Industrial & Engineering Chemistry Research, Vol.39, No.6, 2035-2044, 2000
Batch process planning for waste minimization
Modern environmental regulations and disposal costs as well as shipping regulations can dramatically increase the incentive for recovery of solvents generated by batch chemical processes using an in-house batch distillation. This solvent recovery system is often operated more like a utility system rather than an integral part of the batch process. Without considering the solvent recovery system, the major interest of batch processes is to maximize the productivity, which inevitably maximizes the peak load on the solvent recovery system and consequently on the waste disposal. Therefore, there is an incentive to consider the production plan together with the solvent recovery. In this study, production planning for a batch process including solvent recovery was performed with simulated annealing coupled with a discrete event simulation into estimate factors such as disposal costs, distillation costs, and recovered solvent values. To minimize disposed solvent wastes, it is crucial to use part of the production lines in a multiplant batch process. Consequently, some products are produced earlier and carried in inventory. In this alternative, the increased inventory is balanced against reduced waste disposal. Other potential benefits from process retrofit alternatives such as installing more intermediate storage, more distillation capacity, etc., are reported.