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SuperPro Designer User's Manual PDF
SuperPro Designer User's Manual PDF
User’s Manual
Shawna Berg
Greg Brobst
Josh Edmonds
Allison McGuire
Robyn Menard
Bryan Tracy
Table of Contents
List of Figures.......................................................................................................................3
List of Tables ........................................................................................................................5
0.0 Introduction....................................................................................................................6
1.0 Creating a Design Simulation .......................................................................................6
1.1 Opening SuperPro® Designer .....................................................................................................................6
2.0 Specify Mode of Operation ...........................................................................................7
3.0 Set Default Physical Units .............................................................................................9
4.0 Register Components and Mixtures.............................................................................11
4.1 Register Pure Components ..........................................................................................................................11
4.1.1 Registering Pure Components in Database ................................................................................11
4.1.2 Adding Pure Components not offered in Database ....................................................................13
4.1.2A Introducing a new component into current design ....................................................14
4.1.2B Introducing a new component permanently into Pure Components Database ..........16
4.1.3 Editing Physical Properties of Pure Components.......................................................................16
4.1.4 Adding Physical Properties of Pure Components.......................................................................18
4.2 Defining Special Components .....................................................................................................................25
4.3 Register Stock Mixtures ..............................................................................................................................26
4.3.1 Registering Stock Mixtures in Database ....................................................................................26
4.3.2 Adding Stock Mixtures not offered in Database ........................................................................27
4.3.2A Introducing a new stock mixtures into current design...............................................28
4.3.2B Introducing a new stock mixtures permanently in Stock Mixtures Database............28
4.3.3 Editing Physical Properties of Stock Mixtures...........................................................................29
5.0 Add Unit Procedures .....................................................................................................31
5.1 Editing the Procedure Data..........................................................................................................................42
5.2 Editing the Equipment Data ........................................................................................................................44
5.3 Set Breakpoints............................................................................................................................................48
5.4 Physical Characteristics...............................................................................................................................53
5.4.1 Changing the Color of the Unit Procedure .................................................................................55
5.4.2 Editing the Tag Properties..........................................................................................................56
5.4.2A Changing the Tag Label ............................................................................................56
5.4.2B Editing the Tag Text Style.........................................................................................56
5.4.2C Editing the Appearance of the Tag Frame.................................................................57
5.4.2D Picking Up and Applying an Icon Style....................................................................59
6.0 Adding Streams..............................................................................................................60
6.1 – Types of Streams ......................................................................................................................................60
6.2 – Drawing Streams ......................................................................................................................................62
6.2.1 – Drawing Input Streams............................................................................................................62
6.2.2 – Drawing Output Streams .........................................................................................................63
6.2.3 – Drawing Intermediate Streams ................................................................................................64
6.3 – Viewing and Editing Stream Properties of a Bulk Stream .......................................................................64
6.3.1 – Specifying Stream Components of a Bulk Input Stream (Components, Etc. Tab)..................66
6.3.2 – Editing the Composition of a Bulk Input Stream (Composition, Etc. Tab).............................67
6.3.3 – The Composition, Etc. Tab for an Intermediate or Output Bulk Stream.................................69
6.3.4 – Setting Units (Composition, Etc. Tab) ....................................................................................70
6.3.5 – Setting the Density Value (Density Tab).................................................................................71
6.3.6 – Viewing the Environmental Properties ...................................................................................73
6.3.7 – Adding Comments...................................................................................................................74
6.4 – Viewing and Editing Stream Properties of a Discrete Stream ..................................................................74
6.4.1 – Setting the Description of the Entity for a Discrete Input Stream (Entity Tab) ......................76
6.4.2 – Setting the Flow of the Entity for a Discrete Input Stream (Entity Tab).................................77
6.4.3 – The Entity Tab for an Intermediate or Output Discrete Stream ..............................................77
1
6.4.4 – Specifying Stream Components of a Discrete Input Stream (Components, Etc. Tab) ............78
6.4.5 – Editing the Composition of a Discrete Input Stream (Composition, Etc. Tab) .......................79
6.4.6 – The Composition, Etc. Tab for an Intermediate or Output Discrete Stream ...........................81
6.4.7 – Setting the Density Value (Density Tab).................................................................................82
6.5 – Physical Characteristics............................................................................................................................84
6.5.1 – Changing the Color, Style, and Thickness of the Stream ........................................................86
6.5.2 – Editing the Tag Properties.......................................................................................................87
6.5.2A – Changing the Tag Name.........................................................................................87
6.5.2B – Editing the Tag Text Style......................................................................................88
6.5.2C – Editing the Appearance of the Tag Frame..............................................................89
6.5.2D – Editing the Location of the Stream Tag .................................................................89
6.5.2E – Picking Up and Applying a Stream Style ...............................................................90
7.0 Specify Operations .........................................................................................................92
7.1 Adding/Removing Operations.....................................................................................................................92
7.2 Renaming Operations ..................................................................................................................................96
7.3 Operation Data ............................................................................................................................................97
8.0 Schedule Process ............................................................................................................101
8.1 Specification of Setup Time ........................................................................................................................102
8.1.1 User Specified ............................................................................................................................103
8.1.2 Simulation Specified ..................................................................................................................103
8.1.3 Master-Slave Relationship .........................................................................................................103
8.2 Scheduling Relationships ............................................................................................................................107
8.2.1 Using the “Beginning of the Batch” Relationship......................................................................109
8.2.2 Using the “Previous Operation in the Same Procedure” Relationship .......................................110
8.2.3 Using the “Another Operation in the Same Procedure” Relationship ........................................110
8.2.4 Using the “Another Operation in Another Procedure” Relationship..........................................111
8.3 Process Schedule Information .....................................................................................................................113
8.4 Accessing Gantt Charts ...............................................................................................................................114
9.0 Specify Labor Requirements ........................................................................................115
10.0 Perform Economic Evaluation....................................................................................120
10.1 Specifying Component Costs ....................................................................................................................121
10.2 Stream Costs..............................................................................................................................................123
10.2.1 Product Stream Specification ...................................................................................................123
10.2.2 Output Stream Classification....................................................................................................124
10.2.3 Input Stream Classification ......................................................................................................126
10.3 Equipment Costs........................................................................................................................................127
10.4 Labor & Utility Costs ................................................................................................................................128
10.5 Economic Evaluation Reports ...................................................................................................................129
11.0 Perform Emissions and Environmental Impact Assessment ...................................133
11.1 Defining Pollutant Category for Registered Components and Mixtures ...................................................133
11.1.1 Defining Emissions Pollutant Categories.................................................................................134
11.1.1A User-Defined Emissions Pollutant Categories ........................................................145
11.1.2 Defining Environmental Pollutant Categories..........................................................................146
11.2 Generation of Emissions and Environmental Impact Reports ...................................................................148
11.2.1 Generation of Emissions Report (EMS)...................................................................................149
11.2.2 Generation of Environmental Impact Report (EIR) .................................................................149
11.3 Viewing an Emissions and Environmental Impact Report ........................................................................150
11.4 Interpreting an Emissions and Environmental Impact Report ...................................................................152
11.4.1 Interpreting an Emissions Report .............................................................................................152
11.4.2 Interpreting an Environmental Impact Report..........................................................................153
Glossary.............................................................................................................................................................156
Index..................................................................................................................................................................163
2
List of Figures
Figure 1.1: Specifying Mode of Operation for Plant .............................................................7
Figure 2.1: Changing Mode of Operation within New Flowsheet.........................................8
Figure 3.1: Accessing Physical Units Options.......................................................................9
Figure 3.2: Setting Default Physical Units ..........................................................................10
Figure 4.1: Accessing the Pure Components Database .......................................................12
Figure 4.2: Registering pure components available in database..........................................13
Figure 4.3: Registering pure components not available in database....................................14
Figure 4.4: New Component Registration ...........................................................................15
Figure 4.5: Editing Properties of Pure Components ............................................................16
Figure 4.6: Properties of Pure Components.........................................................................17
Figure 4.7: Registering Stock Mixtures ...............................................................................27
Figure 4.8: Registering a Stock Mixture Not in Database ...................................................28
Figure 5.1: Adding a Unit Procedure.....................................................................................40
