The activated sludge process is one of the most commonly employed domestic and industrial waste treatment process. Different types of mathematical models have been proposed for design and operation of this process, most of which do not consider the relationship between the sludge settling characteristics and the aeration unit performance. This project studies the validity of a model developed by La Motta (2004b) which links the operating parameters of an activated sludge system and the classical limiting flux sludge settling theory. Favorable results were obtained demonstrating that the model predicts very similar values of the parameters of the system in comparison with the parameters observed in an activated sludge pilot plant that is located within installations of the Marrero Wastewater Treatment Plant, New Orleans, Louisiana. This research also demonstrated that the model is a helpful tool for the design and operation of an activated sludge system.

No / Optimal design (vapour load, V and number of stages, N) and operation (reflux ratio, R and batch time, tb) of batch distillation have received significant attention in recent years. In these studies, it has been suggested that V should be set at some upper limit (thought to be optimum) and the optimisation task should be focused on finding the optimum values of N, R and tb, which would minimise the capital investment while maximising an economic objective function usually the profit (P). The major drawback of such optimisation strategy is that there is no constraint on the amount of product (on specification) being produced (NB = no. of batches in a given time) and the overall profit can only be maximised by producing unlimited amount of products. Unplanned and unlimited production of products are not sustainable and may lead to significant losses in the case of large inventory requirements of any excess products produced. In this work, for the first time, the optimal design and operation task for batch distillation is considered with due regards to the market demands (small to large number of batches) of the products being produced. An optimisation problem formulation is presented for the task which is different than those used in the past under unlimited product demand scenario. Simulated Annealing type algorithm is used for the solution of the optimisation problem. With several examples, it will be shown that fixing V a priori (say V < Vopt) will not allow production of NB batches of products with any combination of (N, R, tb) in a given production time. Also it will be shown that with V fixed at say V > Vopt, P will always be <Pmax for any combination of (N, R, tb). The comparisons between the results with and without fixing of V a priori show very clear improvement in the annual profit.

In this study, the effects of bioprocess operation parameters on aromatic amino acid synthesis performance of Bacillus acidocaldarius were investigated. Firstly, in laboratory scale shake-bioreactors, a defined medium was designed in terms of its carbon and nitrogen sources, to achieve the highest cell concentration. Thereafter, the effects of bioprocess operation parameters, i.e., pH and temperature were investigated / and the optimum medium contained (kg m-3): fructose, 8 / (NH4)2HPO4, 5 / CaCl2, 0.2 / KH2PO4, 2 / NaH2PO4.2H2O, 7.318 / Na2HPO4, 0.0438 / Mg(CH3COO)2.4H2O, 87&times / 10-3 / 1 , MgSO4.7H2O / 2&times / 10-3, FeSO4.7H2O / 2&times / 10-3, ZnSO4.7H2O / 15 &times / 10-5, MnSO4.H2O / 2&times / 10-5, CuSO4.5H2O with pH0 =5, T=55&amp / #61616 / C, N=175 min-1. In this medium, the bacteria produced L-tryptophan at the highest concentration of 0.204 kg m-3 and L-phenylalanine at a maximum concentration of 0.0106 kg m-3 with no L-tyrosine production. Finally the fermentation and oxygen transfer characteristics of the bioprocess were investigated in 3.0 dm3 pilot scale bioreactors. The effects of oxygen transfer were investigated at four different conditions at the parameters air inlet rates of QO/VR =0.2, and 0.5 vvm, and agitation rates of N= 250, 500, 750 min-1. The effect of pH was investigated at pH=5 uncontrolled and controlled operations. The variations in cell, fructose, amino acid and organic acid concentrations with the cultivation time / and using the dynamic method, the oxygen uptake rate and the liquid phase mass transfer coefficient values throughout the growth phase of the bioprocess / the yield and maintenance coefficients were determined. The aromatic amino acids produced at the highest and the least amount and frequency were L-tryptophan and L-tyrosine, respectively. The highest L-tryptophan production, 0.32 kg m-3 in 17 hour was at 0.2 vvm and 500 min-1. Among all operations, the highest L-tryptophan was produced at the lowest oxygen transfer condition. Controlled-pH conditions produced more L-tryptophan.

