Preface -- Part I Overview and Background -- 1 Introduction 3 Dipesh Shikchand Patle and Gade Pandu Rangaiah -- 1.1 Process Intensification -- 1.2 Need for Control and Safety Analysis of Intensified Chemical Processes -- 1.3 Studies on Control and Safety Analysis of Intensified Chemical Processes -- 1.4 Scope and Organization of the Book -- 1.5 Conclusions -- References -- 2 Applications and Potential of Process Intensification in Chemical Process Industries 15 Chirla C.S. Reddy -- 2.1 Introduction -- 2.2 Benefits of Process Intensification Techniques -- 2.3 Static Mixers -- 2.4 Process Intensification for Separation Vessels -- 2.5 Process Intensification for Distillation -- 2.6 Process Intensification for Heating -- 2.6.1 Steam Injection Heater -- 2.6.2 Steam/Electric Heaters as a Replacement for Fired Heaters -- 2.6.3 Process Intensification for Flue Gas Heat Recovery -- 2.6.4 Process Heat Exchangers -- 2.6.5 Sonic Horn -- 2.7 Steam Compression -- 2.8 Process Intensification for Carbon Capture -- 2.9 Process Intensification for Vacuum Systems -- 2.10 Process Intensification for Water Deaeration -- 2.11 Process Intensification for Development of Inherently Safer Design (isd) -- 2.12 Process Intensification for Reducing Pressure Relief and Handling Requirements -- 2.12.1 Non-safety Instrumented Solutions for Pressure Relief Systems -- 2.12.2 Safety Instrumented System (SIS) Solutions for Reducing Pressure Relief Requirements -- 2.13 Process Intensification for Wastewater Recovery -- 2.14 Challenges of Process Intensification Techniques -- 2.15 Conclusions -- References -- Part II Procedures and Software for Simulation, Control and Safety Analysis -- 3 Simulation and Optimization of Intensified Chemical Processes 49 Zemin Feng and Gade Pandu Rangaiah -- 3.1 Introduction -- 3.2 Simulation of Chemical Processes -- 3.2.1 Usefulness of Process Simulation -- 3.2.2 Commercial Process Simulators -- 3.2.3 Free Process Simulators -- 3.2.4 Computational Methods for Process Simulation -- 3.3 Procedure for Simulation of (Intensified) Chemical Processes -- 3.3.1 Problem Analysis -- 3.3.2 Basic Process Flow Design -- 3.3.3 Process Intensification and Integration -- 3.3.4 Model Construction -- 3.3.5 Simulation and Convergence -- 3.3.6 Results Analysis -- 3.4 Optimization of (Intensified) Chemical Processes -- 3.4.1 Mathematical Optimization Methods -- 3.4.2 Optimization of Chemical Processes with a Process Simulator -- 3.4.2.1 Optimization Using MATLAB -- 3.4.2.2 Optimization Using Python -- 3.5 Challenges in the Simulation/Optimization of Intensified Chemical Processes -- 3.6 Case Study -- 3.6.1 Problem Analysis -- 3.6.2 Process Flow Design -- 3.6.3 Model Construction -- 3.6.4 Simulation and Convergence -- 3.6.4.1 Process Simulation -- 3.6.4.2 Economic Evaluation Criterion -- 3.6.4.3 Process Optimization -- 3.6.5 Results and Analysis -- 3.7 Conclusions -- References -- 4 Dynamic Simulation and Control of Intensified Chemical Processes 83 Zemin Feng and Gade Pandu Rangaiah -- 4.1 Introduction -- 4.2 Dynamic Simulation of Chemical Processes -- 4.2.1 Understanding Dynamic Simulation -- 4.2.2 Applications of Dynamic Simulation -- 4.2.3 Dynamic Simulation Software -- 4.3 Dynamic Simulation and Control Procedure -- 4.4 Dynamic Simulation and Control of Intensified Chemical Processes -- 4.4.1 Challenges Due to Process Intensification -- 4.5 Process Control -- 4.5.1 Controlled, Manipulated, and Disturbance Variables -- 4.5.2 Typical Control Loop -- 4.5.3 Control Degrees of Freedom -- 4.6 Case Study -- 4.6.1 Steady-state Simulation and Optimization -- 4.6.2 Preparation/Initialization for Dynamic Simulation -- 4.6.3 Control Structure Design -- 4.6.3.1 Composition Control Scheme -- 4.6.3.2 Temperature Control Scheme -- 4.6.4 Tuning of Controller Parameters -- 4.6.5 Analysis of Dynamic Simulation Results -- 4.7 Conclusions -- References -- 5 Safety Analysis of Intensified Chemical Processes 125 Masrina Mohd Nadzir, Zainal Ahmad, and Syamsul Rizal Abd Shukor -- 5.1 Introduction -- 5.2 Safety Analysis in Chemical Process Industry -- 5.2.1 Safety Analysis Tools -- 5.2.1.1 Hazard Identification -- 5.2.1.2 Risk Assessment -- 5.2.1.3 Inherently Safer Design (ISD) -- 5.2.1.4 