Figure 5.2: A Vessel Procedure in a Fermentor.....................................................................40
Figure 5.3: Reversing the Flow Direction of a Unit Procedure .............................................41
Figure 5.4: A Procedure Flowing Right-to-Left ....................................................................42
Figure 5.5: Accessing the Procedure Data Window ..............................................................42
Figure 5.6: The Procedure Data Window for a Batch Process ..............................................43
Figure 5.7: Accessing the Equipment Data Window.............................................................44
Figure 5.8: The Equipment Data Window.............................................................................45
Figure 5.9: Choosing the Equipment for a Unit Operation....................................................46
Figure 5.10: Accessing the Breakpoints Window..................................................................48
Figure 5.11: The Breakpoints Window..................................................................................49
Figure 5.12: The Breakpoint Window with Automatic Material Pull-In...............................50
Figure 5.13: Breakpoint Window with Automatic Push-Out ................................................51
Figure 5.14: The Different Breakpoint Settings ....................................................................52
Figure 5.15: The Breakpoints Sub-menu ...............................................................................53
Figure 5.16: Accessing the Unit Procedure Icon Style Window ...........................................54
Figure 5.17: The Unit Procedure Icon Style Window ...........................................................54
Figure 5.18: Changing the Color of a Unit Procedure Icon...................................................55
Figure 5.19: The Edit Procedure Labels Window .................................................................56
Figure 5.20: The Name Tag: Text Window...........................................................................57
Figure 5.21: The Name Tag: Frame Window........................................................................58
Figure 5.22: Picking Up a Unit Procedure Icon Style ...........................................................59
Figure 5.23: Applying a Unit Procedure Icon Style ..............................................................60
Figure 6.1: Appearance of Bulk and Discrete Streams.........................................................61
Figure 6.2: Different Types of Process Streams ..................................................................61
Figure 6.3: Location of the Connect Mode Button ..............................................................62
Figure 6.4: Input Ports .........................................................................................................63
Figure 6.5: Output Ports.......................................................................................................63
Figure 6.6: How to Reach the Properties Window for a Stream .........................................65
Figure 6.7: Bulk Stream Properties Window.......................................................................65
Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk
Stream ................................................................................................................67
3
Figure 6.9: Steps Taken to Input Ingredient Flows..............................................................68
Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk
Input Stream....................................................................................................69
Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams..................70
Figure 6.12: How to Change Units in SuperPro® ...............................................................71
Figure 6.13: Setting a Known Mixture Density for a Bulk Stream .....................................72
Figure 6.14: Setting the Density Based on Ingredient or Component Contributions ..........73
Figure 6.15: The Environmental Properties Tab for a Bulk Stream ....................................74
Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream ...75
Figure 6.17: Properties Window for a Discrete Input Stream .............................................75
Figure 6.18: Setting the Description of a Discrete Input Stream.........................................76
Figure 6.19: How to Edit the Flow of a Discrete Input Stream ...........................................77
Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams.......................78
Figure 6.21: Adding Components to a Discrete Input Stream.............................................79
Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows 80
Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete
Input Stream....................................................................................................81
Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams....82
Figure 6.25: Setting a Known Mixture Density...................................................................83
Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a
Discrete Stream................................................................................................84
Figure 6.27: How to Reach the Stream Style Window........................................................85
Figure 6.28: The Stream Style Window ..............................................................................85
Figure 6.29: The Colors Window ........................................................................................86
Figure 6.30: How to Reach the Edit Tag Window...............................................................87
Figure 6.31: The Edit Tag Name Window...........................................................................87
Figure 6.32: The Name Tag: Text Window.........................................................................88
Figure 6.33: The Name Tag: Frame Window......................................................................89
Figure 6.34: The Name Tag: Location Window.................................................................90
Figure 6.35: How to Pickup a Stream Style.........................................................................91
Figure 6.36: How to Apply a Stream Style..........................................................................91
Figure 7.1: Unit Procedure Menu ........................................................................................92
Figure 7.2: Operation Interface............................................................................................93
Figure 7.3: >>Add>>Function.............................................................................................94
Figure 7.4: Result of>>Add>>Function ..............................................................................95
Figure 7.5: >>Insert>>Function...........................................................................................96
Figure 7.6: Renaming an Operation.....................................................................................97
Figure 7.7: Accessing Operation Data Interface..................................................................98
Figure 7.8: Operation Data Interface ...................................................................................99
Figure 7.9: Accessing Help Menu .....................................................................................100
Figure 8.1: Accessing the Properties Window of a Unit Operation ..................................101
Figure 8.2: Operation Duration Conditions .......................................................................102
Figure 8.3: Operation Duration: Master-Slave Relationship .............................................104
Figure 8.4: Master-Slave Relationship – Master Procedure Setup ....................................105
Figure 8.5: Master-Slave Relationship – Master Single Operation Setup .........................106
Figure 8.6: Master-Slave Relationship – Master Sequence Operation Setup....................107
4
Figure 8.7: Scheduling Overview Screen ..........................................................................108
Figure 8.8: Scheduling Overview Screen – Start Time Information .................................109
Figure 8.9: Start Time Relationship – Relative to Another Operation in this Procedure ..111
Figure 8.10: Start Time Relationship – Relative to Another Operation in Another
Procedure ............................................................................................................................112
Figure 8.11: Recipe Scheduling Information Command Screen .......................................113
Figure 8.12: Recipe Scheduling Information Data ............................................................114
Figure 8.13: The Gantt Charts Menu .................................................................................115
Figure 9.1: Operation Data Command Screen...................................................................116
Figure 9.2: Operation Conditions Main Screen .................................................................117
Figure 9.3: Operation Operator Specifications ..................................................................118
Figure 9.4: Operation Labor Units Specification...............................................................119
Figure 9.5: Operation Add/Delete Labor ...........................................................................120
Figure 10.1: Component Registration Interface.................................................................121
Figure 10.2: Component Economic Properties Interface...................................................122
Figure 10.3: Stream Specifications Command Interface ...................................................123
Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface ...........124
Figure 10.5: Specifying Output Stream Classifications.....................................................125
Figure 10.6: Specifying Input Stream Classifications .......................................................126
Figure 10.7: Equipment Data Specification Command .....................................................127
Figure 10.8: Equipment Purchase Cost Information..........................................................128
Figure 10.9: Labor Tab for Operation Conditions Interface..............................................129
Figure 10.10: Performing Economic Calculations Interface .............................................130
Figure 10.11: Generating Economic Report Interface.......................................................131
Figure 10.12: Saving EER Interface ..................................................................................131
Figure 10.13: View Economic Evaluation Report Command Screen ...............................132
Figure 11.1: Selecting the component or stock mixture for registering emissions and
environmental classifications........................................................................133
Figure 11.2: Pollutant Categories Window........................................................................134
Figure 11.3: Selection of VOC and Acid gas for emissions consideration .......................144
Figure 11.4: Accessing the Emission Limits Window.......................................................145
Figure 11.5: Adding User-Defined Pollutant Categories...................................................146
Figure 11.6: Selection of hazard and waste considerations ...............................................148
Figure 11.7: Selection steps for generating an emissions report .......................................149
Figure 11.8: Selection steps for generating an environmental impact report ....................150
Figure 11.9: Selection steps for viewing an emissions report ...........................................151
Figure 11.10: Illustration of a stream section from an emissions report ...........................152
Figure 11.11: Illustrates the per batch portion of the emissions report .............................153
List of Tables
Table 5.1: Unit Operations Available in Unit Procedures ....................................................31
Table 11.1: Pollutant Categories...........................................................................................135
5
0.0 Introduction
The following user’s manual is formatted for easy use by both SuperPro® masters and
those with no prior simulation experience. If you have no previous experience with
SuperPro®, read the manual chronologically to ensure that the proper functions are
performed in the correct order. For users familiar with the SuperPro® simulation
package, this manual can be navigated through easily by the use of the table of contents
and index. This particular manual targets a pharmaceutical audience and may leave out
information concerning the software that does not pertain to this industry.
Note: Keywords underlined in blue font are hyperlinked to the glossary to allow the user
to gather additional information, if needed, about a particular term.
In order to perform these basic functions, the user must first be able to open the program
to a blank flowsheet. Section 1.1 will discuss opening SuperPro® Designer.
SuperPro® Designer can be opened by selecting the Shortcut Icon available on your
desktop, or through the Start menu of your computer. Once the program is selected, a
new flowsheet can be opened by selecting:
6
File>>New
After selecting New and before the simulation will open a new flowsheet, the user must
define whether the process is batch or continuous. After choosing to start a new
flowsheet by selecting File and New, the following interface, Figure 1.1, will appear.
The user must choose a primary mode of operation and annual operating time for the
design before the remainder of the designing process can take place. The following
section will discuss the two possible selections for mode of operation in SuperPro®.
• Batch
•
o Scheduling information is required
7
o Plant batch time is calculated
o Stream flows are displayed on a per-batch basis
o Inherently continuous processing steps can be included as unit operations
in either continuous or semi-continuous mode
• Continuous
•
o Scheduling information is not required
o Plant batch time is not calculated
o Stream flows are displayed on a per-hour basis
o Inherently batch processing steps can be included if user specifies
processing time and turnaround time for these steps
• Mixed Mode
•
o Allows user to have continuous and batch procedures in one design
To utilize the mixed mode option, simply choose the mode of operation that is
prominently used in the design (either batch or continuous) and denote specific
operations as continuous or batch by the scheduling options. (See Section 8.0)
When SuperPro® is opened the user is prompted to specify the mode of operation before
a new flowsheet is opened (see Section 1.1). Once a new flowsheet is opened, the mode
of operation can be changed by selecting:
Figure 2.1 depicts the necessary actions to set the mode of operation.
