Table Of ContentNATO ASI Series
Advanced Science Institutes Series
A series presenting the results of activities sponsored by the NATO Science
Committee, which aims at the dissemination of advanced scientific and technological
knowledge, with a view to strengthening links between scientific communities.
The Series is published by an international board of publishers in conjunction with the
NATO Scientific Affairs Division
A Life Sciences Plenum Publishing Corporation
B Physics London and New York
C Mathematical and Physical Sciences Kluwer Academic Publishers
D Behavioural and Social Sciences Dordrecht, Boston and London
E Applied Sciences
F Computer and Systems Sciences Springer-Verlag
G Ecological Sciences Berlin Heidelberg New York Barcelona
H Cell Biology Budapest Hong Kong London Milan
Global Environmental Change Paris Santa Clara Singapore Tokyo
PARTNERSHIP SUB-SERIES
1. Disarmament Technologies Kluwer Academic Publishers
2. Environment Springer-Verlag
3. High Technology Kluwer Academic Publishers
4. Science and Technology Policy Kluwer Academic Publishers
5. Computer Networking Kluwer Academic Publishers
The Partnership Sub-Series incorporates activities undertaken in collaboration with
NATO's Cooperation Partners, the countries of the CIS and Central and Eastern
Europe, in Priority Areas of concern to those countries.
NAT O-PCO DATABASE
The electronic index to the NATO ASI Series provides full bibliographical references
(with keywords and/or abstracts) to about 50000 contributions from international
scientists published in all sections of the NATO ASI Series. Access to the NATO-PCO
DATABASE compiled by the NATO Publication Coordination Office is possible in two
ways:
-via online FILE 128 (NATO-PCO DATABASE) hosted by ESRIN,
Via Galileo Galilei, 1-00044 Frascati, Italy.
-via CD-ROM "NATO Science & Technology Disk" with user-friendly retrieval software
in English, French and German (© wrv GmbH and DATAWARE Technologies Inc.
1992).
The CD-ROM can be ordered through any member of the Board of Publishers or
through NATO-PCO, Overijse, Belgium.
Series F: Computer and Systems Sciences, Vol. 143
Springer
Berlin
Heidelberg
New York
Barcelona
Budapest
Hong Kong
London
Milan
Paris
Santa Clara
Singapore
Tokyo
Batch Processing
Systems Engineering
Fundamentals and Applications
for Chemical Engineering
Edited by
Gintaras V. Reklaitis
School of Chemical Engineering, Purdue University
West Lafayette, IN 47907, USA
Aydin K. Sunol
Department of Chemical Engineering, College of Engineering
University of South Florida, 4202 East Fowler Avenue, ENG 118
Tampa, FL 33620-5350, USA
David W. T. Rippint
Laboratory for Technical Chemistry, Eidgenossische
Technische Hochschule (ETH) Zurich, Switzerland
Oner Hortagsu
Department of Chemical Engineering, Bogazi<;i University
TR-80815 Bebek-Istanbul, Turkey
Springer
Published in cooperation with NATO Scientific Affairs Division
Proceedings of the NATO Advanced Study Institute on Batch Processing
Systems Engineering: Current Status and Future Directions, held in Antalya,
Turkey, May 29 - June 7,1992
Library of Congress Cataloging-in-Publication data applied for
CR Subject Classification (1991): J.6, 1.6, J.2, G.1, J.7, 1.2
ISBN-13: 978-3-642-64635-5 e-ISBN-13: 978-3-642-60972-5
DO I: 10.1007/978-3-642-60972-5
Springer-Verlag Berlin Heidelberg New York
This work is subject to copyright. All rights are reserved, whether the whole or part of the material is
concerned, specifically the rights oftranslation, reprinting, reuse of illustrations, recitation, broadcast
ing, reproduction on microfilms or in any other way, and storage in data banks. Duplication of this
publication or parts thereof is permitted only under the provisions of the German Copyright Law of
September 9, 1965, in its current version, and permission for use must always be obtained from
Springer-Verlag. Violations are liable for prosecution under the German Copyright Law.
© Springer-Verlag Berlin Heidelberg 1996
Softcover reprint of the hardcover 1st edition 1996
Typesetting: Camera-ready by editors
Printed on acid-free paper
SPIN: 10486088 45/3142 - 5 4 3 210
Preface
Batch Chemical Processing, that ancient and resilient mode of chemical manufacture, has in the
past decade enjoyed a return to respectability as a valuable, effective, and, indeed, in many
instances, preferred mode of process operation. Batch processing has been employed in the past
in many sectors of chemical processing industries including food, beverage, pharmaceuticals,
agricultural chemicals, paints, flavors, polymers, and specialty chemicals. The batch mode is
increasingly being rediscovered by sectors that neglected it as the industry is focusing on more
specialized, application tailored, small volume but higher margin products. Moreover, as
information and control technologies have become both more technically accessible and
economically affordable, the operation of batch facilities has become more efficient, gradually
shifting from the conservative and simple operating strategies based on dedicated and cyclically
operating trains to more sophisticated and complex operating strategies involving flexibly
configured production lines using multi-functional equipment and employingjust-in-time inventory
management strategies.
