Sustainable Chemical Process Design 159

Rafiqul Gani, Henrique A. Matos and Ana Isabel Cerqueira de Sousa Gouveia Carvalho

5.1 Introduction 159

5.2 Definition of Concepts 159

5.2.1 Process Retrofit 159

5.2.2 Sustainability 160

5.2.3 Safety 160

5.3 Methodology for Sustainable Process Design 161

5.3.1 Methodology - Continuous Mode 161

5.3.1.1 Step 1: Data Collection 161

5.3.1.2 Step 2: Flowsheet Decomposition 161

5.3.1.3 Step 3: Calculation of Indicators 163

5.3.1.4 Step 4: Indicator Sensitivity Analysis Algorithm 167

5.3.1.5 Step 5: Sensitivity Analysis of Operational Parameters 167

5.3.1.6 Step 6: Generation of New Sustainable Design Alternatives 168

5.3.2 Methodology - Batch Mode 169

5.3.2.1 Step 1: Data Collection 169

5.3.2.2 Step 1A: Transform Equipment Flowsheet into an Operational Flow Diagram 169

5.3.2.3 Step 2: Flow Diagram Decomposition 170

5.3.2.4 Step 3: Calculation of Indicators 170

5.3.2.5 Step 4: Indicator Sensitivity Analysis Algorithm 172

5.3.2.6 Step 5: Sensitivity Analysis of Operational Parameters 172

5.3.2.7 Step 6: Generation of New Sustainable Design Alternatives 172

5.4 SustainPro Software 173

5.4.1 Introduction 173

5.4.2 SustainPro Architecture 173

5.4.3 Supporting Tools 173

5.5 Case Studies 174

5.5.1 Continuous Processes: Biodiesel Production 174

5.5.1.1 Step 1: Collect the Steady-state Data 174

5.5.1.2 Step 2: Flowsheet Decomposition 175

5.5.1.3 Step 3: Calculate the Indicators, the Sustainability and the Safety Metrics 175

5.5.1.4 Step 4: Indicator Sensitivity Analysis (ISA) Algorithm 177

5.5.1.5 Step 5: Process Sensitivity Analysis 177

5.5.1.6 Step 6: Generation of New Design Alternatives 177

5.5.2 Batch Processes: Insulin Case Study 179

5.5.2.1 Step 1: Collect the Steady-state Data 180

5.5.2.2 Step 1A: Transform Equipment Flowsheet in an Operational Flowsheet 180

5.5.2.3 Step 2: Flowsheet Decomposition 180

5.5.2.4 Step 3: Calculate the Indicators, the Sustainability and the Safety Metrics 180

5.5.2.5 Step 4: Indicator Sensitivity Analysis (ISA) Algorithm 183

5.5.2.6 Step 5: Process Sensitivity Analysis 183

5.5.2.7 Step 6: Generation of New Design Alternatives 184 5.6 Conclusions 186

References 186

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