Heat exchanger networks (HENs) are the backbone of heat integration due to their ability in energy and environmental managements. This thesis deals with two issues on HENs. The first concerns with designing of economically optimal Heat exchanger network (HEN) whereas the second focus on optimal operation of HEN in the presence of uncertainties and disturbances within the network. In the first issue, a pinch technology based optimal HEN design is firstly implemented on a 3–streams heat recovery case study to design a simple HEN and then, a more complex HEN is designed for a coal-fired power plant retrofitted with CO2 capture unit to achieve the objectives of minimising energy penalty on the power plant due to its integration with the CO2 capture plant. The benchmark in this case study is a stream data from (Khalilpour and Abbas, 2011). Improvement to their work includes: (1) the use of economic data to evaluate achievable trade-offs between energy, capital and utility cost for determination of minimum temperature difference; (2) redesigning of the HEN based on the new minimum temperature difference and (3) its comparison with the base case design. The results shows that the energy burden imposed on the power plant with CO2 capture is significantly reduced through HEN leading to utility cost saving maximisation. The cost of addition of HEN is recoverable within a short payback period of about 2.8 years. In the second issue, optimal HEN operation considering range of uncertainties and disturbances in flowrates and inlet stream temperatures while minimizing utility consumption at constant target temperatures based on self-optimizing control (SOC) strategy. The new SOC method developed in this thesis is a data-driven SOC method which uses process data collected overtime during plant operation to select control variables (CVs). This is in contrast to the existing SOC strategies in which the CV selection requires process model to be linearized for nonlinear processes which leads to unaccounted losses due to linearization errors. The new approach selects CVs in which the necessary condition of optimality (NCO) is directly approximated by the CV through a single regression step. This work was inspired by Ye et al., (2013) regression based globally optimal CV selection with no model linearization and Ye et al., (2012) two steps regression based data-driven CV selection but with poor optimal results due to regression errors in the two steps procedures. The advantage of this work is that it doesn’t require evaluation of derivatives hence CVs can be evaluated even with commercial simulators such as HYSYS and UNISIM from among others. The effectiveness of the proposed method is again applied to the 3-streams HEN case study and also the HEN for coal-fired power plant with CO2 capture unit. The case studies show that the proposed methodology provides better optimal operation under uncertainties when compared to the existing model-based SOC techniques.

Energy demand for buildings has been rising during recent years. Increasing building energy consumption has caused many energy-related problems and environmental issues. The on-site community energy system application is a promising way of providing energy for buildings. Community energy system usage reduces the primary energy consumption and environmental effects of greenhouse gas (GHG) emissions compared to the implementation of the stand-alone energy systems. Furthermore, due to the increase in electricity price and shortage of fossil fuel resources, renewable energies and energy storage technologies could be great alternative solutions to solve energy-related problems. Generally, the energy system might include various technologies such as internal combustion engine, heat recovery system, boiler, thermal storage tank, battery, absorption chiller, ground source heat pump, heating coil, electric chiller, solar photovoltaics (PV) and solar thermal collectors, and seasonal thermal energy storage. The economic, technical and environmental impacts of energy systems depend on the system design and operational strategy. The focus of this thesis is to propose unified frameworks, including the mathematical formulation of all of the components to determine the optimal energy system configuration, the optimal size of each component, and optimal operating strategy. The proposed methodologies address the problems related to the optimal design of the energy system for both deterministic and stochastic cases. By the use of the proposed frameworks, the design of the energy system is investigated for different specified levels of GHG emissions ratio, and the purpose is to minimize the annual total cost. To account for uncertainties and to reduce the computational times and maintain accuracy, a novel strategy is developed to produce scenarios for the stochastic problem. System design is carried out to minimize the annual total cost and conditional value at risk (CVaR) of emissions for the confidence level of 95%. The results demonstrate how the system size changes due to uncertainty and as a function of the operational GHG emissions ratio. It is shown that with the present-day technology (without solar technologies and seasonal storage), the lowest amount of GHG emissions ratio is 37%. This indicates the need for significant technological development to overcome that ratio to be 10% of stand-alone systems. This thesis introduces novel performance curves (NPC) for determining the optimal operation of the energy system. By the use of this approach, it