Abstract
This paper presents a review of advances that have taken place in the mathematical programming approach to process design and synthesis. A review is first presented on the algorithms that are available for solving MINLP problems, and its most recent variant, Generalized Disjunctive Programming models. The formulation of superstructures, models and solution strategies is also discussed for the effective solution of the corresponding optimization problems. The rest of the paper is devoted to reviewing recent mathematical programming models for the synthesis of reactor networks, distillation sequences, heat exchanger networks, mass exchanger networks, utility plants, and total flowsheets. As will be seen from this review, the progress that has been achieved in this area over the last decade is very significant.
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References
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Reactor Networks
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Distillation
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Heat Exchanger Networks
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Zhu, X. X., O’Neill, B. K., Roach, J. R. and Wood, R. M., “A New Method for the Synthesis of Heat Exchanger Networks Using Area-targeting Approaches,”Comp. Chem Eng.,19, 197(1995).
Zhu, X. X., “Automated Design Method for Heat Exchanger Network Using Block Decomposition and Heuristic Rules,”Comp. Chem. Eng,21,1095 (1997).
Mass Exchange Networks
Alva-Argaez, A. A., Kokossis, C. and Smith, R., “Wastewater Minimization of Industrial Systems Using an Integrated Approach,”Comput. Chem. Eng.,22, S5741 (1998).
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El-Halwagi, M. M. and Manousiouthakis, V., “Synthesis of Mass Exchange Networks,”AIChE J.,35(8), 1233 (1989a).
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El-Halwagi, M. M., “Synthesis of Optimal Reverse-Osmosis Networks for Waste Reduction,”AIChE J.,38(8), 1185 (1992).
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Galan, B. and Grossmann, I. E., “Optimal Design of Distributed Wastewater Treatment Networks,”Ind. Eng. Chem. Res.,37 (10), 4036 (1998).
Garrison, G. W, Cooley, B. L. and El-Halwagi, M. M., “Synthesis of Mass Exchange Networks with Multiple Target Mass Separating Agents,”Dev. Chem. Eng. Min. Proc.,3(1), 31 (1995).
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Gupta, A. and Manousiouthakis, V., “Waste Reduction Through Multicomponent Mass Exchange Network Synthesis,”Comput. Chem. Eng.,18, S585 (1994).
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Lakshmanan, A. and Biegler, L. T., “Reactor Network Targeting for Waste Minimization,”AIChE Symp. Ser,90(303), 128 (1995).
Lee, S. and Park, S., “Synthesis of Mass Exchange Network Using Process Graph Theory,”Comput. Chem. Eng.,20, S201 (1996).
Papalexandri, K. P. and Pistikopoulos, E. N., “A Multiperiod MINLP Model for the Synthesis of Heat and Mass Exchange Networks,”Comp. Chem. Eng.,18(12), 1125 (1994).
Papalexandri, K. P. and Pistikopoulos, E. N., “A Process Synthesis Modeling Framework Based on Mass/Heat Transfer Module Hyperstructure,”Comp. Chem. Eng.,19, S71 (1995).
Papalexandri, K. P. and Pistikopoulos, E. N., “Generalized Modular Representation Framework for Process Synthesis,”AIChE J.,42(4), 1010(1996).
Papalexandri, K. P., Pistikopoulos, E. N. and Floudas, C. A., “Mass Exchange Networks for Waste Minimization: A Simultaneous Approach,”Trans. Inst. Chem. Eng.,72, Part A, 279 (1994).
Richburg, A. and El-Halwagi, M. M., “A Graphical Approach to the Optimal Design of Heat-Induced Separation Networks for VOC Recovery,”AIChE Symp Sen,91(304), 256 (1995).
Srinivas, B. K. and El-Halwagi, M. M., “Optimal Design of Pervaporation Systems for Waste Reduction,”Comp. Chem. Eng.,17(10), 957 (1993).
Srinivas, B. K. and El-Halwagi, M. M., “Synthesis of Combined Heat Reactive Mass Exchange Networks,”Chem. Eng. Sci.,49(13), 2059 (1994b).
Srinivas, B. K. and El-Halwagi, M. M., “Synthesis of Reactive Mass Exchange Networks with General Nonlinear Equilibrium Functions,”AIChE J.,49(3), 463 (1994a).
Wang, Y. P. and Smith, R., “Design of Distributed Effluent Treatment Systems”Chem. Eng Sci.,49(18), 3127 (1994).
Wang, Y. P. and Smith, R., “Wastewater Minimization with Flowrate Constraints,”Trans. Inst. Chem. Eng.,73, Part A, 889 (1995).
