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

arXiv:2611.03673v1 Announce Type: cross 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.