Safety Instrumented Systems -- 5.2.1.5 Human Factors and Safety Culture -- 5.2.1.6 Regulatory Framework and Compliance -- 5.2.1.7 Monitoring and Continuous Improvement -- 5.3 Process Intensification and Safety Analysis -- 5.3.1 Impacts of Process Intensification on Safety -- 5.3.2 Safety Analysis in Intensified Process Design -- 5.3.2.1 Hazard Identification Techniques for Process Intensification Technologies -- 5.3.2.2 Risk Assessment for Process Intensification Technologies -- 5.3.3 Inherently Safer Design Principles Intensified Processes -- 5.4 Safety Management Systems for Intensified Processes -- 5.5 Safety Training and Competency for Intensified Processes -- 5.5.1 Importance of Safety Training and Competency -- 5.5.2 Developing Safety Training and Competency Programs -- 5.5.3 Utilizing a Blended Learning Approach -- 5.5.4 Assessing Training Effectiveness and Continual Improvement -- 5.5.5 Benefits of Effective Safety Training and Competency Management -- 5.6 Case Studies of Safety Analysis in Intensified Processes -- 5.7 Conclusions -- References -- Part III Control and Safety Analysis of Intensified Chemical Processes -- 6 Control of Hybrid Reactive-Extractive Distillation Systems for Ternary Azeotropic Mixtures 157 Zong Yang Kong and Hao-Yeh Lee -- 6.1 Introduction -- 6.2 Steady-state Design of the RED -- 6.3 Dynamic Simulation Setup -- 6.4 Inventory Control Setup -- 6.5 Sensitivity Analysis -- 6.6 Quality Control Structures -- 6.6.1 Control Structure 1 (CS 1) - Simple Temperature Control -- 6.6.2 Control Structure 2 (CS 2) - Triple Point Temperature Control -- 6.6.3 Control Structure 3 (CS 3) - Triple Point Temperature Control Using SVD Analysis -- 6.6.4 Feedforward Control Structure 3 (FF-CS 3) -- 6.7 Control Performance Evaluation -- 6.8 Conclusions -- Acknowledgements -- Acronyms -- Nomenclature -- References -- 7 Process Design and Control of Reactive Distillation in Recycle Systems 183 Mihai Daniel Moraru, Costin Sorin Bildea, and Anton Alexandru Kiss -- 7.1 Introduction -- 7.2 Design of Reactive Distillation Processes -- 7.3 Control of Reactive Distillation Processes -- 7.4 Case Study: RD Coupled with a Distillation-Reactor System and Recycle -- 7.4.1 Basis of Design and Basic Data -- 7.4.2 Process Design -- 7.4.3 Process Control -- 7.4.4 Discussion -- 7.5 Conclusions -- References -- 8 Dynamics and Control of Middle-vessel Batch Distillation with Vapor Recompression 209 Radhika Gandu, Akash Burolia, Dipesh Shikchand Patle, and Gara Uday Bhaskar Babu -- 8.1 Introduction -- 8.2 Conventional Middle-vessel Batch Distillation -- 8.2.1 A Systematic Simulation Approach of CMVBD -- 8.2.1.1 Model Equations -- 8.2.2 Constant Composition Control -- 8.3 Single-stage Vapor Recompression in Middle-vessel Batch Distillation -- 8.3.1 A Systematic Simulation Approach of SiVRMVBD -- 8.4 Performance Specifications -- 8.4.1 Energy Savings -- 8.4.2 Total Annual Cost -- 8.4.3 Greenhouse Gas Emissions -- 8.5 Results and Discussion -- 8.5.1 Conventional Middle-vessel Batch Distillation Column -- 8.5.1.1 Dynamic Composition Profiles -- 8.5.2 Single-stage Vapor Recompression in Middle-vessel Batch Distillation -- 8.5.3 Energetic, Economic, and Environmental Performance: CMVBD vs. SiVRMVBD -- 8.5.4 Constant Composition Control -- 8.5.4.1 SiVRMVBD-GSPI -- 8.5.5 Energetic, Economic, and Environmental Performance: CMVBD vs. Controlled CMVBD and SiVRMVBD -- 8.6 Conclusions -- References -- 9 Safety Analysis of Intensified Distillation Processes Using Existing and Modified Safety Indices 237 Savyasachi Shrikhande, Gunawant K. Deshpande, Gade Pandu Rangaiah, andDipeshShikchandPatle -- 9.1 Introduction -- 9.2 Safety Indices for Process Safety Assessment -- 9.3 Description of Distillation Systems -- 9.3.1 Conventional Sequence of Columns -- 9.3.2 Dividing-Wall Column -- 9.3.3 Dividing-Wall Column with Mechanical Vapor Recompression -- 9.4 Selection of Safety Indices -- 9.5 Results and Discussion -- 9.5.1 Conventional Sequence of Columns -- 9.5.2 Dividing-Wall Column -- 9.5.3 Dividing-Wall Column with Mechanical Vapor Recompression -- 9.5.4 Comparative Analysis -- 9.6 Survey of Engineers and Discussion of their Responses -- 9.7 Improved PRI -- 9.8 Conclusions.