Cost minimization of membrane-based separation systems for H2 recovery: A comparison of two optimization approaches

This paper addresses the optimization of membrane-based processes, with a specific focus on H2 recovery in hydrocarbon processing plants. A comparative analysis of two optimization approaches is conducted for designing H2 recovery systems for a multicomponent gas mixture containing H2/N2/CO2/CO. The main objective is to achieve the desired H2 recovery and product purity levels while minimizing costs. The paper compares two approaches for optimization: the first uses a simulation-based optimization technique with Aspen Custom Modeler/ASPEN Plus, while the second employs a simultaneous optimization method using GAMS (General Algebraic Modeling System). The methods are thoroughly compared, evaluating their strengths and weaknesses through qualitative and numerical assessments. To this end, a reference case was selected from the existing literature. The results obtained indicate that both proposed approaches are suitable for optimizing the design of a two-stage membrane configuration, as evidenced by the similarity of the optimal solutions obtained from both approaches. Subsequently, based on the analysis of numerical values for the optimal design problem for the investigated two-stage membrane configuration, a hybrid strategy for the optimal synthesis and design of multi-stage separation processes is proposed. The study fills a gap in the literature by providing a comprehensive analysis of the advantages and disadvantages of optimization approaches in the context of technology of separation of gases. This research provides valuable insights into the field and offers guidance for selecting appropriate approaches to improve the efficiency and cost-effectiveness of gas separation processes in real-world applications. •Optimization of H2 recovery from multicomponent gas mixture is addressed.•Simulation-based optimization and simultaneous optimization methods are compared.•Both proposed approaches are suitable for optimizing simple membrane configurations.•Similar optimal solutions can be obtained from both of these approaches.•Insights for efficient gas separation in real-world applications are provided.