Process synthesis introduction

Process synthesis is a structured method that allows systematic identification of the most economical process flowsheets. For new processes it must be applied as early as possible during the R&D phase because results of a process synthesis project influence the research program and vice versa. PDC has proven that simultaneous chemical and process R&D provides a significantly higher cost saving potential than the sequential approach applied by most of PDC's customers in the past.

The conventional practice is to improve processes by the optimization of existing designs or smaller stepwise improvements of specific process units (evolutionary design). Although these methods have their added value, the overall process scheme is often not changed. Process Synthesis, also known as Structured Conceptual Process Design, is a technique suitable not only for making a step-change in the existing process but also for synthesizing a process flowsheet from scratch.

The selection of the best process route to convert raw materials into desired products by a sequence of unit operations is a difficult task as a large number of possible process alternatives exist, typically around a billion. This difficulty is compounded by the lack of engineering design data at the time when this enormous number of alternatives needs to be narrowed. The process industry has historically addressed this problem by either relying on experienced engineers to narrow the large list of alternatives based on their "engineering judgement", or by simply ignoring many of the alternatives. As a consequence process flowsheets are typically based on inadequate information and rarely (if ever) changed; yet the choice of a process flowsheet is the primary determinant of the ultimate capital and operating costs!

Process synthesis methods and tools are not just relevant to the design of entirely new processes. The same techniques can be applied to retrofit projects within an existing plant environment, leading to significant savings in capital and operating costs, even in cases where many years of conventional optimization techniques and continuous improvement have already yielded savings. PDC has conducted over 120 industrial process synthesis projects and has consistently beaten existing 'state-of-the-art' designs with 20-80% less capital, energy and operating costs.

PDC has the technology, personnel and experience to make a big impact in your process development efforts.