Introduction to SuperPro Designer for

Batch Processing Modelling

Session outline Getting started SuperPro Designer (SPD) interface Flowsheet drawing and editing Unit procedures initialisation Simulation execution & result checking

Getting started

Process Operation Mode

Process operation mode :

BATCH

vs

CONTINUOUS

Default annual operating time

SuperPro Designer Interface

Maximise the flowsheet

SuperPro Designer Interface

Horizontal drawing size : 2 pages

Some common icons

Start a new worksheet

Open an existing worksheet

Cut / Copy / Paste

Select mode

Connect mode-stream connection

Toolbar for drawing

Solve-Run the simulation

Main unit procedure in SPD Vessel Procedure

Reactor

Seed Reactor

Fermentor

Seed Fermentor

Air-lift Fermentor

Continuous Reaction (Stoichiometric, kinetic, equilibrium)

CSTR

PFR

Fermentor

Seed Fermentor

Environmental (aerobic,

anaerobic, UV radiation)

Filtration

Microfiltration

Ultrafiltration

RO

Diafiltration

Baghouse

Air Filtration

Plate & Frame

Rotary vacuum

Distillation

Flash

Batch

Continuous

Extraction Distillation

Mixer-Settler

Differential

Centrifugal

Absorption

Homogenization

High pressure

Bead milling

Nano milling

Sedimentation

Decanting

Clarification

Thickening

Oil Separation

Flotation

Unit Procedure in SPD

Biochemical case studyBiochemical case study

Component registration View component properties

Biochemical Case Study

Case Study 1

A batch reactor is utilised to produce component C from reactant A and B:

Component C is later separated from A and B by a batch plate &frame filter

Solvent used : Heptane (soluble for A and B but insoluble for C)

Task to be performed : Mass and energy balances Process Scheduling

A + B C

Component registration

Component Database

Nitrogen, N2 Default

Oxygen, O2 Default

Water, H2O Default

Heptane, C7H16 DesignerA New (user define)B New (user define)C New (used define)

Component registration

Databanks in SuperPro

Default component

Component registration

Newly added

Referencecomponent

View component properties

Editing component properties

Component MW Price Value ($/kg)

A 150 Purchase 10

B 25 Purchase 15

C 175 Selling 200

Let’s do changes before we proceed

Time to save your work

Reminder…Reminder…

Always remember to save your work!

Flowsheet drawing and editing

Locating the unit procedures

Stream connection

Editing the flowsheet

Unit Procedures

Looking for help (F1)

Unit Procedures

Adding a process stream

Single click

Connect-modeStream connection

Select mode

(tip: Press ESC button to terminate the stream drawing)

Deleting a stream

Single left click on the stream/unit (turn into read) & press DELETE (on keyboard)

Make sure the cursor is in “Select Mode” (ESC button)

Completing the flowsheetCompleting the flowsheet

Single click

Single click

Double click

Let’s draw our flowsheet Let’s draw our flowsheet before we proceed further……before we proceed further……

Editing a stream elbow

Make sure the cursor is in “Select Mode” (Esc button)

Stream elbow

Make sure the cursor is in “Select Mode” (ESC button)

Editing tag name of the streamEditing tag name of the stream

Changing the Stream ID

Stream ID Change ID to S-101 HeptaneS-102 AS-103 BS-104 EmissionS-105 Rxt outS-106 Wash inS-107 CS-108 B+ HeptaneS-109 Wash out

Let’s do changes before we proceed

Editing the style of a stream

Change Stream thickness: 2ptChange stream colour: brown

Changing the stream title and style

Stream Colour Thickness

Heptane Brown 2 pointsA Brown 2 pointsB Brown 2 pointsEmission Green 1 pointsRxt out Brown 2 pointsWash in Blue 1 pointsC Brown 2 pointsB + Heptane Brown 2 pontsWash out Blue 1 points

(Q: is there a faster way to do so?)

Same style

Pickup style from “Heptane”

Apply style to another streamApply style to another stream

Press Ctrl button to select multiple streams

Complete the style editing for Complete the style editing for the rest of the streams…the rest of the streams…

Editing the style of the iconEditing the style of the icon

Apply the same pick-up & apply to change the style of the filter

Icon colour : blueDescription tag text;Font 10, bold, maroon

Adding a title to the case study

Text modeThis is too small

Change your font here

Save your work

Save file (s)

Initialising a Unit ProcedureInitialising a Unit Procedure

What a Unit Procedure? Initialising an Operation

What is a Unit Procedure?What is a Unit Procedure?

