MSCE  Vol.3 No.7 , July 2015
The Reconstruction Technique of Multi-Product Production and MINLP Mathematical Modelling
Low efficiency, negative impacts on the environment and non-profitable operations are the main shortcomings of out-dated industrial processes. Such systems can be reconstructed and improved in the direction of multi-product operations. The study of this article focuses on the development of a method for multi-product operations by reconstructing out-dated industrial processes. This article contains the theory of a developed method that enables the updating of existing process units and integrated systems on the basis of reconstruction scenarios and pathways. The goals of the set out method are: 1) to maintain the existing process units and chemical plants to a greater extent, 2) to enable the potential for finding new process alternatives and technological solutions, 3) to provide a streamlined operation for all subsystems and total systems, 4) to promote environmental and social responsibilities, and 5) to apply the concept of the presented reconstruction method to non-profitable industrial processes. In regard to multi-product operations, a conceptual model is a suitable tool for the reconstruction of industrial processes. It connects several software tools and so enables quick decision-making between process alternatives. A reconstruction method provides foresight into the possible improvements to existing industrial processes. In comparison with the indirect synthesis of DME (simple reconstruction pathway), the lower operating costs from the direct synthesis of DME (complex reconstruction pathway) were confirmed.

Cite this paper
Hosnar, J. and Kovač-Kralj, A. (2015) The Reconstruction Technique of Multi-Product Production and MINLP Mathematical Modelling. Journal of Materials Science and Chemical Engineering, 3, 59-74. doi: 10.4236/msce.2015.37007.
[1]   Lee, S., Oh, S. and Choi, Y. (2009) Performance and Emission Characteristics of an SI Engine Operated with DME Blended LPG Fuel. Fuel, 88, 1009-1015.

[2]   Papalexandri, K. and Pistikopoulos, E.N. (1993) A Retrofit Design Model for Improving the Operability of Heat Exchanger Networks. In: Pilavachi, P.A., Ed., Energy Efficiency in Process Technology, Springer, Netherlands, 915-928.

[3]   Papalexandri, K. and Pistikopoulos, E.N. (1993) A MINLP Retrofit Approach for Improving the Flexibility of Heat Exchanger Networks. Annals of Operations Research, 42, 119-168.

[4]   Sorak, A. and Kravanja, Z. (2004) MINLP Retrofit of Heat Exchanger Networks Comprising Different Exchanger Types. Computers & Chemical Engineering, 28, 235-251.

[5]   Kovac-Kralj, A. and Glavi, P. (2000) Simultaneous Retrofit of Complex and Energy Intensive Processes—III. Computers Chemical Engineering, 24, 1229.

[6]   Novak-Pintaric, Z. and Kravanja, Z. (2007) Multiperiod Investment Models for the Gradual Reconstruction of Chemical Processes. Chemical Engineering & Technology, 30, 1622-1632.

[7]   Arcoumanis, C., Choongsik, B., Crookes, R. and Eiji, K. (2008) The Potential of Dimethyl Ether (DME) as an Alternative Fuel for Compression-Ignition Engines: A Review. Fuel, 87, 1014-1030.

[8]   Zhou, L., Hu, S., Li, Y. and Zhou, Q. (2008) Study on Co-Feed and Co-Production System Based on Coal and Natural Gas for Producing DME and Electricity. Chemical Engineering Journal, 136, 31-40.

[9]   Larson, E.D. and Yang, H. (2004) Dimethyl Ether (DME) from Coal as a Household Cooking Fuel in China. Energy for Sustainable Development, 8, 115-126.

[10]   Gangadharan, P., Zanwar, A., Zheng, K., Gossage, J.L. and Helen, H. (2012) Sustainability Assessment of Polygeneration Processes Based on Syngas Derived from Coal and Natural Gas. Computers & Chemical Engineering, 39, 105- 117.

[11]   Kova-Kralj, A. and Bencik, D. (2012) Replacing the Existing Methanol Production within DME Production by Using Biogas. Chemical Engineering Transactions, 27, 25-30.

[12]   Kabir, K.B., Hein, K. and Bhattacharya, S. (2013) Process Modelling of Dimethyl Ether Production from Victorian Brown Coal—Integrating Coal Drying, Gasification and Synthesis Processes. Computers & Chemical Engineering, 48, 96-104.

[13]   Srirangan, K., Akawi, L., Moo-Young, M. and Chou, C.P. (2012) Towards Sustainable Production of Clean Energy Carriers from Biomass Resources. Applied Energy, 100, 172-186.

[14]   Swain, P.K., Das, L.M. and Naik, S.N. (2011) Biomass to Liquid: A Prospective Challenge to Research and Development in 21st Century. Renewable and Sustainable Energy Reviews, 15, 4917-4933.

[15]   Ju, F., Chen, H., Ding, X., Yang, H., Wang, X., Zhang, S. and Dai, Z. (2009) Process Simulation of Single-Step Dimethyl Ether Production via Biomass Gasification. Biotechnology Advances, 27, 599-605.

[16]   Trippe, F., Frhling, M., Schultmann, F., Stahl, R., Henrich, E. and Dalai, A. (2013) Comprehensive Techno-Economic Assessment of Dimethyl Ether (DME) Synthesis and Fischer-Tropsch Synthesis as Alternative Process Steps within Biomass-to-Liquid Production. Fuel Processing Technology, 106, 577-586.

