MBSE for Process Analytical Technology- BWON Analysis Case Study

Volatile Organic Compound (VOC) emissions from industrial sources, particularly Benzene, present significant environmental and public health challenges. Regulatory frameworks, such as the U.S. Environmental Protection Agency’s Benzene Waste Operations NESHAP (BWON), mandate strict monitoring of control devices, specifically carbon adsorption canisters, to prevent emission breakthrough. However, current industry practices rely heavily on manual Method 21 testing, a labor-intensive process that creates lagging indicators and increases the risk of non-compliance events. This thesis proposes the design and development of an on-line, automated fugitive emissions monitoring system tailored for carbon canisters using Model-Based Systems Engineering (MBSE). Utilizing the Object-Oriented System Engineering Method (OOSEM) and the Systems Modeling Language (SysML), the study models the physical architecture and behavior of a continuous analyzer system capable of automated daily validation and stream switching. The research demonstrates that an MBSE approach provides explicit, executable traceability from 40 CFR Part 61 regulatory requirements to specific system constraints. By employing parametric modeling, the system simulates operational states—such as initialization, run, and auto-validation—to provide real-time verification of compliance limits. The results indicate that this model-based approach offers a superior alternative to static Piping and Instrumentation Diagrams (P&IDs) and traditional process simulators by integrating regulatory bounds directly into the system design. Ultimately, this automated solution facilitates early detection of canister end-of-life, optimizing replacement intervals, and minimizing human exposure to hazardous pollutants