is possible to identify the optimal operation of the energy system without solving complex optimization procedures. The application of the proposed NPC strategy is investigated for various case studies in different locations. The usage of the proposed strategy leads to the best-operating cost-saving and operational GHG savings when compared to other published approaches. It has shown that other strategies are special (not always optimal) cases of the NPC strategy. Based on the extensive literature review, it is found that it is exceptionally complicated to apply the previously proposed models of seasonal thermal energy storage in optimization software. Besides, the high computational time is required to obtain an optimum size and operation of storage from an optimization software. This thesis also proposes a new flexible semi-analytical, semi-numerical methodology to model the heat transfer process of the borehole thermal energy storage to solve the above challenges. The model increases the flexibility of the storage operation since the model can control the process of the storage by also deciding the appropriate storage zone for charging and discharging. / Thesis / Doctor of Engineering (DEng)

Much of industry is seeking scope economies, but this requires more complex and flexible product realisation. Modelling technologies have potential to support the life cycle engineering of both Economies of Scope and Scale (EoSS) manufacturing systems. However when companies operate in dynamic environments it is not sufficient to model manufacturing systems in isolation. Rather a holistic modelling methodology is needed which can create structural and behavioural models of dependencies between the manufacturing systems, and the business and engineering environments in which they operate; so that a suitable balance between economies of scope and scale can be achieved. This thesis describes the conception and development of a step wised Extended Modelling Methodology (EMM) which facilitates reasoning, and related decision making, about EoSS manufacturing systems. The EMM was conceived from exploratory research in two SMEs, following which it was applied and case tested in a large manufacturing company. Little academic attention to date has been paid to theorising about the link between ‘Economies of Scope and Scale (EoSS) phenomenon' and ‘manufacturing systems design'. Hence many questions about EoSS manufacturing remain unanswered, such as: (1) academic communities need to know what EoSS actually means and how state-of-the-art modelling can support qualitative and quantitative analysis of EoSS system phenomenon; and (2) industry needs to know how they can benefit from EoSS, what attended costs they might incur, and what best balance between scope and scale economies can be achieved. With these general requirements in mind the thesis reports on the conception and industrial application of the EMM. This has: (A) developed new ideas about EoSS, which can be used to characterise EoSS phenomenon; (B) introduced a new way of visualising architectural aspects of EoSS at multiple-levels of abstraction; and (C) with reference to case studies has illustrated the use of multi-level modelling to enable predictions to be made about EoSS benefits and costs.

In this study, the effects of bioprocess design parameters on &amp / #946 / -lactamase production were systematically investigated using wild type Bacillus species. For this purpose, the research programme was carried out in mainly four parts. Initially, potential &amp / #946 / -lactamase producers were screened and Bacillus licheniformis ATCC 25972, a constitutive &amp / #946 / -lactamase producer, was selected. Next, the effects of bioprocess medium components, i.e., carbon sources (glucose, fructose, sucrose, citric acid and glycerol), inorganic nitrogen sources ((NH4)2HPO4 and NH4Cl) and organic nitrogen sources (yeast extract, peptone and casamino acids), were investigated in agitation and heating rate controlled laboratory scale bioreactors. Thereafter, by using the designed medium, the effects of bioprocess operation parameters, i.e., pH and temperature, on &amp / #946 / - lactamase activity were investigated in order to achieve a higher &amp / #946 / -lactamase production. Among the investigated bioprocess conditions, the highest &amp / #946 / - lactamase activity was obtained as 275 U cm-3, in the medium with 10.0 kg m-3 glucose, 1.2 kg m-3 (NH4)2HPO4, 8.0 kg m-3 yeast extract and the salt solution, at pH0=6.0, T=32&deg / C, N=200 min-1, which was 7.9 fold higher than the activity obtained in the reference medium. Finally, using the optimum bioprocess parameters obtained in laboratory scale experiments, the fermentation and oxygen transfer characteristics of the bioprocess were investigated in 3.0 dm3 pilot scale bioreactor, having temperature, pH, foam and stirring rate controls, at Q0/V=0.5 vvm and N=500 min-1 oxygen transfer conditions. The variations in &amp / #946 / - lactamase activity, cell, glucose, amino acid and organic acid concentrations with the cultivation time / the oxygen uptake rate and the liquid phase mass transfer coefficient values were determined. Throughout the bioprocess, overall oxygen transfer coefficient (KLa) varied between 0.008-0.016 s-1 / oxygen uptake rate varied between 0.001-0.003 mol m-3 s-1. Furthermore, rate limiting step analysis was performed / the yield and maintenance coefficients for the bioprocess as well as the kinetic parameters for &amp / #946 / -lactamase were determined.

