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Pistikopoulos EN, Tian Y. Advanced Modeling and Optimization Strategies for Process Synthesis. Annu Rev Chem Biomol Eng 2024; 15:81-103. [PMID: 38594946 DOI: 10.1146/annurev-chembioeng-100522-112139] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 04/11/2024]
Abstract
This article provides a systematic review of recent progress in optimization-based process synthesis. First, we discuss multiscale modeling frameworks featuring targeting approaches, phenomena-based modeling, unit operation-based modeling, and hybrid modeling. Next, we present the expanded scope of process synthesis objectives, highlighting the considerations of sustainability and operability to assure cost-competitive production in an increasingly dynamic market with growing environmental awareness. Then, we review advances in optimization algorithms and tools, including emerging machine learning-and quantum computing-assisted approaches. We conclude by summarizing the advances in and perspectives for process synthesis strategies.
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Affiliation(s)
- Efstratios N Pistikopoulos
- Texas A&M Energy Institute and Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas, USA;
| | - Yuhe Tian
- Department of Chemical and Biomedical Engineering, West Virginia University, Morgantown, West Virginia, USA;
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2
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Iqbal A, Qyyum MA, Ahmad SA, Lam SS. Exploitation of distillation region diagrams for energy-efficient and cost-effective treatment of a hazardous effluent discharged from semi-conductor industries. CHEMOSPHERE 2022; 307:135846. [PMID: 35952790 DOI: 10.1016/j.chemosphere.2022.135846] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/28/2022] [Revised: 06/30/2022] [Accepted: 07/22/2022] [Indexed: 06/15/2023]
Abstract
The hazardous nature of certain azeotropic mixtures has urged the researchers to explore the separation techniques which can impart a contamination free environment. Despite of causing environmental concerns, these azeotropic mixtures are responsible for causing serious health issues to humans and animals. More specifically, in this article, we have taken Tetrahydrofuran (THF) - water azeotropic mixture into consideration. It has been reported that it affects the central nervous system, liver, as well as can cause carcinogenicity. To be more precise, in this article, two different entrainers has been evaluated on their merits of exploiting liquid-liquid phase envelope for separating Tetrahydrofuran-water binary azeotropic mixture. The process flow sheet schematic with n-octane as entrainer (having two distillation regions) has a reduced operating energy requirement by 21.11% while comparing with the Residue Curve Map of n-hexane as entrainer having three distillation regions. The total capital cost for THF-water-n-octane case has been found to be 7.1 $/y × 105 and that of THF-water-n-hexane case has been found to be 9 $/y × 105. However, in both of the cases, the product purity of 99.9% has been achieved for THF. Also, the classical trade-off between capital cost and energy cost has been shown in this study. The salient feature of this work is the use of dynamic simulation to understand the effect of recycle flow rate induced process operational in-feasibility due to distillation region shift.
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Affiliation(s)
- Asma Iqbal
- Department of Chemical Engineering, National Institute of Technology, Srinagar, J&K, India
| | - Muhammad Abdul Qyyum
- Department of Petroleum and Chemical Engineering, Sultan Qaboos University, Muscat, Oman.
| | - Syed Akhlaq Ahmad
- Department of Chemical Engineering, Aligarh Muslim University, Aligarh, India
| | - Su Shiung Lam
- Higher Institution Centre of Excellence (HICoE), Institute of Tropical Aquaculture and Fisheries (AKUATROP), Universiti Malaysia Terengganu, 21030, Kuala Nerus, Terengganu, Malaysia; Henan Province Forest Resources Sustainable Development and High-value Utilization Engineering Research Center, School of Forestry, Henan Agricultural University, Zhengzhou, 450002, China; Sustainability Cluster, School of Engineering, University of Petroleum & Energy Studies, Dehradun, Uttarakhand, 248007, India.