The effects of these trends on the process systems engineering community has been a
renewed intensity of efforts in research and development on computational approaches to
modeling, design, scheduling, and control problems which arise in batch processing. The goal of
the NATO Advanced Study Institute (ASI), held from May 29 to June 7, 1992, in Antalya,
Turkey, was to review state-of-the-art developments in the field of batch chemical process systems
engineering and provide a forum for discussion of the future technical challenges which must be
met. Included in this discussion was a review of the current state of the enabling computing
technologies and a prognosis of how these developments would impact future progress in the
batch domain.
The Institute was organized into two interrelated sections. The first part dealt with the
presentations on the state of the batch processing in the Chemical Process Industries (CPI),
discussion of approaches to design and operation of more complex individual unit operations,
followed by the reviews of the enabling sciences. This four-day program served to set the stage
for a five-day program of discussions on the central problem areas of batch processing systems
VI
engineering. That discussion was preceded by a one-day interlude devoted to software
demonstrations, poster sessions, and small group meetings. A unique feature of this ASI was the
presence of a computer room at the hotel site equipped with an llM RISC workstation, terminals,
and personal computers which could be used for application software demonstrations and trials.
The Institute opened with industrial and academic perspectives on the role of batch
processing systems engineering in the CPI. Two presentations on the status of batch processing
systems engineering in Japan and Hungary provided perspectives on developments in the Far East
and the former eastern block countries. The Japanese innovations in batch plant organization using
moveable vessels offered insights into materials handling arrangements particularly suitable for
multiproduct, smaIl-batch production environments. These presentations were followed by a suite
of papers describing applications in CPI sectors such as polymer processing, food and beverages,
biochemical, specialty chemicals, textile, and leather industries.
The more complex batch unit operations which give rise to special modeling, design, and
control problems were given attention in separate lectures. These included batch distiIlation,
reactors with complex reacting systems, and sorptive separation systems. These presentations
were complemented by expositions on the estimation and unit control issues for these more
complex systems.
The three categories of enabling technologies which were reviewed were simulation,
mathematical programming, and knowledge based systems. The simulation component included
discussion of solution techniques for differential algebraic systems, the elements of
discrete/continuous simulation, and available simulation environments, as well as prospects
offered by advanced computer architectures. The mathematical programming review included a
critical assessment of progress in nonlinear optimization and mixed integer programming domains.
The knowledge based systems program consisted of a review of the field, continued with its
elements and closed with more advanced topics such as machine learning including neural
networks.
During the fifth day, attendees divided into small discussion groups on specific topics,
participated in the software demonstrations and workshops, and participated in the poster sessions.
The software demonstrations included the DICOPT MlNLP solver from Carnegie Mellon
University, the BATCHES simulation system from Batch Process Technologies, and the BATCH
KIT system (a knowledge based support systems for batch operations scheduling) developed at
ETHZurich.
VII
The central problem areas in batch process systems engineering are those of plant and
process design and plant operations. One day was devoted to the former topic, focusing especially
on retrofit design as well as approaches to incorporating uncertainty in the design of processing
systems. The second day was devoted to scheduling and planning, including consideration of the
integration issues associated with linking the control, scheduling, and planning levels of
operational hierarchy. The Institute concluded with plenary lectures on future of batch processing
systems engineering and an open forum on questions which arose or were stimulated during the
course of the meeting.
The ASI clearly could not have convened without the financial resources provided by the
Scientific and Environmental Affairs Division of NATO. The support, advice, and understanding
provided by NATO, especially through the Division Director Dr. L. V. da Cunha, is gratefully
acknowledged. The additional financial support for specific attendees provided by the NATO
offices of Portugal and Turkey and by the US National Science Foundation is highly appreciated.
The enthusiastic and representative participation of the batch processing systems
engineering community was important for the realization of the goals of the ASI. Fortunately, such
participation was realized. Indeed, since the participation represented all the main research groups
in this domain, at one point the meeting concerns were voiced about the dire fate of the field if
some calamity were to visit the conference site. Fortunately, these concerns were abated the next
morning when the participants were greeted by maneuvers of NATO naval forces in Antalya bay.