8
Figure 2.1: Changing Mode of Operation within New Flowsheet
Once selected, the interface shown above in Figure 1.1 will appear and can be used to set
the mode of operation needed for your process.
Note: Though the program allows the user to change the mode of operation during and
after the design process, making a change late in the design will require the user to revise
earlier steps. It is suggested that the user finalize the mode of operation before adding
unit operations and procedures and as early in the design process as possible.
The steps taken to edit the default physical units are depicted below in Figure 3.1.
9
Figure 3.1: Accessing Physical Units Options
After selecting Physical Units Options, the following interface, as shown in Figure 3.2,
will appear.
10
Figure 3.2: Setting Default Physical Units
The default settings for physical units can be changed by using the button and scrolling
through the unit options. The following units are available for the above categories:
Mass in: lbmol, mol, kmol, lb, MT, ton, oz (troy), oz (avdp), g, kg
Note: Though a physical property may be assigned default units, the units can be
changed within streams and operations during the process. In other words, choose
11
default physical units that are most often used in your process or that you want for your
generated data, but understand that these units are not binding for all operations.
The following sections will discuss the process needed to register both categories of pure
components.
Pull-Out
- allows the user to take out a material without directly knowing the amount of material
needed
Figure 4.1 depicts the necessary actions to access the Pure Components Database.
12
Figure 4.1: Accessing the Pure Components Database
Once in the Pure Components Database, shown in Figure 4.1, components can be
registered by selecting the appropriate component and instructing SuperPro® to register
the component. To register pure components available in database:
Figure 4.2 depicts the necessary actions to register pure components available in the
database.
13
Figure 4.2: Registering pure components available in database
Once Register is chosen, the registered component will appear in the Registered Pure
Components section, located on the right side of Figure 4.2.
Note: The Pure Components Database can be altered at any point in the simulation
process. It is not necessary to register all components that will appear in the flowsheet at
one time, but it is recommended that users form the habit of registering components early
in the simulation process to prevent from having to return to the Pure Components
Database multiple times.
The physical constants for the components in the Pure Components Database are
already defined within the database. Unless specified by the program, no additional
physical constants need to be added to these pure components, but can be modified for a
specific design case. Physical properties can only be edited for registered components.
14
If the user is uncertain of the properties of a pure component, the best option may be to
add the new component temporarily. If new accurate information is found later in the
design process, the new component can be inserted into the database permanently.
New
Figure 4.3 visually depicts the necessary actions to register pure components not
available in the database.
After selecting New, the following interface, as shown in Figure 4.4, will appear.
15
Figure 4.4: New Component Registration
Note: SuperPro® will not allow more than one component to have the same local name.
Once a name is denoted for a component, this field cannot be edited without removing
the component completely and introducing it again.
Note: SuperPro® requires that a default component be chosen to add a new component,
but these properties can be manually changed after the component is added.
Once the user is certain the component name is inserted correctly and a default
component is chosen, select OK. The new component will appear in the Registered
Pure Components list with the registered components from the Pure Components
Database. The properties of this component are set by a default component. The
16
property values of the new component can be changed by the procedure described in
Section 4.2, Editing Physical Properties of Pure Components.
Note: Remember that any property not defined by the user is automatically set as the
corresponding property of the default component.
Note: If the component already exists in the Pure Components Database, the program
will ask for confirmation that the properties of the component are to be updated. Once
confirmation is made, the new component will be added to the Pure Components
Database to be used for future design cases.
17
Figure 4.5: Editing Properties of Pure Components
After selecting the Properties option, an interface presenting the ID portion of the
components properties will appear. Within the properties function are the following
categories:
• ID
• Physical (Constant)
• Physical (T-dependent)
• Aqueous
• Economics
• Pollutant Categories
These categories can be chosen by clicking on the tabs located on the top of the interface.
For example, if the Physical (Constant) tab is chosen, the following interface, as shown
in Figure 4.6, will appear on the screen.
18
Figure 4.6: Properties of Pure Components
Because these pure components were registered from the Pure Components Database,
most, if not all, of their physical properties are included. These properties are set as a
default within the simulation program, but can be changed for a particular process. Pure
Components added by the user, as described in Section 4.1.2, will require the user to
manually add the physical properties of the component. A further discussion on
components properties can be found in the following section, Section 4.1.4.
Within the properties function, see Figure 4.6, are the following categories:
• ID
• Physical (Constant)
• Physical (T-dependent)
19
• Aqueous
• Economics
• Pollutant Categories
Note: All of the above mentioned categories are not necessary for all calculations.
However, it is important to recall which properties are defined and which are denoted by
the default component. It is important to provide accurate values for as many properties
as possible to prevent having to define these properties later and from generating errors in
the simulation data.
The following sections will discuss in further detail the properties included in the above
mentioned categories as well as the operations where these properties are utilized. The
user should take note which properties are necessary for particular operations, to ensure
that this property data is accurate.
ID
• Name
This is the formal name of the pure component, either supplied by the simulation
program when the database was developed or by the user when a new component
was introduced. The Name portion of the ID cannot be changed once the pure
component is introduced. The Name can consist of up to 31 characters.
• Trade Name
The Trade Name may or may not be different from the Name of the pure
component. The Trade Name is the name widely known in the market or
industry. This name was either supplied by the simulation program when the
database was developed or by the user when a new component was introduced.
Unlike the Name, however, the Trade Name can be changed later and must be
unique. The Trade Name can consist of up to 31 characters.
• Formula
This property is the formula of the pure component. It was either supplied by the
simulation program when the database was developed or by the user when a new
component was introduced. The Formula can be changed later in the process and
does not have to be unique. The Formula can consist of up to 31 characters.
• Company ID
20
Companies may have their own number system for denoting certain components
used in their process. This tag number is reserved primarily for this purpose.
This property was defined by the user when the new component was introduced,
but can be changed later. Uniqueness is not necessary for this property. The
Company ID can consist of up to 31 characters.
• Is Biomass
•
This property consists simply of a True/False prompt to denote whether or not the
component can be treated as a biomass. This property is used to denote biomass
components within all biological reactors.
Physical (Constant)
Main Properties
• Molecular Weight
• (g/gmol)
o Used in distillation, flash drums, condensers, absorbers,
strippers, electrostatic precipitators, and all reactors
• EIR Report: Environmental Impact Report
-presents information that describes the effects of the process output streams on the
environment
-contains a detailed tabulation of all chemicals that are regulated by the EPA or denoted
as hazardous by the user
Enthalpy of Formation
• (J/gmol)
o Used in energy balances
• Normal Boiling Point
• (°C)
o Used in distillation, flash drums, condensers, and to determine
the phase of a given component
o From this information the simulation program decides whether
to use the density correlation provided by the user or the ideal
gas law to determine density
• Normal Freezing Point
• (°C)
o Used to determine if a given component is in liquid or solid
form
Critical Properties
• Temperature (°C)
o Used in distillation, flash evaporation, and condensation
• Pressure (bar)
o Used in distillation, flash evaporation, and condensation
• Compressibility Factor
21
•
o Used in distillation, flash evaporation, and condensation
• Acentric Factor
• (omega)
o Currently not needed for this version of the simulation program
Miscellaneous
• Henry’s Constant
4 3
• * 10 (atm-m /gmol)
o Used in absorption, stripping, and VOC emission calculations
• Particle Size (microns)
o Used in filters and centrifuges
• Default Volumetric Coefficient
o Used to estimate the density of a stream that contains this
component
Physical (T-dependent)
Density (g/L)
• Used as a conversion between mass and volumetric flow rates and to
calculate the concentration of streams
• Calculated by the following equation:
D = a + bT , where T is in K
• SuperPro® allows the user to enter values for a and b for user defined
components and to edit a and b for components available in the Pure
Components Database
• For densities in the vapor phase, SuperPro® assumes the ideal gas law
and calculates the density accordingly
Evacuate
-complete removal of unit procedure contents
Heat Capacity
(J/gmol-K)
• Liquid/Solid Cp
o Used in energy balances
• Gaseous Cp
22
o Used in energy balances
o Calculated by the following equation:
Cp = abT + cT 2 + dT 3 , where T is in K
o SuperPro® allows the user to enter values for a, b, c, and d for
user defined components and to edit a, b, c, and d for
components available in the Pure Components database
Heat of Vaporization
(J/gmol)
• Currently not needed for this version of the simulation program
• Calculated using the following equations
T
Tr = , where T is in K
Tc
∆Hv = a (1 − T ) , where T is in K
Watson correlation
• SuperPro® allows the user to enter values for a and b for user defined
components and to edit a and b for components available in the Pure
Components Database
Aqueous
Used primarily for the calculation of the environmental properties of streams and for
operations dealing primarily with waste treatment and pollution prevention
operations.
