Process Design and Simulation

Transcription

1 Process Design and Simulation B E-100 HEATX 3 B B4 B3 8 7 V B6 13 COND E-101 E V V E V STEAM 6 B

2 Introduction Process Design and Simulation 2

3 Our Team Dr. Ing. Naveed Ramzan Professor Department of Chemical Engineering University of Engineering and Technology Lahore (54890) Pakistan. BSc Chemical Engineering (Pak) MSc Chemical Engineering(Pak) PhD in Chemical Engineering ( Chair of Plant Design and Safety Technology, BTU Germany) NEBOSH Approved Tutor OHSAS 18001:2007 Lead Auditor (IRCA UK) Resource Person CPD Training for PEC Resource Person PDC, UET Lahore Resource Person SBS Research Publications 52 Book Contributions 4 Book Author 4 Patent 1 3

4 Our Team Engineer Muhammad Athar Process Engineer Project Development Directorate DH Fertilizers Limited, Lahore, Pakistan. Qualification: MS Chemical Engineering (UET, LHR) BS Chemical Engineering (UET, LHR) Professional Experience (More than 4.5 Years) Process Simulation& Project Management Energy Conservation (Certification) DuPont Best Safety Practices Troubleshooting & Commissioning 4

5 SERVICES we offer We feel honored to offer cost effective Training & Advisory solutions to all business organization ISO Quality Management System ISO Environmental Management System OHSAS OH&SMS Process Safety Management HAZOP Occupational Health and Safety Certified Safety Officer ( in line with NEBOSH) Process Simulation and Design Computer Aided Heat Exchanger Design and Simulation Boiler Operation and Performance Enhancement Carbon Foot Print Applied Process Control Systems Industrial Instrumentation

6 Please Introduce Yourself 1. Name of participants. 2. Qualification. 3. Length of experience 4. Year of Graduation 5. Institute from You graduated 6. Any previous experience of any simulation tool Process Design and Simulation 6

7 Training Ground Rules Start on time. Only one conversation, everyone participates Listen for understanding. Be open to new ideas. No one is wrong Ask Why? Try not to repeat points already made. Don t expect course handouts to be replica of presentations Don t expect the tutor to cover each and every slide Go through the slides to be covered next day No rank and no ego Turn off your mobiles on put on silent.

8 Domestic Arrangements

9 Training Schedule 09:00-17:00 Hrs Lunch for 1 hr Coffee / tea morning and afternoon- for 15 minutes

10 What are your course expectations???: Any Question, want to ask at this stage??

11 Course Agenda Day-1 Time Activity 8:30-9:00 Introduction 9:00 9:45 Role of Simulation in Process Design 9:45 10:45 Introduction to Simulation Tools (Aspen Tech Products)+ Aspen Plus User Interface 10:45-11:00 Tea Break 11:00 11:20 Workshop-I 11:20 12:00 Aspen Plus Basics for developing a simulation model 12:00 1:00 Lunch Break 1:00 1:30 Workshop-II 1:30 3:00 Basics of Physical properties model & Property Estimation 3:00 3:20 Workshop-III 3:20 3:45 Tea Break 3:45 4:30 HEATX-Heat Exchanger Modeling 4:30 5:00 Workshop-IV

12 Course Agenda Day-2 8: :30 RadFrac- Multistage separation model 9:30 10:00 Workshop-V 10:00 10:45 RadFrac Convergence 10:45-11:00 Tea Break 11:00 12:00 Pressure Changers Model 12:00 1:00 Lunch Break 1:00-2:00 Workshop-VI 2:00 3:00 Reactor Modeling I 3:00 3:30 Workshop-VII 3:30 4:00 Tea Break 4:00 5:00 Reactor Modeling-II

13 Course Agenda Day-3 Time Activity 8:30-9:00 Workshop-VIII 9:00 10:00 Reactor modeling III 10:00 10:30 Workshop-IX 10:30-11:00 Tea Break 11:00 12:00 Sensitivity Analysis and Acessing Variables 12:00 1:00 Lunch Break 1:00 1:30 Workshop-X 1:30 2:30 Convergence Options in Aspen Plus 2:30 3:30 Design Specifications 3:30 4:00 Tea Break 4:00 5:00 Workshop-XI

14 Course Agenda Day-4 8: :30 Calculator Block : Using the Excel or Fortran Calculator 9:30 10:00 Workshop-XII 10:00 11:00 Sensitivity analysis & Accessing variable 11:00-11:20 Tea Break 11:20 12:00 Workshop-XIII 12:00 1:00 Lunch Break 1:00-2:00 Performing Optimization in Aspen Plus 2:00 2:30 Workshop-XIV 2:30 3:30 Solids Handling in Aspen 3:30 4:00 Tea Break 4:00 4:45 Windows Interoperability+ Maintaining Aspen Plus Simulations +Customizing the Look of your Flowsheet 4:45-5:30 Case Studies