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3
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Bello TO, Bresciani AE, Oller Nascimento CA, Brito Alves RM. Systematic Screening of Ionic Liquids for the Hydrogenation of Carbon Dioxide to Formic Acid and Methanol. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c02910] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Taofeeq O. Bello
- Escola Politécnica, Universidade de São Paulo, São Paulo, São Paulo 05508-010, Brazil
| | - Antonio E. Bresciani
- Escola Politécnica, Universidade de São Paulo, São Paulo, São Paulo 05508-010, Brazil
| | | | - Rita M. Brito Alves
- Escola Politécnica, Universidade de São Paulo, São Paulo, São Paulo 05508-010, Brazil
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Tututi-Avila S, Jiménez-Gutiérrez A, Ramírez-Corona N, Medina-Herrera N. An index to account for safety and controllability during the design of a chemical process. J Loss Prev Process Ind 2021. [DOI: 10.1016/j.jlp.2021.104427] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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5
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Ge X, Yang X, Han Y, Pan Y, Liu B, Liu B. Optimal Design, Proportional–Integral Control, and Model Predictive Control of Intensified Process for Formic Acid Production. 1. Reactive Distillation and Reactive Dividing Wall Column. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c04705] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Xiaolong Ge
- College of Chemical Engineering and Materials Science, Tianjin Key Laboratory of Brine Chemical Engineering and Resource Eco-utilization, Tianjin University of Science and Technology, Tianjin 300457, China
- State Key Laboratory of Chemical Engineering, Tianjin University, Tianjin 300350, China
| | - Xinchuang Yang
- College of Chemical Engineering and Materials Science, Tianjin Key Laboratory of Brine Chemical Engineering and Resource Eco-utilization, Tianjin University of Science and Technology, Tianjin 300457, China
| | - Yicheng Han
- College of Chemical Engineering and Materials Science, Tianjin Key Laboratory of Brine Chemical Engineering and Resource Eco-utilization, Tianjin University of Science and Technology, Tianjin 300457, China
| | - Yu Pan
- College of Chemical Engineering and Materials Science, Tianjin Key Laboratory of Brine Chemical Engineering and Resource Eco-utilization, Tianjin University of Science and Technology, Tianjin 300457, China
| | - Botan Liu
- College of Chemical Engineering and Materials Science, Tianjin Key Laboratory of Brine Chemical Engineering and Resource Eco-utilization, Tianjin University of Science and Technology, Tianjin 300457, China
| | - Botong Liu
- Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
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Ortiz-Espinoza AP, Jiménez-Gutiérrez A, El-Halwagi MM. Gradual Synthesis of Heat Exchanger Networks Taking into Account Economic, Environmental, and Safety Factors. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c04127] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Andrea P. Ortiz-Espinoza
- Departamento de Ingenierı́a Quı́mica, Tecnológico Nacional de México/Instituto Tecnológico de Celaya, Celaya, GTO 38010, México
| | - Arturo Jiménez-Gutiérrez
- Departamento de Ingenierı́a Quı́mica, Tecnológico Nacional de México/Instituto Tecnológico de Celaya, Celaya, GTO 38010, México
| | - Mahmoud M. El-Halwagi
- Artie McFerrin Chemical Engineering Department, Texas A&M University, College Station, Texas 77840, United States
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Ayuso M, Palma AM, Larriba M, Delgado-Mellado N, García J, Rodríguez F, Coutinho JAP, Carvalho PJ, Navarro P. Experimental and CPA EoS Description of the Key Components in the BTX Separation from Gasolines by Extractive Distillation with Tricyanomethanide-Based Ionic Liquids. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c02844] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/03/2023]
Affiliation(s)
- Miguel Ayuso
- Department of Chemical and Materials Engineering, Complutense University of Madrid, E-28040 Madrid, Spain
| | - André M. Palma
- CICECO—Aveiro Institute of Materials, Department of Chemistry, University of Aveiro, 3810-193 Aveiro, Portugal
| | - Marcos Larriba
- Department of Chemical and Materials Engineering, Complutense University of Madrid, E-28040 Madrid, Spain
| | - Noemí Delgado-Mellado
- Department of Chemical and Materials Engineering, Complutense University of Madrid, E-28040 Madrid, Spain
| | - Julián García
- Department of Chemical and Materials Engineering, Complutense University of Madrid, E-28040 Madrid, Spain
| | - Francisco Rodríguez
- Department of Chemical and Materials Engineering, Complutense University of Madrid, E-28040 Madrid, Spain
| | - João A. P. Coutinho
- CICECO—Aveiro Institute of Materials, Department of Chemistry, University of Aveiro, 3810-193 Aveiro, Portugal
| | - Pedro J. Carvalho