[17]   Li, Y.P., Wang, T.J., Yin, X.L., Wu, C.Z., Ma, L.L., Li, H.B., et al. (2010) 100 t/a-Scale Demonstration of Direct Dimethyl Ether Synthesis from Corncob-Derived Syngas. Renewable Energy, 35, 583-587.

[18]   Li, Z., Liu, P., He, F., Wang, M. and Pistikopoulos, E.N. (2011) Simulation and Exergoeconomic Analysis of a Dual- Gas Sourced Polygeneration Process with Integrated Methanol/DME/DMC Catalytic Synthesis. Computers & Chemical Engineering, 35, 1857-1862.

[19]   Kovac-Kralj, A. and Bencik, D. (2011) Replacing an Existing Product’s Production within a Similar Product Production by Using a Replacement Technique. Energy Science & Technology, 2, 79-84.

[20]   Nasehi, S.M., Eslamlueyan, R. and Jahanmiri, A. (2006) Simulation of DME Reactor from Methanol. Proceedings of the 11th Chemical Engineering Conference, Kish Island, 28-30 November 2006.

[21]   Sai Prasad, P.S., Bae, J.W., Kang, S.H., Lee, Y.J. and Jun, K.W. (2008) Single-Step Synthesis of DME from Syngas on Cu-ZnO-Al2O3/Zeolite Bifunctional Catalysts: The Superiority of Ferrierite over the Other Zeolites. Fuel Processing Technology, 89, 1281-1286.

[22]   García-Trenco, A. and Martínez, A. (2014) The Influence of Zeolite Surface-Aluminum Species on the Deactivation of CuZnAl/Zeolite Hybrid Catalysts for the Direct DME Synthesis. Catalysis Today, 227, 144-153.

[23]   García-Trenco, A., Valencia, S. and Martínez, A. (2013) The Impact of Zeolite Pore Structure on the Catalytic Behavior of CuZnAl/Zeolite Hybrid Catalysts for the Direct DME Synthesis. Applied Catalysis A: General, 468, 102-111.

[24]   Zhang, M.H., Liu, Z.M., Lin, G.D. and Zhang, H.B. (2013) Pd/CNT-Promoted CuZrO2/HZSM-5 Hybrid Catalysts for Direct Synthesis of DME from CO2/H2. Applied Catalysis A: General, 451, 28-35.

[25]   Biegler, L.T., Grossmann, I.E. and Westerberg, A.W. (1997) Systematic Methods of Chemical Process Design. Prentice Hall PTR, Upper Saddle River.

[26]   Duran, M.A. and Grossmann, I.E. (1986) Simultaneous Optimization and Heat Integration of Chemical Processes. AIChE Journal, 32, 123-138.

[27]   Kravanja, Z. and Novak-Pintaric, Z. (2006) Optimiranje procesov: Zbrano gradivo. Fakulteta za kemijo in kemijsko tehnologijo, Univerza v Mariboru, Maribor.

[28]   Ropotar, M. and Kravanja, Z. (2006) Implementation of Efficient Logic-Based Techniques in the MINLP Process Synthesizer MIPSYN. In: Marquardt, W. and Pantelides, C., Eds., Computer Aided Chemical Engineering, Elsevier, Amsterdam, 233-238.

[29]   Jackson, J.R. and Grossmann, I.E. (2002) High Level Optimization Model for the Retrofit Planning of Process Networks. Industrial Engineering Chemistry Research, 41, 3762-3770.

[30]   Turton, R., Bailie, R.C., Whiting, W.B. and Shaeiwitz, J.A. (2009) Analysis, Synthesis, and Design of Chemical Processes. Prentice Hall, Upper Saddle River.

[31]   Towarmalani, M. and Sahinidis, N.V. (2005) A Polyhedral Branch-and-Cut Approach to Global Optimization. Mathematical Programming, 103, 225-249.

[32]   Yomamoto, Y.S. (1995) Ulmann’s Encyclopedie of Industrial Chemistry. Completely Revised Edition, Vol. A24, VCH, New York, 540-543.

[33]   Aktas, B. (2012) Production of Dimethyl Ether: Feasibility Study. Free Docs., 1-7.

[34]   Clausen, L.R., Elmegaard, B., Ahrenfeldt, J. and Henriksen, U. (2011) Thermodynamic Analysis of Small-Scale Dimethyl Ether (DME) and Methanol Plants Based on the Efficient Two-Stage Gasifier. Energy, 36, 5805-5814.

[35]   Zheng, D. and Cao, W. (2007) Retrofitting for DME Process by Energy-Flow Framework Diagram. Chemical Engineering and Processing: Process Intensification, 46, 2-9.

[36]   ASPEN PLUS (2002) User Manual Release 11.1. Aspen Technology Inc., Cambridge.

[37]   Yee, T.F. and Grossmann, I.E. (1990) Simultaneous Optimization Models for Heat Integration—II. Heat Exchanger Networks Synthesis. Computers & Chemical Engineering, 14, 1165-1184.

[38]   GAMS (2007) Beta 22.4: The Solver Manuals. GAMS Development Corporation, Washington DC.