalah
IPDC bagi proses kimia dengan mudah, cekap dan sistematik. Tetapi, kaedah IPDC
yang dihasilkan tidak mengambilkira sebarang aspek kelestarian di dalam
analisisnya. Kajian ini bertujuan untuk menghasilkan satu kaedah bantuan computer
bagi proses rekabentuk dan kawalan bersepadu (menampungIPDC) bagi sistem
reaktor. Kaedah sistematik ini dihasilkan bagi memastikan bahawa proses ini adalah
lebih ekonomi, boleh dikawal dan mampan bagi memenuhi spesifikasi kualiti
produk. Masalah menampungIPDC bagi system reaktor, biasanya dirumuskan
sebagai masalah pengoptimuman generik yang diselesaikan dengan dibahagikan
kepada enam peringkat: (i) pra-analisis, (ii) analisis rekabentuk, (iii) analisis
rekabentuk pengawal, (iv) analisis ekonomi, (v) analisis kemampanan, dan (vi)
pemilihan akhir dan pengesahan. Menggunakan termodinamik dan gambaran proses,
ruang carian terbatas dikenalpasti. Ruang penyelesaian ini dikurangkan lagi untuk
memenuhi kekangan rekabentuk proses, kawalan dan ekonomi di peringkat 2, 3 dan
4. Aspek kelestarian kemudiannya dianalisis di peringkat 5 untuk memenuhi
kekangan kemampanan, sehingga di peringkat akhir semua penyelesaian (calon)
disusun mengikut kriteria prestasi tertentu (fungsi objektif). Rekabentuk terakhir
yang dipilih kemudiannya disahkan melalui simulasi atau eksperimen. Di peringkat
pertama, konsep rantau tercapai (AR) ini digunakan untuk mencari penyelesaian yang
optimum dari segi keadaan operasi. Sasaran bagi penyelesaian optimum ini
ditakrifkan dan dipilih pada titik maksimum rajah AR. Ia dijangka bahawa calon
pada titik maksimum rajah ini akan menunjukkan nilai yang lebih tinggi, oleh itu
pengesahan penyelesaian optimum bagi masalah menampungIPDC untuk sistem
reaktor. Selain itu, kalkulator kemampanan (SustainPlus©) juga dibangunkan dalam
kajian ini di mana pengiraan serentak tiga indeks kelestarian (satu-dimensi, dua-
dimensi dan tiga-dimensi) boleh dilakukan dalam satu analisis tunggal. Kemudian,
kaedah ini diuji dengan menggunakan dua kes yang berbeza; (i) penghasilan
sikloheksanon dalam sistem tangki reaktor pengacau berterusan, dan (ii) penghasilan
biomass dalam dua sistem bioreaktor berterusan. Berdasarkan dua kajian kesini,
keputusan menunjukkan bahawa penyelesaian optimum dari segi rekabentuk,
rekabentuk pengawal, ekonomi dan kemampanan adalah yang terbaik pada titik
tertinggi rajah AR. Ia menunjukkan bahawa kaedah menampungIPDC yang
dicadangkan mampu untuk mencari penyelesaian optimum yang memenuhi
rekabentuk, pengawal, ekonomi dan kemampanan kriteria dengan cara yang mudah,
cekap dan sistematik.
