LAPSE:2026.0410
Published Article

LAPSE:2026.0410
Superstructure Framework for Feasibility and Flexibility Analysis Methods in Modular Plant Design
June 12, 2026
Abstract
Modular plant design requires assessing whether independently characterized process requirements and module capabilities are compatible-a challenge that established methods address incompletely. Feasibility and flexibility analysis, as well as Quality by Design, typically assume integrated single-domain models where all variables belong to one coherent description, yet modular design involves domains that originate from different sources, evolve independently, and connect through interface variables. This work proposes Quantified Constraint Satisfaction Problems (QCSPs) as a formulation for interface-level suitability assessment: universal quantification encodes properties that must hold across their entire admissible range (e.g., physical properties, uncertain or environment-dependent characteristics requiring robustness), while existential quantification encodes variables where at least one feasible value must exist (e.g., critical process parameters, control inputs, configuration options). By operating over domain interfaces rather than requiring integrated system models, the formulation accommodates heterogeneous information sources within a common problem specification, with uncertainty handled through probabilistic intervals governed by a global confidence threshold. The framework supports both finite-domain solving on pre-evaluated datasets and numeric solving through on-demand model evaluation. A bioreactor suitability case study provides proof-of-concept, illustrating how the framework accommodates realistic problem complexity and offering initial observations on method selection trade-offs.
Modular plant design requires assessing whether independently characterized process requirements and module capabilities are compatible-a challenge that established methods address incompletely. Feasibility and flexibility analysis, as well as Quality by Design, typically assume integrated single-domain models where all variables belong to one coherent description, yet modular design involves domains that originate from different sources, evolve independently, and connect through interface variables. This work proposes Quantified Constraint Satisfaction Problems (QCSPs) as a formulation for interface-level suitability assessment: universal quantification encodes properties that must hold across their entire admissible range (e.g., physical properties, uncertain or environment-dependent characteristics requiring robustness), while existential quantification encodes variables where at least one feasible value must exist (e.g., critical process parameters, control inputs, configuration options). By operating over domain interfaces rather than requiring integrated system models, the formulation accommodates heterogeneous information sources within a common problem specification, with uncertainty handled through probabilistic intervals governed by a global confidence threshold. The framework supports both finite-domain solving on pre-evaluated datasets and numeric solving through on-demand model evaluation. A bioreactor suitability case study provides proof-of-concept, illustrating how the framework accommodates realistic problem complexity and offering initial observations on method selection trade-offs.
Record ID
Keywords
Design Under Uncertainty, Information Management, Interdisciplinary, Modelling and Simulations, Optimization, Process Design
Subject
Suggested Citation
Pamperin J, Mädler J, Koch A, Viedth I, Urbas L. Superstructure Framework for Feasibility and Flexibility Analysis Methods in Modular Plant Design. Systems and Control Transactions 5:1650-1658 (2026) https://doi.org/10.69997/sct.186670
Author Affiliations
Pamperin J: Dresden University of Technology, Process-to-Order Group, Dresden, Saxony, Germany
Mädler J: FLEXCELERATE Solutions GmbH, Dresden, Saxony, Germany
Koch A: Dresden University of Technology, Process-to-Order Group, Dresden, Saxony, Germany
Viedth I: Dresden University of Technology, Process-to-Order Group, Dresden, Saxony, Germany
Urbas L: Dresden University of Technology, Chair of Process Control Systems, Dresden, Saxony, Germany
Mädler J: FLEXCELERATE Solutions GmbH, Dresden, Saxony, Germany
Koch A: Dresden University of Technology, Process-to-Order Group, Dresden, Saxony, Germany
Viedth I: Dresden University of Technology, Process-to-Order Group, Dresden, Saxony, Germany
Urbas L: Dresden University of Technology, Chair of Process Control Systems, Dresden, Saxony, Germany
Journal Name
Systems and Control Transactions
Volume
5
First Page
1650
Last Page
1658
Year
2026
Publication Date
2026-06-12
Version Comments
Original Submission
Other Meta
PII: 1650-1658-244-SCT-5-2026, Publication Type: Journal Article
Record Map
Published Article