Wang, Y P. and Smith, R., “Wastewater Minimization,”Chem. Eng Sci.,49(7), 981 (1994a).
Wilson, S. and Manousiothakis, V., “Minimum Utility Cost for a Multicomponent Mass Exchange Operation,”Chem. Eng. Sci,53(22), 3887 (1998).
Zhu, M. and El-Halwagi, M. M., “Synthesis of Flexible Mass Exchange Networks,”Chem. Eng. Commun.,138,193 (1995).
Zhu, M. and El-Halwagi, M. M., “Synthesis of Flexible Separation Networks for Waste Management,” AIChE Meeting, San Francisco (1994).
Utility Systems
Bruno, J. C., Fernandez, F., Castells, F. and Grossmann, I. E., “A Rigorous MINL Model for the Optimal Synthesis and Operation of Utility Plants,”Trans IChemE,76A, 246 (1998).
Chang, C. T. and Hwang, J. R., “A Multiobjetive Programming Approach to Waste Minimization in the Utility Systems of Chemical Processes,”Chem. Eng. Sci.,51, 3951 (1996).
Colmenares, T. R. and Seider, W. D., “Synthesis of Utility Systems Integrated with Chemical Processes,”Ind. Chem. Eng. Res.,28, 84 (1989).
Diaz, M. S. and Bandoni, J. A., “A Mixed Integer Optimization Strategy for a Large Scale Chemical Plant in Operation,”Cornput. Chem. Eng,20, 531 (1996).
Hui, C. W. and Natori, Y., “An Industrial Application Using Mixed-Integer Programming Technique: A Multirperiod Utility System Model,”Comput. Chem. Eng,20, sl577 (1996).
Iyer, R. R. and Grossmann, I. E., “Optimal Multi-period Operational Planning for Utility Systems,”Comput. Chem. Eng.,21, 787 (1997).
Kaliventzeff, B., “Mixed-Integer Non Linear Programming and its Applications to the Management of Utility Networks,”Eng Opt.,18, 183(1991).
Maia, L O. A. and Qassim, R. Y., “Synthesis of Utility Systems with Variable Demands Using Simulated Annealing,”Comput. Chem. Eng,21(9), 947 (1997).
Maia, L. O. A., Vidal de Carvalho, L. A. and Qassim, R. Y., “Synthesis of Utility Systems by Simulated Annealing,”Comput. Chem. Eng,19(4), 481 (1995).
Marechal, F. and Kaliventzeff, B., “Effect Modeling and Optimization, a New Methodology for Combining Energy and Environment Synthesis of Industrial Processes,”Applied Thermal Engineering,17(8-10), 981(1997b).
Marechal, F. and Kaliventzeff, B., “Heat a Power Integration a MILP Approach for Optimal Integration of Utility Systems,” Proc. 22nd Symp. European Working Party of Use of Computers in Chemical Engineering,” COPE’91, Barcelona (1991).
Marechal, F. and Kaliventzeff, B., “Identify the Optimal Pressure Levels in Steam Networks Using Integrated Combined Heat and Power Method,”Chem. Eng. Sci.,52(17), 981 (1997a).
Marechal, F. and Kaliventzeff, B., “Process Integration: Selection of the Optimal Utility System,”Comput. Chem. Eng.,22, sl49 (1998).
Marechal, F. and Kaliventzeff, B., “Targeting the Minimum Cost of Energy Requirements : a New Graphical Technique for Evaluating the Integration of Utility Systems,”Comput. Chem. Eng, s225 (1996).
Mavromatis, S. P. and Kokossis, A. C., “Conceptual Optimization of Utility Networks for Operational Variations. I: Targets and Level Optimization,”Chem. Eng Sci.,53(8), 1585 (1998a).
Mavromatis, S. P. and Kokossis, A. C., “Conceptual Optimization of Utility Networks for Operational Variations. II: Network Development and Optimization,”Chem. Eng. Sci.,53(8), 1609 (1998b).
Papoulias, S. A. and Grossmann, I. E., “A Structural Optimization Approach in Process Synthesis. I: Utility Systems,”Comput. Chem. Eng.,7, 695 (1983).
Petroulas, T. and Reklaitis, G. V., “Computer Aided Synthesis and Design of Plant Utility Systems,”AIChE J.,30, 69 (1984).
Wilkendorf, F., Espuña, A. and Puigjaner, L., “Minimization of the Annual Cost for Complete Utility Systems,”Trans IChemE,76A, 239 (1998).