vii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xiii
LIST OF ABBREVIATIONS xvi
LIST OF SYMBOLS xviii
LIST OF APPENDICES xx
1 INTRODUCTION
1.1 Research Background
1.2 Problem Statement
1.3 Objectives of the Research
1.4 Scope of the Research
1.5 Significant Of the Research
1.6 Thesis Organization
1
1
3
3
4
4
5
viii
2 LITERATURE REVIEW
2.1 Integrated Process Design And Control
2.2 Sustainability
2.2.1 One-Dimensional Sustainability Index
2.2.2 Two-Dimensional Sustainability Index
2.2.3 Three-Dimensional Sustainability Index
2.3 Sustainable Integrated Process Design and Control
2.4 Summary
6
6
9
12
20
21
22
22
3 FRAMEWORK OF SUSTAINABLE INTEGRATED
PROCESS DESIGN AND CONTROL FOR
REACTOR SYSTEMS
3.1 Problem Formulation
3.2 Decomposition Based-Solution Strategy
3.3 Defining Optimal Design Target
3.4 Tools Integration
3.5 Algorithm of Sustainable Integrated Process Design
and Control for Reactor System
3.6 Summary
24
25
27
34
37
38
42
4 SUSTAINPLUS: A SOFTWARE IN CALCULATING
SUSTAINABILITY INDEX OF REACTOR SYSTEMS
4.1 SustainPlus Overview
4.2 SustainPlus Framework
4.3 SustainPlus Implementation
4.3.1 Starting for SustainPlus
4.3.2 Part I: Introduction
4.3.3 Part II: Problem Definition
4.3.4 Part III: Data Input
4.3.5 Par IV: Analysis
43
44
45
46
46
46
47
48
49
ix
4.4 SustainPlus Application
4.4.1 Cyclohexanone Reaction Process
4.5 Summary
51
51
61
5 CASE STUDY APPLICATIONS: RESULT AND
DISCUSSION
5.1 Application of the Methodology for a Single
Continuous-Stirred Tank Reactor System
5.1.1 Process Description
5.1.2 Problem Formulation
5.1.3 Decomposition-based Solution Strategy
5.2 Application of the Methodology for Retrofitting of
Two Continuous Bioreactors System Operated in
Series
5.2.1 Process Description
5.2.2 Problem Formulation
5.2.3 Decomposition-based Solution Strategy
5.3 Summary
62
62
63
63
65
75
75
76
78
90
6 CONCLUSION AND FUTURE WORK
5.1 Summary
5.2 Future Work
5.3 Publication
92
92
94
95
REFERENCES 98
Appendix A - C 102-116
x
LIST OF TABLES
TABLE NO. TITLE PAGE
4.1 Feed condition for cyclohexanone production 53
5.1 Values of residence time with the corresponding
process-controlled and design-manipulated variables at
different CSTR designs
67
5.2 Economic analysis for each candidates 70
5.3 Analysis of cyclohexanone production by using
SustainPlus©
71
5.4 Analysis of cyclohexanone production (scale index) 71
5.5 Final result of multi-objective function. The best
candidate is highlighted in bold
72
5.6 Existing Design for Microbes Production 76
5.7 Values of design analysis for proposed and existing
design
79
5.8 Values of controller structure analysis for R-101 81
5.9 Economic analysis for each candidates 82
5.10 Detailed result of sustainability analysis by using
SustainPlus©
with A1s and B1s as the scale index for
each point (A1s and B1s are the scaled value of A1 and
B1)
82
5.11 Sustainability analysis for R-101 83
5.12 The percentage of the performance objective for
proposed design, A1 compared to the existing design,
B1
84
5.13 Final result of multi-objective function for R-101 84
5.14 Design analysis for second reactor 85
5.15 Values of controller structure analysis for R-201 87
5.16 Economic analysis for each candidates 88
xi
5.17 Detailed result of sustainability analysis by using
SustainPlus©
with A2s and Bs as the scaled index for
each point
88
5.18 Indexes of sustainability for both design of R-201 89
5.19 Sustainability comparison for the whole system 89
5.20 The percentage of the performance objective for
proposed design, A2 compared to the existing design,
B2
90
5.21 Final result of multi-objective function. The best
candidate is highlighted in bold
90
6.1 Detail Information of the Published Journal 96
A.1 Environmental metrics of atmospheric acidification
(Shadiya and High, 2012)
102
A.2 Environmental metrics of aquatic acidification (Shadiya
and High, 2012)
102
