Gas separations are often required in chemical processes, e.g. air separation, ethylene production, etc. These are often challenging and costly processes because of the low temperature and high pressure needed if vapour-liquid phase separations are involved. This thesis focuses on hybrid membrane-distillation separations as an opportunity to develop more energy-efficient separation processes. In a typical ethylene plant, recovery, the separation and purification of the cracked product are economically important. The focus of this thesis is on the ‘C2splitter’ which separates the desired product, ethylene, from ethane. Cryogenic distillation, which is currently used to separate the binary ethylene-ethane mixture, is extremely expensive in terms of both capital and operating costs, especially because of refrigerated cooling requirements. Hybrid membrane-distillation processes are able to effectively separate low-boiling compounds and close-boiling mixtures and to reduce energy consumption, relative to cryogenic distillation. However, hybrid membrane-distillation processes present challenges for process modelling, design and operation. There are two major challenges associated with the modelling of hybrid processes for low temperature separations: i) the complex interaction between the process and the refrigeration system and ii) the large number of structural options, e.g. conventional column, membrane unit or hybrid membrane-distillation separation, where the distillation column can be integrated with the membrane unit to form a sequential, parallel, ‘top’or ‘bottom’ hybrid scheme. This thesis develops a systematic methodology to design, screen, evaluate and optimise various design alternatives. Schemes are evaluated with respect to energy consumption, i.e. power consumption of process and refrigeration compressors, or energy costs. In the methodology, process options are screened first for feasibility, based on numerous simulations and sensitivity analyses. Then, the feasible options are evaluated in terms of energy consumption and compared to the performance of a conventional distillation column. Finally, economically viable schemes are optimised to identify the most cost-effective heat-integrated structure and operating conditions. The methodology applies models for multi-feed and multi-product distillation columns, the membrane, compressor and refrigeration system; heat recovery opportunities are systematically captured and exploited. For the separation of relatively ideal mixtures, modified shortcut design methods, based on the Fenske-Underwood-Gilliland method are appropriate because they allow fast evaluation without needing detailed specification of column design parameters (i.e. number of stages, feed and side draw stage locations and reflux ratio). The modifications proposed by Suphanit (1999) for simple column design are extended to consider multi-feed and/or multi-product columns. The complex column designs based on the approximate calculations method are validated by comparison with more rigorous simulations using Aspen HYSYS. To design the hybrid system, a reliable and robust membrane model is also needed. To predict the performance of the module model, this work applies and modifies detailed membrane model (Shindo et al., 1985) and approximate method (Naylor and Backer, 1955) to avoid the need for initial estimates of permeate purities and to facilitate convergence. Heat integration opportunities are considered to reduce the energy consumption of the system, considering interactions within the separation process and with the refrigeration system. A matrix-based approach (Farrokhpanah, 2009) is modified to assess opportunities for heat integration. The modified heat recovery model eliminates the need to design the refrigeration cycle and uses a new simple, linear model that correlates the ideal (Carnot) and a more accurately predicted coefficient of performance. This work develops a framework for optimising important degrees of freedom in the hybrid separation system, e.g. permeate pressure, stage cut, side draw molar flow rate and purity, column feed and side draw locations. Heat recovery options between: i) column feeds and products; ii) the membrane feed and products and iii) the associated refrigeration system are considered. A deterministic and a stochastic optimisation algorithm are applied and compared for their efficiency of solving the resulting nonlinear optimisation problem. The new approach is demonstrated for the design and optimisation of heat-integrated sequential and parallel hybrid membrane-distillation flowsheets. Case study results show that hybrid scheme can reduce energy cost by 11%, compared to distillation, and that parallel schemes have around 8% lower energy costs than sequential hybrid schemes. These results suggest hybrid membrane-distillation processes may be competitive with distillation when applied for ethylene-ethane separations, but that further development of suitable membranes may still be needed.

The synthesis of a number of alkyl esters such as methyl lactate, methyl decanoate, and ethyl benzoate via esterification in a reactive distillation is quite challenging. It is due to the complexity in the thermodynamic behaviour of the chemical species in the reaction mixture in addition to the difficulty of keeping the reactants together in the reaction section. One of the reactants (in these esterification reactions) having the lowest boiling point can separate from the other reactant as the distillation continues. This can result in a significant drop in the reaction conversion in a conventional reactive distillation whether it is a batch or a continuous column. To overcome this challenge, new different types of batch reactive distillation column configurations: (1) integrated conventional (2) semi-batch (3) integrated semi-batch (4) integrated dividing-wall batch distillation columns have been proposed here. Four esterification reaction schemes such as (a) esterification of lactic acid (b) esterification of decanoic acid (c) esterification of benzoic acid (d) esterification of acetic acid are investigated here. A detailed dynamic model based on mass, energy balances, chemical reaction, and rigorous thermodynamic (chemical and physical) properties is considered and incorporated in the optimisation framework within gPROMS (general PROcess Modelling System) software. It is found that for the methyl lactate system, the i-SBD operation outperforms the classical batch operations (CBD or SBD columns) to satisfy the product constraints. While, for the methyl decanoate system, the i-DWCBD operation outperforms all CBD, DWBD and sr-DWBD configurations by achieving the higher reaction conversion and the maximum product purity. For the ethyl benzoate system, the performance of i-CBD column is superior to the CBD process in terms of product quality, and conversion rate of acid. The CBD process is found to be a more attractive in terms of operating time saving, and annual profit improvement compared to the IBD, and MVD processes for the benzyl acetate system. / The Higher Committee for Education Development in Iraq (HCED)

In the last decade Process Synthesis has been an emerging active area of research. Since 1999 at COMPS, we have continuously applied this technique to many studies and recently have carefully started to consider the integration of this technique with others to simplify multilevel process design. In this regard the need for new tools that do not require very accurate data or experimental technique has become an imperative for the initial analysis of systems. This thesis presents some of these results.Process synthesis requires new rapid tools for the assessment and comparison of new technologies (possibilities) in the process development stage.This thesis examines and formulates process synthesis problems in the case of separation processes (separation with mixing , separation with reaction).Using simple generic vectorial tools, the thesis addresses the folowing issue: How the topology and mapping of the process vector field defines patterns that may be used for alternative process synthesis solution and design (structure selection ,stability analysis or controllability etc...) . The tools presented are intended for preliminary process design and feasibility studies and will allow for simple comparisons of various options.The key principle used in the study is the exploitation of the generic vectorial representation of fundamental physical phenomena (separation, mixing , reaction) in the process models as used for process synthesis and analysis.The demonstrated power of this approach is that it allows one to exploit the formal mathematical similarities between the different processing modes. Extensive topological Reactive Column Profile has been generated and analysed, offering new insights for manipulation of process behaviour in process synthesis and design. The significance of the contribution of this research is in offering extended fundamental insigths in creating process synthesis options for reactive-separations systems, creating the essential structural basis for subsequent mathematical optimisation of the performanceof process designs.