Without question, the active participation of the distinguished lecturers, session chairs, reviewers,
and participants made this Advanced Study Institute a great success. Thanks are due to all!
Most of the manuscripts were updated considerably beyond the versions made available
to attendees during the Institute and we thank the authors for their diligent work. We sincerely
appreciate Springer-Verlag's understanding with unforeseeable delays with the manuscript as well
as their kind assistance throughout this endeavor. Special thanks are due to Dr. Hans Wossner and
1. Andrew Ross.
Finally, the organizers would like to recognize the help of the following individuals and
organizations without whom the Institute would have considerably diminished if not ineffective:
Sermin Gonen~ (now Sunol), Muzaffer Kapanoglu, Praveen Mogili, <;:agatay Ozdemir, Alicia
Balsera, Shauna Schullo, Nihat Giirmen, C. Chang, and Burak Ozyurt for assistance with
brochures, program, re-typing, indexing, and correspondence; Dean M. Kovac and Chairman R.
Gilbert of University of South Florida for supplementary financial support; Bogazi~i Turizm Inc.
VIII
and Tamer Tours for local arrangements in Turkey and social programs; IBM Turkey, especially
Mtinire Ankol, for the RISC Station and personal computers; Canan Tamerler and Vildan Din~bR§
(ASI's Angels) for tireless help accompanied by perpetual smiles throughout the AS I; and Falez
Hotel management and staff, especially Filiz Giiney, for making our stay a very pleasant one.
The idea of organizing a NATO ASI on systems engineering goes back to 1988 and was
partially motivated by AKS's desire to do something in this domain at home for Turkey. However,
its realization was accompanied by personal losses and impeded by unanticipated world events.
A week before the proposal was due AKS lost his best friend, mentor, and mother, Mefharet
Sunol. The Institute had to be postponed due to the uncertainties arising from the Gulf crisis. A
few months before finalization ofthis volume, our dear friend and esteemed colleague, Prof David
W. T. Rippin passed away. It is fitting that this proceedings volume be dedicated to the memories
of Mefharet Sunol and David Rippin.
Gintaras V. Reklaitis and Aydm K. Sunol
West Lafayette, Indiana and Tampa, Florida
September 1996
List of Contributors and Their Affiliation
Organizing Committee and Director
Dner Horta~su, Chemical Engineering Department, Bogazi~i Universitesi, Istanbul, Turkey
Gintaras. V. Reklaitis, School of Chemical Engineering, Purdue University, USA
David W.T. Rippin, Technical Chemistry Lab, ETH Zurich, Switzerland
Director: Aydm K. Sunol, Chemical Engineering Department, University of South Florida, USA
Main Lecturers and Their Current Affiliation
Michel Lucet, Rhone Poulenc, France
Sandro Macchietto, Imperial College, UK
Rodger Sargent, Imperial College, UK
A1irio Rodriguez, University of Porto, Portugal
John F. MacGregor, McMaster University, Canada
Christos Georgakis, Lehigh University, USA
Arthur W. Westerberg, Carnegie Mellon University, USA
Ignacio E. Grossmann, Carnegie Mellon University, USA
Giresh S. Joglekar, Batch Process Technologies, USA
Jack W. Ponton, University of Edinburgh, UK
Kristian M. Lien, Norwegian Institute of Technology, Norway
Luis Puigjaner, Catalunya University, Spain
Special Lecturers
Mukul Agarwal, ETH Zurich, Switzerland
RIdvan Berber, Ankara Universitesi, Turkey
Cristine Bernot, University of Massachusetts, USA
x
Ali Cmar, lIT, USA
Shinji Hasebe, Kyoto University, Japan
Laszlo Halasz, ETH, Switzerland
Gyula Kortvelyessy, SZEVIKI R&D Institute, Hungary
Joe Pekny, Purdue University, USA
Dag E. Ravemark, ETH, Switzerland
Nilay Shah, Imperial College, University of London, UK
Eva Sorensen, University ofTrondheim, Norway
Venkat Venkatasubramanian, Purdue University, USA
Zentner M. G., Purdue University, USA
Denis L.J. Mignon, Universite Catholique de Louvain, Belgium
Session Chairs (In Addition to Organizers and Lecturers)
Yaman Arkun, Georgia Tech, USA
Tiirker Giirkan, METU, Turkey
lisen Onsan, Bogazi~i Universitesi, Turkey
Canan Ozden, METU, Turkey
L. H. Garcia-Rubio, University of South Florida, USA
Additional Poster Contributors
Bela Csukas, Vezsprem University, Hungary
Bilgin Klsakiirek, METU, Turkey
