process optimization using cape-open tools
TRANSCRIPT
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Co-LaN 2017
Process Optimization using CAPE-OPEN Tools
Ross Taylor, Harry Kooijman, and Jingsong Zhou
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Co-LaN 2017
Outline
Rating and Cost Estimation
Export to Column Vendor Tools
Faster Rate-Based Column Simulations
Iconography
Equation-Oriented (and Rate-Based) Parallel Column Model
Other Topics
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Column Rating and Cost Estimation in ChemSep
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Pointer hovers over column icon to display summary which includes cost estimates
Overlaid images not to same scale
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Column Rating and Cost Estimation in ChemSep
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Open ChemSep GUI to see new rating panel with cost estimation
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Column Rating and Cost Estimation in ChemSep
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Desire to compare process lineups on economic basis - Need for basic cost information in PME - Actual cost calculations performed in UO
Simple cost functions in ChemSep - Sum costs of vessel, internals, and heat exchangers - Add energy cost (but pumping costs ignored here) - To be documented
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Export to Vendor Tools
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Click on Vendor Tools Save file in desired format Open vendor tool
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Export to Vendor Tools
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KGTower from Koch Glitsch
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SulCol from Sulzer ChemTech
Export to Vendor Tools
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WinSorp from Raschig GmbH
New: Export to Vendor Tools
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Faster Rate-Based Models
Rate-based models inevitably slower than equilibrium stages - Actual number of stages (not some hypothetical lower number) - Flow models other than mixed require extensive matrix computations
New rate-calculation procedures speed up these models - Speed increase depends on number of components - Nearly 20 times faster for 50 stage debutanizer with 42 compounds
COSE compounds - Require frequent calls to PME for basic property information - ChemSep now writes same to local databank - Calculation time decrease when used with ChemSep thermo - Significant aid when troubleshooting – reduces need for PME
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Iconography
CAPE-OPEN icon in some PMEs do not adequately represent UO
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Icons not representative
Only one has a condenser
Only one has reboiler
Multiple products appear as one
Multiple feeds appear as one
Multiple ChemSep UOs in UNISIM Design
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Iconography
Adaptive icons in COCO - Reflect actual configuration - Automatically change when configuration changes
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ChemSep writes icon structure to sep file in COCO format
COCO reads sep file, checks if icon has been changed
If new icon, COCO asks to update icon
UO could write icon as SVG image
PME reads UO output, determines from checksum if icon changed
PME displays new icon
Iconography
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Is COCO the only PME that permits newly designed icons?
Dividing Wall Column (DWC) icons for COCO
Iconography
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Dejanović et al. Aromatics DWC
Dividing Wall Columns
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Dejanovic, I., Matijasevic, L., Jansen, H., & Olujic, Z. (2011). Designing a packed dividing wall column for an aromatics processing plant. Industrial & Engineering Chemistry Research, 50(9), 5680-5692.
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Co-LaN 2017
Dejanović et al. Aromatics DWC
Dividing Wall Columns
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Dejanovic, I., Matijasevic, L., Jansen, H., & Olujic, Z. (2011). Designing a packed dividing wall column for an aromatics processing plant. Industrial & Engineering Chemistry Research, 50(9), 5680-5692.
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Generally modeled as multi-column systems
Dividing Wall Columns
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Dejanović et al. Aromatics DWC Multi-column model
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Co-LaN 2017
Generally modeled as multi-column systems
Dividing Wall Columns
Generally modeled as multi-column systems
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Multi-column model in UNISIM Design
Dejanović et al. Aromatics DWC
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Dividing Wall Columns
Generally modeled as multi-column systems
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Dejanović et al. Aromatics DWC Multi-column model in COCO
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Dividing Wall Columns
Generally modeled as multi-column systems
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DWC icon hides subflowsheet Multi-column model in COCO
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Dividing Wall Columns
ChemSep Parallel Column Model (PCM)
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Equation-based ChemSep PCM Dejanović et al. Aromatics DWC
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Dividing Wall Columns
Dejanović et al. Aromatics DWC Modelled Using ChemSep PCM
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Dividing Wall Columns
Generally modeled as multi-column systems
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Satellite Column System
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Dividing Wall Columns
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Generally modeled as multi-column systems
Satellite Column System in COCO (easy to converge)
Satellite Column System
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Generally modeled as multi-column systems
Dividing Wall Columns
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Satellite Column System Satellite Column System in COCO (hard to converge)
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Dividing Wall Columns
Generally modeled as multi-column systems
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Satellite Column System in UNISIM Design
Satellite Column System
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Dividing Wall Columns
ChemSep Parallel Column Model (PCM)
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Equation-based ChemSep PCM (very easy to converge)
Satellite Column System
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Maldistribution Models
ChemSep PCM can be used to model maldistribution
Redistributors modeled as stages with no mass transfer
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Equivalent PCM Structure Billingham and Lockett Maldistribution Model
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Maldistribution Models
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Equivalent PCM Structure Schultes Maldistribution Model
ChemSep PCM can be used to model maldistribution
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ChemSep PCM can be used to model maldistribution
Maldistribution Models
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Significant influence of the number of redistributors
0.85
0.87
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0.99
0 0.1 0.2 0.3 0.4 0.5 0.6
Pro
duct
Purity
f
4 redistributors
2 redistributors
Top
Top
Bottom
Bottom
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Other Matters
Thermo 1.0 vs Thermo 1.1 - Some ChemSep users unable to use Thermo 1.1 - ChemSep NOT in favor of deprecating 1.0 while this state continues
Specific gravity at 60 F as property constant
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Conclusion
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New in ChemSep Version 7.2 - Fitting of Group Contribution Model (e.g. UNIFAC) Parameters - Rapid rating and costing - Export to column vendor tools
Faster rate-based simulation (much faster in some cases)
Wish List - Adaptable and editable icons in all but COCO (which already has them) - Pointing at a UO displays simulation summary for that UO (possible in COCO) - Do not deprecate Thermo 1.0 until all users can easily use Thermo 1.1 - Specific gravity at 60 F as property constant
Propose CAPE-OPEN Cost Library (COCL) of basic callable functions - Cost of metal - Cost of steam at different levels - Cost of pressure vessel - M+S index + Energy cost functions imply currency (basis should be US dollar)
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Co-LaN 2017
Parallel Column Model - Dividing Wall Columns, Maldistribution, Multi-column Systems
Coming Soon to ChemSep Version 8
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Multiple column model in COCO One equation-based model ChemSep Version 8