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Process Systems Engineering — The Way Ahead
Essay by Alexia Olvera
In today’s environment, there are major changes occurring in the process industries, the increasing global warming, the changes in the world economic and the advances in technology have created new problems, new opportunities, and new markets. Tighter environmental constraints and tighter requirements for hygiene, health and safety on the plant mean that processes must be more closely monitored and controlled. There is a notable increase in food processing and packaging and in the development of "prepared foods" with an ever-expanding range of additives to improve texture, flavor and shelf life. They are usually manufactured in batch or semi-continuous, and subsequent weighing and packaging operations add more difficulty to the production process. The process started in the early sixties, when the first steps were taken towards on integrated approach to design with the development of flowsheeting packages. Originally, these were merely concerned with steady state simulation, but it was not long before their scope was extended to deal with steady state design. At the same time, engineers in industry were concerned with linking process design to downstream design activities — equipment design, plant layout, pipework design, instrumentation etc. In the late seventies, the emphasis shifted towards a broader view of design objectives, a recognition that plants must be designed to operate satisfactorily over a range of conditions. With the recession in the process industries in the early eighties, and the resulting fall in demand for new plants, the emphasis shifted even more to efficient operation and use of existing plant, and their extension and adaptation by retrofitting. As techniques and hardware have improved, so management have become more confident in the use of more sophisticated control, in on—line optimization, and in the upwards extension of computer—based techniques into the higher levels of operations management. There is now a huge international activity across the whole range of process systems engineering, and a comprehensive survey is quite impracticable. What follows therefore is a personal account of recent problems, ideas and developments that I have come across and found to be particularly interesting or significant. It can be argued that detailed modelling of individual units or processes, with the associated experimental studies, is a matter for chemists, physicists and chemical engineers, and that the process systems engineer is concerned only with the use of models in design, control, operations planning, etc. Some might go a little further, and admit to an interest in the general methodology of modelling, such as statistical parameter fitting, the design of experiments for optimum parameter determination or model discrimination, and model reduction techniques. However, the methodology and the individual studies are inextricably mixed, and it is impossible to carry out the one without an understanding of the other. Indeed, I would go further, and claim that the modelling process is nowadays the essential route by which we acquire our understanding of the physical and chemical processes we study. We first analyse the process into component mechanisms which are fully understood, and hence for which we already have adequate models, and then ensure that their interconnections are correctly represented in the model. We are then in a position to simulate the behaviour of the complete system and compare the results with experiment; significant discrepancies will lead us back to a reexamination of the elementary mechanisms, or of the modelling of their interactions. Thus process systems engineering is not a specialized area for mathematically minded chemical engineers — it is the very core of the discipline of chemical engineering itself.