• Diffusivity Properties
6
o In Water *10 (cm2/s)
Used in VOC emissions calculations
3
o In Air *10 (cm2/s)
Used in VOC emissions calculations
• Bio-Degradation Properties
o Intermediate Stream
23
-a stream that carries material out of a unit procedure and into a different unit procedure.
Components and flowrates for an intermediate stream are usually calculated by
SuperPro®. The exception is when the Pull-Out operation is used.
Kmaxo
o (mg substrate/g biomass-h)
Used in biodegradation reaction rate calculations in
aerobic biooxidation
Denotes the maximum biodegradation rate constant
o Ks
o (mg/L)
Used in biodegradation reaction rate calculations in
aerobic biooxidation
Denotes the half-saturation constant
• Oxygen Ratios
o
o Clean-in-Place (CIP)
o -used for cleaning processes using a cleaning agent
o BODu/COD(g/g)
Used to calculate BODu value in stream based on the
COD value of each component
Denotes the ratio of the ultimate biochemical oxygen
demand to the COD of the component
o BOD5/BODu
o (g/g)
Used to calculate the BOD5 value in stream based on
the COD value of each component
Denotes the ratio of the five-day BOD to the ultimate
BOD value
24
• Nitrogen Ratios
o TKN: Total Kjeldahl Nitrogen
o (g N/g)
Used to calculate the TKN value of the streams
Denotes the Kjeldahl nitrogen contribution of the
component
o NH3: Ammonia Nitrogen (g N, as NH3/g)
Used to calculate the NH3 value of the streams
o NO3-NO2 : Nitrate/Nitrite Nitrogen
o (g N, as NO3, NO2)/g)
Used to calculate the NO3-NO2 value of streams
Denotes the NO3-NO2 contribution of the component
• Log10 (octanol/water)
o Currently not needed for this version of the simulation program
o Used to indicate the hydrophobicity of a component
o Helps determine a component’s tendency to become sludge
• Carbon ratio
o TOC: Total Organic Carbon
o (g C/g)
Used to calculate the TOC values of streams
Denotes the organic carbon contribution of a
component
• Phosphorus ratio
o TP: Total Phosphorus
o (g P/g)
Used to calculate the TP value of streams
Denotes the phosphorus contribution of a component
o CaCO3 (CaCO3/g)
Used to calculate the CaCO3 value of streams
Denotes the CaCO3 contribution of the component
• Solids Ratios
o Solid?
User can define if component is a dissolved or
suspended solid
o TS: Total Solids (g solids/g substance)
Used to calculate the TS value of streams
Denotes the fraction of a component that is dissolved or
present as a suspended solid
o TSS/TS: Total Suspended Solids (g TSS/g TS)
Used to calculate the total TSS value of a stream based
on the TSS values of the stream components
25
Denotes the fraction of solid component that is
suspended in solution
o VSS/TSS: Volatile Suspended Solids
o (g VSS/g TSS)
Used to calculate the total VSS value of a stream based
on the VSS values of the stream components
Denotes the fraction of the suspended solid component
that is biodegradable
Measured as the organic fraction that oxidizes at
550±50°C that comes off as a gas
o DVSS/VSS: Degradable Volatile Suspended Solids
o (g
DVSS/g VSS)
Used to calculate the total DVSS value of a stream
based on the DVSS values of the stream components
Denotes the fraction of the volatile suspended solid of
the component that is biodegradable
o VDS/TDS: Volatile Dissolved Solids
o (g VDS/g TDS)
Used to calculate the total VDS value of a stream based
on the VDS values of the stream components
Denotes the fraction of the dissolved solid of a
component that is volatile
o DVDS/VDS: Degradable Volatile Dissolved Solids
o (g
DVDS/g VDS)
Used to calculate the total DVDS value of a stream
based on the DVDS values of the stream components
Denotes the fraction of the volatile dissolved solid
amount of a component that is biodegradable
Economics
• Error! Reference source not found. ($/kg)
o Used in economic calculations
• Selling Price
• ($/kg)
o Used in economic calculations
• Waste Treatment or Disposal Cost
• ($/kg)
o Used to estimate waste treatment and disposal costs
o If no cost is specified, the program will estimate the cost from
the contribution of the components
• Supplier
o Name
o Comments
26
Pollutant Categories
Emissions Report
• VOC
o Specific
VCM
TVOS
EVOS
HAP-VOC
o Other
• Particulate
o Removal by Emission (%)
o Specific
Biological
Radionuclide
Asbestos
Cr+6
Metal
Dioxin
LOC
HAP
o Other
• Acid Gas
o HAP-Acid
o Acid (Non-HAP)
• ETG
o HAP-Gas
o Gas (Non-HAP)
• CO
• NOx
• SO2
• Base
Environmental Impact Report
• Is Hazardous?
o Selecting option (clicking mouse on empty box), denotes that
component is hazardous
o Threshold (ppm)
Specifies the concentration level that would signify an
entire stream is hazardous
27
o If the presence of a hazardous component is higher than the
threshold concentration, the entire stream is denoted as
hazardous
• Is in the SARA 313 Report?
o If selected, this component is included in the SARA-313
Chemicals section of the Environmental Impact Report (EIR)
• Is in the EIR Report: Environmental Impact Report
• ?
o If selected, this component is included in the 33/50 EPA
Program Report and is included in the 33/50 Chemicals section
of the EIR report
• Is Reported in Solid Wastes?
o If selected, the component will be included in the Solid Waste
section of the EIR report and should be tracked through the
solid waste streams in the design
• Is Reported in Liquid Wastes?
o If selected, the component will be included in the Liquid
Wastes section of the EIR report and should be tracked through
the liquid waste streams in the design
• Is Reported in Emissions?
o If selected, the component will be included in the Emissions
section of the EIR report and should be tracked through all
emissions streams in the design
A more extensive discussion of how to categorize pollutants can be found in the
following section, Section 11.0.
If a primary biomass is formed in a reaction and both the primary biomass and water
components have been specified, the simulation program will automatically adjust
intracellular water amount to satisfy the biomass water content specified in registration.
28
Note: The primary biomass component relates to components that have the Is option
selected.
The following sections will discuss the process needed to register both categories of
stock mixtures.
Note: Refer back to Figure 4.1: Accessing the Pure Components Database to see the
necessary actions to access the Stock Mixtures Database.
Figure 4.7 depicts the Stock Mixture Database the process required to register a stock
mixture for a particular process.
29
Figure 4.7: Registering Stock Mixtures
Note: If the user is uncertain of the properties of a stock mixture, the best option may be
to add the new mixture temporarily. If new accurate information is found later in the
design process, the new mixture can be inserted into the database permanently.
30
4.3.2A Introducing a new stock mixture into current
design
Registering stock mixtures not available in the database requires different actions than
described above. Once the user reaches the Stock Mixtures Database, as depicted in
Figure 4.7, the new mixtures need to be added. To register stock mixtures not available in
database select:
New
Figure 4.8 depicts the necessary actions to register stock mixtures not available in the
database.
31
Note: If the mixture already exists in the Stock Mixture Database, the program will ask
for confirmation that the properties of the mixture are to be updated. Once confirmation
is made, the new mixture will be added to the Stock Mixture Database to be used for
future design cases
After selecting the Properties option, an interface presenting the ID portion of the
components properties will appear. Within the properties function are the following
categories:
• ID
• Composition
• Economics
These categories can be chosen by clicking on the tabs located on the top of the interface.
Note: All of the above mentioned categories are not necessary for all calculations.
However, it is important to recall which properties are defined and which are denoted by
the default component. It is important to provide accurate values for as many properties
as possible to prevent having to define these properties later and from generating errors in
the simulation data.
ID
• Name
This is the formal name of the stock mixture, either supplied by the simulation
program when the database was developed or by the user when a new mixture
was introduced. The Name portion of the ID cannot be changed once the stock
mixture is introduced. The Name can consist of up to 31 characters.
• Trade Name
The Trade Name may or may not be different from the Name of the stock
mixture. The Trade Name is the name widely known in the market or industry.
This name was either supplied by the simulation program when the database was
developed or by the user when a new component was introduced. Unlike the
Name, however, the Trade Name can be changed later and must be unique. The
Trade Name can consist of up to 31 characters.
32
• Local Name
Companies may have their own number system for denoting certain mixtures used
in their process. This tag number is reserved primarily for this purpose. This
property was defined by the user when the new mixture was introduced, but can
be changed later. Uniqueness is not necessary for this property. The Local Name
can consist of up to 31 characters.
