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The paper proposes a multi-level approach for process synthesis using process superstructure optimisation. More specifically, we address the introduction of detailed reactor models to explore the effects of non-ideal reactor behaviour during the process synthesis activity after the initial screening of design candidates has been completed using ideal reactor models and high-level design trends extracted to narrow the design space to a few promising process structures. The approach focuses on heterogeneously catalysed gas-phase reaction systems due to their prominence in industrial practice and is illustrated with examples in styrene and acetic acid production.

Multi-level Reactor Optimisation in the Conceptual Design of Processes with Heterogeneous Catalytic Reactors