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Authors = Srinivas Palanki ORCID = 0000-0002-6016-4619

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16 pages, 4394 KiB  
Article
Advanced Process Control Strategies for Efficient Methanol Production from Natural Gas
by Md Emdadul Haque and Srinivas Palanki
Processes 2025, 13(2), 424; https://doi.org/10.3390/pr13020424 - 5 Feb 2025
Viewed by 1528
Abstract
Natural gas-to-methanol plants are receiving renewed interest with the significant increase in shale gas availability. Methanol serves as a crucial raw material for producing various industrial and consumer goods as well as key platform chemicals, including acetic acid, methyl tertiary butyl ether, dimethyl [...] Read more.
Natural gas-to-methanol plants are receiving renewed interest with the significant increase in shale gas availability. Methanol serves as a crucial raw material for producing various industrial and consumer goods as well as key platform chemicals, including acetic acid, methyl tertiary butyl ether, dimethyl ether, and methylamine. In this research, a dynamic model is developed for Natgasoline’s methanol manufacturing plant. A hierarchical control system comprising Dynamic Matrix Control (DMC) and a basic regulatory control loop is constructed using this dynamic model to minimize methanol losses and utility costs under various process upsets. A subspace identification methodology is used to develop rigorous DMCplus controller models. The simulation results in the ASPEN manufacturing software platform show that the DMCplus controller developed in this study can reduce methanol losses by 96% and utility requirements by 40%. The controller is robust to feed flow variations of ±10%. Furthermore, disturbances due to the variation in hydrogen content in the syngas are also successfully rejected by the controller. This hierarchical multivariable control system performs significantly better than the traditional regulatory PID control strategy in optimizing the methanol process under process constraints. Full article
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15 pages, 1680 KiB  
Article
Plant-Wide Modeling and Economic Analysis of Monoethylene Glycol Production
by Md Emdadul Haque, Namit Tripathi, Srinivas Palanki, Qiang Xu and Krishna D. P. Nigam
Processes 2022, 10(9), 1755; https://doi.org/10.3390/pr10091755 - 2 Sep 2022
Cited by 5 | Viewed by 10752
Abstract
Monoethylene glycol (MEG) is used to produce polyester fibers and polyethylene terephthalate resins. It is also utilized in antifreeze, pharmaceuticals, and cosmetics applications. In this research, we consider the development of a novel process plant that produces MEG from ethylene. The proposed ethylene-to-ethylene [...] Read more.
Monoethylene glycol (MEG) is used to produce polyester fibers and polyethylene terephthalate resins. It is also utilized in antifreeze, pharmaceuticals, and cosmetics applications. In this research, we consider the development of a novel process plant that produces MEG from ethylene. The proposed ethylene-to-ethylene oxide (EO) plant is integrated with an EO-to-MEG plant to reduce utility costs and recover high-value products. Energy-saving opportunities are analyzed via heat integration tools. Furthermore, a multitube glycol reactor is used in conjunction with a novel MTO catalyst in the ethylene-to-EO reactor. Our results demonstrate that the integrated EO/EG plant produces ethylene glycols with that same purity and product recovery as conventional designs. A comparative economic assessment based on a 200,000 t/y plant indicates that process integration techniques can reduce costs significantly. Full article
(This article belongs to the Special Issue Chemical Process Modelling and Simulation)
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