Scribd
Upload
122 views

Process Simulation Essentials

This presentation discusses how process simulators are used to model chemical processes. It covers how simulators perform heat and mass balances, use property databases and thermodynamic models, and allow modeling of unit operations. Engineers use simulators to model existing facilities, optimize processes, study different conditions, and connect to control systems. The presentation emphasizes best practices like using accurate property data, validating thermodynamic models, building models incrementally, and handling recycles carefully. Common mistakes discussed include inaccurate plant data, treating simulators like games, lacking process understanding, and neglecting engineering judgment.

Uploaded by

aalbuhse
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
122 views

Process Simulation Essentials

This presentation discusses how process simulators are used to model chemical processes. It covers how simulators perform heat and mass balances, use property databases and thermodynamic models, and allow modeling of unit operations. Engineers use simulators to model existing facilities, optimize processes, study different conditions, and connect to control systems. The presentation emphasizes best practices like using accurate property data, validating thermodynamic models, building models incrementally, and handling recycles carefully. Common mistakes discussed include inaccurate plant data, treating simulators like games, lacking process understanding, and neglecting engineering judgment.

Uploaded by

aalbuhse
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 26

Process Simulation

Essentials

www.chemstations.c
om

How can we help more?


If there are additional topics within the presentation
slide deck or the simulation examples that you
would like to see addressed, let us know.

If you would like to share any materials you have


with other professors, Chemstations can either be a
reference or a repository.

What are we going to cover today?


What does a process simulator do?
Best Practices
Common Mistakes

What does a process simulator do?


Heat and mass balances around unit
operations & whole processes
Calculation of what happens with vapor,
liquid, solid in unit operations cooling,
heating, separating or changing phase

Mass & Energy Balance

What does a process simulator do?


Heat and mass balances around unit
operations & whole processes
Calculation of what happens with vapor,
liquid, solid in unit operations cooling,
heating, separating or changing phase
Have databanks of
physical properties of chemicals
thermodynamic models for vapor-liquid
equilibria
mathematical models for common unit
operations

Databank, Equations, Unit Ops

What do engineers do with process


simulators?
Model existing facilities
Parts or whole plants
Troubleshoot issues
Optimize energy/material use & costs
Increase throughput
Study what happens if conditions are
different

Connect to control system for


monitoring / control
Design new facilities

Best Practices
Start with good physical property
data
Choose & validate your
thermodynamic model
Build model one step at a time
Handle recycles with care

Start with good physical property


data
Which heat capacity curve is correct?
Heat capacity: experimental vs predicted
55
50

Cp (Btu / lbmol*dF)

45
40

CP A
CP B

35
30
25
20
0

20

40

60

80

Temperature (dF)

100

120

140

How to determine if properties are


good

Operational data is great


Pilot plant data is good
Lab data is ok
Literature data is sometimes
not bad
Predicted data isbrave

Learn how to choose


thermodynamics

How do you choose your thermo


model?

Experience with thermo is


necessary
Articles / books can teach you
basics
Compare to data for
important systems

Validate your thermodynamic model


Inspect TPxy diagrams
Run some flash calculations &
inspect results
Have a qualitative idea of what
the phase separation will look
like

Learn how to read Txy, Pxy, Txx, xy


diagrams

One step at a time!

Start simple

Add piece-by-piece & converge at


each step

Handle recycles with care

Calculations get more complicated

Put in a good initial estimate


Specify this flow rate to stabilize calculations!

Let the simulator calculate this flowrate

Start off with loop open to get


estimate

Common Mistakes
Matching plant data
How accurate are the measuring
devices? Last calibrated?
Were all measurements taken at same
steady state conditions?
Are you ignoring trace chemicals?
Neglecting to examine different
conditions (cooling water can average
90F in Houston summer)

Other Common Mistakes


Simulators get played like a video game
Converged doesnt mean correct

Understand your process before modeling


If you dont know what youre doing, youll
get the wrong answer

These are tools; you are the engineer


Garbage in = garbage out
Use engineering judgment, not necessarily
default options

Takeaways from today


Process simulators are powerful tools
to help make it easier to solve a wide
range of engineering problems
You will encounter these tools when
you graduate & should get familiar
with them
Like any tool, its important to know
how to properly use it to get the best
results

Learn more!

Use a simulator to revisit homework problems!


Find a mentor! Find examples!
Learn Tpxy plotsapplied thermodynamics
Read a book!
Edwards, _Chemical Engineering in Practice_,
kindle edition.
Seider, Lewin, _Product and Process Design
Principles_
Kaes, _Refinery Process Modeling_

Read a magazine article!

You might also like