A.3 Environmental metrics of euthrophication (Shadiya and
High, 2012)
102
A.4 Environmental metrics of global warming (Shadiya and
High, 2012)
103
A.5 Environmental metrics of aquatic oxygen demand
(Shadiya and High, 2012)
103
A.6 Environmental metrics of aquatic life (Shadiya and
High, 2012)
104
A.7 Environmental metrics of ozone depletion (Shadiya and
High, 2012)
105
A.8 Environmental metrics of photochemical smog (Shadiya
and High, 2012)
106
B.1 Heat of reaction index (Shadiya and High, 2012) 108
B.2 Flammability index (Shadiya and High, 2012) 108
B.3 Corrosity index (Shadiya and High, 2012) 108
B.4 Explosivity index (Shadiya and High, 2012) 109
B.5 Toxic exposure index (Shadiya and High, 2012) 109
B.6 Temperature index (Shadiya and High, 2012) 109
B.7 Equipement safety index (Shadiya and High, 2012) 110
B.8 Safety level of process structure index (Shadiya and
High, 2012)
110
B.9 Pressure index (Shadiya and High, 2012) 110
B.10 Carcinogenic score for social index (Shadiya and High,
2012)
111
xii
B.11 Others type of damage in analyze health risk (Shadiya
and High, 2012)
111
C.1 Others type of damage in analyze health risk (Shadiya
and High, 2012)
112
C.2 Determination of quantity class (Vincent, 2005) 112
C.3 Determination of frequency class (Vincent, 2005) 112
C.4 Determination of hazard class chemical (Vincent, 2005) 113
C.5 Determination of hazard class environment (Vincent,
2005)
114
C.6 Relation between threshold and hazard class
environment (Vincent, 2005)
115
C.7 Determination of potential exposure class (Vincent,
2005)
116
C.8 Determination of potential chemical risk (Vincent, 2005) 116
xiii
LIST OF FIGURES
FIGURE NO. TITLE PAGE
2.1 Workflow diagram of the IPDC methodology (Hamid,
2010)
8
2.2 Chemical processes impact towards surrounding
(Carvalho, 2009)
10
2.3 Triple bottom line of sustainability (Adams, 2006) 11
2.4 The ecological fingerprint of BASF Socio-Eco-
Efficiency metrics (Sailing, 2005)
13
2.5 Flow diagram for sustainability assessment (Martins,
2008)
15
2.6 m-SAS framework in finding the sustainable process
design (Othman, 2009)
16
2.7 Metrics used in sustainability evaluator (Shadiya and
High, 2012)
17
3.1 Sustainable integrated process design and control
methodology for reactor systems
29
3.2 Attainable Region Diagram for reactor systems
(Hamid, 2010)
30
3.3 Determination of the optimal of design control for a
reactor using the attainable region diagram (Hamid,
2011)
36
3.4 Determination of the optimal of design control for a
reactor using the attainable region diagram at different
temperatures (Hamid, 2011)
36
3.5 The tools integration framework of SustainIPDC 37
4.1 User interface for SustainPlus© for assessing
sustainability index
44
4.2 The software framework of SustainPlus©
45
4.3 Part I - Introduction in SustainPlus© tool 47
4.4 Part II - Problem definition in SustainPlus© tool 48
xiv
4.5 Part III - Data input in SustainPlus©
49
4.6 Part IV - Analysis in SustainPlus© tool 50
4.7 Summary indexes in part IV of SustainPlus©
50
4.8 Process flow diagram of cyclohexanone production 52
4.9 Components selection interface of SustainPlus© tool 54
4.10 Reactants selection interface of SustainPlus© tool 55
4.11 Products selection interface of SustainPlus© tool 56
4.12 Reactants data input interface of SustainPlus© tool 57
4.13 Products data input interface of SustainPlus© tool 57
4.14 Water usage input interface of SustainPlus© tool 58
4.15 Energy data input interface of SustainPlus© tool 59
4.16 Others data input interface of SustainPlus© tool 59
4.17 Summary indexes for the design at the highest point of
AR diagram for the production of cyclohexanone
60
5.1 Attainable region diagram for Ca with respect to Cb at
394.26 K
66
5.2 Attainable region diagram for the desired
concentration of b with respect to reactant, Ca, and its
corresponding derivatives of Cb with respect to
disturbance Ca at feed.
