Optimal Configuration of Gas Solid Separation Equipment Using Mixed Integer Nonlinear Programming

Abstract

The separation of solid particles from gas-solid process streams is an important unit operation in many chemical processes. Out of the many different types of separation equipment that are used for gas-solid separation, cyclone separators are widely used for their operational flexibility, efficiency and capital cost. This study focused on the design of an optimal configuration for several cyclones used in a fertilizer plant. The granulation step in the fertilizer plant leads to using different size cyclones and a different number of cyclones in series or parallel or a mix of both arrangements. A Mixed Integer Nonlinear Programming (MINLP) model is formulated to find the best cyclone arrangement with the optimal number of cyclones and dimensions from several combinations of 1D3D and 2D2D cyclones arranged in parallel-series for a high volume and heavy loading of solid particles. The objective function was to minimize the total cost, including the operating cost and the capital cost. The results indicated that a maximum of 90% efficiency is achieved with a parallel-series arrangement of 1D3D and 2D2D cyclones to be an optimal configuration for the maximum reduction in pollution level.