Identifier

etd-10062010-132750

Degree

Doctor of Philosophy (PhD)

Department

Chemical Engineering

Document Type

Dissertation

Abstract

The objective of this research is to propose, develop and demonstrate a methodology for the optimal integration of bioprocesses in an existing chemical production complex. Chemical complex optimization is determining the optimal configuration of chemical plants in a superstructure of possible plants based on economic, environmental and sustainable criteria objective function (triple bottomline) and solves a mixed integer non linear programming problem. This research demonstrated the transition of production of chemicals from non-renewable to renewable feedstock. A conceptual design of biochemical processes was converted to five industrial scale designs in Aspen HYSYS® process simulator. Fourteen input-output block models were created from the designs based on the mass and energy relations. A superstructure of plants was formed by integrating the bioprocess models into a base case of existing plants in the lower Mississippi River corridor. Carbon dioxide produced from the integrated complex was used for algae oil and new chemicals production. The superstructure had 978 equality constraints, 91 inequality constraints, 969 continuous variables and 25 binary variables. The optimal solution gave a triple bottomline profit of $1,650 million per year from the base case solution of $854 million per year (93% increase). Raw material costs in the optimal solution decreased by 31% due to the exclusion of the costly ethylbenzene process. The utility costs for the complex increased to $46 million per year from $12 million per year. The sustainable costs to the society decreased to $10 million per year from $18 million per year (44% decrease). The bioprocesses increased the pure carbon dioxide sources to 1.07 million metric tons per year from 0.75 million metric tons per year for the base case (43% increase). The pure carbon dioxide vented to the atmosphere was reduced to zero in the optimal structure from 0.61 million metric tons per year (100% decrease) by consumption in the complex. The methodology can be used by decision makers to evaluate energy efficient and environmentally acceptable plants and have new products from greenhouse gases. Based on these results, the methodology could be applied to other chemical complexes in the world for reduced emissions and energy savings.

Date

2010

Document Availability at the Time of Submission

Release the entire work immediately for access worldwide.

Committee Chair

Pike, Ralph W Jr

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