recycle loop design with pro/ii - wonderware...
TRANSCRIPT
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Mike Donahue
Technical Support
SimSci by Schneider Electric
Recycle Loop Design with PRO/II
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Agenda
●Recycle Background
●Process Simulation Background
●Recycle Convergence
●Recycle Convergence Strategy
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Recycle Background
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Recycle Definition
●A recycle stream is a term denoting a process stream that returns material or enthalpy from a downstream process unit back to an upstream process unit
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Recycle Loops
● Independent Loops
● Interconnected Loops
●Nested Loops
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Tear Stream Definition
●A tear stream is any stream that “opens” a loop. It is a stream that PRO/II will update until two consecutive iterations are within the specified tolerance
●A tear stream is not a recycle stream
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Tear Streams?
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
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One Option
Selecting the sequence = Selecting the tear streams
Tear streams Calculation sequence
R1, R2 U1, (U2, U3, U4, U5, U6), U7
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
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Minimum Tear Stream (MTS)
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
Tear streams Calculation sequence
S4 U1, (U4, U5, U6, U2, U3), U7
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^ Process Simulation Background
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Steady State Modular Approach
●Sequential-Modular
˃ Flowsheet is decomposed (sequenced)
˃ Calculations are performed one unit at a time
˃ Iterate tear streams
˃ Most commercial steady state simulators use a sequential approach
●Simultaneous-Modular
˃ Flowsheet is developed as a collection of sub-flowsheets (SFS)
˃ Each SFS and collection of streams are solved together
Steady State
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PRO/II is a Sequential Modular Simulator
●Recycles automatically handled
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Recycle Definition
● Intuitive
˃ Clear / understandable error messages
˃ Problems localized to individual unit operations / recycles
●Robust
˃ The resolution is divided-up into several subsets that are treated sequentially
˃ This facilitates rigorous convergence, even in presence of extremely complex modules that are treated in an autonomous way
●Good heuristics for initialization and convergence
˃ No over-specifications (inconsistencies)
˃ Recycles estimates not required
˃ Recycle blocks not required
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Sequential Solver Challenges
●The main challenge with a SMA
˃ Inefficient sequencing
˃ Inefficient recycles
●The combination of these issues lead to potentially long calculation times
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Sequential Modular Approach (SMA)
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Sequential Solvers
●Computation Time – Multiple passes are typically required to solve the flowsheet
~ 1,000
4 hours / 500
~ 30 seconds
~ 50% increase in speed
~ 500 increase in computing power
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Sequencing Challenges
●How many tear streams?
●What order should we converge the units (partitioning)?
●Convergence Method?
●Many publications address tear stream determination and partitioning:
Sargent and Westerberg 1964
Forder and Hutchison 1969
Barkley and Motard 1972
Motard and Westerberg 1979
Gunderson and Hertzberg 1982
Lakshminarayanan and Rao 1991
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PRO/II Sequencing Algorithms
●Minimum Tear Stream Algorithm (SimSci Method)
˃ Default
˃ Uses improved algorithms based on Motard and Westerberg
˃ Improved by SimSci
●Alternate Method (Process Method)
˃ Determines the sequence based partially on the input order
●Explicitly Defined by User
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PRO/II Sequencing Algorithms
● If there are no recycle streams in your flowsheet, the SimSci sequence algorithm will determine the correct calculation sequence automatically
● If the flowsheet has recycle streams:
˃ First, the sequence algorithm is driven by reducing the number of tear streams in your flowsheet
˃ Secondly, the sequence algorithm is driven by the recycle stream estimates provided by you
●We recommend that you always provide a recycle stream estimate for each recycle loop
●These estimates will cause the calculation sequence algorithm to select the recycle streams as tear streams
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PRO/II Sequencing Algorithms
●Controllers / Optimizers
˃ Single variable controllers which affect units within loops will be included in the loops
˃ Multi-variable controllers and optimizers will not be included in the affected loop
Be careful here – you may want to employ a user defined sequence
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PRO/II Sequencing Algorithms
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Recycle Convergence
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Convergence
●A flowsheet has converged when the stream values (material, temperature, and pressure) stop changing within the degree of tolerance for two successive loop iterations
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Convergence
●Default is to converge all streams in the loop
●Optionally can choose to converge only tear streams
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Tear Stream Identification
● Identify the tear streams
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Recycle Tolerance
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Tolerance
●Default Criteria
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All 3 must be met
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Acceleration Methods
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Acceleration Methods
●Direct-substitution
˃ Default method for recycle convergence in PRO/II. Last computed values for the tear streams are used for the next trial solution of the recycle loop.
˃ Generally stable
˃ Potentially slow
●Wegstein
˃ Provides rapid solution of recycles using an acceleration factor based on the convergence characteristics shown by previous iterations
˃ Note: This method does not work well when multiple recycle streams are interacting
●Broyden acceleration
˃ Based on the "Householder" method, which allows for rapid, stable solution of recycle loops
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Acceleration Methods
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User-Specified Recycle Loops
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Recycle Convergence Strategy
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Recycle Challenges
● In closed loops (no purge), the recycle stream has the potential to do one of two things:
a) Build up
b) Deplete to zero
Unless the makeup rate is exactly equal to consumption + the other losses
●Consumption is known (typically) – what are the other losses?
●Major Challenges:
˃ Losses from the recycle components are usually insensitive to the recycle amount
˃ Small variations in makeup result in large recycle changes
˃ A large number of iterations are required to adapt to a small change in makeup
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Recycle Strategy
Solution
1) Reference Stream to “Break the Recycle”
2) Use a Calculator / Controller / Splitter Specification
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Recycle Strategy
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Recycle Strategy
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Recycle Strategy
● Identify the tear streams
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Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
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Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
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Recycle Strategy
<
Unit Tolerances Recycle Tolerances
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Recycle Strategy
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Recycle Strategy
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Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
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Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
●Set appropriate tolerance (mass balance)
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Recycle Strategy
Iterations vs. Tolerance Recycle Methane
Simulation time for 318 iterations – 38 seconds
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Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
●Set appropriate tolerance (mass balance)
●Use acceleration
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Acceleration Methods
●Minimize controllers (recycle streams) with stream splitters
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
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Recycle Strategy
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
●When using Controllers (use control)
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Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
●When using Controllers (use control)
●Use reference streams to redefine the tearing process and eliminate thermal recycles
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Recycle Strategy
●Try not to spend too much effort (time) initially designing recycle loops
●PRO/II is extremely robust at solving complex loops (out-of-the-box)
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