Composition
Available Ingredients
Mixtures can be made up of either:
• Pure Components
• Other Stock Mixtures
Ingredient Composition
Can be defined as either:
• Mass
• Molar
Density (g/L)
• Used as a conversion between mass and volumetric flow rates and to
calculate the concentration of streams
• Calculated by the following equation:
D = a + bT , where T is in K
• SuperPro® allows the user to enter values for a and b for user defined
components and to edit a and b for mixtures available in the Stock
Mixtures database
• For densities in the vapor phase, SuperPro® assumes the ideal gas law
and calculates the density accordingly
Economics
• Purchasing Price ($/kg)
o Used in economic calculations
o Can be set by user or calculated from components
• Supplier
o Name
o Comments
33
5.0 Add Unit Procedures
After the components in the process have been specified, it is necessary to add the Unit
Procedure in the process to the simulation. A unit procedure is a piece of equipment in
which a sequence of modeled unit operations takes place. However, before the unit
procedures are added, it is important for the user to understand which unit procedures are
capable of certain functions, or unit operations, that are needed for the particular process.
Table 5.1, below, lists the unit procedures that SuperPro® offers that are useful in
bioprocesses along with the unit operations available for each unit procedure.
34
In an Air-Lift Fermenter Agitate Pressurize
Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Crystallize React (Equilibrium)
Evacuate React (Kinetic)
Extract/Phase Shift React (Stoichiometric)
Ferment (Kinetic) Steam-in-Place (SIP)
Ferment (Stoichiometric) Transfer In
Gas Sweep Transfer Out
Heat Vaporize/Concentrate
Hold Vent
Continuous Reaction Procedures
Stoichiometric: In a Clean-in-Place (CIP)
Fermenter Ferment (Stoichiometric)
Hold
Stoichiometric: In a Seed Clean-in-Place (CIP)
Fermenter Ferment (Stoichiometric)
Hold
Stoichiometric: In an Air-Lift Clean-in-Place (CIP)
Fermenter Ferment (Stoichiometric)
Hold
Kinetic: In a Fermenter Clean-in-Place (CIP)
Ferment (Kinetic)
Hold
Kinetic: In a Seed Fermenter Clean-in-Place (CIP)
Ferment (Kinetic)
Hold
Environmental: Well-Mixed Bio-oxidize*
Aerobic BioOxidation Hold
Environmental: Plug Flow Bio-oxidize*
Aerobic BioOxidation Hold
Environmental: Trickling Bio-oxidize*
Filtration Hold
Environmental: Anoxic Bio-oxidize*
Reaction Hold
Environmental: Hold
Neutralization Neutralize*
Environmental: Wet Air Hold
Oxidation Oxidize*
Environmental: Incineration Hold
Incinerate*
Environmental: UV Hold
Radiation Radiate*
35
Filtration Procedures
Microfiltration (Batch) Charge Steam-in-Place (SIP)
Clean-in-Place (CIP) Transfer In
Concentrate (Batch)* Transfer Out
Hold
Microfiltration (feed and Charge Steam-in-Place (SIP)
bleed) Clean-in-Place (CIP) Transfer In
Concentrate (feed & bleed)* Transfer Out
Hold
Ultrafiltration (Batch) Charge Steam-in-Place (SIP)
Clean-in-Place (CIP) Transfer In
Concentrate (Batch)* Transfer Out
Hold
Ultrafiltration (feed and Charge Steam-in-Place (SIP)
bleed) Clean-in-Place (CIP) Transfer In
Concentrate (feed & bleed)* Transfer Out
Hold
Reverse Osmosis (Batch) Charge Steam-in-Place (SIP)
Clean-in-Place (CIP) Transfer In
Concentrate (Batch)* Transfer Out
Hold
Reverse Osmosis (feed and Charge Steam-in-Place (SIP)
bleed) Clean-in-Place (CIP) Transfer In
Concentrate (feed & bleed)* Transfer Out
Hold
Diafiltration Charge Hold
Clean-in-Place (CIP) Steam-in-Place (SIP)
Concentrate(Batch) Transfer In
Diafilter* Transfer Out
Dead End Clean-in-Place (CIP)
Filter*
Hold
Steam-in-Place (SIP)
Nutsche Charge Hold
Clean-in-Place (CIP) Purge / Inert
Cool React (Stoichiometric)
Dry Cake Steam-in-Place (SIP)
Filter* Transfer In
Gas Sweep Transfer Out
Heat Wash Cake
Plate & Frame Cake Wash Hold
Clean-in-Place (CIP) Steam-in-Place (SIP)
Filter* Transfer Out
Gas Sweep
36
Rotary Vacuum Clean-in-Place (CIP)
Filter*
Hold
Steam-in-Place (SIP)
Air Filtration Filter*
Hold
Steam-in-Place (SIP)
Belt Filter*
Hold
Granular Media Filter*
Hold
Electrostatic Precipitation Hold
Precipitate*
Centrifugation Procedures
In a Decanter Centrifuge Centrifuge*
Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Disk-Stack Centrifuge*
Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Bowl Centrifuge*
Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Basket Charge Purge / Inert
Clean-in-Place (CIP) Steam-in-Place (SIP)
Filter* Transfer In
Gas Sweep Transfer Out
Hold Wash Cake
Centritech Centrifuge*
Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Homogenization Procedures
High-Pressure Clean-in-Place (CIP)
Hold
Homogenize*
Steam-in-Place (SIP)
37
Bead Milling Clean-in-Place (CIP)
Hold
Homogenize*
Steam-in-Place (SIP)
Chromatography/Adsorption Procedures
Gel Filtration Elute* Regenerate
Equilibrate Steam-in-Place (SIP)
Hold Wash*
Load*
PBA Chromatography Elute* Regenerate*
Equilibrate* Steam-in-Place (SIP)
Hold Wash*
Load*
EBA Chromatography Elute* Regenerate*
Equilibrate* Steam-in-Place (SIP)
Hold Wash*
Load*
Ion Exchange (for Hold
Demineralization) Load*
Regenerate*
Wash*
Drying Procedures
Freeze Charge Hold
Clean-in-Place (CIP) Steam-in-Place (SIP)
Cool Transfer In
Dry* Transfer Out
Extraction Procedures
In a Mixer-Settler Clean-in-Place (CIP)
Extract*
Hold
Differential Clean-in-Place (CIP)
Extract*
Hold
Centrifugal Clean-in-Place (CIP)
Extract*
Hold
Steam-in-Place (SIP)
Phase Change Procedures
Crystallization (Continuous) Clean-in-Place (CIP)
Crystallize*
Hold
38
Storage Procedures
Batch: Blending Tank Agitate Pressurize
Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Evacuate Steam-in-Place (SIP)
Extract / Phase Split Store*
Gas Sweep Transfer In
Heat Transfer Out
Hold Vent
Batch: Flat Bottom Tank Agitate Pressurize
Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Evacuate Steam-in-Place (SIP)
Extract / Phase Split Store*
Gas Sweep Transfer In
Heat Transfer Out
Hold Vent
Batch: Receiver Agitate Pressurize
Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Evacuate Steam-in-Place (SIP)
Extract / Phase Split Store*
Gas Sweep Transfer In
Heat Transfer Out
Hold Vent
Batch: Horizontal Tank Agitate Pressurize
Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Evacuate Steam-in-Place (SIP)
Extract / Phase Split Store*
Gas Sweep Transfer In
Heat Transfer Out
Hold Vent
Batch: Vertical On Legs Agitate Pressurize
Tank Charge Pull In
Clean-in-Place (CIP) Pull Out
Cool Purge / Inert
Evacuate Steam-in-Place (SIP)
Extract / Phase Split Store*
Gas Sweep Transfer In
Heat Transfer Out
Hold Vent
39
Batch: Silo Charge Pull Out
Clean-in-Place (CIP) Store Solids*
Hold Transfer In
Pull In Transfer Out
Continuous: Blending Tank Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Store*
Continuous: Flat Bottom Clean-in-Place (CIP)
Tank Hold
Steam-in-Place (SIP)
Store*
Continuous: Receiver Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Store*
Continuous: Horizontal Tank Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Store*
Continuous: Vertical On Clean-in-Place (CIP)
Legs Tank Hold
Steam-in-Place (SIP)
Store*
Continuous: Silo Clean-in-Place (CIP)
Hold
Store Solids*
Continuous: Hopper Clean-in-Place (CIP)
Handle Solids Flow*
Hold
Heat Exchange Procedures
Heating Clean-in-Place (CIP)
Heat*
Hold
Electric Heating Clean-in-Place (CIP)
Heat*
Hold
Cooling Clean-in-Place (CIP)
Cool*
Hold
Steam-in-Place (SIP)
Heat Exchanging Clean-in-Place (CIP)
Exchange Heat*
Hold
Steam-in-Place (SIP)
40
Heat Sterilization Clean-in-Place (CIP)
Hold
Sterilize*
Mixing Procedures
Bulk Flow Clean-in-Place (CIP)
Hold
Mix*
Steam-in-Place (SIP)
Bulk Flow: Custom Clean-in-Place (CIP)
Hold
Mix*
Steam-in-Place (SIP)
Bulk Flow: Mixture Making Clean-in-Place (CIP)
Hold
Mix*
Steam-in-Place (SIP)
Bulk Flow: Tumble Charge Mix Solids*
Clean-in-Place (CIP) Transfer In
Hold Transfer Out
Discrete Flow Clean-in-Place (CIP)
Hold
Mix*
Splitting Procedures
Bulk Flow Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Split*
41
Formulation and Packaging Procedures
Filling Clean-in-Place (CIP)
Fill*
Hold
Steam-in-Place (SIP)
Tableting Clean-in-Place (CIP)
Hold
Steam-in-Place (SIP)
Tablet*
Transport (near) Procedures
Liquids: Pump Clean-in-Place (CIP)
Hold
Pump
Steam-in-Place (SIP)
Generic Boxes
Discrete: Bulk to Discrete Clean-in-Place (CIP)
Convert to Discrete*
Hold
Discrete: Discrete to Bulk Clean-in-Place (CIP)
Convert to Bulk*
Hold
After the necessary unit procedures have been determined, the user can add those unit
procedures to the simulation.
