Synthesis of bulk solids processing systems

A systematic procedure for the synthesis of bulk solids processing systems guides the user in an evolutionary manner to generate flowsheet alternative s to transform a solids feed with given attributes into products with desir ed attributes. The first step is to select a functional structure based on the primary objective of the processing system. This is followed by the sel ection of equipment for the functional structure. In the third step, the fu nctional structure is expanded by adding other necessary unit operations to form a flowsheet. This is accompanied by the assignment of a suitable equi pment unit to each unit operation. Storage and transportation units are the n added to the flowsheet in the fourth step. Rules and heuristics to help m ake decisions at each step are presented, as well as simulations used to ev aluate flowsheet alternatives. Design variables are identified and short-cu t models based on discretized population balance equations are used to quan tify equipment performance. The procedure is illustrated with commercial ex amples including the production of potash, pesticide granules aspirin and a n azo dye.