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Abstract: In this article the optimal selection of the reboiler vessels, rectification columns and connection pipes with regard to reboiler swelling, and tray and pipe flooding is investigated. Since the reboilers are constrained by liquid swelling, while pipes and columns are constrained by flooding it is important to pair the equipment so that the vapor rate limitations are as close as possible, thus ensuring maximal equipment capacity usage. Calculations at 1 and 0.25bar pressure are performed for the standardized 1.6, 2.5, 4 and 6.3m3 reboiler vessels [Rührbehälter Basler Norm, N 253, 1977] and sieve tray rectification columns with nominal diameters ranging from 0.2 up to 0.6m. The dynamic operation of the batch distillation process having the vapor load and reflux ratio as input profiles is evaluated by formulating and solving an optimal control problem constrained by the hydraulic limitations. The open-loop optimization problem is solved using a dedicated Matlab tool – OptCon – which implements the multiple shooting strategy and the large-scale non-linear programming problem is handled by the HQP engine. [Copyright &y& Elsevier]

Abstract: This article presents the modeling and optimization of an industrial batch reactor operation with regard to production safety constraint which is represented by the reactor content swelling. Swelling occurs due to the evacuation of a coupled product which passes through the liquid in order to reach the reaction mass surface. In order to model the reaction system a chemical model linked to a hydrodynamic model is developed. The goal of the optimization is to calculate the temperature and pressure profiles which maximize conversion rates, without exceeding the maximum reactor level. The optimal temperature profile is calculated using the optimal control optimization method and the results show that a productivity increase of up to 36% can be achieved as compared to the industrial process. [Copyright &y& Elsevier]