Leveraging Aspen HYSYS

Simulation to Develop
Confident and Capable
Operators
DATE
CONFIDENTIAL
 Introduction and Background
• Ascensus Specialties started producing liquid Sodium Borohydride in Elma, WA in

1976. The site expanded in 1995 to add a dry Sodium Borohydride plant. It has grown

to be a global supplier, servicing over 25 countries worldwide. Liquid and Dry Sodium

Borohydride is used in a variety of applications including: pulp and paper, refineries,

textiles, pharmaceuticals, and even in the production of beer.

• The onsite hydrogen plant is a key piece in the Sodium Borohydride process.

Hydrogen gas is made using a steam/methane reformation process.

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 Challenges Faced
• Aging workforce retiring, gap forming to less • Infrequent hydrogen plant shutdowns
experienced operators. limited exposure for operator training

• Lacked tools to get new

operators' exposure without
hands-on time
• How to communicate
or document tacit
knowledge?
• Lengthy startups/shutdowns
that span multiple shifts.

• High cost of overtime when having to

schedule extra staff for planned
startups/shutdowns.
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 Simulation Based Training

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Why HYSYS?
• Rigorous and dynamic modeling capabilities

• Used by engineering team in-house

• Realistic training scenarios

• Support and community

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 Ascensus’
Inprocess
Operational
Expertise
Insights

Collaboration with Inprocess

• Historical plant data
• Operational experience
• Core business of process simulation
• >90 OTS projects executed
• Tailored training scenarios and malfunctions

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Overview of Model Development
and OTS

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 OTS Architecture

• IIS: Inprocess Infrastructure Suite

• ITOP: Inprocess Training for Operators
• ICOM: Inprocess Competency Management tool

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Communication Layers Inprocess Infrastructure Suite DeltaV SimulatePro

Aspen HYSYS Dynamics

© Inprocess
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General Plant Overview from Operator Station

© AInprocess
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Compression Section (plant inlet)

© Inprocess
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 Steam circuit

© Inprocess
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PSA

© Inprocess
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Instructor screens and functionalities Actual on-site panel functionalities

Key Performance Indicators (KPI) for training

© Inprocess
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Malfunctions Real Face plate functionalities

Plot tools

© Inprocess
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Keys areas and features implemented

Complex Model: chemical reactions and the compositionchange to be captured.

Model tuning to capture plant behavior not easy: small plant → less dampening of process upsets or
environmental factors.

The model isn’t straightforward due to the Pressure Swing Adsorption (PSA) process sequences and recycle
stream.

The PSA process in the model is set up to mirror the different cycle times that occur in the actual plant
operation.

Additional fine-tuning is required to simulate the reactors accurately under low flow conditions, the model was
customized with additional calculation blocks.

Malfunctions and scenarios to be built ad hoc to correctly reproduce actual dynamics and because non
standard blocks plus side calculations are introduced in the model.

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Training Structure

Startup/Shutdown Scenarios Malfunctions

• Two types of startup can be • Able to simulate rate • Indication of high oxygen in
practiced using the OTS – change for downstream reformer
cold startup and hot restart. user.
• A cold startup typically • Loss of cooling water to hydrogen
only happens once or plant.
twice per year.
• Advanced decision making
• A hot restart is typically without procedures
caused by a power
interruption.

• A full shutdown of the

hydrogen plant typically
happens once or twice per
year.

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Real-Life Facts: OTS in Action

An operator, new to gas compressor An operator in training used the OTS to

switching, first practices on the OTS, then practice resetting an induced draft fan and
successfully executes the task in the plant lighting the pilot flame, as well as the
without issues. procedure for restarting the hydrogen plant
after a shutdown. The following night, a power
outage occurred, and this operator successfully
applied these exact procedures in the real
plant, efficiently managing the unexpected
shutdown.
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Ongoing Applications

Maintaining Competency Immediate Response Drills Validating assumptions during PHA

• Already certified hydrogen • High temperature shutdown • What would happen if we opened
operators have used the in the reformer. this valve – consequences
OTS to refresh their memory evaluated.
on startup and shutdown
activities. • This is the only area we
can get hands on practice
• The OTS has the ability without causing a process
to simulate a PSA valve upset.
leak. We have used this
to practice
troubleshooting this
section of the hydrogen
plant.

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Benefits
• Reduced annual overtime spend by $60-90K
• Reduced startup time by 12 hours
• Estimated 50% reduction in time required for
operator competency development
• Updated and improved operator procedures
based on OTS learnings I sleep better at night with more capable operators
thanks to the OTS.
• New operators comfortable bringing
hydrogen plant up solo mid-shift after - Jared Fraisure – Site Director
practicing on OTS
• More capable and confident operators Overall, the OTS has been instrumental in bridging the experience gap from
which drives safety, reliability and quality an aging workforce, accelerating skill development, reducing overtime costs,
improvements and increasing site leadership's confidence in the competency of the
operations team.

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Ascensus OTS Operator Survey Feedback
Enhanced Safety Operations: 100% reported increased ability to operate the plant safely.

Stability in Operations: 90% reported enhanced plant operations.

Informed Decision-Making: 80% got a deeper understanding of their operational decisions' impacts.

Preparedness for Upsets: 70% feel more equipped to handle unexpected operational upsets.

Overall Operator Improvement: 100% believe they have become better operators.

"It will allow new hydrogen operators to be more efficient over a shorter time. Some operators go years without experiencing startups and
shutdowns, and with this simulator you can go in any time and get that experience.”

"I am much more comfortable with interpretation of normal operations after using the simulator, like after power blips where we have to take
quick actions to get it up running again. “

“How did you ever certify an operator before the OTS??”

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Achieving a successful OTS deployment

• Ownership at site

• Operator buy-in – HYSYS based critical

• Collaboration and engagement

• Ongoing support

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Working
Together for
What Matters

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