Large-scale DAE-constrained optimization applied to a modified spouted bed reactor for ethylene production from methane

Design and Multiobjective Dynamic Optimization of Superheaters for Load-Following Operation in Pulverized Coal Power Plants

Pulverized coal power plants are increasingly participating in aggressive load-following markets, therefore necessitating the design and optimization of primary superheaters for flexible operations. These superheaters play a critical role in maintaining the final steam temperature of the steam turbine, but their high operating temperatures and pressures make them prone to failure. This study focuses on the optimal design of future-generation primary superheaters for a fast load-following operation. To achieve this, a detailed first-principles model of a primary superheater is developed along with submodels for stress and fatigue damage. Two single-objective optimization problems are solved: one for minimizing metal mass as a measure of capital cost and another for minimizing pressure drop on the steam side as a measure of operating cost. Since these objective functions conflict, a multiobjective optimization problem is executed using a weighted metric methodology. Results from these optimization studies show that the base case design can violate stress constraints during the aggressive load-following operation. However, by optimizing the design variables, it is possible to not only satisfy tight stress constraints but also achieve the desired number of allowable cycles and adhere to the steam outlet temperature constraint. In addition, the optimized design reduces either the metal mass or the steam-side pressure drop compared to that of the base case design. Importantly, this approach is not limited to primary superheaters alone but can also be applied to similar high-temperature heat exchangers in other applications.

An α-Model Parametrization Algorithm for Optimization with Differential-Algebraic Equations

An optimization task with nonlinear differential-algebraic equations (DAEs) was approached. In special cases in heat and mass transfer engineering, a classical direct shooting approach cannot provide a solution of the DAE system, even in a relatively small range. Moreover, available computational procedures for numerical optimization, as well as differential- algebraic systems solvers are characterized by their limitations, such as the problem scale, for which the algorithms can work efficiently, and requirements for appropriate initial conditions. Therefore, an αDAE model optimization algorithm based on an α-model parametrization approach was designed and implemented. The main steps of the proposed methodology are: (1) task discretization by a multiple-shooting approach, (2) the design of an α-parametrized system of the differential-algebraic model, and (3) the numerical optimization of the α-parametrized system. The computations can be performed by a chosen iterative optimization algorithm, which can cooperate with an outer numerical procedure for solving DAE systems. The implemented algorithm was applied to solve a counter-flow exchanger design task, which was modeled by the highly nonlinear differential-algebraic equations. Finally, the new approach enabled the numerical simulations for the higher values of parameters denoting the rate of changes in the state variables of the system. The new approach can carry out accurate simulation tests for systems operating in a wide range of configurations and created from new materials.

Oxidative Coupling of Methane for Ethylene Production: Reviewing Kinetic Modelling Approaches, Thermodynamics and Catalysts

Ethylene production via oxidative coupling of methane (OCM) represents an interesting route for natural gas upscaling, being the focus of intensive research worldwide. Here, OCM developments are analysed in terms of kinetic mechanisms and respective applications in chemical reactor models, discussing current challenges and directions for further developments. Furthermore, some thermodynamic aspects of the OCM reactions are also revised, providing achievable olefins yields in a wide range of operational reaction conditions. Finally, OCM catalysts are reviewed in terms of respective catalytic performances and thermal stability, providing an executive summary for future studies on OCM economic feasibility.