The Centre for Process Systems Engineering

1. The Centre for Process Systems Engineering Prof David Bogle Director

2. Who we are • Multi-institutional research centre • Imperial - Chemical Engineering, Computing, Earth Science & Engineering, Electrical Engineering • UCL - Chemical Engineering, Electrical Engineering • World-class departments at Imperial & UCL • Multi-disciplinary academic staff from a wide range of disciplines with international reputation • Excellence in research - 5* Chem. Eng. (ICL and UCL) & Computing in the UK Govt. Research Assessment (RAE)

3. Objectives • To advance knowledge in the area of Process Systems Engineering • To promote and facilitate the widespread adoption of systems engineering methodologies • To influence National, EU and International policy and standards • To educate graduate students to the highest international level • To offer world class knowledge transfer services to industry • To undertake complete lifecycle of research and development: from proof of concept to commercialisation • To address and support short, medium and long term industrial research needs on an industry-wide and company-specific manner

4. What we do – Managing Complexity • We perform research and develop integrated models, methodologies and tools to enable scientist, engineers and managers understand, capture, operate and manage complex, multi-scaled natural, engineering and industrial systems through • Requirements and functional analysis • Modelling and design • Control • Simulation • Optimisation • Experiment Design • Visualisation

5. What we do • Traditionally we have focused on the industrial Process sector • Oil and gas • Petrochemicals • Pharmaceuticals • Fine chemicals • Environmental Engineering • Polymers • Food and beverage • Consumer goods

6. Where are the Process Industries going? • The Middle and Far East… • Bulk and Specialty Chemicals • New feedstocks, zero emissions, non-conventional energy sources, new catalysis, better chemistry, size • Vision – Step change in process/plant efficiency with respect to space, time, energy, raw materials, safety and the environment • Functional Materials • Industrial (White) Biotechnology • Sustainable manufacturing and supply chains • Energy and Water www.suschem.org

7. Multi scale systems modelling and engineering Recognition of length and time scales

8. CPSE Research across multiple size and time scales • From nano-scale (molecular) to micro-scale (particles, crystals) to meso-scale (materials, equipment, products) to mega-scale (supply chain networks, environment) • Integrated modelling, design and optimisation where possible

9. Core competencies - Managing Complexity • Modelling and simulation • Optimisation • Optimal design and operation • Optimisation under uncertainty • Risk management • Control

10. Generic Research Programme • Product and process design • Process operations and supply chain management • Control and measurement • Modelling and numerical methods

11. Product and Process Engineering Biological Systems Engineering Energy Systems Engineering Molecular Systems Engineering Generic research programme Managing complexity

12. ICL Chem Eng Claire Adjiman Amparo Galindo (molecular) Charles Immanuel George Jackson (molecular) Sakis Mantalaris (biological) Costas Pantelides Stratos Pistikopoulos Roger Sargent (Emeritus) Nilay Shah ICL Computing Berc Rustem ICL Earth Science and Engng Nigel Brandon (energy) UCL Chem Eng David Bogle Vivek Dua Eric Fraga Lazaros Papageorgiou Eva Sorensen UCL Elec Eng Nina Thornhill ICL Elec Eng John Allwright Imad Jaimoukha Richard Vinter Industrial Visiting Professor Roger Benson CPSE Academic Staff

13. CPSE Management team • Prof David Bogle, Director • Prof Nilay Shah, Financial Director • Prof Berc Rustem, Associate Director • Prof Paul Rutter, External Relations Consultant • Dr Harris Makatsoris, Industrial Research Development Officer

14. Facts and Figures - CPSE • Multi-discipline, multi-university, engineering faculty-wide research centre • 22 academic staff • 83 full time research staff and PhD students – over 70 research projects • On average over £6m per annum of research income (since 1990) by industry and government • Strong industrial support (CPSE Industrial Consortium) • Strong international brand-name recognition (keynote lectures) • Queens Award for Higher and Further Education 2002 • International Centre for Process Systems Engineering (iCPSE)

15. Joint research partnership with Georgia Tech CPSE - iCPSE • Inaugurated March 2005 • An international hub for Process Systems Engineering • Global industry-academic alliance • Expanded industrial consortium and links with industry • Unparalleled pool of expertise

16. enterprise Shabbir Ahmed (ISyE) plant site Gary May (ECE) Matthew Realff (ChBE) Jay Lee (ChBE) process Thanos Nenes (ChBE) Joseph Schork (ChBE) Ron Rousseau (ChBE) meso Cliff Henderson (ChBE) Martha Gallivan (ChBE) Pete Ludovice (ChBE) molecular Product Process GT CPSE Faculty

17. GT’s Competencies Materials Engineering Microelectronics • Traditional PSE • Supply Chain / Logistics • Process Design • Process Optimization • Process Control Fuel Cells, Batteries Biological Engineering

18. Mathematical Modeling of Mini-emulsion Polymerization • Charles Immanuel, ICL • Population Balance modeling • Reactor/particle level • Martha Gallivan, GT • Kinetic Monte Carlo modeling • Intraparticle level • Mass action kinetics does not hold • F. Joseph Schork, GT • Experimental • Model Validation • Mechanistic Studies • Coordination

19. Mathematical Modeling of Mini-emulsion Polymerization • Progress To Date • Monte Carlo Modeling • Basic Particle Model Constructed • Adding Diffusion • Population Balance Model • Emulsion Polymerization Model Exists • Droplet Ripening Model Being Developed

20. Supply Chain Collaborative Research Nilay Shah Lazaros Papageorgiou Stratos Pistikopoulos Shabbir Ahmed Jay Lee Matthew Realff

21. Supply Chain Research Themes • Uncertainty • What are effective representations and solution procedures to help the management of large scale supply chains under significant uncertainty? • Multi-Scale, Multi-Agent System • Distributed agents with local objective / constraint and detailed local knowledge • Global goals, information, and interactions, coarser-scale knowledge • Performance Measures • How do we devise metrics of profit, customer service and environmental impact? • Time Criticality • How do we deal with response times may be required to be very rapid compared to the supply chain dynamics?

