Robust simulation and optimization methods for natural gas liquefaction processes

Thesis: Ph. D., Massachusetts Institute of Technology, Department of Chemical Engineering, 2018.Cataloged from PDF version of thesis.Includes bibliographical references (pages 313-324).Natural gas is one of the world's leading sources of fuel in terms of both global production and consumption. The abundance of reserves that may be developed at relatively low cost, paired with escalating societal and regulatory pressures to harness low carbon fuels, situates natural gas in a position of growing importance to the global energy landscape. However, the nonuniform distribution of readily-developable natural gas sources around the world necessitates the existence of an international gas market that can serve those regions without reasonable access to reserves. International transmission of natural gas via pipeline is generally cost-prohibitive beyond around two thousand miles, and so suppliers instead turn to the production of liquefied natural gas (LNG) to yield a tradable commodity. While the production of LNG is by no means a new technology, it has not occupied a dominant role in the gas trade to date. However, significant growth in LNG exports has been observed within the last few years, and this trend is expected to continue as major new liquefaction operations have and continue to become operational worldwide. Liquefaction of natural gas is an energy-intensive process requiring specialized cryogenic equipment, and is therefore expensive both in terms of operating and capital costs. However, optimization of liquefaction processes is greatly complicated by the inherently complex thermodynamic behavior of process streams that simultaneously change phase and exchange heat at closely-matched cryogenic temperatures. The determination of optimal conditions for a given process will also generally be nontransferable information between LNG plants, as both the specifics of design (e.g. heat exchanger size and configuration) and the operation (e.g. source gas composition) may have significantly variability between sites. Rigorous evaluation of process concepts for new production facilities is also challenging to perform, as economic objectives must be optimized in the presence of constraints involving equipment size and safety precautions even in the initial design phase. The absence of reliable and versatile software to perform such tasks was the impetus for this thesis project. To address these challenging problems, the aim of this thesis was to develop new models, methods and algorithms for robust liquefaction process simulation and optimization, and to synthesize these advances into reliable and versatile software. Recent advances in the sensitivity analysis of nondifferentiable functions provided an advantageous foundation for the development of physically-informed yet compact process models that could be embedded in established simulation and optimization algorithms with strong convergence properties. Within this framework, a nonsmooth model for the core unit operation in all industrially-relevant liquefaction processes, the multi-stream heat exchanger, was first formulated. The initial multistream heat exchanger model was then augmented to detect and handle internal phase transitions, and an extension of a classic vapor-liquid equilibrium model was proposed to account for the potential existence of solutions in single-phase regimes, all through the use of additional nonsmooth equations. While these initial advances enabled the simulation of liquefaction processes under the conditions of simple, idealized thermodynamic models, it became apparent that these methods would be unable to handle calculations involving nonideal thermophysical property models reliably. To this end, robust nonsmooth extensions of the celebrated inside-out algorithms were developed. These algorithms allow for challenging phase equilibrium calculations to be performed successfully even in the absence of knowledge about the phase regime of the solution, as is the case when model parameters are chosen by a simulation or optimization algorithm. However, this still was not enough to equip realistic liquefaction process models with a completely reliable thermodynamics package, and so new nonsmooth algorithms were designed for the reasonable extrapolation of density from an equation of state under conditions where a given phase does not exist. This procedure greatly enhanced the ability of the nonsmooth inside-out algorithms to converge to physical solutions for mixtures at very high temperature and pressure. These models and submodels were then integrated into a flowsheeting framework to perform realistic simulations of natural gas liquefaction processes robustly, efficiently and with extremely high accuracy. A reliable optimization strategy using an interior-point method and the nonsmooth process models was then developed for complex problem formulations that rigorously minimize thermodynamic irreversibilities. This approach significantly outperforms other strategies proposed in the literature or implemented in commercial software in terms of the ease of initialization, convergence rate and quality of solutions found. The performance observed and results obtained suggest that modeling and optimizing such processes using nondifferentiable models and appropriate sensitivity analysis techniques is a promising new approach to these challenging problems. Indeed, while liquefaction processes motivated this thesis, the majority of the methods described herein are applicable in general to processes with complex thermodynamic or heat transfer considerations embedded. It is conceivable that these models and algorithms could therefore inform a new, robust generation of process simulation and optimization software.by Harry Alexander James Watson.Ph. D