68
5.3 Attainable region diagram for the desired
concentration of b with respect to reactant, Ca, and its
corresponding derivatives of Cb and hr with respect to
manipulated variable F
69
5.4 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed flow
rate, Ff for point A
73
5.5 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed flow
rate, Ff for point B
73
5.6 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed flow
rate, Ff for point C
74
5.7 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed
concentration, Ca,f for point A
74
5.8 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed
concentration, Ca,f for point B
74
xv
5.9 Dynamic open loop responses of desired product
concentration Cb to a ±5% step change in feed
concentration, Ca,f for point C
75
5.10 Process flow diagram of two continuous bioreactors
system operated in series (Vanavil, 2014)
76
5.11 Attainable region diagram of R-101 for CS1 with
respect to CX1
79
5.12 Controller structure analysis for R-101 80
5.13 Level controller structure for R-101 with set-point of
A1 and B1
81
5.14 Attainable region diagram of R-201 for CS2 with
respect to CX2
85
5.15 Sensitivity and controller structure analysis for R-201 86
5.16 Level controller proposed for controller structure
selection of R-201
87
xvi
LIST OF ABBREVIATIONS
AIChE - American Institute of Chemical Engineers
AR - Attainable Region
ASW - Aspen Simulation Workbook
CEI - Chemical Exposure Index
CSTR - Continuous-stirred tank reactor
DS - Decision Support
EIA - Equipment and Inventory Analysis
FTA - Fault Tree Assessment
HAZOP - Hazard and Operability
HAZOPExpert - Software in HAZOP Analysis
IChemE - Institution of Chemical Engineers
IPDC - Integrated Process Design and Process Control
LCA - Life Cycle Analysis/Assessment
MINLP - Mixed Integer Non-Linear Programming
MIDO - Mixed Integer Dynamic Optimization
m-SAS - Modular-based Sustainability Assessment and Selection
NPEI - Net Potential Economic Impact
NPV - Net Present Value
ROR - Rate of Return
SA - Sustainability Analysis
SustainIPDC - Sustainable Integrated Process Design and Process Control
SustainPlus - Sustainability Calculator
SustainPRO - Sustainability Tool in retrofitting the chemical processes
WAR - Waste Reduction
WBCSD - World Business Council for Sustainable Development
xvii
1D - One-Dimension
2D - Two-Dimension
3D - Three-Dimension
xviii
LIST OF SYMBOLS
A - Area
CS - Controller structure
d - Disturbance variables
dy/dd - Sensitivity of controlled variable respect to disturbance
dy/du - Sensitivity of controlled variable respect to manipulated
𝐺 - Set of independent variables
i - Category of objective function
j - Specific term of each category
J - Multi-objective function
T - Temperature
u - Manipulated design variables
v - Set of chemical system variables
x - Set of process state variables
y - Set of controlled variable
Y - Set of binary decison variables
θ - Set of constitutive variables
Ca,f - Feed concentration of component a
Cb,f - Feed concentration of component b
Cc,f - Feed concentration of component c
Cd,f - Feed concentration of component d
CD - Cost of depreciation per year
Ff - Feed flowrate
hr - Reactor height
𝐼1 - Income of the product
𝐼2 - Cost of raw material
xix
k1 - Kinetic Rate
Pi,j - Objective term
Pricei - Price of product i ($/kg)
Pricej - Price of raw material j ($/kg)
Prodi - Draw rate of product i (kg/year)
Prodj - Feed of rate of raw material j (kg/year)
P1 - Process design objective
P2,1 - Sensitivity of dy/dd objective
P2,2 - Sensitivity of dy/du objective
P3 - Profit function objective
P4 - Sustainability objective
Ra - Rate law of component a
𝑇𝑚𝑖𝑛 - Minimum temperature
𝑇𝑚𝑎𝑥 - Maximum temperature
VR - Reactor Volume
wi,j - Weight factor af each objective term
xi - Mole fraction of feed component i
Tbi - Boiling point temperature
Tmi - Melting point temperature
xx
LIST OF APPENDICES
APPENDIX TITLE PAGE
A One-dimensional Sustainability Index of
Environmental Metrics
102
B One-dimensional Sustainability Index of Social Metrics 108
C Three-dimensional Sustainability Index 112
1
CHAPTER 1
INTRODUCTION
1.1 Research Background
Chemical processes have been traditionally designed by a sequential
approach consisting of initial process design, which is based on steady state
economic calculations followed by the synthesis of a controller structure that is
generally based on heuristic controllability measures. Thus, the process design and
process control aspects have been generally studied independently. This traditional
sequential design approach is often inadequate since the process design can
significantly affect the process control of the systems (Malcom et al., 2007). Another
drawback has to do with how process design decisions influence the controllability
of the process to assure that design decisions give the optimum economic and the
best control performance, controller design issues need to be considered
simultaneously with the process design issues (Miranda et al., 2008). The research
area of combining process design and controller design considerations is referred
here as integrated process design and controller design (IPDC).
Integrated Process Design and Control (IPDC) methodology was developed
which is able to identify and obtain an optimal solution for the IPDC problem for
2
chemical processes in an easy, simple and efficient way (Hamid, 2011). However,
the developed methodology for the IPDC did not consider sustainability aspect in the
early chemical processes design stage. Designing controllable and also sustainable
process is one of the key challenges for sustainable development of chemical
processes. Chemical process design can be further improved by including
sustainability aspect within the developed IPDC method to ensure that the design is
more cost efficient and controllable, as well as sustainable to meet product quality
specifications. This can be achieved by extending the developed model-based IPDC
method encompasses sustainability aspect.
