Prof. Sandro Macchietto

Galvanin F, Barolo M, Bezzo F, Macchietto Set al., 2010, A Backoff Strategy for Model-Based Experiment Design Under Parametric Uncertainty, AICHE JOURNAL, Vol: 56, Pages: 2088-2102, ISSN: 0001-1541

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• Citations: 40

Ishiyama EA, Coletti F, Macchietto S, Paterson WR, Wilson DIet al., 2010, Impact of Deposit Ageing on Thermal Fouling: Lumped Parameter Model, AICHE JOURNAL, Vol: 56, Pages: 531-545, ISSN: 0001-1541

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• Citations: 42

Coletti F, Macchietto S, Polley GT, 2010, Effects of fouling on performance of retrofitted heat exchanger networks; a thermo-hydraulic based analysis, 20th European Symposium on Computer Aided Process Engineering (ESCAPE), Publisher: ELSEVIER SCIENCE BV, Pages: 19-24, ISSN: 1570-7946

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• Citations: 6

Ishiyama EM, Coletti F, Macchietto S, Paterson WR, Wilson DIet al., 2010, Erratum: Impact of deposit ageing on thermal fouling: Lumped parameter model, AIChE Journal, Vol: 56, Pages: 1671-1671

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Lone S, Cockerill T, Macchietto S, 2010, The techno-economics of a phased approach to developing a UK carbon dioxide pipeline network, Journal of Pipeline Engineering, Vol: 9, Pages: 223-234

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Galvanin F, Barolo M, Bezzo F, Macchietto Set al., 2010, A Backoff-based Strategy to Improve Robustness in Model-based Experiment Design Under Parametric Uncertainty, 7th International Conference on the Foundations of Computer-Aided Process Design (FOCAPD), Publisher: CRC PRESS-TAYLOR & FRANCIS GROUP, Pages: 623-630

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Lone S, Cockerill TT, Macchietto S, 2010, Techno-economics of a phased approach to developing a UK carbon dioxide pipeline network, First International Forum on Transport of CO2 by pipeline

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Coletti F, Macchietto S, 2010, VALIDATION OF A NOVEL MODEL FOR SHELL AND TUBE HEAT EXCHANGERS UNDERGOING CRUDE OIL FOULING, 14th International Heat Transfer Conference, Publisher: AMER SOC MECHANICAL ENGINEERS, Pages: 741-750

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• Citations: 1

Coletti F, Macchietto S, 2009, Multi-scale modelling of refinery pre-heat trains: Effect of crude fouling on energy recovery, carbon emission and economics

Pre-heat trains (PHTs) in crude distillation units are complex networks of heat exchangers used to recovery up to 60-70% of all the energy necessary for primary fractionation. Efficiency of the train is severely impaired by fouling, the deposition of unwanted material on the thermal surfaces. Economic losses related to this problem was estimated of the order of 1.2 billion dollars p.a. in the United States alone when the price of oil was significantly cheaper. Maintenance issues as well as health and safety hazards are also related to this problem that oil refineries have been facing for decades. Experimental evidences show that fouling rates are function of crude composition and process conditions, namely temperature and velocity. It has also been demonstrated that, for a given crude composition, threshold conditions of temperatures and velocities exist below which no fouling occurs. However, the complex chemical and physical mechanisms underlying fouling deposition are still poorly understood. For this reason, both design and monitoring techniques, based on highly empirical fouling factors, have substantially not changed over the past 40 years. To tackle this long standing problem in a systematic way, a large scale interdisciplinary research project, CROF (for CRude Oil Fouling) has been established. The project, coordinated in 8 subprojects, aims at providing a platform to investigate fundamental parameters leading to deposition, to provide a framework for predicting deposition and avoiding it by design and to formulate methods for mitigation. Within the CROF framework, a multi-scale, first principles model for a shell and tube heat exchanger was developed and validated against data from an ExxonMobil refinery. The model is dynamic, distributed and accounts for local variation of physical properties. Several scales of investigation are considered simultaneously. At the tube level, the interactions between operating conditions and fouling are captured by coupling

