# Presentation: 562937

## Mass Integration for Process Design

- Vasilios Manousiouthakis
- Chemical Engineering Department
- UCLA
- United Engineering Foundation
- November 18, 1999
- Lake Arrowhead, CA

##  Mass Integration

** ****Tool: **Minimum Mass Utility Cost for Mass Exchanger Networks
**	**with Fixed or Variable, Single Component Targets** **
** ****Objective:**
-  **Unit Operations:** Mass Exchangers
-   **Framework:** Conservation of Mass
- 		  1st and 2nd Laws of Thermodynamics
-   Mass cascades from high to low chemical potential
-   **Concepts:** Mass Pinch Analysis, Composition Interval Diagrams,
-                      Mass Exchange Diagram

## Energy Conservation

- Heat Integration

**Waste Minimization**

- Mass Integration

- HEN

- MEN

- Mass Load

- Cold

- Lean

- Hot

- Rich

## Minimum Mass Utility 1

- V , yi

- V , yo      yu

- L , xo  xu

- L , xi

- y*

- yi

- yu

- yo

- xi

- xo

- xu

- x*

- 0

- M

## Minimum Mass Utility 2

- y*

- yi

- xi

- x*

- yu

- xu

- V , yi

- V , yoyu

- L , xo  xu

- L , xi

- yo

- xo

- -m

## Mass Integration: Zinc Recovery - Metal Finishing Plant

- Regeneration

- Rinse
- Bath

- Spray
- Roaster

- Absorber

- Pickling
- Bath

- Rinse
- Water
- Makeup

- S2

- S1

- Rinse
- Water

- Pickled Metal

- Pickle
- Solution

- Metal
- Workpieces

- Spent Pickle Liquor

- Water

- Treated Rinse Water

- Zinc-Free
- Spent Solution

- HCl

- Hydrochloric
- Acid

- FeO, Fe2O3

- R1

- R2

- Pickle
- Solution
- Makeup

- 1

- 2

- Cost: 	          $ 0.4159 /s

**Mass Integration: Zinc Recovery - Metal Finishing Plant**

## Mass Integration: Zinc Recovery - Metal Finishing Plant

- Mass
- Exchange
- Network

- Rinse
- Bath

- Spray
- Roaster

- Absorber

- Pickling
- Bath

- Rinse
- Water
- Makeup

- S1

- S2

- S1

- S2

- Rinse
- Water

- Pickled Metal

- Pickle
- Solution

- Metal
- Workpieces

- Spent Pickle Liquor

- Water

- Treated Rinse Water

- Zinc-Free
- Spent Solution

- HCl

- Hydrochloric
- Acid

- FeO, Fe2O3

- To
- Regeneration

- R1

- R1

- R2

- R2

- Pickle
- Solution
- Makeup

## R (water) - S1 (Resin)	 y = 0.376 (x+) + 0.0001,	= 10 - 4

- R (water) - S2 (Phosphate)	 y = 0.845 (x+),		= 10 - 4

-   V	    yi	      yu		    xi	      xu	      c
- kg/s	kg/kg	kg/kg		kg/kg	  kg/kg	    $/kg

- R1   0.1     0.045   0.02	S1   0.0015  0.075   0.7
- R2   1.5     0.03     0.001	S2     0.004    0.05     0.03

- Rich Streams

- Lean Streams

- Equilibrium Data

- Input Output Data

- Zinc Chloride

**Mass Integration: System Data**

## Mass Integration: Composition Interval Diagram

**Mass Integration: Composition Interval Diagram**

## Mass Integration: Optimal Design

- To
- Regeneration

- Rinse
- Bath

- Spray
- Roaster

- Absorber

- Pickling
- Bath

- Rinse
- Water
- Makeup

- S2

- S1

- S2

- S1

- Rinse
- Water

- Pickled Metal

- Pickle
- Solution

- Metal
- Workpieces

- Spent Pickle Liquor

- Water

- Treated Rinse Water

- Zinc-Free
- Spent Solution

- HCl

- Hydrochloric
- Acid

- FeO, Fe2O3

- R1

- R1

- R2

- R2

- Pickle
- Solution
- Makeup

- 1

- 2

- 3

##  Multicomponent Mass Integration

** ****Tool: **Minimum Mass Utility Cost for Mass Exchanger Networks
**	**with Multicomponent Targets** **
** ****Objective:**
-  **Unit Operations:** Mass Exchangers
-   **Framework:** 1st and 2nd Laws of Thermodynamics
-   Infinite DimEnsional State Space (IDEAS)
-   Conservation of Mass
-   Mass cascades from high to low chemical
-   potential for each component
-   **Concepts:** Composition Interval Diagrams, Mass Exchange
- 	          Diagrams for Each Component

## Multicomponent Mass Integration: Infinite DimEnsionAl State-Space (IDEAS)

- MEN

- . . . . . . . .

- . . . .

- . . . . .

-  . . . . . . . .

