Design standardization of unit operations for reducing the capital intensity and cost of small‐scale chemical processes

Abstract

A methodology is proposed to reduce the cost and capital intensity of small-scale chemical processes by creating new opportunities for economies of numbers through standardizing the equipment designs across multiple processes. We depart from asynchronous design of single-processes and adopt a common-functionality based simultaneous design of multiple processes that use similar unit operations. A generalized cost function is used to appropriately balance the trade-offs between economies of scale and economies of numbers. An optimization-based framework for design standardization is developed and illustrated using two case studies. The first involves the simultaneous synthesis of methanol and ammonia processes, and the second addresses the optimal synthesis of multi-column natural gas liquid (NGL) fractionation processes for different natural gas sources. We observe that considerable reduction in capital intensity of small-scale processes is possible through equipment standardization.

Modular supply chain optimization considering demand uncertainty to manage risk

“…where DR x,Ω ð Þ is the expected downside risk; ψ θ ð Þ is defined using the target service level Ω; and SL θ ð Þ which is the service level for the scenario θ as shown by Equation (8).…”

“…Also, engineers and suppliers gain more experience repeated production of standardized units; this results in lower capital cost and improved production lead time. 8,9 Recent literatures focus on the supply chain consisting of modular processes, because it's benefits are better appreciated at this level.…”

Operability and control in process intensification and modular design: Challenges and opportunities

“…Current efforts toward process intensification and modularization through PSE approaches can be generally classified as the following: Design and optimization Process design, synthesis, and intensification — especially highlighting the phenomena‐based approaches to generate innovative process solutions 35‐37 Optimization of modular production — to compare the efficiency, economics, and/or reliability of numbering up vs. scaling up 12,38,39 Optimal operation and control Operability analysis — including steady state and dynamic feasibility, flexibility, controllability analysis, and so on 31,40 Advanced model‐based control — especially highlighting the need for distributed and decentralized model‐based control in intensified and modular systems, as well as integrated considerations of design, control (and scheduling) 22,41 Dynamic/periodic operation — to purposefully perturb operation along an optimal trajectory by exploiting process nonlinearity and output multiplicity 42,43 Supply chain optimization and operational planning of modular production — especially highlighting the flexibility and mobility of modular processing 44,45 …”

“…Design and optimization Process design, synthesis, and intensification — especially highlighting the phenomena‐based approaches to generate innovative process solutions 35‐37 Optimization of modular production — to compare the efficiency, economics, and/or reliability of numbering up vs. scaling up 12,38,39 …”