- CICECO—Aveiro Institute of Materials, Department of Chemistry, University of Aveiro, 3810-193 Aveiro, Portugal
| | - Pablo Navarro
- CICECO—Aveiro Institute of Materials, Department of Chemistry, University of Aveiro, 3810-193 Aveiro, Portugal
- Department of Chemical Engineering, Autónoma University of Madrid, E-28049 Madrid, Spain
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Qin Y, Xiao Z, Guo S, Zeng J, Fan S, Liu J. Inherent Safety Analysis for a Difluoro-Chloromethane (F22) Pyrolysis Process under an Unsteady State. JOURNAL OF CHEMICAL ENGINEERING OF JAPAN 2020. [DOI: 10.1252/jcej.19we090] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Yangmei Qin
- School of Chemical Engineering, Sichuan University
| | - Zeyi Xiao
- School of Chemical Engineering, Sichuan University
| | - Shimeng Guo
- School of Chemical Engineering, Sichuan University
| | - Jiying Zeng
- School of Chemical Engineering, Sichuan University
| | - Senqing Fan
- School of Chemical Engineering, Sichuan University
| | - Jingyun Liu
- School of Chemical Engineering, Sichuan University
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Tian Y, Pappas I, Burnak B, Katz J, Pistikopoulos EN. A Systematic Framework for the synthesis of operable process intensification systems – Reactive separation systems. Comput Chem Eng 2020. [DOI: 10.1016/j.compchemeng.2019.106675] [Citation(s) in RCA: 30] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
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10
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Park S, Xu S, Rogers W, Pasman H, El-Halwagi MM. Incorporating inherent safety during the conceptual process design stage: A literature review. J Loss Prev Process Ind 2020. [DOI: 10.1016/j.jlp.2019.104040] [Citation(s) in RCA: 31] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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11
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Srinivasan R, Srinivasan B, Iqbal MU, Nemet A, Kravanja Z. Recent developments towards enhancing process safety: Inherent safety and cognitive engineering. Comput Chem Eng 2019. [DOI: 10.1016/j.compchemeng.2019.05.034] [Citation(s) in RCA: 27] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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12
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Tian Y, Pistikopoulos EN. Synthesis of operable process intensification systems: advances and challenges. Curr Opin Chem Eng 2019. [DOI: 10.1016/j.coche.2018.12.003] [Citation(s) in RCA: 20] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
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Ortiz-Espinoza AP, Kazantzi V, Eljack FT, Jiménez-Gutiérrez A, El-Halwagi MM, Kazantzis NK. Framework for Design Under Uncertainty Including Inherent Safety, Environmental Assessment, and Economic Performance of Chemical Processes. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b02349] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
| | | | - Fadwa T. Eljack
- Department of Chemical Engineering, Qatar University, P.O. Box 2713, Doha, Qatar
| | | | - Mahmoud M. El-Halwagi
- Artie McFerrin Chemical Engineering Department, Texas A&M University, College Station, Texas 77840, United States
| | - Nikolaos K. Kazantzis
- Department of Chemical Engineering, Center for Resource Recovery and Recycling, Worcester Polytechnic Institute, Worcester, Massachusetts 01609, United States
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Hu Y, Su Y, Jin S, Chien IL, Shen W. Systematic approach for screening organic and ionic liquid solvents in homogeneous extractive distillation exemplified by the tert-butanol dehydration. Sep Purif Technol 2019. [DOI: 10.1016/j.seppur.2018.10.030] [Citation(s) in RCA: 58] [Impact Index Per Article: 11.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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Tian Y, Pistikopoulos EN. Synthesis of Operable Process Intensification Systems—Steady-State Design with Safety and Operability Considerations. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b04389] [Citation(s) in RCA: 30] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Yuhe Tian
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
- Texas A&M Energy Institute, Texas A&M University, College Station, Texas 77843, United States
| | - Efstratios N. Pistikopoulos
- Artie McFerrin Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
- Texas A&M Energy Institute, Texas A&M University, College Station, Texas 77843, United States
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Contreras-Zarazúa G, Sánchez-Ramírez E, Vázquez-Castillo JA, Ponce-Ortega JM, Errico M, Kiss AA, Segovia-Hernández JG. Inherently Safer Design and Optimization of Intensified Separation Processes for Furfural Production. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b03646] [Citation(s) in RCA: 38] [Impact Index Per Article: 6.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- G. Contreras-Zarazúa
- Department of Chemical Engineering University of Guanajuato, Noria Alta S/N, Guanajuato, Gto. 36000, Mexico
