Design and intensification of industrial DADPM process

Anne Maria Benneker, Aloysius G.J. van der Ham, B. de Waele, A.J. de Zeeuw, Henderikus van den Berg

Research output: Contribution to journalArticleAcademicpeer-review

1 Citation (Scopus)

Abstract

Process intensification is an essential method for the improvement of energy and material efficiency, waste reduction and simplification of industrial processes. In this research a Process Intensification methodology developed by Lutze, Gani and Woodley at the Computer Aided Process Engineering Center (CAPEC) at DTU in Denmark is used for the intensification of the 4,4′-methylenedianiline (DADPM) process at Huntsman B.V. in the Netherlands. The goal of this research was the extension of the DTU methodology for applicability on running, industrial processes and improvement of the Huntsman process, focus is on reduction of operation costs. We have shown in the DADPM case that an analysis of the performance per section or unit operation and the mutual interactions provide essential additional information that is not being detected by the DTU method. We demonstrated how good engineering practice and heuristics can also reduce the number of process options that have to be modelled in detail. Selection of the optimal process is done based on a quantitative analysis of several intensified process options which all obey all required constraints. Equipment models were built in Excel and integrated in an Aspen Plus process flowsheet containing 27 different process options. A sensitivity analysis is done using Aspen, yielding the optimized and intensified process for DADPM production. Energy costs for the DADPM process are reduced by 24% using a combination of both heuristic and methodology-based intensification. We conclude that the method developed by Lutze et al. is a valuable tool for PI and process analysis and synthesis. The extension developed using heuristics, provides additional insight, traces the process weak points, facilitates implementation of new technology and reduces calculations.
Original languageEnglish
Pages (from-to)39-50
Number of pages12
JournalChemical engineering and processing : process intensification
Volume109
DOIs
Publication statusPublished - 2016

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Flowcharting
Computer aided engineering
Process engineering
Sensitivity analysis
Costs
Chemical analysis

Keywords

  • METIS-321797
  • IR-103939

Cite this

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Design and intensification of industrial DADPM process. / Benneker, Anne Maria; van der Ham, Aloysius G.J.; de Waele, B.; de Zeeuw, A.J.; van den Berg, Henderikus.

In: Chemical engineering and processing : process intensification, Vol. 109, 2016, p. 39-50.

Research output: Contribution to journalArticleAcademicpeer-review

TY - JOUR

T1 - Design and intensification of industrial DADPM process

AU - Benneker, Anne Maria

AU - van der Ham, Aloysius G.J.

AU - de Waele, B.

AU - de Zeeuw, A.J.

AU - van den Berg, Henderikus

PY - 2016

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KW - METIS-321797

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DO - 10.1016/j.cep.2016.08.009

M3 - Article

VL - 109

SP - 39

EP - 50

JO - Chemical engineering and processing : process intensification

JF - Chemical engineering and processing : process intensification

SN - 0255-2701

ER -