Figure 5.1 below depicts the steps needed to add a vessel procedure in a fermentor.
42
Figure 5.1: Adding a Unit Procedure
After the procedure is selected, the Add Step cursor will appear:
Click on the simulation where you want the unit procedure to appear. A visual of the
procedure will then appear on the flowsheet. For the example of a vessel procedure in a
fermentor, the following image will appear to represent the procedure:
43
Note: To move a unit procedure after it has been added to the simulation, click on the
procedure and drag it to the new location. If more than one procedure needs to be
moved, select each procedure by pressing the Shift button and left-clicking. Once all
procedures are highlighted (they will appear red), click and drag them to the new
location. Precise movements of one pixel can be made using the arrow keys on the
keyboard.
Each unit procedure has a unique appearance that correlated to how the equipment would
appear in reality.
To add more procedures, follow the same steps until all of the procedures needed in the
process are present.
It is important to pay close attention to the location and orientation of each procedure
when adding it to the simulation. SuperPro® will automatically add the procedure in the
standard left-to-right orientation. However, it is often necessary to show the procedure
flowing right-to-left. This needs to be done immediately after the procedure is added,
before any streams are connected. To change the orientation of the procedure, right click
on the procedure to open the menu, and select:
After Flip has been selected, the input and output ports will flow right-to-left, as shown
in Figure 5.4.
44
Figure 5.4: A Procedure Flowing Right-to-Left
After all of the necessary unit procedures are added to the simulation, the user then has
the option to edit the procedure data within each unit procedure.
Procedure Data
45
Figure 5.6: The Procedure Data Window for a Batch Process
The Scheduling tab allows the user to designate the operating mode of the procedure.
There are only two fields on this tab that are editable by the user. The number of cycles
per batch can be specified, and it can be told to operate in Stagger Mode. More
information on scheduling can be found in Chapter 8. The other tabs in the Procedure
Data window include Throughput, in which the user can choose to include the procedure
in the throughput analysis, and Description, which is a blank text box that allows the user
to enter comments about the procedure.
Note: For a batch process, the Continuous option on the Scheduling tab is gray and
cannot be selected by the user. For procedures that are running constantly during a
continuous process, this option will be available.
46
5.2 Editing the Equipment Data
After the unit procedures are added to the simulation, it is necessary to set the equipment
data in order for the simulation to accurately represent the desired procedure.
To open the Equipment Data Window, right click on the procedure and select:
Equipment Data
After Equipment Data has been selected, the following window will appear:
47
Figure 5.8: The Equipment Data Window
• Equipment
• Purchase Cost
• Adjustments
• Scheduling
• Throughput
• Comments
• Allocation
Note: This section will be focusing on the Equipment tab. For information about Cost
Analysis, refer to Chapter 10. For information about Scheduling, refer to Chapter 8.
48
The different sections of the Equipment tab include selection, size, and description.
Selection
49
used by the procedure. To ensure that the shared equipment is being used by
the other procedure, perform the same steps to choose the equipment.
Note: The selection of the equipment takes place under the Select option in
the Selection section of the Equipment tab. The other option, Request New
is not editable by the user, due to the fact that SuperPro® automatically
determines the type of equipment used based on the unit procedure. Also note
that equipment can only be shared in batch processes. For a continuous
process, separate equipment is required. Therefore, in a continuous process,
the Select option appears gray and is not editable by the user.
Size
• The Size Section of the Equipment tab allows the user to set the equipment
size or have SuperPro® perform the calculations. If the user chooses to size
the equipment, the simulation is in Error! Reference source not found.. If
SuperPro® is instructed to perform the calculations, the simulation is in
Error! Reference source not found..
Description
• The Description section of the Equipment tab contains information about the
physical aspects of the equipment. The information includes:
o Name
o Type
o Number of Units
o Error! Reference source not found.
o Error! Reference source not found.
o Error! Reference source not found.
o Error! Reference source not found.
o Height
o Diameter
o Design Pressure
o Error! Reference source not found.
When in Design Mode, the areas that are editable by the user are: Max.
Volume, Max. Allowable Working Volume/Vessel Volume Ratio,
Height/Diameter Ratio, Design Pressure, and whether the vessel is an ASME
Vessel. All other areas are calculated and set by SuperPro®.
When in Rating Mode, the areas that are editable by the user are: Number of
Units, Volume, Height/Diameter Ratio, Design Pressure, and whether the
vessel is an ASME Vessel. All other areas are calculated and set by
SuperPro®.
50
5.3 Set Breakpoints
During the simulation process, it is sometimes necessary to have SuperPro® stop at a
certain unit procedure when performing the mass and energy balances. This can be done
by setting Error! Reference source not found..
Set Breakpoints…
51
Figure 5.11: The Breakpoints Window
In some special cases, there are other options available. If there is an automatic material
pull-in, an option will be present to insert a breakpoint after the automatic pull-in, as is
show in the figure below:
52
Figure 5.12: The Breakpoint Window with Automatic Material Pull-In
53
Figure 5.13: Breakpoint Window with Automatic Push-Out
There are three different settings that can be chosen when designating breakpoints:
To set and activate a breakpoint, click once on the box next to the operation that will
follow directly after the breakpoint. When a breakpoint is set and active, it will be
designated by a black check in the square. Once a breakpoint is set and active, it can be
changed to set and inactive by clicking once more on the square. A set but inactive
breakpoint is designated by a black check in a gray square. To remove or clear the
breakpoint, click again on the box and the check will be removed. These three settings
are illustrated in Figure 5.14.
54
Figure 5.14: The Different Breakpoint Settings
After breakpoints have been set, a red circle with a white X appears on the simulation
where the breakpoint is located. If a breakpoint is set but inactive, it appears as a gray
circle with a white X. These indicators can be seen in Figure 5.15 below. The menu
changes slightly after breakpoints are added to include a sub-menu for editing
breakpoints. The new menu appearance is shown in the figure below:
55
Figure 5.15: The Breakpoints Sub-menu
The Edit option allows the user to return to the Breakpoint Window to edit the
breakpoints. The Clear All option removes all breakpoints, the Activate All option
activates all of the set breakpoints, and the Deactivate All option deactivates all set
breakpoints.
Note: If there are no deactivated breakpoints, there will not be an Activate All option on
the Breakpoints sub-menu. Likewise, if there are no activated breakpoints, there will not
be a Deactivate All option on the Breakpoints sub-menu.
To reach the Unit Procedure Icon Style Window, right-click on the icon and select:
56
Figure 5.16: Accessing the Unit Procedure Icon Style Window
After Edit… has been selected, the following window will appear:
57
5.4.1 Changing the Color of the Unit Procedure
By adding a color scheme to the simulation, the user can organize sections of the process.
Different sections of the simulation can be colored to indicate different purposes within
the overall simulation, such as production fermentation versus a purification procedure.
To change the color of the unit procedure icon, it is first necessary to open the Unit
Procedure Icon Style Window, as described above.
1) Click on the Icon tab at the top of the Unit Procedure Icon Style Window.
Note: The Icon tab will automatically appear on top when the Unit Procedure
Icon Style Window is opened.
Note: Changing the color of the unit procedure icon does not change the color of the tag
under the unit procedure. This option will be shown in the next section.
58
5.4.2 Editing the Tag Properties
The Tag is the description that can be seen in Figure 5.2: A Vessel Procedure in a
Fermentor underneath the unit procedure icon. It is often useful to alter the tag properties
for descriptive as well as aesthetic purposes.
To access the Edit Procedure Labels Window, right-click on the procedure and select:
Edit Labels…
After Edit Labels… has been selected, the following window will appear:
The Procedure Name and Equipment name can both hold up to 15 characters, while the
Procedure Description can hold up to 31 characters. The label will appear with the
Procedure Name and Equipment Name on one line, separated by a “/” delimiter, and the
Procedure Description will follow on the next line:
1) Click on the Name Tag: Text tab at the top of the Unit Procedure Icon Style
Window. For information on how to reach the Unit Procedure Icon Style
window, refer to Section 5.4.1.