| | - E. Sánchez-Ramírez
- Department of Chemical Engineering University of Guanajuato, Noria Alta S/N, Guanajuato, Gto. 36000, Mexico
| | - J. A. Vázquez-Castillo
- Faculty of Chemical Sciences, Autonomous University of Chihuahua, Circuito Universitario 8, Campus II, Chihuahua, Chihuahua 31125, Mexico
| | - J. M. Ponce-Ortega
- Chemical Engineering Department, Universidad Michoacana de San Nicolás de Hidalgo, Morelia, Michoacán 58060, México
| | - M. Errico
- Department of Chemical Engineering, Biotechnology and Environmental Technology, University of Southern Denmark, Campusvej 55, DK-5230 Odense M, Denmark
| | - A. A. Kiss
- School of Chemical Engineering and Analytical Science, Centre for Process Integration, The University of Manchester, Sackville Street, The Mill, Manchester M13 9PL, United Kingdom
- Sustainable Process Technology, University of Twente, PO Box 217, 7500 AE Enschede, The Netherlands
| | - J. G. Segovia-Hernández
- Department of Chemical Engineering University of Guanajuato, Noria Alta S/N, Guanajuato, Gto. 36000, Mexico
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Castillo-Landero A, Ortiz-Espinoza AP, Jiménez-Gutiérrez A. A Process Intensification Methodology Including Economic, Sustainability, and Safety Considerations. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b04146] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Arick Castillo-Landero
- Chemical Engineering Department, Instituto Tecnológico de Celaya, Celaya, Guanajuato, 38010 México
| | - Andrea P. Ortiz-Espinoza
- Chemical Engineering Department, Instituto Tecnológico de Celaya, Celaya, Guanajuato, 38010 México
| | - Arturo Jiménez-Gutiérrez
- Chemical Engineering Department, Instituto Tecnológico de Celaya, Celaya, Guanajuato, 38010 México
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Gu J, You X, Tao C, Li J, Gerbaud V. Energy-Saving Reduced-Pressure Extractive Distillation with Heat Integration for Separating the Biazeotropic Ternary Mixture Tetrahydrofuran–Methanol–Water. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b03123] [Citation(s) in RCA: 31] [Impact Index Per Article: 5.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Jinglian Gu
- School of Chemistry and Chemical Engineering, Chongqing University, Chongqing 401331, China
| | - Xinqiang You
- Fujian Universities Engineering Research Center of Reactive Distillation Technology, College of Chemical Engineering, Fuzhou University, Fuzhou 350116, Fujian China
| | - Changyuan Tao
- School of Chemistry and Chemical Engineering, Chongqing University, Chongqing 401331, China
| | - Jun Li
- School of Chemistry and Chemical Engineering, Chongqing University, Chongqing 401331, China
| | - Vincent Gerbaud
- Université de Toulouse, INP, UPS, LGC (Laboratoire de Génie Chimique), 4 allée Emile Monso, F-31432 Cedex 04, Toulouse, France
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Castillo-Landero A, Jiménez-Gutiérrez A, Gani R. Intensification Methodology To Minimize the Number of Pieces of Equipment and Its Application to a Process To Produce Dioxolane Products. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.7b05229] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Arick Castillo-Landero
- Departamento de Ingeniería Química, Instituto Tecnológico de Celaya, Celaya, GTO 38010, México
| | | | - Rafiqul Gani
- PSE for SPEED, Skyttemosen 6, DK-3450 Allerod, Denmark
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Ortiz-Espinoza AP, Jiménez-Gutiérrez A, El-Halwagi MM. Including Inherent Safety in the Design of Chemical Processes. Ind Eng Chem Res 2017. [DOI: 10.1021/acs.iecr.7b02164] [Citation(s) in RCA: 33] [Impact Index Per Article: 4.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Andrea P. Ortiz-Espinoza
- Departamento de
Ingeniería Química, Instituto Tecnológico de Celaya, Celaya, Guanajuato 38010, México
| | - Arturo Jiménez-Gutiérrez
- Departamento de
Ingeniería Química, Instituto Tecnológico de Celaya, Celaya, Guanajuato 38010, México
| | - Mahmoud M. El-Halwagi
- Department of Chemical Engineering, Texas A&M University, College Station, Texas 77843, United States
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24
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Process evaluation on the separation of ethyl acetate and ethanol using extractive distillation with ionic liquid. Sep Purif Technol 2017. [DOI: 10.1016/j.seppur.2017.03.011] [Citation(s) in RCA: 46] [Impact Index Per Article: 6.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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25
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Roy N, Eljack F, Jiménez-Gutiérrez A, Zhang B, Thiruvenkataswamy P, El-Halwagi M, Mannan MS. A review of safety indices for process design. Curr Opin Chem Eng 2016. [DOI: 10.1016/j.coche.2016.07.001] [Citation(s) in RCA: 69] [Impact Index Per Article: 8.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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