Geometric partial differential equations: Surface and bulk processes

The workshop brought together experts representing a wide range of topics in geometric partial differential equations ranging from analyis over numerical simulation to real-life applications. The main themes of the conference were the analysis of curvature energies, new developments in pdes on surfaces and the treatment of coupled bulk/surface problems

Numerical Modeling of High-Pressure Partial Oxidation of Natural Gas

High-Pressure Partial Oxidation (HP-POX) of natural gas is one of the techniques in the synthesis gas production by non-catalytic reforming. On the path to emissions reduction, all operating facilities must be optimized to satisfy environmental regulations. In a rapidly changing economic and political environment, technological development from lab-scale to demo-scale, and industrial-scale is no longer feasible. Therefore, new research and design methods must be applied. One of such methods commonly used in science and industry is numerical modeling, which utilizes Computational Fluid Dynamics (CFD), Reduce Order Models (ROMs), kinetic, and equilibrium models. The CFD models provide details about flow field, temperature distribution, and species conversion. However, the computational effort required to conduct such calculations is significant. The computationally expensive CFD models cannot be effectively used in the reactor optimization. Herewith, other modeling techniques utilizing kinetic and equilibrium models do not provide necessary details for process optimization and can only be used for adjustments of boundary conditions, investigation of specific processes occurring in the reactor, or development of sub-models for CFD. A numerical investigation was conducted to validate existing CFD models against benchmark experiments. The results reveled that the CFD model is sensitive to modeling parameters, when simulating complex flows where turbulence-chemistry interaction occurs. Moreover, it was shown that the results sensitivity increases along with the oxidizer/fuel inlet velocities ratio. Based on the conducted experiments, the CFD model validation resulted in definition of the modeling parameters suitable for modeling of HP-POX of natural gas. Based on the validated CFD model, a ROM for HP-POX of natural gas was developed. The model assumes that the reactor consists of several zones characterized by specific conversion processes. Moreover, the model considers inlet streams dissipation upon the injection, and includes several optimization stages that allows model adjustments for any reactor geometry and boundary conditions. It was shown that the developed ROM can reproduce global reactor characteristics at non-equilibrium conditions unlike other ROMs, kinetic, or equilibrium models. Moreover, the validation against CFD results showed that the ROM can correctly account for the \gls{rtd} in the reactors of different geometries and volumes without extensive additional optimization. Finally, new experiments were designed and conduced at semi-industrial HP-POX facility at TU Bergakademie Freiberg. The experiments aimed to study the influence of different oxidizer/fuel velocities ratios on the reactants mixing and process characteristics at high operating pressures. The high velocity difference between oxidizer and fuel was achieved by injection of High-Velocity Oxidizer (HVO). The experiments showed no significant influence of the HVO on the global reactor characteristics and overall species conversion process. However, the numerical analysis of the experimental results demonstrated that the oxidation zone is affected by the oxidizer inlet velocity, and becomes less efficient in the fuel conversion when the oxidizer/fuel inlet velocities ratio is increased. In summary, a sophisticated numerical model validation was conducted and sensitivity of the numerical results to the modeling parameters was carefully studied. The novel natural gas conversion technique was experimentally studied. Based on the conducted experiments and numerical evaluation a ROM was developed. The ROM is capable of producing high accuracy results and greatly decreases the computational effort and time needed for reactor development and optimization