- DN

- Inlets

- Outlets

## Multicomponent Mass Integration: Example

- Flow
- 0.125
- 0.375
- 0.125
- Cost
- 1.0

- y1i
- 0.040
- 0.024
- 0.024
- x1i
- 0.00

- y1o
- 0.016
- 0.016
- 0.016
- x1o
- 0.008

- y2i
- 0.042
- 0.042
- 0.074
- x2i
- 0.000

- y2o
- 0.002
- 0.010
- 0.010
- x2o
- 0.025

- Stream
- R1
- R2
- R3
- L

- y1 = 4.0 x1  ,   y2 = 2.0 x2

- Input-Output Data

- Equilibrium Data

## Multicomponent Mass Integration: Network Design

**Multicomponent Mass Integration: Network Design**

- Our recent results can identify minimum utility cost for the multicomponent MEN problem

- Multicomponent Minimum Utility Cost $1.0/min

- R2

- L

- R3

- R1

- R2

- R3

- R1

- 1

## Multicomponent Mass Integration Network Data

## Multicomponent Mass Integration: Mass Exchange Diagrams

**Component 1**

**Component 2**

- y1

- x2

- y2

- x1

**Mass Load (x10****-3****)**

**Mass Load (x10****-3****)**

- Minimum Utility Cost
- $1.0/min

- Minimum Utility Cost
- $1.0/min

- 0.008

- 0.016

- 0.024

- 0.032

- 0.040

- 1

- 2

- 3

- 4

- 5

- 6

- 7

- 8

- 0.008

- 0.004

- 3

- 1+2+3

- 0.02

- 0.04

- 0.06

- 0.08

- 5

- 10

- 15

- 20

- 25

- 1+2+3

- 3

- 0.025

- 0.013

- 0.038

## Multicomponent Mass Integration:First Component based Network Design

- Above network does not meet second component specifications for R1, R2
- Above network requires utility cost > $1.21/min to meet second component specifications

- 2

- 5

- 4

- 3

- 1

- Pinch

- R1

- R3

- L

- R1

- R2

- L

- R3

- R2

- 0.375/0.024;0.042

- 0.008;0.024

- 0.125/0.024;0.074

- 0.024;0.050

- 0.006;0.025

- 0.001;0.001

- 1.0/0.0;0.0

- 0.125/0.040;0.042

- 0.016;0.012

- 0.016;0.017

- 0.016;0.011

- 0.008;0.006

##          Globally Optimal

-       Distillation Networks
-           Minimum Utility

## Petlyuk

- I

- II

- III

- IV

- V

- VI

- A+B+C

- A

- B

- C

- Column

## IDEAS Representation of Petlyuk Column

## Slide 21

## Slide 22

## Slide 23

## Slide 24

## Slide 25

## Slide 26

## Slide 27

## Slide 28

## Slide 29

## Slide 30

## Slide 31

## Slide 32

## Slide 33

## Slide 34

## Slide 35

## Slide 36

##          Globally Optimal

-       Distillation Networks
-       Minimum Plate Area
-       for Fixed Utility Cost

## Slide 38

## Slide 39

## Slide 40

## Slide 41

## Slide 42

## Slide 43

##          Globally Optimal

- Reaction/Distillation Networks

## Motivation

- Reactor and Distillation networks impact waste generation at two levels: Processing and Recycling
- Design of such networks typically pursued through convex and/or mixed integer programs which do not guarantee global optimality.

## Infinite DimEnsionAl State-space (IDEAS)

- 	States: Composition, Enthalpy
- 	Infinite number of states
- 	Distribution Network (DN): allows for stream mixing
- 	Process Blocks (RXN, MEN, HEN) external to DN
- 	Includes ALL possible designs
- 	Convex Programs: Local optima are global

## IDEAS Representation of a Reaction/Distillation

-                                Network

## ?

- 250K

- 10 kg-moles/hr

- 0.95 A

- 0.05 B

- 250K

- 10 kg-moles/hr

- 0.10 A

- 0.90 B

- Determine the globally minimum utility cost over any

-              complex reactor/distillation network

## Slide 49

## Reverse Exchangers

## Reactor/Distillation Conventional Design Minimum Utility Design

- Utility Cost: $0.773/hr

## State-space representation of conventional 

- State-space representation of conventional
-                      optimal design

## Temperature-Heat Exchanged Diagram

-  Minimum Utility Conventional Design

## IDEAS Optimal Design Minimum Utility

- Utility Cost: $0.365/hr

## IDEAS Convergence Characteristics

## Temperature-Heat Exchanged Diagram

-     Minimum Utility IDEAS Design

## Slide 57

## Slide 58

## Reactor/Distillation Conventional Design Minimum TAC Solution

- LTAC: $10,358

## IDEAS Optimal Design LTAC

- LTAC: $6,487/yr

## Conclusions

- 	Infinite DimEnsionAl State-space (IDEAS) process
- 		representation includes all possible processes
- 	Resulting problem formulations are convex
- 	IDEAS designs are flexible and may be used to represent
- 		a wide variety of processes
- 	For reaction/distillation networks, IDEAS designs have
- 		lower utility cost and TAC than conventional
- 		designs

## ACKNOWLEDGEMENTS

- Mahmoud El-Halwagi
- Ashish Gupta
- Stevan Wilson
- James Drake