Application of Decomposition Methodology to Solve Integrated Process Design and Controller Design Problems for Reactor-Separator-Recycle Systems

This paper presents the integrated process design and controller design (IPDC) for a reactor-separator-recycle (RSR) system and evaluates a decomposition methodology to solve the IPDC problem. Accordingly, the IPDC problem is solved by decomposing it into four hierarchical stages: (i) preanalysis, (ii) design analysis, (iii) controller design analysis, and (iv) final selection and verification. The methodology makes use of thermodynamic-process insights and the reverse design approach to arrive at the final process-controller design decisions. The developed methodology is illustrated through the design of a RSR system involving consecutive reactions, A ↔ B → C and shown to provide effective solutions that satisfy design, control and cost criteria. The advantage of the proposed methodology is that it is systematic, makes use of thermodynamic-process knowledge and provides valuable insights to the solution of IPDC problems for RSR systems.