22. Current projects underway • Network design/strategy • Capacity and product portfolio planning under uncertainty • Global network retrofit for a pharmaceutical company • Network design with transfer price optimisation • Optimal resource planning and contract appraisal for a subcontractor • Design of a next-generation hydrogen supply chain • Complexity in supply chains • Optimal supply chain planning/policies • Paints supply chain optimisation • Business process optimisation to improve a flavours supply chain • Multi-scale planning and scheduling for pharmaceuticals • Oil products supply chain optimisation • Vaccines supply chain optimisation • Analysis and optimisation of VMI systems • SCP in petrochemical complexes • Supply chain operations/control • Hybrid MILP/CLP techniques for scheduling • SCM for fast moving, short-lifecycle products • Parametric control for supply chain operations

23. Managing Risk in Process Design • Technological development is a source of uncertainty and risk • Detailed models needed to assess new technologies • account for complex phenomena, e.g. non-uniform mixing • account for complex interactions • Need for effective quantitative risk management methodologies • Objectives: • Based on a detailed model which captures the sources of risk arising from a new technology, … • … quantify the inherent risk of the technology for a given design • … minimise the inherent risk through design

24. Nominal values of model parameters Construction & formal validation of detailed process model Uncertainty in model parameters Deterministic optimisation Nominal design & operating point Global sensitivity analysis (GSA) Examine effect of uncertainty on process performance …taking account of process controls Critical uncertain parameters Scenario-based optimisation Large numbers of scenarios designed to sample effectively the space of uncertainty …applied to large, highly nonlinear models Managing Risk in Process Design Proposed methodology

25. Managing Risk in Process Design Results and future programme • Developed global multi-parameter sensitivity analysis: • Improved analysis to account for • performance constraints • ability of process to adapt to uncertainty via control • Developed efficient scenario-based optimisation technique: • Improved scenario generation based on sensitivity analysis results • Demonstrated ability to quantify risk in existing design and to generate improved designs based on a distributed reactor model. • Future joint programme: • Consider both technical and financial risk – operations and investment • Stochastic methodologies, interval methods, min-max optimization • Multi-scale – molecular to supply chain

26. Major initiatives planned • Molecular Systems Engineering programme • Develop computational platform to tackle process and product design problems using molecular level information • £3m EPSRC project over 4 yrs • Strong industrial support (in-kind, secondments, additional funding) • Urban Energy Systems (through IC-EFL) • 5 PIs involved • Integrated Clean production of Fossil Fuels • ‘Game-changing’ approach to production of fossil fuels and related products. Employ integrated systems approach to design, optimise and control new processes. • In collaboration with IC-EFL - Proposal stage currently targeting Shell • £5m over 5 yrs • Exploring industrial collaborations for biomass/biofuels production • Managing Risk

27. Knowledge & Technology Transfer ‘From day one, CPSE was set up to ensure that science and technology could be transferred to industry’ Professor Roger Sargent (CPSE’s Founder and 1st Director)

28. Knowledge & Technology Transfer Industrial Research Consortium Graduates, Secondments Partnerships Dissemination Fundamental Research Applied Research DevelopmentEvaluation Demonstration Licensing Spin-off Companies Case Studies Collaborative Projects Industrial Projects • PSE Ltd • Britest Ltd • PAROS Ltd 3+ yrs 3 yrs 3 – 12 months

29. CPSE Industrial Research Consortium

30. Summary • Wide role for systems thinking – contribution of iCPSE • Critical mass, interdisciplinary skills and expertise • R&D pipeline: industry can leverage • Major producer of trained researchers • Strong links with industry • Track record of scientific achievement, effective collaboration and technology transfer

31. Need more information? Please log on to www.cpse.imperial.ac.uk Or Contact Dr Harris Makatsoris Industrial Research Development Officer Imperial College London Roderic Hill Building South Kensington campus London SW7 2AZ tel +44 (0)20 7594 1247 fax +44 (0)20 7594 6606 email h.makatsoris@imperial.ac.uk

32. CPSE: Brand-name recognition The Queen’s Annivarsary Prize 2002 “for Higher and Further Education”

33. Supply chain problems Strategic 1 2 3 4 5 “Time” dimension 6 7 8 9 10 Planning Operational 11 12 13 14 15 Storage locations Customers Suppliers 10 mfg 20 mfg “Space” dimension • Examples • Redesign logistics network • Campaign planning at a primary manufacturing site • Real-time supply chain management and control; Collaborative Manufacturing & Scheduling • Negotiation of long term supply contracts • Improved design of primary manufacturing processes and plants • Long-term manufacturing capacity planning and value-chain management