Source reduction from chemical plants using on-line optimization

An effective approach for source reduction in chemical plants has been demonstrated using on-line optimization with flowsheeting (ASPEN PLUS) for process optimization and parameter estimation and the Tjao-Biegler algorithm implemented in a mathematical programming language (GAMS/MINOS) for data reconciliation and gross error detection. Results for a Monsanto sulfuric acid plant with a Bailey distributed control system showed a 25% reduction in the sulfur dioxide emissions and a 17% improvement in the profit over the current operating conditions. Details of the methods used are described.