A Simulation-Driven Digital Workflow Integrating Bayesian Optimization for Early-Stage Process Design: A Methyl Acetate Production Case Study

Abstract

Methyl acetate production via direct carbonylation of dimethyl ether and carbon monoxide involves strong nonlinear interactions among reactor operation, recycle structure, and energy consumption, making conventional simulation-based optimization computationally demanding. In this work, a data-driven framework integrating steady-state process simulation, surrogate modeling, and Bayesian optimization was developed for process intensification. A dataset of 2730 steady-state simulations was generated using a Python-based automated process simulation workflow and a structured design of experiments across the operating domain. Surrogate models were trained to predict carbon conversion yield (C-yield) and cost of specific energy consumption (C-SEC), with neural network-based models showing the best predictive performance and robustness. These models were integrated into a multi-objective Bayesian optimization framework to identify optimal operating regions. Results indicate that high C-yield (up to ~95%) can be achieved with reduced energy cost through lower recycle flow rates and compression demand. Pareto analysis revealed a nonlinear trade-off between C-yield and C-SEC, where further improvements near the conversion limit require disproportionately higher energy input. Validation against rigorous simulations showed deviations below 3% for C-yield and 10% for C-SEC.