Sustainable solutions by integrating process synthesis-intensification

Abstract A practical way to generate sustainable design alternatives, counter ongoing challenges and future problems is to develop methods that are generic in nature and can be applied over a wide search space to determine innovative and hybrid/intensified unit operations (unit-ops). In this research, a systematic framework based on a 3-stage approach for sustainable process design is presented and its application to generate intensified and more sustainable alternatives highlighted. Within this framework, the phenomena-based synthesis methodology is extended in terms of a wider range of applications and ability to determine more feasible solutions. The framework with the extended methodology is capable of generating innovative solutions involving solid-liquid and liquid-liquid systems in addition to vapor-liquid and membrane systems that could be generated previously. Further, the phenomena database is expanded so that with the new list of phenomena and basic structures, new and intensified unit operations (membrane crystallization, membrane bio-reactor to name a few) are generated. The applicability of step by step method available through the framework is demonstrated through a case study involving the production of bio-succinic acid. In this case study, a novel superstructure network of alternatives is generated, from which an optimal processing route is identified. This processing route is then designed and analysed to identify process bottlenecks, based on which a set of targets for improvement are defined. Then, by applying an extended phenomena-based synthesis methodology; non-trade off, more sustainable and intensified solutions to produce bio-succinic acid are generated and verified through rigorous processes simulation.