Process Flowsheets
Bandoni, J. A. and Diaz, M. S., “A Mixed Integer Optimization Strategy for a Large Scale Chemical Plant in Operation,”Comp. Chem. Eng,20, 531 (1996).
Bandoni, J. A., Diaz, M. S. and Brignole, E. A., “Automatic Design and Optimization of Natural Gas Plants,”Ind. Eng. Chem. Res.,36, 2715 (1997).
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Daichendt, M. M. and Grossmann, I. E., “Preliminary Screening for the MINLP Synthesis of Process Systems I: Aggregation and Decomposition Techniques,”Comput. Chem. Engng,18, 663 (1994b).
Daichendt, M. M. and Grossmann, I. E., “Integration of Hierarchical Decomposition and Mathematical Programming for the Synthesis of Process Flowsheets,”Computers and Chemical Engineering,22, 147 (1998).
Diwekar, U. M., Grossmann, I. E. and Rubin, E. S., “MINLP Process Synthesizer for a Sequential Modular Simulator”Industrial & Engineering Chemistry Research,31, 313 (1992a).
Diwekar, U. M., Frey, C. M. and Rubin, E. S., “Synthesizing Optimal Flowsheets. Application to IGCC System Environmental Control,”Industrial & Engineering Chemistry Research,31, 1927 (1992b).
Douglas, J. M., “A Hierarchical Decision Procedure for Process Synthesis,”AIChE J.,31, 353 (1985).
Douglas, J. M., “Conceptual Design of Chemical Process,” McGraw-Hill (1988).
Douglas, J. M., “Synthesis of Multistep Reaction Processes,” In Foundations of Computer-Aided Design, Cache-Elsevier, Amsterdam (1990).
Duran, M.A. and Grossmann, I. E., “Simultaneous Optimization and Heat Integration of Chemical Processes,”AIChE J.,32, 123 (1986).
Duran, M. A. and Grossmann, I. E., “A Mixed-integer Nonlinear Programming Algorithm for Process Systems Synthesis,”AIChE J.,32, 592 (1986b).
Fonyo, Z. and Mizsey, P., “A Global Approach to the Synthesis and Preliminary Design of Integrated Total Flowsheets,” AIChE Annual Meeting, Chicago (1990).
Fraga, E. S., “The Automated Synthesis of Complex Reaction/ Separation Processes Using Dynamic Programming,”Trans. Inst. Chem. Eng,74A, 249 (1996).
Friedler, F., Tarjan, K., Huang, Y. W. and Fan, L. T., “Graph-theoretic Approach to Process Synthesis: Polynomial Algorithm for Maximal Structure Generation,”Comp. Chem. Eng.,17, 929 (1993).
Friedler, F., Kovacs, Z. and Fan, L. T., “Parametric Study of Separation Network Synthesis: Extreme Properties of Optimal Structures,”Suppl. Comp. Chem. Eng,19, 107 (1995).
Friedler, F., Verga, J. B. and Fan, L. T., “Algorithmic Approach to the Integration of Total Flowsheet Synthesis and Wase Minimization,”Chem. Eng Sci.,50, 1218 (1995).
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Grossmann, I. E., “Mixed-Integer Programming Approach for the Synthesis of Integrated Process Flowsheets”Comp. Chem. Eng.,9,463(1985).
Grossmann, I. E., “MINLP Optimization Strategies and Algorithms for Process Synthesis,” In Foundations of Computer-Aided Design, Cache-Elsevier, Amsterdam (1990a).
Grossmann, I. E., “Mixed-integer Nonlinear Programming Techniques for the Synthesis of Engineering Systems,”Res. Eng. Des.,1, 205 (1990b).
Grossmann, I. E., “Mixed-Integer Optimization Techniques for Algorithmic Process Synthesis,”Advances in Chemical Engineering,23,Process Synthesis, 171 (1996).
Grossmann, I. E. and Daichendt, M. M., “New Trends in Optimization-based Approaches for Process Synthesis,”Computers and Chemical Engineering,20, 665 (1996).
Grossmann, I. E., Yeomans, H. and Kravanja, Z., “A Rigorous Disjunctive Optimization Model for Simultaneous Flowsheet Optimization and Heat Integration,”Computers and Chemical Engineering,22, S157 (1998).
Harsh, M. G., Saderne, P. and Biegler, L. T., “Mixed Integer Flowsheet Optimization Strategy for Process Retrofits. The Debottlenecking Problem,”Computers and Chemical Engineering,13, 947 (1989).
Johns, W. D. and Romero, D., “Automated Generation and Evaluation of Process Flowsheets,”Comp. Chem. Eng.,3, 251 (1979).
