This paper provides a multi-aspect comparison of selected methods of ethyl acetate production and shows the possibility of further reactive distillation process integration and sophisticated intensification including process stream regeneration. The production pathways were selected with respect to their practical applicability and sufficient experimental and feasibility studies already published. A total of four case studies were designed and compared: conventional process set-up (ethyl acetate is produced in a chemical reactor) is designed as a base case study; reactive distillation with a separation unit is derived from the conventional process set-up. The mechanical and chemical approach to reactive distillation process intensification and integration were assumed: reactive distillation column with a stripper and reactive distillation column with an auxiliary chemical reaction (ethylene oxide hydration). Process models were compiled in the Aspen Plus software. Complex process flowsheets of selected case studies including separation and regeneration were designed and optimized. Three different points of view were applied to evaluate the selected process benefits and drawbacks. Process energy, economy, and safety were assessed. As a result, a reactive distillation column with an auxiliary chemical reaction has been proven to be the most suitable pathway for ethyl acetate production assuming all three evaluated aspects.

Optimal steam process drive sizing is crucial for efficient and sustainable operation of energy-intense industries. Recent years have brought several methods assessing this problem, which differ in complexity and user-friendliness. In this paper, a novel complex method was developed and presented and its superiority over other approaches was documented on an industrial case study. Both the process-side and steam-side characteristics were analyzed to obtain correct model input data: Driven equipment performance and efficiency maps were considered, off-design and seasonal operation was studied, and steam network topology was included. Operational data processing and sizing calculations were performed in a linked MATLAB^®–Aspen Plus^® environment, exploiting the strong sides of both software tools. The case study aimed to replace a condensing steam turbine by a backpressure one, revealing that: 1. Simpler methods neglecting frictional pressure losses and off-design turbine operation efficiency loss undersized the drive and led to unacceptable loss of deliverable power to the process; 2. the associated process production loss amounted up to 20%; 3. existing bottlenecks in refinery steam pipelines operation were removed; however, new ones were created; and 4. the effect on the marginal steam source operation may vary seasonally. These findings accentuate the value and viability of the presented method.

Multi-objective (energy–economic–safety) assessment of ethyl acetate production involving a heat pump is presented in this paper. The heat pump is designed to intensify ethyl acetate separation and to reduce the total operating cost. Two ethyl acetate production pathways are upgraded using a heat pump, conventional process and reactive distillation column with a separation unit. Detailed process models including the heat pump environment have been compiled and optimized in the Aspen Plus software. Both benefits and drawbacks of including the heat pump in the processes are evaluated using three different points of view: process energy, economics, and safety. As a result, using a heat pump is highly recommended in both conventional process and reactive distillation column with a separation unit. As a higher level of process integration is achieved using a heat pump, economic aspects are improved; however, safety aspects deteriorate. The final decision on the suitability of using a heat pump depends on whether it is proposed for an existing plant, or a completely new plant is designed. In a new plant, the concept of a thermally coupled process (reactive distillation column with a stripper column) has been proven to be the most promising.

The aim of this contribution is to provide an overview of the calculation procedures of risk analysis, that is, the effects and consequences of pool fires. Fires and explosions are the most significant and most common causes of damage to equipment and of injuries and death in industry. Damages are a direct consequence of the generated heat flux. Mathematical tools for the prediction of heat flux at a distance can be divided into four classes: semi-empirical models, field models, integral models and zone models. Semi-empirical modeling is a relatively simple technique providing models predicting heat flux at a distance. There are two types of semi-empirical models: point source models and surface emitter models. By their nature, semi-empirical models depend strongly on experimental data. Correlations are able to describe the general features of a fire. Semi-empirical models are ideal for routine hazard assessment purposes because they are mathematically simple, and hence easily understood. However, if more models describing the same phenomenon are available, significant differences in the heat flux prediction can be expected. In this contribution, differences in the prediction of the heat flux from pool fires are discussed.