Operator training simulators (OTS) are software tools for training process operators in large-scale industrial applications. Here, we describe the development, implementation and training of an OTS for a large-scale industrial plant for bioethanol production. The design of the OTS is based on conceptual analysis (previously reported by us in this journal) of various configuration alternatives and training procedures at the plant. In this article, we report on how the conceptual design is used in simulation models and graphical user interfaces and how the design is applied for training of operators in the real plant environment. The results imply that OTS would be time- and cost-efficient tools for application in the biotechnological industry.

A rise in CO₂ and other greenhouse gases’ concentration from gas refinery flares and furnaces in the atmosphere causes environmental problems. In this work, a new process was designed to use waste gas (flue gas and flare gas) of a domestic gas refinery to produce pure hydrogen in a membrane reactor. In particular, the process foresees that the energy and CO₂ content of flue gas can provide the heat of the mixed reforming reaction to convert flare gas into hydrogen. Furthermore, the characteristics of the feed stream were obtained via simulation. Then, an experimental setup was built up to investigate the performance of a membrane reactor allocating an unsupported dense Pd-Ag membrane at the mentioned conditions. In this regard, a Ni/CeO₂ catalyst was loaded in the membrane reformer for mixed reforming reaction, operating at 450 °C, in a pressure range between 100 and 350 kPa and a gas hourly space velocity of around 1000 h−1. The experimental results in terms of methane conversion, hyd... [more]

Gas separation for industrial, energy, and environmental applications requires low energy consumption and small footprint technology to minimize operating and capital costs for the processing of large volumes of gases. Among the separation methods currently being used, like distillation, amine scrubbing, and pressure and temperature swing adsorption, membrane-based gas separation has the potential to meet these demands. The key component, the membrane, must then be engineered to allow for high gas flux, high selectivity, and chemical and mechanical stability at the operating conditions of feed composition, pressure, and temperature. Among the new type of membranes studied that show promising results are the inorganic-based and the metal-organic framework-based mixed-matrix membranes (MOF-MMMs). A MOF is a unique material that offers the possibility of tuning the porosity of a membrane by introducing diffusional channels and forming a compatible interface with the polymer. This review d... [more]

These last few decades, membranes and monoliths have been increasingly used as stationary phases for chromatography. Their fast mass transfer is mainly based on convection, which leads to reduced diffusion, which is usually observed in resins. Nevertheless, poor flow distribution, which causes inefficient binding, remains a major challenge for the development of both membrane and monolith devices. Moreover, the comparison of membranes and monoliths for biomolecule separation has been very poorly investigated. In this paper, the separation of two proteins, bovine serum albumin (BSA) and lactoferrin (LF), with similar sizes, but different isoelectric points, was investigated at a pH of 6.0 with a BSA-LF concentration ratio of 2/1 (2.00 mg·mL−1 BSA and 1.00 mg·mL−1 LF solution) using strong cation exchange membranes and monoliths packed in the same housing, as well as commercialized devices. The feeding flow rate was operated at 12.0 bed volume (BV)/min for all devices. Afterward, bound L... [more]

A simulation model can accurately capture the details of product recipes in a batch process. By incorporating enhanced capabilities for making key assignment decisions in the simulation executive a model can mimic the experiential knowledge and rules employed in operating a process. As the process complexity and problem size increase using the mathematical programming (MP) techniques to generate schedules becomes increasingly difficult. A simulation run typically takes very little computation time and generates a schedule that is verifiable. Moreover, the model can be used to explore a wide range of parametric space to evaluate alternate policies and the impact of process uncertainties. Although there is no guarantee of optimality, the quality of schedules thus generated is very good and can be deployed in operations. In this paper the decision-making capabilities of the BATCHES simulator are presented with its application to a set of scheduling problems reported extensively in the lit... [more]

Carbon molecular sieve membranes (CMSMs) are an important alternative for gas separation because of their ease of manufacture, high selectivity due to molecular sieve separation, and high permeance. The integration of separation by membranes and reaction in only one unit lead to a high degree of process integration/intensification, with associated benefits of increased energy, production efficiencies and reduced reactor or catalyst volume. This review focuses on recent advances in carbon molecular sieve membranes and their applications in membrane reactors.

