introduction of process modelling and simulation of batch process ptt 303/2 process modelling and...
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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