Kirkwood, R. L., Locke, M. H. and Douglas, J. M., “A Prototype Expert System for Synthesizing Chemical Process Flowsheets,”Comp. Chem. Eng,12, 329 (1988).
Kocis, G. R. and Grossmann, I. E., “Relaxation Strategy for the Structural Optimization of Process Flow Sheets,”Ind. Eng. Chem. Res.,26, 1869 (1987).
Kocis, G. R. and Grossmann, I. E., “A Modeling and Decomposition Strategy for the MINLP Optimization of Process Flowsheets,”Comput. Chem. Engng.,13, 797 (1989).
Kravanja, Z. and Grossmann, I. E., “PROSYN, An MINLP Process Synthesizer,”Comput. Chem. Engng.,14, 1363 (1990).
Kravanja, Z. and Grossmann, I. E., “PROSYN-An Automated Topology and Parameter Process Synthesizer”Computers and Chemical Engineering,17, S87 (1993).
Kravanja, Z. and Grossmann, I. E., “New Developments and Capabilities in PROSYN-An Automated Topology and Parameter Process Synthesizer”Computers Chem. Engng,18, 1097 (1994).
Kravanja, Z. and Grossmann, I. E., “A Computational Approach for the Modelling/Decomposition Strategy in the MINLP Optimization of Process Flowsheets with Implicit Models,”Ind. Eng. Chem. Research,35, 2065 (1996).
Kravanja, Z. and Grossmann, I. E., “Multilevel-hierarchical MINLP Synthesis of Process Flowsheets,”Computers and Chemical Engineering 21, S421 (1997).
Papalexandri, K. P. and Pistikopoulos, E. N., “A Process Synthesis Modeling Framework Based on Mass/Heat Transfer Module Hyperstructure,”Comp. Chem. Eng.,19, S71 (1995).
Papalexandri, K. P. and Pistikopoulos, E. N., “Generalized Modular Representation Framework of Process Synthesis,”AIChE J.,42, 1010(1996).
Reneaume, J. M., Joulia, X. and Koehret, B., “Development of a Process Synthesizer in a Modular Environment,”Suppl. Comp. Chem. Eng,19, S33 (1995).
Rippin, D. W. T., “Introduction: Approaches to Chemical Process Synthesis,” in Foundations of Computer-Aided Design, Siirola, J. J., Grossmann, I. E. and Stephanopoulos, G. (eds.) Cache-Elsevier, Amsterdam (1990).
Schembecker, G., Simmrock, K. H. and Wolff, A., “Synthesis of Chemical Process Flowsheets by Means of Cooperating Knowledge Integrating Systems,” Institution of Chemical Engineers Symposium Series,” 133 (1994).
Siirola, J. J. and Rudd, D. F., “Computer-Aided Synthesis of Chemical Process Designs,”Ind. Eng. Chem. Fundam.,10, 353 (1971).
Smith, E. M., “On the Optimal Design of Continuos Processes” PhD. Dissertation. Imperial College of Science, Technology and Medicine, London U.K. (1996).
Smith, E. M. B. and Pantelides, C. C., “Design of Reaction/Separation Networks using Detailed Models,”Suppl. Comp. Chem. Eng.,19, S83(1995).
Stephanopoulos, G. and Westerberg, A. W., “Studies in Process Synthesis. II. Evolutionary Synthesis of Optimal Process Flowsheets,”Chem. Eng Sci.,31, 195 (1976).
Turkay, M. and Grossmann, I. E., “Logic-Based MINLP Algorithms for the Optimal Synthesis of Process Networks,”Comp. Chem. Eng.,20, 959 (1996a).
Turkay, M. and Grossmann, I. E., “Disjunctive Optimization Techniques for the Optimization of Process Systems with Discontinuous Investment Costs. Multiple Size Regions,”Ind. Eng. Chem. Res.,35, 2611 (1996b).
Turkay, M. and Grossmann, I. E., “Structural Flowsheet Optimization with Complex Investment Cost Functions, ”Computers and Chemical Engineering,22, 673 (1998).
Yeomans, H. and Grossmann, I. E., “A Systematic Modeling Framework of Superstructure Optimization in Process Synthesis,” accepted for publication (1998).
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Grossmann, I.E., Caballero, J.A. & Yeomans, H. Mathematical programming approaches to the synthesis of chemical process systems. Korean J. Chem. Eng. 16, 407–426 (1999). https://doi.org/10.1007/BF02698263
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DOI: https://doi.org/10.1007/BF02698263