Two-Stage Stochastic Integrated Product and Process Design for Conceptual Design of Flexible Sustainable Production Plants

High Resolution Image Download MS PowerPoint Slide As the chemical industry transitions toward sustainable production, integrated product and process design emerges as a vital task to improve resource and cost efficiency. However, current product and process design approaches typically fall short of flexibility considerations to address prevailing uncertainties during plant operation. We propose a two-stage stochastic programming (TSP) formulation for integrated product and process design, demonstrated on hybrid biorefineries for renewable fuel production. First-stage process design decisions are coupled with second-stage recourse decisions on feedstock selection, product formulation, and process operation; the uncertain variables pertain to key economic parameters and renewable feedstock availability. Compared to the deterministic benchmark, the TSP results in different chemical pathway selection and sizing with enhanced flexibility toward uncertainty in feedstock and energy supply, as well as product demand, 9% higher expected profits, and reduced fluctuations in production rate. In addition, the flexible process maintains economic viability in unfavorable scenarios where nominal designs incur losses. These findings underscore how decision-making in the early stages of process development benefits from uncertainty and flexibility considerations.