15 Role of Simulation in Process Design Process Design and Simulation 15

16 Simulation Process Design and Simulation 16

17 1: What is Modeling Modelling and Simulation Description of any complete system in mathematical terms is called a mathematical model 2: What is Simulation Solving the modeling equations either numerically or analytically Process Design and Simulation 17

18 Process Simulation Simulation is a process of designing an operational model of system and conducting experiments with this model for the purpose either of understanding the behaviour of the system or of evaluating alternative strategies for the development or operation of the system.it has to be able to reproduce selected aspects of the behaviour of the system modelled to an accepted degree of accuracy(thome, 1993) Process Design and Simulation 18

19 Simulation and Modelling Problem in Process Engineering Nano Micro Meso Macro Mega Molecular Processes, Active sites Bubbles, Drops, Particles, Eddies Reactors, Columns, Exchangers, Pumps, Compressors,... Production Plants, Petrochemical Complexes Environment, Atmosphere Oceans Soils Lit.: Charpentier, J.-C.; Trambouze, P.: Process Engineering and problems encountered by chemical and related Industries in the near future. Revolution or cointinuity? Chemical Enginering and Processing 37(1998)

20 Simulation and Modelling Problem in Process Engineering 20

21 Why Process Simulation Simulation as core activity in Research & Development, Design & Operation 21

22 Process Simulation Applications in Chemical Process Industries Chemical Process Industries Oil & Gas Refining Petrochemicals Basic Organic Chemicals Inorganic Chemicals Fine Chemicals Biotechnology Metallurgy Polymers Paper and Wood Energy Nuclear Industry Environment Applications Offshore exploration, Gas processing, Pipeline transport, Surface Treatment etc. Gasoline and Fuels Hydrocarbon based chemicals, Methanol, Monomers Intermediates, Solvents, Detergents, Dyes etc Ammonia, Sulphuric acid, Fertilizers Pharmaceuticals, Cosmetics Food and Bioproducts Steel, Aluminium, Copper etc Polyethylene, PVC, Polystyrene, Fibers etc Paper pulp Power plants, Coal Gasification Water Treatment, Safety Water cleaning etc.

23 Process Simulation Tools Objectives of Process Simulation Tools: Optimizing the design and performance of product assets Increasing throughput and yield, improving quality, and reducing energy costs Responding more quickly to unexpected events or changes in customer demand Managing the profitability of operations in real-time. 24

24 Types of Process Simulation Tools In process engineering two types of simulations tools are used: Steady-State Simulators: Or Static simulators. Typically used in process design, they simulate the process at steady state conditions, usually at the design operating conditions. In this kind of tools Time is not a variable. Dynamic models: consider time as a variable and simulate the process over a period of time. A dynamic simulation can be used to estimate or illustrate the response, over time, to a change in the process. 25

25 Steady State Process Simulation Tools The steady state simulation tool produce a static simulation, which typically used in process design, to simulate the process at steady state conditions, usually at the design operating conditions. This simulator don t use Time as variable. These simulation tools allow the engineer to do easily and strictly mass balance and energy balance for a high variety of chemical and petrochemical processes. Equipment and instrument design, plant design, capital costs, and technical evaluations are all dependent on such calculations. 26

26 Steady State Process Simulation Tools All of this tools contains: A Physical and chemical properties Data Base for several elements and compounds, and different methods to calculate the properties of mix. A Drawing tool, which can help to produce the Process Flow Diagrams (PFD). A Pre-modelled unit operation; like abortion columns, heaters, reactors, etc. There are several different software for the steady state process simulation as: - Pro-II - Aspen plus - Winsim - Chemcad - Others 27

27 Methodological levels in Steady State Process Simulation

28 Dynamic Process Simulation Tools Dynamic simulation tools consider time as a variable and simulate the process over a period of time. A dynamic simulation can be used to estimate or illustrate the response, over time, to a change in the process. This technology is commonly used for design and revamp studies, operator training, testing of DCS configurations and the development of operating procedures. Several of the steady state software tools have an especial module to produce the dynamic simulation of the process. For example Aspen Dynamics 29

29 Process Simulation Targets Process Simulation Steady State Simulation Debottlenecking Revamping Operation Optimization,design etc. Heat integration etc. Sensitivity, maintenance Process Control Real time optimization Dynamic Simulation Operation Start up, Shut down, safety Operator Training Disturbance Simulation Operational failures Safety examinations, design

