Accounting for costs in attainable-region-based reactor–separation network synthesis: Models, tradeoffs, and insights

In reaction engineering, the attainable region defines the set of all possible states attainable in the outlet stream of any steady-state reactor network, given specified feed and reaction kinetics. Costs in approaches that aim to determine the attainable region are often neglected, resulting in targets that require expensive processes. In this work, we propose modeling methods that allow us to account for costs in reactor–separation synthesis while accurately identifying the attainable region. Our goal is to holistically analyze cost trade-offs within the attainable region as well as provide a method to obtain practical targets to be used as benchmarks. We generate the attainable region using the continuous stirred tank reactor (CSTR) equivalence principle and introduce separation models accounting for costs to perform the required separation tasks. Through several case studies, we show how some subregions, typically close to the attainable region boundary, are expensive to achieve.