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Galvanin F, Barolo M, Macchietto S, Bezzo Fet al., 2009, Optimal Design of Clinical Tests for the Identification of Physiological Models of Type 1 Diabetes Mellitus, INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, Vol: 48, Pages: 1989-2002, ISSN: 0888-5885

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• Citations: 28

Coletti F, Macchietto S, 2009, Predicting Refinery Energy Losses Due to Fouling in Heat Exchangers, 10th International Symposium on Process Systems Engineering, Publisher: ELSEVIER SCIENCE BV, Pages: 219-224, ISSN: 1570-7946

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• Citations: 8

Coletti F, Macchietto S, 2009, A heat exchanger model to increase energy efficiency in refinery pre heat trains, 19th European Symposium on Computer Aided Process Engineering, Publisher: ELSEVIER SCIENCE BV, Pages: 1245-1250, ISSN: 1570-7946

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• Citations: 8

Galvanin F, Barolo M, Macchietto S, Bezzo Fet al., 2009, On the Optimal Design of Clinical Tests for the Identification of Physiological Models of Type 1 Diabetes Mellitus, 10th International Symposium on Process Systems Engineering, Publisher: ELSEVIER SCIENCE BV, Pages: 183-188, ISSN: 1570-7946

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Coletti F, Macchietto S, 2008, Modeling of fouling in crude oil pre-heat trains to reduce energy losses and carbon emissions

A large amount of energy in oil refineries is used to heat the crude oil in furnaces, following a pre-heat train (PHT), a network of heat exchangers which maximise energy recovery from the hot products. The crude oil flowing in the exchangers deposits unwanted layers of material (fouling) which impede the energy recovery and can obstruct the flow of oil in the pipes. This results in severely decreased thermal and hydraulic efficiencies, large production losses (due to throughput reduction and need for periodic cleaning shut-downs). Energy recovery losses in the PHT must be compensated by substantial increase in fuel burned in the furnace, with large CO2 emission. Avoiding or minimising fouling is therefore important. Fouling deposition is not well understood, and current exchanger designs (based on empirical fouling factors) and mitigation solutions (ranging from use of chemical additives to mechanical cleaning devices) do not prevent efficiency losses. A US$ 5.4M project (CROF, for CRude Oil Fouling), involving a consortium of universities supported EPSRC and industry, is presently underway, aiming at producing a step change in understanding, data, predictive models and methods for the improved design and operation of PHT. In this paper, a detailed dynamic, distributed mathematical model for a single tubular heat exchanger with fouling is proposed. By including local effects of process variables (temperature and velocity) and deposition mechanisms, the model accounts for interactions between fouling layer and fluid flow and reproduces well overall experimental behaviour. Various retrofit options for individual heat exchangers are assessed and their energy and CO2 release impact established. For the future, it is envisaged to use the approach to simulate and optimise the design and operation of the overall energy recovery network, its cleaning schedules and energy efficiency strategies. Results so far indicate the return on such work can be substantial.

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Franceschini G, Macchietto S, 2008, Novel Anticorrelation Criteria for Design of Experiments: Algorithm and Application, AICHE JOURNAL, Vol: 54, Pages: 3221-3238, ISSN: 0001-1541

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• Citations: 11

Franceschini G, Macchietto S, 2008, Model-based design of experiments for parameter precision: State of the art, CHEMICAL ENGINEERING SCIENCE, Vol: 63, Pages: 4846-4872, ISSN: 0009-2509

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• Citations: 476

Franceschini G, Macchietto S, 2008, Anti-correlation approach to model-based experiment design: Application to a biodiesel production process, INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, Vol: 47, Pages: 2331-2348, ISSN: 0888-5885

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• Citations: 18

Franceschini G, Macchietto S, 2008, Novel anticorrelation criteria for model-based experiment design: Theory and formulations, AICHE JOURNAL, Vol: 54, Pages: 1009-1024, ISSN: 0001-1541