In the batch modeling mode, a Unit Procedure may consists of various Operations:

Reactor procedure: feed charge, reaction, product withdraw, etc

Filtration procedure: filtration, cake wash, CIP, etc

In continuous modeling mode, a Unit Procedure= Unit Operation

Hierarchy in batch modelingHierarchy in batch modeling

Operation(s) level

Procedure(s) level

Entire plant

The same for continuous process modeling

Function of each unit procedureFunction of each unit procedureVessel Procedure (P-1):Acts as a batch reactor to carry out reaction: A + B CHeptane is used to dissolve components A & B, to aid separation in P-2Plate and Frame Filtration (P-2):Component C is not dissolved in heptane, hence is filtered out by the filter clothHeptane is used to wash out the trapped heptane ( and also the dissolved A & B) from the filter cake

Stream specificationStream specification

Click to insert Heptane here

Heptane flow =800 kg/batch

Ingredient flow

T, P = default

Set spec for Stream A & BSet spec for Stream A & B

Stream ID ComponentAmount

(kg/batch)Temperature

Pressure

Heptane

A

B

Heptane

A

B

800

50

40Default

Working sessionDo not forget to save your work !!!

A question to ponder…A question to ponder…

Q: Why do we only specify the inlet stream?

Sequential modular approach Sequential modular approach

Individual equipment blocks may require iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

Adding operations to P-1Adding operations to P-1

3 Charge operation (to charge A, B and heptane respectively)1 React (Stoichiometric) operation (for reaction to be carried out)1 Transfer Out operation (to deliver product to next unit)

Adding operations to P-1Adding operations to P-1

Add new operation before the currently selected operation

Add new operation at the end of the list

Initialising operations in P-1Initialising operations in P-1

Initialising CHARGE-1Initialising CHARGE-1

Vol. flowrate=100 L/min

Setup time = 5 min

800 kg heptane

Emission calculation(next slide…)

Emission calculationEmission calculation

Click to perform emission calculation

OK, next operation (CHARGE-2)

OK, previous Operation (none)

Previous operation (same tab –none)

Next operation (same tab)

Go to selected operation

Initialising CHARGE operationInitialising CHARGE operationOperation Operating condition Emission

CHARGE-1 Charge 800kg/batch of heptane using stream “Heptane”Setup time= 5 minProcess time : 100L/min

Perform heptane emission on this stream

CHARGE-2 Charge 50 kg/batch of A (limiting component) using Stream “A”Setup time = 5minProcess time: calculated based on 20 kg/min

Nil

CHARGE-3 Charge 40/kg batch of B using Stream “B” (B is in excess)Setup time = 5 minProcess time : calculated based on 20 kg/min

Please complete the initialisation of CHARGE-2 & CHARGE-3

Initialising REACT-1 & TRANSFER-OUT-1

Operation Operating condition Volumes Reaction

REACT-1 Final temp = 50 °CHeat transfer agent:

steamProcess time = 6 hourLeave other values as

defaults

Max Allowable working/ vessel

volume: 80 %

Extent of reaction = 95 %

Reaction stoichiometry

A + B C

TRANSFER-OUT-1

Using stream “Rxt out”

Duration: same as Cloth Filtration in P-2 (using

Master-Slave Relationship)

Nil

Initilising REACT-1 in P-1Initilising REACT-1 in P-1

SteamProcess time

= 6 h

Final temp = 50 °C

Max allowable volume = 80 %

Initialising REACT-1 in P-1Initialising REACT-1 in P-1

Reaction extent = 95 %

Edit reaction stoichiometry

Rename reaction

Add reaction(s)

Delete stoichiometry (when needed)

Molar stoichiometry

OK, next operation (Transfer-out)

