Use of Multiscale Data-Driven Surrogate Models for Flowsheet Simulation of an Industrial Zeolite Production Process

The production of catalysts such as zeolites is a complex multiscale and multi-step process. Various material properties, particle size or moisture content, well operating parameters—e.g., temperature amount composition input flows—significantly affect the outcome each process step, hence determine properties final product. Therefore, design optimization processes task, which can be greatly facilitated with help numerical simulations. This contribution presents modeling framework for dynamic flowsheet simulation zeolite sequence consisting four stages: precipitation in batch reactor; concentration washing block centrifuges; formation droplets drying spray dryer; burning organic residues chain rotary kilns. techniques methods were used to develop applied models. For synthesis reactor, multistage strategy was used, comprising discrete element method simulations, data-driven surrogate modeling, population balance modeling. stage consisted several multicompartment decanter centrifuges alternating water mixers. described by co–current dryer model developed applying two-dimensional approach. kilns, multi-compartment describes gas–solid reaction counter–current solids gas flows.