Module 4 Structure of Process Simulator Week 11
Module 4 Structure of Process Simulator Week 11
Module 4:
Computer Aided Solution of the Process Flow-sheet
1
Structure of a
Chemical Process Simulator
Role of Process Simulation
What is Simulation?
E-2 Separator
E-3 Pump
E-1 Reactor
N4 (mol/s)
0.9 (mol A /mol)
0.10 (mol B/mol)
85°C
E-2 Separator
E-3 Pump
E-1 Reactor
N4 (mol/s)
0.9 (mol A /mol)
0.10 (mol B/mol)
85°C
• Unit operations
– Mixing point:
• 4 unknowns (Na1, Nb1, N4, T1); 3 eq. (2 mat. Ba., 1 en. Bal.) 1 local d.o.f.
– Reactor
• 7 unknowns (Na1, Nb1, Na2, Nb2, Nc2, T1, Qr); 4 eq. (2 atomic species balances, 1 en.bal, 1 conv. spec.) 3
local d.g.f.
– Separator
• 8 unknowns (Na2, Nb2, Nc2, Na3, Nb3, Nc3, N4, Qs); 5 eq. (3 mat. bal., 1 en. Bal., 1 split spec.) 3 local
d.g.f.
• Overall process
– 7 local d.g.f. (1+3+3); 7 ties (Na1, Nb1, Na2, Nb2, Nc2, N4, T1 counted twice) 0 d.g.f.
Cyclic Process –
Degree of freedom analysis
Na2 (mol A/s)
Nb2 (mol B/s)
Na1 (mol A/s) Na3 (mol A/s)
Nc2 (mol C/s)
P-1 Nb1 (mol B/s) Nb3 (mol B/s)
100 mol A/s
Nc3 (mol C/s)
20 °C 90 °C
T1 °C
30 °C
E-2 Separator
E-3 Pump
E-1 Reactor
N4 (mol/s)
0.9 (mol A /mol)
0.10 (mol B/mol)
85°C
• MS EXCEL solution
– Initial estimate of the recycle set to 100 mol/s and assumed value of mixing point
temperature of 50°C.
– The value of N4a is varied until the calculated recycle flow rate (N4c) equals the
assumed value of N4a that drives the value of (N4a-N4c) to zero.
– Once the flow rates are correct, the mixing point temperature will be varied to
determine the values that drives DH =0 for the adiabatic mixer
• Process simulator solution
Spreadsheets: very tempting
but be careful!
• Hidden equations?
• Range checking?
• Hidden/implicit defaults?
• Thermo physical properties?
• Do you REALLY know what it does?
• Has it really been validated on YOUR kind of
problem?
• Has it been properly documented?
Design & analysis through process
simulation/optimization
Divider
Develop
process
model
Define
Problem Divider
Collect
additional
Separator data
Mixer Reactor
Analyze
results Chemical Plant
Solve model
equations
Steady state simulation - solve
algebraic equations
Develop
process
model
h(x, y) = 0
Define
Problem
Divider
Collect
additional
Mixer Reactor Separator data
Analyze
results
Chemical Plant
Solve model
equations -
AE solver
Process optimization - minimize
function s.t. constraints
Develop
process
model
h(x, y) = 0
Define
Problem Divider
Collect
additional
Mixer Reactor Separator data
Analyze
results Chemical Plant
Solve model
Min (x, y)
equations -AE
solver + NLP s.t g(x, y) 0
method h1 (x,y) = 0
Dynamic simulation - solve ordinary
differential equations
dx/dt = f(x,y)
Develop
process
model
h(x, y) = 0
Define
Problem Divider
Collect
additional
Mixer Reactor Separator data
Analyze
results Chemical Plant
Solve model
equations -
DAE solver
Problem Definition -
What information do we need?
Divider
Equipment
Mixture Unit Process Known data
compounds operations flowsheet data
Operating
data
Problem Definition -
What do we need to select (from a
simulator)?
Divider
Thermo-
Mixture Unit Process Library models
compounds operations flowsheet
Method of
solution
Some Definitions
• .......
The fundamentals
– Dynamic simulation
• Sequential Modular
• Equation Solving (Simultaneous nonmodular)
• Simultaneous Modular
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Numerical strategies
• Equation oriented strategy - simultaneous solution
– Write down the entire set of equation
– Identify the constraints
– Solve the non linear system
• Method of solution
– Newton Raphson
– Secant
• Tearing = selecting certain output variables from a set of equations
as known values so that the remaining variables can be solved by
serial substitution
Iterate flowsheet
repeatedly until
streams r1 and
r2 are within a
prescribed
tolerance.