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• Citations: 38

Macchietto S, 2008, Sustainable Energy Futures, and what we can do about it, 18th European Symposium on Computer Aided Process Engineering (ESCAPE-18), Publisher: ELSEVIER SCIENCE BV, Pages: 1051-1051, ISSN: 1570-7946

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Macchietto S, Coletti F, 2007, A design method for improving oxygenation in perfusion bioreactors using scaffold microchannels., 2nd Conference on Foundations of Systems Biology in Engineering, Pages: 337-342

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Galvanin F, Macchietto S, Bezzo F, 2007, Model-based design of parallel experiments, INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, Vol: 46, Pages: 871-882, ISSN: 0888-5885

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• Citations: 67

Franceschini G, Macchietto S, 2007, Validation of a model for biodiesel production through model-based experiment design, INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, Vol: 46, Pages: 220-232, ISSN: 0888-5885

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• Citations: 40

Coletti F, Macchietto S, 2007, Simple 3D Vascularization Models For Perfusion Bioreactors, 10th Symposium on Computer Applications in Biotechnology

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Coletti F, Macchietto S, 2007, A design method for improving oxygenation in perfusion bioreactors using scaffold microchannels, Stuttgart, FOSBE 2007, 2nd Conference on Foundations of Systems Biology in Engineering, Publisher: Fraunhofer IRB Verlag, Pages: 337-342

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Galvanin F, Macchietto S, Bezzo F, 2007, Model-based design of parallel experiments in dynamic systems, I&EC Research, Vol: 46, Pages: 871-882

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Coletti F, Macchietto S, Elvassore N, 2006, Mathematical modeling of three-dimensional cell cultures in perfusion bioreactors, INDUSTRIAL & ENGINEERING CHEMISTRY RESEARCH, Vol: 45, Pages: 8158-8169, ISSN: 0888-5885

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• Citations: 72

Coletti F, Macchietto S, Elvassore N, 2006, Mathematical modeling of three-dimensional cell cultures in perfusion bioreactors – Part II, Amsterdam, 16th European Symposium on Computer Aided Process Engineering and 9th International Symposium on Process Systems Engineering, Publisher: Elsevier, Computer-Aided Chemical Engineering Series, 21B, Pages: 1699-1704

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Coletti F, Macchietto S, 2006, Cells Culture in Perfusion Bioreactors: Analysis and Selection of Scaffold Channelling Structure Based on Reynolds and Peclet Numbers, Publisher: American Institute of Chemical Engineers, Pages: 54-54

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Galvanin F, Barolo M, Bezzo F, Macchietto Set al., 2006, A Framework for Model-based Design of Parallel Experiments in Dynamic Systems, Amsterdam, 16th European Symposium on Computer Aided Process Engineering and 9th International Symposium on Process Systems Engineering, Publisher: Elsevier, Computer-Aided Chemical Engineering Series, 21A, Pages: 249-254

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Franceschini G, Macchietto S, 2005, Validation of a model for a biodiesel production process through model-based experiment design for parameter precision, Pages: 6116-6141

Advanced model-based experiment design techniques are a reliable tool for rapid development, refining and validation of process models. When dealing with complex reaction networks, the current techniques show convergence problems if one tries to plan a set of experiments for the estimation of all the parameters. In a previous work (Franceschini & Macchietto 2005), a methodology to overcome this problem had been proposed and described through the application to a case study (a biodiesel production process). The aim of this paper is to present the results of the parameter estimation, which was carried out using the data collected under the optimally designed experimental conditions. In the light of these results, the procedure proposed for the experiment design will be assessed in term of advantages and limitations, and possible solutions to overcome the problems will be mentioned. Regarding the case study, the model was almost completely validated in just one iteration of the experiment design procedure and was then used for an optimisation study, the results of which will be presented here in order to identify the effect of the most important operating variables on the process yield.

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