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In this work, we present an integrated approach to synthesize process intensification systems with guaranteed flexibility and safety performances. The synthesis of intensified equipment/flowsheets is addressed through the Generalized Modular Representation Framework (GMF), which utilizes an aggregation of multifunctional mass/heat exchange modules to represent chemical processes. Thus, the optimal design options are investigated as mass- and heat-transfer opportunities using superstructure-based optimization techniques without a prepostulation of plausible configurations. To ensure that the designs can be operated under a specified range of uncertain parameters, a multiperiod GMF representation is developed based on the critical operating conditions identified by flexibility test. Risk assessment, accounting for equipment failure frequency and consequence severity, is incorporated as a constraint into this synthesis model to derive inherently safer designs. The resulting safely operable intensified systems, which are represented via phenomenological modules, are then identified as corresponding equipment-based flowsheets and validated with steady-state simulation. We demonstrate the proposed approach through a case study for the production of methyl tert-butyl ether. The results indicate that safety and operability considerations can result in significant changes in the structural and operating parameters of the optimal intensified design configuration.

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In this article, the importance of considering operability and control criteria in the analysis and design of intensified and modular processes is discussed. We first analyze the impact on operability of key factors including: (i) degrees of freedom, (ii) process constraints, (iii) numbering up vs. scaling up, and (iv) dynamic/periodic operation. Comparative examples are presented to showcase the pros and cons in intensified/modular systems vs. their conventional counterparts from operability and control aspects. Then we look into metrics and tools to address these challenges such as: (i) flexibility analysis, (ii) operability‐based design, and (iii) advanced model‐based control. Considering different conceptual design stages as synthesis intensification, steady‐state design, and dynamic operational optimization, we highlight the need to incorporate different levels of operability considerations. Future research opportunities and perspectives are also identified, particularly emphasizing the importance of a holistic strategy for integrated design, operability, and control of intensified and modular process systems.

In this work, we develop an envelope of design solutions for combined intensified reaction/separation systems. The attainable region-based continuous flow stirred tank reactor equivalence principle is applied to characterize design boundaries for a given chemistry independent of process design. The thermodynamic-based Generalized Modular Representation Framework is then employed to generate candidate process alternatives along the design boundaries. The proposed approach is showcased via a case study on olefin metathesis. We also highlight the need to incorporate the attainable region-based constraints into synthesis strategies to assist effective bounding of design/intensification space.