ECOS 2012

The 8-volume set contains the Proceedings of the 25th ECOS 2012 International Conference, Perugia, Italy, June 26th to June 29th, 2012. ECOS is an acronym for Efficiency, Cost, Optimization and Simulation (of energy conversion systems and processes), summarizing the topics covered in ECOS: Thermodynamics, Heat and Mass Transfer, Exergy and Second Law Analysis, Process Integration and Heat Exchanger Networks, Fluid Dynamics and Power Plant Components, Fuel Cells, Simulation of Energy Conversion Systems, Renewable Energies, Thermo-Economic Analysis and Optimisation, Combustion, Chemical Reactors, Carbon Capture and Sequestration, Building/Urban/Complex Energy Systems, Water Desalination and Use of Water Resources, Energy Systems- Environmental and Sustainability Issues, System Operation/ Control/Diagnosis and Prognosis, Industrial Ecology

Man-portable power generation devices : product design and supporting algorithms

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Chemical Engineering, 2006.This electronic version was submitted by the student author. The certified thesis is available in the Institute Archives and Special Collections.Includes bibliographical references (p. 351-380).A methodology for the optimal design and operation of microfabricated fuel cell systems is proposed and algorithms for relevant optimization problems are developed. The methodology relies on modeling, simulation and optimization at three levels of modeling detail. The first class of optimization problems considered are parametric mixed-integer linear programs and the second class are bilevel programs with nonconvex inner and outer programs; no algorithms exist currently in the open literature for the global solution of either problem in the form considered here. Microfabricated fuel cell systems are a promising alternative to batteries for manportable power generation. These devices are potential consumer products that comprise a more or less complex chemical process, and can therefore be considered chemical products. With current computational possibilities and available algorithms it is impossible to solve for the optimal design and operation in one step since the devices considered involve complex geometries, multiple scales, time-dependence and parametric uncertainty. Therefore, a methodology is presented based on decomposition into three levels of modeling detail, namely system-level models for process synthesis,(cont.) intermediate fidelity models for optimization of sizes and operation, and detailed, computational fluid dynamics models for geometry improvement. Process synthesis, heat integration and layout considerations are addressed through the use of lumped algebraic models, general enough to be independent of detailed design choices, such as reactor configuration and catalyst choice. Through the use of simulation and parametric mixed-integer optimization the most promising process structures along with idealized layouts are selected among thousands of alternatives. At the intermediate fidelity level space-distributed models are used, which allow optimization of unit sizes and operation for a given process structure without the need to specify a detailed geometry. The resulting models involve partial differential-algebraic equations and dynamic optimization is employed as the solution technique. Finally, the use of detailed two- and three-dimensional computational fluid dynamics facilitates geometrical improvements as well as the derivation and validation of modeling assumptions that are employed in the system-level and intermediate fidelity models. Steady-state case studies are presented assuming a constant power demand;(cont.) the methodology can be also applied to transient considerations and the case of variable power demand. Parametric programming provides the solution of an optimization problem, the data of which depend on one or many unknown real-valued parameters, for each possible value of the parameter(s). In this thesis mixed-integer linear programs are considered, i.e., optimization programs with affine functions involving real- and integervalued variables. In the first part the multiparametric cost-vector case is considered, i.e., an arbitrary finite number of parameters is allowed, that influence only the coefficients of the objective function. The extension of a well-known algorithm for the single-parameter case is presented, and the algorithm behavior is illustrated on simple examples with two parameters. The optimality region of a given basis is a polyhedron in the parameter space, and the algorithm relies on progressively constructing these polyhedra and solving mixed-integer linear programs at their vertices. Subsequently, two algorithmic alternatives are developed, one based on the identification of optimality regions, and one on branch-and-bound. In the second part the single-parameter general case is considered,(cont.) i.e., a single parameter is allowed that can simultaneously influence the coefficients of the objective function, the right-hand side of the constraints, and also the coefficients of the matrix. Two algorithms for mixed-integer linear programs are proposed. The first is based on branch-and-bound on the integer variables, solving a parametric linear program at each node, and the second is based on decomposition of the parametric optimization problem into a series of mixed-integer linear and mixed-integer nonlinear optimization problems. For the parametric linear programs an improvement of a literature algorithm for the solution of linear programs based on rational operations is presented and an alternative based on predictor-continuation is proposed. A set of test problems is introduced and numerical results for these test problems are discussed. The algorithms are then applied to case studies from the man-portable power generation. Finally extensions to the nonlinear case are discussed and an example from chemical equilibrium is analyzed. Bilevel programs are hierarchical programs where an outer program is constrained by an embedded inner program.(cont.) Here the co-operative formulation of inequality constrained bilevel programs involving real-valued variables and nonconvex functions in both the inner and outer programs is considered. It is shown that previous literature proposals for the global solution of such programs are not generally valid for nonconvex inner programs and several consequences of nonconvexity in the inner program are identified. Subsequently, a bounding algorithm for the global solution is presented. The algorithm is rigorous and terminates finitely to a solution that satisfies e-optimality in the inner and outer programs. For the lower bounding problem, a relaxed program, containing the constraints of the inner and outer programs augmented by a parametric upper bound on the optimal solution function of the inner program, is solved to global optimality. For the case that the inner program satisfies a constraint qualification, a heuristic for tighter lower bounds is presented based on the KKT necessary conditions of the inner program. The upper bounding problem is based on probing the solution obtained in the lower bounding procedure. Branching and probing are not required for convergence but both have potential advantages.(cont.) Three branching heuristics are described and analyzed. A set of test problems is introduced and numerical results for these test problems and for literature examples are presented.by Alexander Mitsos.Ph.D

Proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress

Published proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress, hosted by York University, 27-30 May 2018

Primary Structure and Solution Conditions Determine Conformational Ensemble Properties of Intrinsically Disordered Proteins

Intrinsically disordered proteins (IDPs) are a class of proteins that do not exhibit well-defined three-dimensional structures. The absence of structure is intrinsic to their amino acid sequences, which are characterized by low hydrophobicity and high net charge per residue compared to folded proteins. Contradicting the classic structure-function paradigm, IDPs are capable of interacting with high specificity and affinity, often acquiring order in complex with protein and nucleic acid binding partners. This phenomenon is evident during cellular activities involving IDPs, which include transcriptional and translational regulation, cell cycle control, signal transduction, molecular assembly, and molecular recognition. Although approximately 30% of eukaryotic proteomes are intrinsically disordered, the nature of IDP conformational ensembles remains unclear. In this dissertation, we describe relationships connecting characteristics of IDP conformational ensembles to their primary structures and solution conditions. Using molecular simulations and fluorescence experiments on a set of base-rich IDPs, we find that net charge per residue segregates conformational ensembles along a globule-to-coil transition. Speculatively generalizing this result, we propose a phase diagram that predicts an IDP\u27s average size and shape based on sequence composition and use it to generate hypotheses for a broad set of intrinsically disordered regions (IDRs). Simulations reveal that acid-rich IDRs, unlike their oppositely charged base-rich counterparts, exhibit disordered globular ensembles despite intra-chain repulsive electrostatic interactions. This apparent asymmetry is sensitive to simulation parameters for representing alkali and halide salt ions, suggesting that solution conditions modulate IDP conformational ensembles. We refine the ion parameters using a calibration procedure that relies exclusively on crystal lattice properties. Simulations with these parameters recover swollen coil behavior for acid-rich IDRs, but also uncover a dependence on sequence patterning for polyampholytic IDPs. These contributions initiate an endeavor to elucidate general principles that enable prediction of an IDP\u27s conformational ensemble based on primary structure and solution conditions, a goal analogous to structure prediction for folded proteins. Such principles would provide a molecular basis for understanding the roles of IDPs in physiology and pathophysiology, guide development of agents that modulate their behavior, and enable their rational design from chosen specifications