Sustainability is based on balancing three principal objectives: environmental
protection, economic growth, and societal equity. Metrics and indicators are used to
assess the sustainability performance of a process or a system, to evaluate the
progress toward enhancing sustainability, and to assist decision makers in evaluating
alternatives. There are one-dimensional (1D), two-dimensional (2D) and three-
dimensional (3D) sustainability indices that will be used in this study. In order to
make it more easily in measuring the sustainability in chemical processes, a new
computer-aided tool that combined all three dimension of sustainability index has
been successfully developed.
Solving IPDC problem together with the sustainability criteria may cause
complexity in the optimization problem. To obtain solutions for this problem will
require a huge computational effort which makes this approach impractical for
solving real industrial problems. In order to overcome the complexity of the Sustain-
IPDC problem and obtain an achievable optimal solution, a decomposition approach
is used in this study. The decomposition approach has been applied in managing and
solving the complexity of different optimization problems in chemical engineering
(Hamid, 2011). The basic idea is that in optimization problems with constraints, the
search space is defined by the constraints within which all feasible solutions lie and
the objective function helps to identify one or more of the optimal solutions. The
constraint equations are solved in a pre-determined sequence such that after every
sequential sub-problem, the search space for feasible solutions is reduced and a sub-
3
set of decision variables are fixed. When all the constraints are satisfied, it remains to
calculate the objective function for all the identified feasible solutions to locate the
optimal solution. In this study, the decomposition solution strategy has been adopted
to develop a new framework of model-based methodology for solving Sustain-IPDC
problem.
1.2 Problem Statement
Previously, IPDC methodology was developed which is able to identify and
obtain an optimal solution for the IPDC problem for reactor systems in an easy,
simple and efficient way (Hamid, 2011). However, the developed methodology for
the IPDC did not consider sustainability aspect. Designing controllable and also
sustainable process is one of the key challenges for sustainable development of
reactor systems since reactor is the hard part of the chemical design before any other
parts of the design. Reactor system process design can be further improved by
including sustainability aspect within the developed IPDC method to ensure that the
design is more cost efficient and controllable, as well as sustainable to meet product
quality specifications. This can be achieved by extending the developed model-based
IPDC method for reactor systems encompass sustainability aspect.
1.3 Objectives of the Study
The objective for this study is to develop a new framework of model-based
methodology, which is able to identify and obtain an optimal solution for the
Sustain-IPDC problem for reactor systems.
4
1.4 Scope of the Study
In order to achieve the abovementioned objective, several scopes have been
planned:
1. Developing a new model-based methodology for Sustain-IPDC for reactor
systems.
2. Developing a sustainability calculator called SustainPlus©
for reactor systems
that simultaneously calculate three sustainability indexes (1D, 2D, 3D) in one
single analysis.
3. Integrating different available tools in every single stage (such as Microsoft
excel, Aspen HYSYS and MATLAB) in the proposed Sustain-IPDC
methodology.
4. Testing the performance of the proposed Sustain-IPDC methodology in
solving complex reactor system problems.
1.5 Significant of the Study
The significant of this study is that the proposed methodology allows the
process engineer in finding the optimal solution for a Sustain-IPDC problem for
reactor systems in a systematic, efficient and fast. In addition, the proposed
methodology can be used not only for industrial purpose but also for academic
purpose.
5
1.6 Thesis Organization
The thesis is organized into six chapters which are (1) introduction, (2)
literature review, (3) sustainable integrated process design and control methodology
for reactor systems, (4) SustainPlus©: a software for calculating sustainability index
of reactor systems, (5) result and discussion, and (6) conclusion and
recommendation. In Chapter one, the background of research, problem statement,
research objectives, research scopes, significant of the research are presented. Then,
in Chapter two, the literature review on the previous research activities is discussed
in more details, which includes the development of the IPDC methodology,
sustainability indices that have been measured by the previous researchers and the
IPDC methodology upgrading. The methodology development for the Sustain-IPDC
is detailed out in Chapter three which consists of problem formulation and the
decomposition-based solution strategy. In addition, the SustainPlus© software, a
computer-aided tool used to calculate the sustainability index is discussed in Chapter
four, which includes the overview, framework, implementation and application of the
tool. In Chapter five, there are two case studies are presented to test the performance
of Sustain-IPDC methodology with the help of the developed SustainPlus© tool; the
design of the single reactor system and the retrofitting of two reactors system.
Finally, the conclusion and recommendation of the research are presented in Chapter
six.
98
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