59
2) To remove the tag completely, click on the box in front of Show Label to remove
the “x”.
3) To change the font of the tag, click on the Font button to open a separate font
window in which the user can select the desired font, size, and font style.
4) To change the color of the tag text, click on the Font button to open the font
window and click on the drop down menu labeled Color to choose from a list of
colors.
5) To change the color of the background of the tag, click on the Color button on the
Name Tag: Text tab to open a separate color window in which the user can select
the desired color. Note that a color can be chosen only if the text background is
specified as Opaque. If the desired background is clear, choose the Transparent
option. This will allow any lines behind the tag to show through.
In addition to editing the text of the tag, it is also possible to have a frame around the tag.
The following section with discuss this option.
1) Click on the Name Tag: Frame tab at the top of the Unit Procedure Icon Style
Window.
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2) Click the circle in front of the style of choice. Choices include solid, dotted,
dashed, dash-dot, dash-dot-dot, and invisible.
3) Click the circle in front of the thickness of choice. Note that different thicknesses
are only available for solid lines. All options other than 1 pt are non-editable
when a style other than solid is selected.
4) Click on the button marked Colors… to open a separate color window in which
the user can select the desired color.
Because there are so many options to customize the appearance of the unit procedure icon
and tag, SuperPro® has a function that allows the user to pick up a style and apply it to
another unit procedure icon and tag.
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5.4.2D Picking Up and Applying an Icon Style
To pick up an icon style, right-click on the unit procedure icon and select:
An alternate way to pickup a unit procedure icon style is to click the button on the
Visual Objects Toolbar along the right side of the SuperPro® window.
After a unit procedure icon style has been picked up, it is possible to apply that style to
another unit procedure. To do this, right-click on the unit procedure icon and select:
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Figure 5.23: Applying a Unit Procedure Icon Style
An alternate way to apply a unit procedure icon style is to click the button on the
Visual Objects Toolbar along the right side of the SuperPro® window.
• Bulk streams have flow rates such as kg/h or kg/batch, where the amount of
medium in the stream is apparent in the value of the flow rate.
• Discrete streams have flow rates such as vials/batch or bottles/batch, where each
vial contains a particular mass or volume, making it possible to calculate the
amount of medium in the stream.
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Note: It is not necessary to specify explicitly the nature of the stream. SuperPro® will
automatically designate the type of stream based on which Error! Reference source not
found. the stream is connected.
Discrete flow is only available for five of the unit procedures that SuperPro® offers.
These procedures include Flow Mixing, Flow Splitting, Generic Boxes, Grinding, and
Shredding. Flow mixers and flow splitters use the same type of stream as inputs and
outputs, so, for example, a discrete flow mixer will have a discrete output. Generic boxes
allow the user to change a discrete stream to a bulk stream and vice versa. Discrete
grinders and shredders have discrete inputs and bulk outputs. For more information on
these unit operations, refer back to Section 5.0.
SuperPro® distinguishes between bulk and discrete streams in three ways: the color of
the stream, the appearance of the port, and the stream properties. For a bulk stream, the
stream is drawn black and the input port is designated by an arrow. For a discrete stream,
the stream is drawn blue and the input port is designated with a small square next to the
arrow. These differences can be seen on a flow splitter shown below in Figure 6.1.
Note: Discrete flows are also designated as DS-101 (as opposed to S-101) and the
procedure description is automatically set as “Discrete Flow Splitting” for the flow
splitter using discrete flows. If an operation has a discrete flow in, it must also have a
discrete flow out.
In addition to the two types of streams, there are three categories of process streams:
Input Stream
, Intermediate Stream
, and Error! Reference source not found.. These streams are highlighted below in
Figure 6.2.
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Figure 6.2: Different Types of Process Streams
• To enter Connect Mode, click the Connect Mode button on the main toolbar:
When in Connect Mode, the cursor will change to the Connect Mode Cursor:
Note: The simulation will remain in connect mode after you draw the stream(s). To
leave connect mode and return to Select Mode
, click the Arrow button next to the Connect Mode button.
• To enter Temporary Connect Mode, hold down the Control (Ctrl) key on the
keyboard and double-click to begin the stream. To end the stream, double-click
again.
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6.2.1 Drawing Input Streams
► In Connect Mode:
1) Hold the Ctrl key and double-click on an open area to begin the stream. After
beginning the stream, it is no longer necessary to hold the Ctrl key.
2) To change the direction of the stream, click once on the open area. The stream
will bend at a 90 degree angle. Click once more to change direction again.
3) Click once on an input port to connect the stream to the unit operation.
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► In Temporary Connect Mode:
1) Hold the Ctrl key and double-click on an output port to begin the stream. After
beginning the stream, it is no longer necessary to hold the Ctrl key.
2) To change the direction of the stream, click once on the open area. The stream
will bend at a 90 degree angle. Click once more to change direction again.
3) Double-click on an open area to end the stream.
1) Hold the Ctrl key and double-click on an output port to begin the stream. After
beginning the stream, it is no longer necessary to hold the Ctrl key.
2) To change the direction of the stream, click once on the open area. The stream
will bend at a 90 degree angle. Click once more to change direction again.
3) Click once on an input port of another unit operation to end the stream.
Note:
• It is not necessary to draw stream elbows for intermediate streams. The stream
drawn by clicking an output port and ended by clicking an input port. SuperPro®
will automatically place elbows in the stream where needed. These elbows can
later be edited to place the stream in the best location.
• If an elbow is placed in an undesirable location, a right click will remove the
elbow.
• Connect Mode can be exited without finishing the current stream by pushing the
Esc key on the keyboard. The stream being drawn will be aborted.
• A stream must be in a horizontal position in order to be connected to a port.
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The properties window for a bulk stream has four tabs: Composition, etc., Density,
Env. Properties, and Comments. To access the properties window for a stream, right-
click on the stream and select:
Simulation Data
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Figure 6.7: Bulk Stream Properties Window
The interface presented in the above figure can be used to specify the components and
flowrates of streams. The following sections will describe these functions in further
detail.
1) Begin by clicking the Composition, Etc. tab along the top of the properties
window. (See Figure 6.8 below).
2) Choose either Components or Stock Mixtures based on the ingredient to be
added.
3) Choose the component or stock mixture to be added in the Registered
Ingredients List.
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Note: If the component or mixture to be added does not appear on the list of
Registered Ingredients, refer to Section 4.1.1 on how to register components.
4) Click the >>> button to add the component or stock mixture to the stream.
Figure 6.8 below depicts the necessary actions to specify the stream components of a
bulk input stream.
Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk Stream
Once pure components and stock mixtures are registered in the Simulation Data
Interface, the user has the option to edit the composition of each component in a stream.
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• Setting the total flowrate and the mass composition of the stream
Note: When setting ingredient flows, SuperPro® will automatically calculate the total
flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be
manually edited and the boxes appear gray.
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1) Select Mass Composition by clicking on the small circle in front of “Mass
Composition” in the Set area below the Composition area.
2) Click on the cell in the Mass Comp. column to enter edit mode.
3) Input the mass composition in percentage form (%).
4) Enter the total flowrate for the stream. This can be done in either mass flow or
volumetric flow. Click on the circle in front of the flow of choice, and the box
will change to edit mode.
Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk Input Stream
Note: SuperPro® will automatically calculate the ingredient flows based on the mass
composition and total flowrate. Therefore the component flows cannot be manually
altered while setting mass compositions.
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While the Density, Env. Properties, and Comments tabs are the same for all three types
of streams, the Composition, Etc. tab is different for an input stream than for an
Intermediate or Output stream. Figure 6.11 below shows the Composition, Etc. tab for
Intermediate and Output streams.
Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams
Note: The only difference between this section for Intermediate and Output Streams
and that for Input Streams is the lack of the Registered Ingredients section. SuperPro®
will automatically calculate the components and flows of the streams based on the inputs
and unit operations and, therefore, this section does not need to be included.
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6.3.4 Setting Units (Composition, Etc. Tab)
1) To change the units of the mass, volume, composition, or concentration, click on
the drop-down arrow next to the unit of choice.
2) Select the desired from the drop-down menu.
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Figure 6.13: Setting a Known Mixture Density for a Bulk Stream
3) If the density is unknown, SuperPro® can calculate the density based on the
contribution to each ingredient in the stream.
4) Click the circle in front of the word “Calculated” to access the Volumetric
Contribution Coefficients area.
5) Click the circle in front of “Ingredient
6) ” or “Component
7) ” based on the data to be inputted. If all of the ingredients are pure components,
there will be no difference between the Ingredients and Components options.
8) Click on the cell in the Coefficient column to enter edit mode.
9) Enter the desired coefficient.
