Thesis Archive
Optimization of abnormal operations in chlor-alkali process plants.
Gumilao, Thamania Keith C.
Abstract:
The chlor-alkali industry is one of the earliest chemical processes that was industrialized as early as the 19th century. Its major products include chlorine (Cl2) gas, hydrogen (H2) gas, and sodium hydroxide (NaOH) solution. The gaseous products are further processed in a burner to produce hydrochloric acid (HCl). On the other hand, the NaOH solution, which usually comes out as a dilute solution, is concentrated to desired concentration or is further dried and compacted into pellets. With a variety of application of its products, a crisis caused by raw material shortage, power interruption, or equipment failure in a chlor-alkali production plant can greatly affect other industries. The chlor-alkali industry is highly dependent on water and electricity. With the threats on water supply and energy sources because of climate change, the industry can face probable shortage or crisis. Computer models can help reduce financial loses during crisis. In this paper, a mathematical model is developed to optimize the operating condition of the process units during a crisis. Material and energy balances are primarily used. This model is tested using different case studies. The perturbations introduced in the model are freshwater scarcity, equipment operability limitations, product mix restrictions, and partial equipment shutdown. Optimal responses of the process units are determined, and annual operating profit is maximized in each case study. The model developed allows the process engineer to gain insights for operational adjustments to be done on a chlor-alkali process plant during a crisis. The mathematical model serves as a main tool for decision makers in determining the configurations of the plant operation to minimize losses during perturbed situations.
Adviser:
Tan, Raymond R.
Aviso, Kathleen
[email protected]
[email protected]