Gerd Kaibel

Process Synthesis and Design in Industrial Practice

Abstract This contribution will demonstrate how a large chemical company, BASF, carries out process synthesis and process design in practice. First of all, the synthesis of a chemical process has to be included in the companys process chain, and the physical and chemical properties of at least the main components and their mixtures have to be known. It is then possible to formulate possible alternative solutions for the specific process. This can be done in two different ways: using a knowledge-based method with heuristic rules or using a method based on thermodynamics, often accompanied by special mathematical procedures (MINLP). The process synthesis phase is followed by a process design phase. Suggestions must be validated by means of economic comparison. Suitable tools for process synthesis and design include CAPE tools; suitable tools for validation include miniplants. This will be demonstrated using several non-standard processes as examples. The synthesis and design of dividing wall columns and of reactive distillations will be described. Mention will be made of the limitations of this procedure, and there will be some comments on future research needs as well as some general remarks on combined fluid-solid processes and hybrid processes.