Ce travail de thèse constitue le prolongement direct des travaux de thèse Chachuat (2001) sur l'optimisation dynamique et la commande optimale des stations de traitement de petite taille. L'objectif est d'aller plus loin en s'intéressant aux dimensionnement et fonctionnement optimaux des stations de traitement des eaux usées de toute taille. Ainsi, dans une première étape, l'optimisation des stations de traitement de petite taille a été abordée. Contrairement à ce qui a été fait jusqu'à maintenant : (i) l'aération n'est plus alternée, mais continue, (ii) le décanteur n'est plus considéré comme parfait, mais son fonctionnement est modélisé à l'aide d'une série de 10 couches de décantation, (iii) la méthode d'optimisation développée est fondée sur la méthode des sensibilités implémentée au sein du logiciel de simulation et optimisation dynamiques gProms, utilisé dans toute la thèse. L'influence du modèle du décanteur sur la minimisation de l'énergie d'aération a été particulièrement analysée. Dans une deuxième étape, les stations de traitement de grande taille sont considérées. Plus spécifiquement, le modèle benchmark développé par le réseau européen COST a été utilisé pour décrire leur fonctionnement. Un « foreignobject » a été développé pour que la simulation et l'optimisation du fonctionnement de ces stations soient possibles sous gProms. L'optimisation a notamment montré que la consommation d'énergie d'aération pouvait être réduite d'au moins de 30% par rapport au fonctionnement actuel de ces stations. Dans une troisième étape, l'optimisation du dimensionnement des stations de traitement de grande taille a été étudiée. Une superstructure a ainsi été définie avec plusieurs (cinq) réacteurs et un décanteur. Toutes les possibilités de recyclage et de court-circuit entre les réacteurs d'une part et entre les réacteurs et le décanteur d'autre part sont prises en compte. L'objectif était de déterminer la meilleure structure et les valeurs optimales des volumes des réacteurs qui permettent de minimiser le coût total tout en respectant les contraintes réglementaires sur les rejets.Par ailleurs, une optimisation multicritère de la station optimale résultante a été réalisée. Elle a permis de déterminer l'ensemble de Pareto des solutions qui minimisent la consommation énergétique (d'aération et de pompage) et maximisent la qualité de l'effluent. La quatrième et dernière partie de ce travail s'intéresse à la modélisation, simulation et optimisation de la station de traitement de Verulam près de Durban en Afrique du Sud. Des mesures expérimentales ont été réalisées sur cette station et le modèle ASM1 a été utilisé pour décrire son fonctionnement. Une analyse d'estimabilité des paramètres a été d'abord réalisée pour déterminer les paramètres du modèle qui peuvent être estimés à partir des mesures expérimentales disponibles. Les paramètres estimables ont ensuite été identifiés à l'aide de gProms. Le modèle ainsi identifié a été validé et ensuite utilisé pour optimiser le fonctionnement énergétique de cette station / This work is a direct extension of the PhD thesis of Chachuat (2001) on dynamic optimization and optimal control of small size wastewater treatment plants. The objective is to go further by focusing on optimal design and operation of wastewater treatment plants of any size. Thus, in a first part, optimization of small size wastewater treatment plants was studied. Contrary to what has been done so far: (i) the aeration is no longer alternating, but continuous, (ii) the settler is not considered perfect, but its operation is modeled using a series of 10 sedimentation layers, (iii) the optimization approach developed is based on the method of sensitivities implemented wthin the dynamic simulation and optimization software gProms, used throughout this work. The influence of the settler model on the minimization of aeration energy was particularly investigated. In a second part , the large size treatment plants are considered . More specifically, the benchmark model developed by the European network COST was used to describe their operation. A "foreign object" was developed in order to make the simulation and optimization of these plants possible using gProms. The optimisation showed that the aeration energy consumption could be reduced by at least 30 % compared to the current operation of these plants . In a third part, the optimization of the design of the wastewater treatment plant was studied. A superstructure has been defined with several (five) reactors and a settler. All the possibilities of recycling and by-passes between the reactors on the one hand and between the reactors and the settler on the other are considered. The objective was to determine the best structure and the optimal values of the reacter volumes that minimize the net present value while respecting the regulatory constraints. On the other hand, a multi-objective optimization problems of the treatment plant was carried out. It allawed to determine the Pareto set of solutions that minimize the energy consumption (pumping and aeration) and maximize the effluent quality. The fourth and last part of this work focuses on modeling, simulation and optimization of the treatment plant of the city of Verulam in the area of Durban in South Africa. Experimental measurements were carried out on the plant and the ASM1 model was used to describe its operation. An estimability analysis was first performed in order to determine the model parameters that can be estimated from the available experimental measurements . The estimable parameters were then identified using gProms . The identified model was validated and then used to optimize the energy function of this plant

