Flowsheet analysis, hierarchical design

Heuristic based approaches are more relevant for structured products. The most well known heuristic based approach is the hierarchical decomposition method developed by Douglas (Douglas, 1988). In the first level of this method one only looks at the input-output structure of the process. In subsequent levels more detail is added, finally ending with the entire flowsheet. Design decisions are made by using heuristics and short-cut models. An alternative method is due to Siirola (1996) means end analysis. In this method the properties of the feedstock and the desired products are compared. Tasks are defined to eliminate the property differences between the feedstock and the desired product. 

The flowsheet synthesis of continuous chemical-like process can be performed following a systematic strategy known as the hierarchical approach. The procedure, initially proposed by Jim Douglas and coworkers in the decade 1980-90 [1, 2], describes the conceptual design process as a logical sequence of analysis and synthesis steps grouped in levels. Each level involves a flowsheet development mechanism based on design decisions. The result is not a unique solution but a collection of alternative flowsheets from which an evaluation procedure eliminates the less attractive ones. 

The hierarchical approach is a simple but powerful methodology for the development of process flowsheets. It consists of a top-down analysis organized as clearly defined sequence of tasks aggregated in levels. Each level handles a fundamental conceptual problem input/output structure, reactor design, structure of separa-... 

At each level of the Hierarchical Approach the feasibility of design alternatives are evaluated by means of an Economic Potential (EP). This index is a measure of profitability representing the difference between earnings and expenses on yearly basis. EP must be high enough to accept further reduction at the other levels of flowsheet development. If EP is not positive and high enough, the analysis stops. It is worthy to note that the raw material costs dominate the operation costs in chemical process industries by more than 60%, particularly in commodities. 

Within each of the three general approaches toward process synthesis, key decisions are made about the flowsheet design that have a bearing on the operability characteristics of the plant. For example, in a hierarchical procedure (Ref. 6) we will make decisions about whether the plant is batch or continuous, what types of reactors are used, how material is recycled, what methods and sequences of separation are employed, how much energy integration is involved, etc. In a thermodynamic pinch analysis, we typically start with some flowsheet information, but we must then decide what streams or units to include in the analysis, what level of utilities are involved, what thermodynamic targets are used, etc. In an optimization approach, we must decide the scope of the superstructure to use, what physical data to include, what constraints to apply, what disturbances or uncertainties to consider, what objective function to employ, etc (Ref. 7). 

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