The Centre for Process Systems Engineering

Prof David Bogle

Director

Who we are Multi-institutional research centre

Imperial - Chemical Engineering, Computing, Earth Science & Engineering, Electrical Engineering

UCL - Chemical Engineering, Electrical Engineering

World-class departments at Imperial & UCL Multi-disciplinary academic staff from a wide range of disciplines with

international reputation Excellence in research - 5* Chem. Eng. (ICL and UCL) & Computing

in the UK Govt. Research Assessment (RAE)

Objectives To advance knowledge in the area of Process Systems Engineering

To promote and facilitate the widespread adoption of systems engineering methodologies

To influence National, EU and International policy and standards

To educate graduate students to the highest international level

To offer world class knowledge transfer services to industry

To undertake complete lifecycle of research and development: from proof of concept to

commercialisation

To address and support short, medium and long term industrial research needs on an

industry-wide and company-specific manner

What we do – Managing Complexity

We perform research and develop integrated models, methodologies and tools to enable scientist, engineers and managers understand, capture, operate and manage complex, multi-scaled natural, engineering and industrial systems through

Requirements and functional analysis

Modelling and design

Control

Simulation

Optimisation

Experiment Design

Visualisation

What we do

Traditionally we have focused on the industrial Process sector

Oil and gas

Petrochemicals

Pharmaceuticals

Fine chemicals

Environmental Engineering

Polymers

Food and beverage

Consumer goods

Where are the Process Industries going? The Middle and Far East… Bulk and Specialty Chemicals

New feedstocks, zero emissions, non-conventional energy sources, new catalysis, better chemistry, size

Vision – Step change in process/plant efficiency with respect to space, time, energy, raw materials, safety and the environment

Functional Materials Industrial (White) Biotechnology Sustainable manufacturing and supply chains Energy and Water

www.suschem.org

Multi scale systems modelling and engineering

Recognition of length and time scalesRecognition of length and time scales

From nano-scalenano-scale (molecular) to micro-scalemicro-scale (particles, crystals)

to meso-scalemeso-scale (materials, equipment, products)

to mega-scalemega-scale (supply chain networks, environment) Integrated modelling, design and optimisation where possible

CPSE Research across multiple size and time scales

Core competencies- Managing Complexity

Modelling and simulation Optimisation

Optimal design and operationOptimisation under uncertainty Risk management

Control

Generic Research Programme

Product and process design

Process operations and supply chain management

Control and measurement

Modelling and numerical methods

Generic research programme Generic research programme Managing complexityManaging complexity

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CPSE Academic Staff

ICL Chem Eng Claire Adjiman Amparo Galindo (molecular) Charles Immanuel George Jackson (molecular) Sakis Mantalaris (biological) Costas Pantelides Stratos Pistikopoulos Roger Sargent (Emeritus) Nilay ShahICL Computing Berc RustemICL Earth Science and Engng Nigel Brandon (energy)

UCL Chem Eng David Bogle Vivek Dua Eric Fraga Lazaros Papageorgiou Eva SorensenUCL Elec Eng Nina ThornhillICL Elec Eng John Allwright Imad Jaimoukha Richard VinterIndustrial Visiting Professor Roger Benson

CPSE Management team

Prof David Bogle, Director

Prof Nilay Shah, Financial Director

Prof Berc Rustem, Associate Director

Prof Paul Rutter, External Relations Consultant

Dr Harris Makatsoris, Industrial Research Development

Officer

Facts and Figures - CPSE Multi-discipline, multi-university, engineering faculty-wide research centre

22 academic staff

83 full time research staff and PhD students – over 70 research projects

On average over £6m per annum of research income (since 1990) by industry and government

Strong industrial support (CPSE Industrial Consortium)

Strong international brand-name recognition (keynote lectures)

Queens Award for Higher and Further Education 2002

International Centre for Process Systems Engineering (iCPSE)

Joint research partnership with Georgia Tech CPSE - iCPSE Inaugurated March 2005

An international hub for Process Systems Engineering Global industry-academic alliance

Expanded industrial consortium and links with industry

Unparalleled pool of expertise

Process Product

molecular

meso

process

plant site

enterprise

Matthew Realff (ChBE)

Shabbir Ahmed (ISyE)

Jay Lee (ChBE)

Gary May (ECE)

Pete Ludovice (ChBE)

Cliff Henderson (ChBE)Martha Gallivan (ChBE)

Ron Rousseau (ChBE)

Thanos Nenes (ChBE) Joseph Schork (ChBE)

GT CPSE Faculty

GT’s Competencies

Traditional PSE• Supply Chain / Logistics• Process Design• Process Optimization• Process Control

MaterialsEngineering Microelectronics

Fuel Cells, Batteries

BiologicalEngineering

Mathematical Modeling of Mini-emulsion Polymerization Charles Immanuel, ICL

Population Balance modeling Reactor/particle level

Martha Gallivan, GT Kinetic Monte Carlo modeling Intraparticle level Mass action kinetics does not hold

F. Joseph Schork, GT Experimental

Model Validation Mechanistic Studies Coordination

Mathematical Modeling of Mini-emulsion Polymerization Progress To Date

Monte Carlo Modeling Basic Particle Model Constructed Adding Diffusion

Population Balance Model Emulsion Polymerization Model Exists Droplet Ripening Model Being Developed

Supply Chain Collaborative Research

Nilay ShahLazaros PapageorgiouStratos Pistikopoulos

Shabbir AhmedJay LeeMatthew Realff

Supply Chain Research Themes

•UncertaintyWhat are effective representations and solution procedures to help the management of large scale supply chains under significant uncertainty?