Optimization techniques are typically used to improve economic performance of batch processes, while meeting product and environmental specifications and safety constraints. Offline methods suffer from the parameters of the model being inaccurate, while re-identification of the parameters may not be possible due to the absence of persistency of excitation. Thus, a practical solution is the Nonlinear Model Predictive Control (NMPC) without parameter adaptation, where the measured states serve as new initial conditions for the re-optimization problem with a diminishing horizon. In such schemes, it is clear that the optimum cannot be reached due to plant-model mismatch. However, this paper goes one step further in showing that such re-optimization could in certain cases, especially with an economic cost, lead to results worse than the offline optimal input. On the other hand, in absence of process noise, for small parametric variations, if the cost function corresponds to tracking a feasi... [more]

There has always been a dispute about the energy efficiency and energy cost of electro-driven and turbo-driven blast furnace (BF) blast processes. In order to find where the problem lies, energy efficiency analysis models and energy cost analysis models of electro-driven and turbo-driven blast processes were established, and the differences between the two driving processes in terms of theoretical minimum steam consumption, energy efficiency and energy cost were studied. The results showed that the theoretical minimum steam consumption of a blast process depends on steam thermodynamic properties and is unrelated to drive mode and drive process. A certain overlapped interval between electro-driven and turbo-driven blast processes in terms of energy efficiency exists. The equation for calculating the standard coal coefficient of steam was proposed, and the relationship to judge strengths and weaknesses of the two driving modes in terms of energy efficiency and energy cost was established... [more]

We wish to correct Table 5 of the published paper in Processes [1].[...]

Delivery systems with a solid dispersed phase can be produced in a melt emulsification process. For this, dispersed particles are melted, disrupted, and crystallized in a liquid continuous phase (melt emulsification). Different to bulk crystallization, droplets in oil-in-water emulsions show individual crystallization behavior, which differs from droplet to droplet. Therefore, emulsion droplets may form liquid, amorphous, and crystalline structures during the crystallization process. The resulting particle size, shape, and physical state influence the application properties of these colloidal systems and have to be known in formulation research. To characterize crystallization behavior of single droplets in micro emulsions (range 1 µm to several hundred µm), a direct thermo-optical method was developed. It allows simultaneous determination of size, size distribution, and morphology of single droplets within droplet clusters. As it is also possible to differentiate between liquid, amorp... [more]

Polymers range from synthetic plastics, such as polyacrylates, to natural biopolymers, such as proteins and DNA.[...]

This contribution describes a novel process systems engineering framework that couples advanced control with sustainability evaluation for the optimization of process operations to minimize environmental impacts associated with products, materials and energy. The implemented control strategy combines a biologically-inspired method with optimal control concepts for finding more sustainable operating trajectories. The sustainability assessment of process operating points is carried out by using the U.S. EPA’s Gauging Reaction Effectiveness for the ENvironmental Sustainability of Chemistries with a multi-Objective Process Evaluator (GREENSCOPE) tool that provides scores for the selected indicators in the economic, material efficiency, environmental and energy areas. The indicator scores describe process performance on a sustainability measurement scale, effectively determining which operating point is more sustainable if there are more than several steady states for one specific product m... [more]

Despite continuous research effort, patients with type 1 diabetes mellitus (T1D) experience difficulties in daily adjustments of their blood glucose concentrations. New technological developments in the form of implanted intravenous infusion pumps and continuous blood glucose sensors might alleviate obstacles for the automatic adjustment of blood glucose concentration. These obstacles consist, for example, of large time-delays and insulin storage effects for the subcutaneous/interstitial route. Towards the goal of an artificial pancreas, we present a novel feedback controller approach that combines classical loop-shaping techniques with gain-scheduling and modern H ∞ -robust control approaches. A disturbance rejection design is proposed in discrete frequency domain based on the detailed model of the diabetic Göttingen minipig. The model is trimmed and linearised over a large operating range of blood glucose concentrations and insulin sensitivity values. Controller parameters are... [more]

