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Technical, Economic, and Sustainability Evaluation Integrated with PI System Monitoring: A Case Study on Different
Matheus Vittori Ferreira1, André Ferreira Young2, José Carlos Costa da Silva Pinto1
1Escola de Química, Universidade Federal do Rio de Janeiro, Av. Athos da Silveira Ramos, 149, Rio de Janeiro 21945-970, Brazil.
ACS Omega
|August 18, 2025
Summary
Process optimization for acetone production through isopropyl alcohol dehydrogenation enhances economic feasibility. Integrating a PI System for real-time monitoring and analysis significantly improves safety and key performance indicators (KPIs).
Area of Science:
- Chemical Engineering
- Process Systems Engineering
Background:
- Process optimization, monitoring, and control are vital for chemical plant efficiency and financial stability.
- Climate concerns and market demands necessitate cost reduction, quality maintenance, increased production, and eco-friendly solutions.
Purpose of the Study:
- To evaluate alternative process configurations for acetone production via isopropyl alcohol dehydrogenation.
- To assess the economic feasibility and potential production increase through temperature optimization and energy source changes.
Main Methods:
- Simulated alternative scenarios for acetone production process configurations.
- Conducted a temperature optimization case study for the reactor.
- Performed technical-economic analyses for each scenario.
- Developed a PI System environment for real-time monitoring, KPI tracking, and anomaly detection.
Main Results:
- The combined energy source change and temperature optimization scenario proved economically feasible.
- Achieved a 5.2% increase in revenues and a 0.26% reduction in production costs.
- Attained a net present value (NPV) of US$4.63 million, 372% higher than the baseline.
Conclusions:
- Associating process data with a data historian and analyzer enables live testing, enhances safety, and deepens KPI monitoring.
- Technical-economic evaluations combined with real-time data analysis are crucial for validating process improvements.