Transfer out stream

Click here to selectMaster-and-Slave to calculate duration

To quit Vessel Procedure

Select the MasterProcedure

Select the Master Operation in

Master Procedure

Initialising Transfer OutInitialising Transfer Out

Master-Slave RelationshipMaster-Slave Relationship

Slave

Master

Master operation – processing step that control the duration of another operation (slave)When simulation is executed, duration calculation for the slave operation will be bypassed (note: M&E balances affected), until the master operation is metBoth master and slave operation may exist in the same procedure or in another procedure

Working sessionLet’s try before we proceed further…

Initialising operation for P-2Initialising operation for P-2

Cloth Filtration operation (by default, to filter product C)

Cake Wash operation (to wash out left over trapped A & B in filter cake)

Transfer Out operation (to deliver product)

Adding operations to P-2Adding operations to P-2

Initialising operations for P-2Initialising operations for P-2

Initialising FILTER-1Initialising FILTER-1Operation Operating condition Scheduling

FILTER-1 Particulate component removal: 95% C (assuming that A & B are completely soluble in Heptane & C is virtually insoluble).LOD (loss on drying) = 35% (this value cause a portion of heptane & any soluble component to be held in the wet cake 65% is insoluble C).Filtrate stream: “B + Heptane”

By default, first operation of any batch unit procedure is scheduled to start at the beginning of the batchStart time: relative to the START of TRANSFER-OUT-1 operation in P-1 procedure

Initialising FILTER-1Initialising FILTER-1Scheduling

C = 95% removal

LOD = 35%

Filtrate

By default

Filtration will only start when product is

transferred out from P1

Initialising CAKE-WASH-1 & Initialising CAKE-WASH-1 & TRANSFER-OUT-1TRANSFER-OUT-1

Operation Operation condition

CAKE-WASH-1

Wash In stream: “Wash in”Wash Out stream: “Wash out”Wash solvent: heptane (click on “Composition”, select “Auto-adjust”, the program will estimate a value automatically)Wash time: 30 minutesWash type: slurry (Note: A “slurry” wash will essentially dilute the soluble components trapped in the cake and remove most of them in the wash stream, whereas a “displacement” wash will remove the soluble components form the cake in a plug-flow fashion.)

TRANSFER-OUT-1

Transfer out using stream “C”Duration: calculated based on 10kg/min

Working sessionWorking sessionRemember to save your file !

Simulating a flowsheetSimulating a flowsheetExecute the simulation

Viewing the results

Simulating a process:1. Menu bar: Task/ Solve M&E balances2. Press “Ctrl 3”3. Solve icon in menu bar4. Press “F9”

Result viewingResult viewing

1. Calculated output variables for each oeration can be viewed by revisiting the corresponding Operation Data dialog windows

2. To see the calculated equipment sizes, right click on the unit procedure icon & choose the Equipment Data… option

3. The contents of a piece of equipment as a function of time can be viewed by right clicking on a unit procedure and selecting Equipment Contents or Operation Sequence

4. The calculated flowrates and compositions of intermediate & output streams can be viewed by in the Simulation Data dialog windows of each stream

Result viewingResult viewing

5. A list of reports can be viewed in Reports: Stream Reports (SR) Economic Evaluation Report (EER) Itemized Cost Report (ICR) Cash Flow Report (CFR) Throughput Analysis Report (THR) Environmental Impact Assessment Report (EIR) Emission Reports (EMS) Input Data Report (EDR) Equipment Report (EQR)

Let’s visit the one by one…Let’s visit the one by one…

Equipment operation dataEquipment operation data

Calculated heptane emission: 0.028%

Equipment dataEquipment data

Calculated vessel volume: 1628 L

Equipment contentEquipment content

Stream simulation dataStream simulation data

Generating a stream reportGenerating a stream report

Check your scheduling resultsCheck your scheduling results

Reaction A B C

MW

Initial content, miO (kg)

Initial mol, niO (kg-mol)

X= 95% (based on A)

Current mol, n (kg-mol)

Current content, m (kg)

nAO-nAOX nBO-nBOX

-

-

nAOX

+

Check your scheduling resultCheck your scheduling result

Heptane charge =____kg/batch (stream specification)

Volumetric flowrate=___L/min (in Operation Data/CHARGE-1)

Task: Find out the density of the heptane stream

from your simulation sheet Verify the heptane charging duration

calculated by SPD heptane

Do not just take the computer’s word as it is, please check your results accordingly!!!

Remember the GIGO principle