This research aims to assess the causes of inefficient and unstable operation of centrifugal compressors and turboexpanders in process gas applications in order to provide a solution for performance restoration and enhancement. It encompasses thermodynamic and flow evaluations to examine the efficiency and operating range improvement options of new units. Besides, this work is complemented by a technoeconomic analysis to provide a rounded outcome from these studies. In order to achieve the desired objectives, a novel integrated approach has been developed to assess the design and performance of multi-stage centrifugal compressors. The proposed systematic methodology involves five basic elements including evaluation of compressor selection, compressor sizing and casing structure, performance prediction at the design and off-design conditions, modelling of efficiency and head deterioration causes; and stage design evaluation. This will contribute towards evaluating the geometrical parameters of the new units’ designs at the early preliminary design phase, and thus, will be useful to identify the options for efficiency and operating range enhancements. For installed units, this approach can be implemented to assess the cause of inefficient and unstable operation by assessing the available operation data. A method was developed to predict the performance curve of multi-stage centrifugal compressor based on a stage stacking technique. This approach considers the advantages of Lüdtke and Casey-Robinson methods with an incorporation of a methodology for compressor selection and sizing to generate more accurate results. To emphasize the validity of the developed model, it has been evaluated for both low and high flow coefficient applications. The obtained results show a significant improvement in the estimated efficiency, pressure ratio, shaft power and operating range as compared with the existing methods. The centrifugal compressor is designed to run under various operating conditions and different gas compositions with the primary objective of high efficiency and reliability. Therefore, a new iterative method has been developed to predict the equivalent compressor performance at off-design conditions. This technique uses the performance parameters at design conditions as a reference point to derive the corresponding performance characteristics at numerous suction conditions with less dependency on the geometrical features. Through a case study on a gas transport centrifugal compressor, it was found that the developed approach can be applied for design evaluation on the expected variation of working conditions, and for the operation diagnosis of installed units as well. Furthermore, a parametric study has been conducted to investigate the effect of gas properties on the stage efficiency, surge margin, and compressor structure. The obtained results support the need for considering the gas properties variation when the off-design performance is derived. To evaluate the impact of internal blockage on the performance parameters, this study proposed an approach to model the effect of non-reactive deposits, which has been qualified using four operation cases and the obtained results are compared with the internal inspection findings from the stage overhauling process. This also covers the influential aspects of flow blockage on the technical and economic values. Since the main challenge here is to analyze the process gas composition in real time, the influences of the non-reactive deposits have been compared with the effect of the unanticipated gas composition change. Subsequently, it has turned out that the pressureratio parameter is not enough to assess the possibility of flow blockage and unexpected gas properties change. Moreover, it was observed that the stage discharge pressure was more sensitive to the fouled aftercooler comparing with suction and internal blockage. However, the effect of contaminated aftercooler on the surge point and discharge pressure and temperature of the upstream stage was found greater than its impact on the shaft power. Thus, a substantial surge margin reduction was detected when the first stage was operating with a fouled aftercooler comparing with the measured reduction as a result of unanticipated gas properties change. Furthermore, a larger pressure ratio drop was measured in the case of liquid carryover which revealed a more significant impact of the two phases densities difference comparing with the gas volume fraction (GVF) effect. The possibility of hydrate formation has been assessed using hydrate formation temperature (HFT) criteria. Additionally, this research highlights a number of challenges facing the selection of typical centrifugal stage design by assessing the contribution of design characteristics on the operating efficiency and stable flow range. Besides, an empirical-based-model was established to select the optimum impeller and diffuser configurations in order to make a compromise decision based on technical and economic perspective. It was concluded that there is no absolute answer to the question of optimum rotor and stator configuration. The preliminary aerothermodynamic evaluation exposed that the selection of the optimum impeller structure is governed by several variables: stage efficiency, pressure loss coefficient, manufacturing cost, required power cost, resonance frequency and stable operating range. Hence, an evaluation is required to compromise between these parameters to ensure better performance. Furthermore, it was argued throughout this study that the decision-making process of the typical stage geometrical features has to be based upon the long-term economic performance optimization. Thus, for higher long-term economic performance, it is not sufficient to select the characteristics of the impeller and diffuser geometry based on the low manufacturing cost or efficiency improvement criterion only. For turboexpanders, a simple and low cost tool has been developed to determine the optimum turboexpander characteristics by analysing the generated design alternatives. This approach was used in designing a turboexpander for hydrocarbon liquefaction process. Moreover, since the turboexpanders are expected to run continuously at severe gas conditions, the performance of the selected turboexpander was evaluated at different inlet flow rates and gas temperatures. It has turned out that designing a turboexpander with the maximum isentropic efficiency is not always possible due to the limitations of the aerodynamic parameters for each component. Therefore, it is necessary to assess the stage geometrical features prior the construction process to compromise between the high capital cost and the high energetic efficiency.