There is currently much interest in pomegranate juice because of the high content of phenolic compounds. Moreover, the interest in the separation of bioactive compounds from natural sources has remarkably grown. In this work, for the first time, the Punica granatum L. (pomegranate) juice—clarified by using polyvinylidene fluoride (PVDF) and polysulfone (PSU) hollow fiber (HF) membranes prepared in the laboratory—was screened for its antioxidant properties by using different in vitro assays, namely 2,2-diphenyl-1-picrylhydrazyl (DPPH), 2,2'-azino-bis-(3-ethylbenzothiazoline-6-sulphonic acid) (ABTS), Ferric Reducing Antioxidant Power (FRAP), and β-carotene bleaching tests, and for its potential inhibitory activity of the carbohydrate-hydrolysing enzymes, α-amylase and α-glucosidase. The effects of clarification on quality characteristics of the juice were also investigated in terms of total phenols, flavonoids, anthocyanins, and ascorbic acid. Experimental results indicated that PVDF mem... [more]

Representing the uncertainties with a set of scenarios, the optimization problem resulting from a robust nonlinear model predictive control (NMPC) strategy at each sampling instance can be viewed as a large-scale stochastic program. This paper solves these optimization problems using the parallel Schur complement method developed to solve stochastic programs on distributed and shared memory machines. The control strategy is illustrated with a case study of a multidimensional unseeded batch crystallization process. For this application, a robust NMPC based on min⁻max optimization guarantees satisfaction of all state and input constraints for a set of uncertainty realizations, and also provides better robust performance compared with open-loop optimal control, nominal NMPC, and robust NMPC minimizing the expected performance at each sampling instance. The performance of robust NMPC can be improved by generating optimization scenarios using Bayesian inference. With the efficient parallel... [more]

Hot-melt extrusion is commonly applied for forming products, ranging from metals to plastics, rubber and clay composites. It is also increasingly used for the production of pharmaceuticals, such as granules, pellets and tablets. In this context, mathematical modeling plays an important role to determine the best process operating conditions, but also to possibly develop software sensors or controllers. The early models were essentially black-box and relied on the measurement of the residence time distribution. Current models involve mass, energy and momentum balances and consists of (partial) differential equations. This paper presents a literature review of a range of existing models. A common case study is considered to illustrate the predictive capability of the main candidate models, programmed in a simulation environment (e.g., MATLAB). Finally, a comprehensive distributed parameter model capturing the main phenomena is proposed.

Steam reforming of ethanol in the membrane reactor using the Pd77Ag23 membrane was evaluated in Ni/CeO₂ and Co/CeO₂ at atmospheric pressure. At 673 K, the H₂ yield in the Pd77Ag23 membrane reactor over Co/CeO₂ was found to be higher than that over Ni/CeO₂, although the H₂ yield over Ni/CeO₂ exceeded that over Co/CeO₂ at 773 K. This difference was owing to their reaction mechanism. At 773 K, the effect of H₂ removal could be understood as the equilibrium shift. In contrast, the H₂ removal kinetically inhibited the reverse methane steam reforming at low temperature. Thus, the low methane-forming reaction rate of Co/CeO₂ was favorable at 673 K. The addition of a trace amount of Ru increased the H₂ yield effectively in the membrane reactor, indicating that a reverse H₂ spill over mechanism of Ru would enhance the kinetical effect of H₂ separation. Finally, the effect of membrane performance on the reactor performance by using amorphous alloy membranes with different compositions was evalua... [more]

Homogenizers are commonly used to produce oil-in-water emulsions that consist of emulsifier-coated oil droplets suspended within an aqueous phase. The functional attributes of emulsions are usually controlled by selecting appropriate ingredients (e.g., surfactants, co-surfactants, oils, solvents, and co-solvents) and processing conditions (e.g., homogenizer type and operating conditions). However, the functional attributes of emulsions can also be tailored after homogenization by manipulating their composition, structure, or physical state. The interfacial properties of lipid droplets can be altered using competitive adsorption or coating methods (such as electrostatic deposition). The physical state of oil droplets can be altered by selecting an oil phase that crystallizes after the emulsion has been formed. The composition of the disperse phase can be altered by mixing different kinds of oil droplets together to induce inter-droplet exchange of oil molecules. The local environment of... [more]

