Integrating process design and control: An application of optimal control to chemical processes

In this paper, the optimal design of process systems generically used in chemical industries is studied. The closely coupled nature of optimal design specification of the equipment, the determination of the optimal process parameters in steady-state, moreover, some issues of the application of optimal control is shown. The solution of the overall optimization problem including (i) optimal design of the equipment and (ii) specification of its optimal control strategy can be found relying on two different design concepts, namely, on the conventionally used sequential or, on the newly emerged simultaneous design approaches. This paper gives the theoretical background of the ideas and presents a comparative summary of the approaches. The two approaches are contrasted to each other in which the effects of the interaction of optimal process design and optimal control is highlighted. A new simultaneous optimization procedure providing economic and operability benefits over the traditional stand-alone approach is proposed. The applicability of the idea is demonstrated by means of a design study carried out for optimal design of a coaxial heat exchanger and a reactive distillation column for the synthesis of ethyl tert butyl ether (ETBE), relying on the benefits of the utilization of optimal control.