LAPSE:2026.0410
This Record
External Link

https://doi.org/10.69997/sct.186670
Publisher Version
Download
Meta
Record Statistics
Record Views
275
Version History
[v1] (Original Submission)
Jun 12, 2026
Verified by curator on
Jun 12, 2026
This Version Number
v1
Citations
Most Recent
This Version
URL Here
https://psecommunity.org/LAPSE:2026.0410
Record Owner
PSE Press
Links to Related Works
References Cited
- Baldea M, Edgar TF, Stanley BL, Kiss AA. Modular manufacturing processes: status, challenges, and opportunities. AIChE Journal 63:4262-4272 (2017) https://doi.org/10.1002/aic.15872
- Becker T, Lier S, Werners B. Value of modular production concepts in future chemical industry production networks. European Journal of Operational Research 276:957-970 (2019) https://doi.org/10.1016/j.ejor.2019.01.066
- Hohmann L, Kössl K, Kockmann N, Schembecker G, Bramsiepe C. Modules in process industry ? a life cycle definition. Chemical Engineering and Processing: Process Intensification 111:115-126 (2017) https://doi.org/10.1016/j.cep.2016.09.017
- Lier S, Paul S, Ferdinand D, Grünewald M. Modulare verfahrenstechnik: apparateentwicklung für wandlungsfähige produktionssysteme. Chemie Ingenieur Technik 88:1444-1454 (2016) https://doi.org/10.1002/cite.201600015
- O'Connor JT, Kowall CP, Haapala KR, Agrawal NV, Paul BK. Specialty chemicals production case study: economic analysis of modular chemical process intensification versus conventional stick?built approaches. J Adv Manuf & Process 3: (2021) https://doi.org/10.1002/amp2.10102
- Schindel , Polyakova , Harding , Weinhold , Stenger , Grünewald , Bramsiepe . General approach for technology and process equipment assembly (PEA) selection in process design. Chemical Engineering and Processing - Process Intensification 159:108223 (2021) https://doi.org/10.1016/j.cep.2020.108223
- Harding D, Polyakova M, Nowara D, Rech S, Grünewald M, Bramsiepe C. New process function-based selection and configuration methodology for process equipment assemblies (peas) exemplified on the unit operation distillation. Chemical Engineering and Processing - Process Intensification 168:108531 (2021) https://doi.org/10.1016/j.cep.2021.108531
- Swaney RE, Grossmann IE. An index for operational flexibility in chemical process design. part I: formulation and theory. AIChE Journal 31:621-630 (2004) https://doi.org/10.1002/aic.690310412
- Bansal V, Perkins JD, Pistikopoulos EN. Flexibility analysis and design using a parametric programming framework. AIChE Journal 48:2851-2868 (2004) https://doi.org/10.1002/aic.690481213
- International Council for Harmonisation, "ICH Quality Guidelines Q8-Q12, " 2005-2019. Available: https://www.ich.org
- Yu LX, Amidon G, Khan MA, Hoag SW, Polli J, Raju GK, Woodcock J. Understanding pharmaceutical quality by design. AAPS J 16:771-783 (2014) https://doi.org/10.1208/s12248-014-9598-3
- Holden JM. Many lives, many masters, by brian L. weiss. J Near-Death Stud 11:57-61 (1992) https://doi.org/10.1007/bf01082738
- Maedler, J., I. Viedt, J. Lorenz, and L. Urbas, "Requirements to a digital twin-centered concept for smart manufacturing in modular plants considering distributed knowledge, " in Computer Aided Chemical Engineering, vol. 49, Elsevier, 2022, pp. 1507-1512. doi: 10.1016/B978-0-323-85159-6.50251-7
- Koch A, Hamedi N, Furtner L, Kock T, Klose A, Mädler J. Standards for information models considering knowledge distribution in modular plants. 2023 IEEE 21st International Conference on Industrial Informatics (INDIN) :1-7 (2023) https://doi.org/10.1109/indin51400.2023.10218218
- Klose A, Merkelbach S, Menschner A, Hensel S, Heinze S, Bittorf L, Kockmann N, Schäfer C, Szmais S, Eckert M, Rüde T, Scherwietes T, da Silva Santos P, Stenger F, Holm T, Welscher W, Krink N, Schenk T, Stutz A, Maurmaier M, Stark K, Hoernicke M, Unland S, Erben S, Kessler F, Apitz F, Urbas L. Orchestration requirements for modular process plants in chemical and pharmaceutical industries. Chem Eng & Technol 42:2282-2291 (2019) https://doi.org/10.1002/ceat.201900298
- VDI 2776-3:2024, Process engineering plants - Modular plants - Safety of modular plants, Jan. 2024.
- Gent, I. P., P. Nightingale, and K. Stergiou, "QCSP-Solve: A Solver for Quantified Constraint Satisfaction Problems, " 2005.
- Mamoulis N, Stergiou K. Algorithms for quantified constraint satisfaction problems. Lecture Notes in Computer Science :752-756 (2004) https://doi.org/10.1007/978-3-540-30201-8_60
- Qureshi AJ, Dantan JY, Bruyere J, Bigot R. Set based robust design of mechanical systems using the quantifier constraint satisfaction algorithm. Engineering Applications of Artificial Intelligence 23:1173-1186 (2010) https://doi.org/10.1016/j.engappai.2010.02.003
- Grossmann IE, Floudas CA. Active constraint strategy for flexibility analysis in chemical processes. Computers & Chemical Engineering 11:675-693 (1987) https://doi.org/10.1016/0098-1354(87)87011-4
- Floudas CA, Gümü? ZH, Marianthi G Ierapetritou . Global optimization in design under uncertainty: feasibility test and flexibility index problems. Ind. Eng. Chem. Res. 40:4267-4282 (2001) https://doi.org/10.1021/ie001014g
- VDI/VDE/NAMUR 2658-4:2022, Automation engineering of modular systems in the process industry - Modellierung von Moduldiensten, Oct. 2022.
- Tolksdorf G, Cameron DB, Theißen M. DEXPI 2.0: synergistic integration of PFD and p&id in a unified digital model. Chemie Ingenieur Technik 97:1065-1069 (2025) https://doi.org/10.1002/cite.70009
- Hu J, Aminzadeh M, Wang Y. Searching feasible design space by solving quantified constraint satisfaction problems. Journal of Mechanical Design 136: (2013) https://doi.org/10.1115/1.4026027
- IEC 61512-1, Batch control - Part 1: Models and terminology, 1997
(0.1 seconds)
[0.1 s]