•Multi-Scale, Multi-Agent System Distributed agents with local objective / constraint and detailed local knowledgeGlobal goals, information, and interactions, coarser-scale knowledge

•Performance MeasuresHow do we devise metrics of profit, customer service and environmental impact?

•Time CriticalityHow do we deal with response times may be required to be very rapid compared to the supply chain dynamics?

Current projects underway Network design/strategy

Capacity and product portfolio planning under uncertainty Global network retrofit for a pharmaceutical company Network design with transfer price optimisation Optimal resource planning and contract appraisal for a subcontractor Design of a next-generation hydrogen supply chain Complexity in supply chains

Optimal supply chain planning/policies Paints supply chain optimisation Business process optimisation to improve a flavours supply chain Multi-scale planning and scheduling for pharmaceuticals Oil products supply chain optimisation Vaccines supply chain optimisation Analysis and optimisation of VMI systems SCP in petrochemical complexes

Supply chain operations/control Hybrid MILP/CLP techniques for scheduling SCM for fast moving, short-lifecycle products Parametric control for supply chain operations

Managing Risk in Process Design

Technological development is a source of uncertainty and risk

Detailed models needed to assess new technologies account for complex phenomena, e.g. non-uniform mixing account for complex interactions

Need for effective quantitative risk management methodologies

Objectives: Based on a detailed model which captures the sources of risk

arising from a new technology, … … quantify the inherent risk of the technology for a given design … minimise the inherent risk through design

Managing Risk in Process Design

Construction & formal validation of detailed process model

Global sensitivity analysis (GSA) Examine effect of uncertainty on process performance

…taking account of process controls

Nominal design & operating point

Uncertainty in model parameters Deterministic optimisation

Nominal values of

model parameters

Scenario-based optimisationLarge numbers of scenarios designed to sample effectively the space of uncertainty

…applied to large, highly nonlinear models

Critical uncertain parameters

Proposed methodology

Managing Risk in Process Design

Results and future programme Developed global multi-parameter sensitivity analysis:

Improved analysis to account for performance constraints ability of process to adapt to uncertainty via control

Developed efficient scenario-based optimisation technique: Improved scenario generation based on sensitivity analysis results Demonstrated ability to quantify risk in existing design and to generate

improved designs based on a distributed reactor model.

Future joint programme: Consider both technical and financial risk – operations and investment Stochastic methodologies, interval methods, min-max optimization Multi-scale – molecular to supply chain

Major initiatives planned Molecular Systems Engineering programme

Develop computational platform to tackle process and product design problems using molecular level information

£3m EPSRC project over 4 yrs Strong industrial support (in-kind, secondments, additional funding)

Urban Energy Systems (through IC-EFL) 5 PIs involved

Integrated Clean production of Fossil Fuels ‘Game-changing’ approach to production of fossil fuels and related products.

Employ integrated systems approach to design, optimise and control new processes.

In collaboration with IC-EFL - Proposal stage currently targeting Shell £5m over 5 yrs

Exploring industrial collaborations for biomass/biofuels production Managing Risk

Knowledge & Technology Transfer

‘From day one, CPSE was set up to ensure

that science and technology could be

transferred to industry’

Professor Roger SargentProfessor Roger Sargent

(CPSE’s Founder and 1(CPSE’s Founder and 1stst Director) Director)

Knowledge & Technology Transfer

Industrial Research

Consortium Partnerships Dissemination

Case Studies

Collaborative Projects

Licensing

Graduates, Secondments

Spin-off Companies

•PSE Ltd

•Britest Ltd

•PAROS Ltd

FundamentalResearch

AppliedResearch

DevelopmentEvaluation

Demonstration

Industrial Projects

3+ yrs 3 yrs 3 – 12 months

CPSE Industrial Research Consortium

Summary

Wide role for systems thinking – contribution of iCPSE

Critical mass, interdisciplinary skills and expertise

R&D pipeline: industry can leverage

Major producer of trained researchers

Strong links with industry

Track record of scientific achievement, effective collaboration and

technology transfer

Need more information?

Please log on to www.cpse.imperial.ac.ukOr

Contact Dr Harris MakatsorisIndustrial Research Development OfficerImperial College LondonRoderic Hill BuildingSouth Kensington campusLondon SW7 2AZtel +44 (0)20 7594 1247fax +44 (0)20 7594 6606email h.makatsoris@imperial.ac.uk

The Queen’s Annivarsary Prize 2002“for Higher and Further Education”

CPSE: Brand-name recognition

Supply chain problems“T

ime”

dim

ensi

on

“Space” dimension

Strategic

Planning

Operational

Suppliers 10 mfg 20 mfg Storage locations

Customers

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

Examples• Redesign logistics network • Campaign planning at a primary manufacturing site• Real-time supply chain management and control; Collaborative Manufacturing & Scheduling • Negotiation of long term supply contracts• Improved design of primary manufacturing processes and plants • Long-term manufacturing capacity planning and value-chain management