30 Process Design & Simulation Commercial Softwares

31 Computational Fluid Dynamic (CFD) Tools Computational Fluid Dynamics involves the analysis, simulation and study of fluid, heat and mass transfer; chemical reactions and associated engineering phenomena by solving mathematical and numerical equations through computer based simulation. CFD is based on finite elements calculations. The simulation software divides the 3D surface in discrete cells creating a mesh. The software creates and calculates the Navier Stokes equations for every cell within the mesh starting from defined boundary conditions. It is possible to define calculation objectives, for instance pressure, temperature, and flow velocity, at selected sites of the simulated volume. 32

32 Computational Fluid Dynamic (CFD) Tools The following analyses can be performed: 2D and 3D analysis of Newtonian fluids External and internal flows Steady-state and transient-state flows Compressible and non-compressible flows Laminar, turbulent and transitional flow regimes Flows with vortex Multicomponent flows Heat transference effects Gravitational effects. There are several different CFD software as: - Comsol - Fluent - Ansys - Floworks - Flow Science 33

33 Required Competency 34

34 Impact on Chemical Process Industry 35

35 Design and Analysis through process simulation Divider Mixer Reactor Separator A Chemical Plant is our real world

36 Main steps of process simulation Develop process model Define problem Mixer Reactor Divider Separator Collect additional data Analyze results Chemical Plant Solve model equation

37 Problem definition What information do we need? Divider Mixer Reactor Separator Chemical Plant Stream data Mixture Compounds Unit Operations Process flowsheet Known data Equipment data Operating data

38 Problem definition What do we need to define? Divider Mixer Reactor Separator Chemical Plant Unit models Mixture Compounds Unit Operations Process flowsheet Library Thermomodels Method of solution

39 AspenTech Products & Aspen Plus Graphical User Interface 40

40 Lesson Objectives Aspen Tech Company Information List of AspenTech Products

41 AspenTech Company Information Advanced System for Process Engineering (ASPEN) Project conducted at the Massachusetts Institute of Technology (MIT) in Cambridge Massachusetts, from 1976 to 1981 Over 2000 Employees world wide HQ in Cambridge, MA (Boston) Offices in 35 Countries Public held since 1994, NASDAQ

42 Products Process Engineering» Process simulation Chemicals (10 products : AspenPlus)» Process simulation Oil&Gas (8 products : AspenHYSYS)» Process simulation Refining (11 products : Aspenadsim+)» Process simulation Batch/Pharma (8 products :Aspenproperties)» Model Deployment (3 products : AspenModelrunner)» Equipment modeling (8 products :AspenAcol+)» Basic Engineering (2 products :AspenKbase)» Economic Evaluation (3 products : Aspn Icarus Project Manager) Advance Process Control (14 products : Aspen Apollo, Aspen IQ) Planning & Scheduling (10 products : Aspen Advisor, Aspen MBO) Supply & Distribution (3 products : Aspen Retail) Production Management & Execution (16 products : Aspen 0server)

43 Products Aspen Plus Aspen Plus is the most popular product (accounted 48% of sales in 1995) a steady state modeling system built around the core technology Properties PLUS It is a database of chemicals properties underlying its other products, popular with customers ~ developed inhouse modeling software Other modules» offers to the customers ~ license separately» use with its other products to model subsystems used in highly specialized chemicals processing application.

44 Flowsheet Simulation

45 Flowsheet Simulation

46 General Simulation Problem

47 Approaches to Flowsheet Simulation

48 Integrated Software System

49 Good Flow sheeting Practice

50 Why Aspen Plus?

51 Starting with Aspen Plus 54

52 The User Interface

53 FlowSheet Definition

54 FlowSheet Definition

55 Graphic Flowsheet Operations--Blocks

56 Graphic Flowsheet Operations-- Streams

57 Using the Mouse Button

58 Modifying Blocks and Streams

59 Exercise-I 62

60 FlowSheet Definition

61 FlowSheet Definition

62 Basic Input to Run Aspen Plus Simulation 65

63 Aspen Plus User Interface

64 Data Browser

65 Data Browser

66 Functionality of Forms

67 Help

68 Basic Input

69 Status Indicators

70 Example

71 Setup

72 Setup Specification Form

73 Setup Run Types

74 Setup Units

75 Components

76 Component Specification Form

77 Entering Components

78 Find

79 Pure Component DataBanks

80 Pure Component DataBanks

81 Properties

82 Properties Specification Form

83 Streams

84 Streams Input Form

85 Blocks

86 Blocks

87 Starting the Run

88 Control Panel

89 Reviewing Results

90 Exercise-II July 06,

91 Exercise-II