Sequential modular approach
• Most common approach
Plant Retrofits
Process
Synthesis
Process simulation
Dynamic simulation
Economic evaluation for training
Design estimation
Process Simulation
• Evaluate Ideas Operating Plant
Steady state, • Existing Performance
Dynamics
Process Synthesis
Propose process • Generate Ideas Set
configuration Pinch technology objective
& design Train of columns targets
• Training
– Material and energy balances
– Basic course on process simulation
– Thermodynamic, phase equlibria and model selection
– Specific topics in thermophysical property calculation
• Electrolytes
• Polymer systems
• Kinetic data and kinetic modeling
– Specific topics in unit operation modeling
• heat exchangers design
• Batch distillation and reaction
• heat integration
– Process dynamics and control and dynamic process simulation
– Economic factors, cost analysis and energy consumption
– Batch process modelling
– Environmental impact and environmental evaluation
– Control system
… Process Simulation: the procedure…
• Run the base case
– The base case is a complete representation of the plant (or
part of the plant) in which the goals are
• the closure of the degree of freedom analysis
• the convergence of all the variables
– The base case may not correspond to the goals to be
achieved
– The base case is the starting point of ‘what if analysis’
– The base case is the validation procedure for
thermodynamic models and for data used
– The base case is the validation for the unit operation models
used in terms of:
• Reliability
• Convergence and numerical methods
• Completeness of the results
– The base case is the validation for the reaction modeling
and for the kinetic assumption
… Process Simulation: the procedure…
• Fine tune the base case by adjusting
– Thermodynamic models and parameters (thermodynamic
analysis)
– Kinetic models
– Lumping of components
• Assign Design Specification to each block
– Assign internal design specification which involves variables and
equation of specific blocks, such as solvent recovery, outlet
temperature, number of stages, reflux ratio,…
– The simulator will close again the degree of freedom analysis by
considering the new design specification
– The simulator will solve the unit operation by varying an
indicated variable so that the design specification is met
– Different way of performing such task in different process
simulators
… Process Simulation: the procedure…
• Sensitivity Analysis ….
– identify key sensitivities & their engineering consequences
(efficiency vs. structure)
– focus on what really matters (ie. what has a serious effect)
– allocate design margins accordingly
… Process simulation; the procedure…
• Design specification for the entire process
– Is the natural result of a correct sensitivity analysis
– Allows to define a given process condition by modifying
a variable in any part of the process
– IS a one – to – one relationship between specification
and variable
• Case Studies
– Run the simulation with different operating condition
– Different from the sensitivity analysis
– The simulation converges completely for each process
condition
… Process Simulation: the procedure.
• Optimization
– Is the procedure that allow to find the best conditions in
terms of a well defined objective function
– The objective function may be:
• Energy consumption
• Operating cost
• Equipment cost
• Environmental impact
• ….
– The number of variables is more than one
– Points of attention:
• Multiple minimum
• Feasible and non-feasible path
• Numerical convergence
Process simulation: the recipe.
• Design the flow sheet connectivity
• Components definition
• Physical - Chemical properties definition
• Feed conditions definition
• Unit operation internal definitions for each unit
operation involved in the process
• Process specification definition (design specifications)
• Analysis tools
– Sensitivity analysis
– Case studies
– Optimization
• Cost analysis and evaluation
Structure of a Process Simulator
Results obtainable
Verification of the process operating conditions
Information on intermediate streams (not measured)
Enthalpy balances information
Verification of the plant specifications
Validation of phase equilibrium models for the real system to
be used in similar conditions
Influence of the operative parameters on the process
specifications
Process De-bottlenecking for each individual section
A priori Identification of process control strategies and tuning
of instrumentation
Possibility to verify security systems behavior for variation of
process condition
Problems involved
• Availability of all the required thermodynamic properties of the
pure components involved
• Definition of an accurate thermodynamic model (Equations of
state or Excess Gibbs energy model) for binary and multi-
component mixtures
• Availability of all the necessary interaction parameters
• Availability of all the necessary unit operations modules
• Necessity of defining dummy operations, non always easy to
identify
• Tear streams identification to achieve rapid convergence if in
presence of recycles
• Necessity of defining user models and user thermo (In C++,
FTN or VB - VBA)
Conclusions
• Process simulation is a powerful methodology for
– Material and energy balances in steady state conditions
– Material and energy balances in dynamic condition
– Investigation of process dynamics and batch process
– Implementation of a control strategy
• Sensitivity analysis
– “Pre-flight drill”!
Industrial Processes are complex