Introduction of Process Modelling and Simulation of Batch Process

PTT 303/2 PROCESS MODELLING AND SIMULATIONSEM 1 (2013/2014)

Subject covered

Modeling and optimization of batch and

continuous processes

Batch Process Scheduling

Resources and inventory tracking

Cost analysis & project economic evaluation

Throughput Analysis & Debottlenecking

What is “Process Simulation”?

Q: What does the word “simulate” mean?

Building a process model Predicting how a process would actually behave Performing an experiment (on computer)

Incentives: Highly cost effective Reasonably accurate Proactive approach

Sequential modular approach Individual equipment blocks may require

iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

Sequential modular approach

Objectives of simulation

ProcessThroughput

BatchSize / Batch

Cycle Time

• Raw Materials• Labor• Utilities• Capital Expenses

Product(s)

Waste

Commercial process simulators

Oil, Gas &Petrochemicals

Oleo Chemicals

Specialty Chemicals

Aspen Plus

HYSYS

Provision

Design II

SuperPro

SS Simulation

Dynamic Simulation

Batch

Solids

Pinch

Phys Prop

Sizing & Costing

Economics

Rating

Sensitivity Analysis

Optimization

SuperPro Designer (SPD)

Water PurificationWastewater TreatmentAir Pollution Control

BioPro Designer

SuperPro Designer

BatchPro Designer

EnviroPro Designer

BiotechnologyBio-Fuels

Fine ChemicalsPharmaceuticalsFood ProcessingMineral Processing

SchedulePro Scheduling and Debottlenecking of Multi-Product Facilities

Available tools

• Intuitive user interface

• Wide variety of unit operation models

• Databases for components and mixtures

• M&E Balances of Integrated Processes

• Equipment Sizing and Costing

• Project Economic Evaluation

• Process Scheduling & Cycle Time Analysis

• Throughput Analysis & Debottlenecking

• Environmental Impact

• Detailed Reports and Charts for the Above

User Interface of SuperPro Designer

Double-Click

Detailed Modeling using Unit Procedures and Operations

Operations Gantt Chart

Equipment Occupancy Chart

• How can I schedule production during the next 6-18 months?

• How can I schedule operations in an R&D facility?

• How to adjust scheduling if priorities change?

• Can I fit a new product into my facility?

Scheduling Questions

Resource Demand Chart

Labor Demand Chart

Raw Materials

Equipment

Labor

Consumables

Lab/QC/QA

Waste Trtm/Disp

Utilities

Cost Breakdown

Raw materials$0.88/g39.6%

Facility$0.54/g24.4%

Consumables$0.65/g29.1%

• What is the required capital investment for a new

plant?

• How much would it cost to make a kilo of product?

• Which process is better for making this product? A or

B?

• How can I reduce the operating cost of a process?

Cost Analysis Questions

Stream Dialog – Env. Properties Tab

INTELLIGEN, INC.

Environmental Impact Report

Bottleneck identification

• How much product can I make in this plant?

• What limits the current production level?

• What is the capital investment for increasing production?

Debottlenecking Questions

Course overview• Lab 1

Overview of process simulationFlowsheet development

• Lab 2 Unit procedures initialisation

• Lab 3Process schedulingResource & inventory tracking

• Lab 4Equipment ratingProject economic evaluation

• Lab 5 – Biochemical case study• Lab 6 – Throughput analysis & debottlenecking strategies