This paper reports the findings of a FP7 project (DEMCAMER) that developed materials (catalysts and membranes) and new processes for four industrially relevant reaction processes. In this project, active, stable, and selective catalysts were developed for the reaction systems of interest and their production scaled up to kg scale (TRL5 (TRL: Technology Readiness Level)). Simultaneously, new membranes for gas separation were developed; in particular, dense supported thin palladium-based membranes for hydrogen separation from reactive mixtures. These membranes were successfully scaled up to TRL4 and used in various lab-scale reactors for water gas shift (WGS), using both packed bed and fluidized bed reactors, and Fischer-Tropsch (FTS) using packed bed reactors and in prototype reactors for WGS and FTS. Mixed ionic-electronic conducting membranes in capillary form were also developed for high temperature oxygen separation from air. These membranes can be used for both Autothermal Reformin... [more]

This paper presents an experimental study of the self-initiation reaction of n-butyl acrylate (n-BA) in free-radical polymerization. For the first time, the frequency factor and activation energy of the monomer self-initiation reaction are estimated from measurements of n-BA conversion in free-radical homo-polymerization initiated only by the monomer. The estimation was carried out using a macroscopic mechanistic mathematical model of the reactor. In addition to already-known reactions that contribute to the polymerization, the model considers a n-BA self-initiation reaction mechanism that is based on our previous electronic-level first-principles theoretical study of the self-initiation reaction. Reaction rate equations are derived using the method of moments. The reaction-rate parameter estimates obtained from conversion measurements agree well with estimates obtained via our purely-theoretical quantum chemical calculations.

An electromagnetic continuous casting mould designed is proposed with a non-uniform slit distribution structure. This design has aimed to reduce the number of slits so that the mould’s strength is enhanced, whilst maintaining a similar metallurgy effect. In this paper, the metallurgy effect for the designed mould is investigated through the magnetic field distribution along the casting direction, the uniformity feature in the vicinity of the meniscus region, the temperature variation of the molten alloy pool and the mould wall. The results show that the designed mould achieved a similar effect as compared to the original mould; however, the configuration is simplified. This research highlights the topic of mould structure optimization, which would enable the Electromagnetic continuous casting (EMCC) technique to be utilized with greater ease by industry.

Application of titanium dioxide (TiO₂) as a photocatalyst has presented a promising avenue for the safe photocatalytic degradation of pollutants. Increasing levels of the release of pharmaceuticals in the environment and formation of the intermediates during their degradation may impose health and environmental risks and therefore require more attention. Photocatalytic degradation of acetylsalicylic acid (aspirin) was carried out in the presence of the TiO₂-filled polymeric film as a photocatalyst under solar light irradiation. The polymeric film incorporates TiO₂ in the matrix, which acts as a photocatalyst under solar illumination and degrades the acetyl salicylic acid (ASA) into a range of organic compounds before complete demineralization (formation of carbon dioxide and water as final products). Among the intermediates, acetic acid was found to be present in a larger amount compared to other organic acids. The qualitative/quantitative analyses of the intermediates resulted in the... [more]

The authors wish to correct Table A1 of the published paper in Processes [1].[...]

In this paper, measurable disturbance compensation techniques are analyzed, focusing the problem on the input-output and disturbance-output time delays. The feedforward compensation method is evaluated for the common structures that appear between the disturbance and process dynamics. Due to the presence of time delays, the study includes causality and instability phenomena that can arise when a classical approach for disturbance compensation is used. Different feedforward configurations are analyzed for two feedback control techniques, PID (Proportional-Integral-Derivative) and MPC (Model Predictive Control) that are widely used for industrial process-control applications. The specific tuning methodology for the analyzed process structure is used to obtain improved disturbance rejection performance regarding classical approaches. The evaluation of the introduced disturbance rejection schemes is performed through simulation, considering process constraints in order to highlight the adv... [more]

In production of electricity from coal, integrated gasification combined cycle plants typically operate with conventional packed bed reactors for the water-gas shift reaction, and a Selexol process for carbon dioxide removal. Implementation of membrane reactors in place of these two process units provides advantages such as increased carbon monoxide conversion, facilitated CO₂ removal/sequestration and process intensification. Proposed H₂-selective membranes for these reactors are typically of palladium alloy or ceramic due to their outstanding gas separation properties; however, on an industrial scale, the cost of such materials may become exorbitant. High-performance polymeric membranes, such as polybenzimidazoles (PBIs), present themselves as low-cost alternatives with gas separation properties suitable for use in such membrane reactors, given their significant thermal and chemical stability. In this work, the performance of a class of high-performance polymeric membranes is assesse... [more]