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Figure 6.14: Setting the Density Based on Ingredient or Component Contributions
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Figure 6.15: The Environmental Properties Tab for a Bulk Stream
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Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream
After you have selected Simulation Data, the following window will appear:
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6.4.1 Setting the Description of the Entity for a Discrete
Input Stream (Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will
automatically be on top when the properties window appears.
2) Click on the text box next to Name under the Description area to enter the name
of the entity (for example, bottle or vial). If the entity is present in more than one
area of the process, both entities should be given the same name.
3) To set the Bulk Conversion Factor
4) , first choose the units and click the circle next to mass or volume depending on
preference. Then click the text box next to Bulk Amount Per Entity to enter the
number. Units are in g/entity or cm3/entity. If the entity is present in more than
one area of the process, both entities should be given the same bulk conversion
factor.
5) To set the purchasing price, click the text box next to Purchasing Price and enter
the price. Units are given in $/entity.
6) To set the selling price, click on the text box next to Selling Price and enter the
price. Units are given in $/entity.
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6.4.2 Setting the Flow of the Entity in the Input Stream
(Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will
automatically be on top when the properties window appears.
2) Click on the text box in the Flow area to enter the number of entities per batch.
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Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams
Note: The only difference here is the inability to alter the description and flowrates of
the entity. SuperPro® will automatically update the description and flow of the entity
based on the input entity.
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Figure 6.21: Adding Components to a Discrete Input Stream
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Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows
Note: When setting ingredient flows, SuperPro® will automatically calculate the total
flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be
manually edited and the boxes appear gray.
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Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete Input
Stream
Note: SuperPro® will automatically calculate the ingredient flows based on the mass
composition and total flowrate. Therefore the component flows cannot be manually
altered while setting mass compositions.
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Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams
Note: SuperPro® will automatically calculate the components and flows of the streams
based on the inputs and unit operations, so these fields cannot be edited by the user.
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Figure 6.25: Setting a Known Mixture Density
3) If the density is unknown, SuperPro® can calculate the density based on the
contribution to each ingredient in the stream.
4) Click the circle in front of the word “Calculated” to access the Volumetric
Contribution Coefficients area.
5) Click the circle in front of “Ingredient
6) ” or “Component
7) ” based on the data to be inputted. If all of the ingredients are pure components,
there will be no difference between the Ingredients and Components options.
8) Click on the cell in the Coefficient column to enter edit mode.
9) Enter the desired coefficient.
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Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a Discrete
Stream
Note that intermediate and output streams from flow mixers or splitters do not include a
Density tab. This is because the density of the intermediate and output streams are the
same as the input stream.
To reach the Stream Style Window, right-click on the stream and select:
Style >> Edit Style…
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Figure 6.27: How to Reach the Stream Style Window
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6.5.1 Changing the Color, Style, and Thickness of the
Stream
Colors, styles, and thicknesses can be used to classify streams and provide an indication
of the nature of a stream. For example, if a stream contains a hazardous substance, it can
be changed to a specific color, along with all other streams containing hazardous
substances, to allow the user and other readers to recognize that the stream contains a
hazardous substance. Entire sections of a process can also be edited to be a specific
color, separating the section from the rest of the process. The following steps describe
how to change the color, style, and thickness of a stream.
1) Click on the Stream Line tab at the top of the Stream Style window.
Note: The Stream Line tab will automatically appear on top when the Stream
Style window is opened.
2) Click the circle in front of the style of choice. Choices include solid, dotted,
dashed, dash-dot, dash-dot-dot, and invisible.
3) Click the circle in front of the thickness of choice. Note that different thicknesses
are only available for solid lines. All options other than 1 pt are non-editable
when a style other than solid is selected.
4) Click on the button marked Colors… to open a separate color window.
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6.5.2 Editing the Tag Properties
In addition to colors, the appearance and location of the stream tags can be edited, as well
as the actual text of the tag. The following sections explain how to change these
properties.
After Edit Tag Name… is selected, the following window will appear:
To change the tag name, enter the desired name in the text box and click OK to accept
the change.
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6.5.2B Editing the Tag Text Style
6) Click on the Name Tag: Text tab at the top of the Stream Style Window. For
information on how to reach the Stream Style window, refer to 6.5 Physical
Characteristics.
7) To remove the tag completely, click on the box in front of Show Label to remove
the “x”.
8) To change the font of the tag, click on the Font button to open a separate font
window in which the user can select the desired font, size, and font style.
9) To change the color of the tag text, click on the Font button to open the font
window and click on the drop down menu labeled Color to choose from a list of
colors.
10) To change the color of the background of the tag, click on the Color button on the
Name Tag: Text tab to open a separate color window in which the user can select
the desired color. Note that a color can be chosen only if the text background is
specified as Opaque. If the desired background is clear, choose the Transparent
option. This will allow any lines behind the tag to show through.
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6.5.2C Editing the Appearance of the Tag Frame
1) Click on the Name Tag: Frame tab at the top of the Stream Style Window.
2) Click the circle in front of the style of choice. Choices include solid, dotted,
dashed, dash-dot, dash-dot-dot, and invisible.
3) Click the circle in front of the thickness of choice. Note that different thicknesses
are only available for solid lines. All options other than 1 pt are non-editable
when a style other than solid is selected.
4) Click on the button marked Colors… to open a separate color window in which
the user can select the desired color.
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Figure 6.34: The Name Tag: Location Window
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Figure 6.35: How to Pickup a Stream Style
An alternate way to pickup a stream style is to click the button on the Visual Objects
Toolbar along the right side of the SuperPro® window.
To apply the style to another stream, right-click on the stream and select:
Style…>>Apply Style
Note: If the style of a stream has not been picked up, the Apply Style option will not be
present.
An alternate way to apply a stream style is to click the button on the Visual Objects
Toolbar along the right side of the SuperPro® window.
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7.0 Specify Operations
Once the user has added unit procedures and input, output, and intermediate streams, it is
necessary to specify the Operation that will occur within each piece of equipment. The
design in its current state is inactive. The pieces of equipment and piping between units
are present, but nothing is actually happening. Individual pieces of equipment allow for a
wide variety of operations. It is important for the user to specify operations from simply
mixing and fermenting to transferring stream contents in and out of units. The following
sections will describe in further detail how to add, remove, and insert operations in
SuperPro®.
Add/Remove Operations
Note: This option is only available for processes in the batch or semi-continuous modes.
The following figure, the Operation Interface, will appear in the design window.
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Figure 7.2: Operation Interface
The available operations will be different for different types of unit procedures. For
example, a fermentation procedure, as in Figure 7.2, gives the user twenty-four options
for types of operations, where a mixing tank only has three options. To access a list of
the available operations, refer back to Table 5.1.
To add a particular operation, simply click on the desired operation in the left-hand
Available Operations Column and select:
>>Add>>
The selected operation will then be added to the right-hand Operation Sequence
Column. Additional operations can be added to the operation sequence, however, the
SuperPro® functions >>Add>> and >>Insert>> are sensitive to the order in which they
are utilized.
For example, if the operation sequence presented in Figure 7.3 below is the current
sequence and the user wants to incorporate a TRANSFER OUT operation after the
FERMENT operation, simply:
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1
Once these steps are taken, TRANSFER OUT will be added as an operation following
the FERMENT operation, as shown in Figure 7.4.
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Figure 7.4: Result of >>Add>> Function
To add an operation between two current operations, the >>Insert>> function needs to be
utilized. For example, to insert a TRANSFER IN operation before the FERMENT
operation and after the CHARGE operation, simply:
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Figure 7.5: >>Insert>> Function
Once operations are added or inserted in the operation sequence, they can be deleted by
highlighting the particular operation and selecting the Delete button, as shown above in
Figure 7.5.
Note: It is important to develop the proper operation sequence early in the process.
Once additional specifications are made in the simulation, the operation sequence can be
changed or reordered, however changing the sequence may cause problems with
scheduling and other design parameters.
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Figure 7.6: Renaming an Operation
The user is given the option to rename an operation to allow for easy reference, such as,
for example, saying “Charge Glucose” versus “Charge Water” or to utilize the
terminology familiar to a particular business.
Figure 7.7 below represents the steps need to access the Operation Data Interface for a
particular operation.
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Figure 7.7: Accessing Operation Data Interface
For example, if Charge-1 were selected from the above figure, the following interface, in
Figure 7.8 would appear.
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Figure 7.8: Operation Data Interface
As showing in Figure 7.8 above, the Operation Data Interface allows the user to
manually input operation characteristics for the following categories:
• Operation Conditions
• Emissions
• Labor, etc.
• Description
• Scheduling
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For more complicated operations, such as reactions and fermentations, additional tabs
such as Reactions and Volume will be present. For these types of operations, the user is
required to specify the kinetic and stoichiometric data as well as the maximum allowable
and minimum allowable volume for that procedure. For additional information on the
functions of each individual operation, refer to the Help menu of SuperPro® that is
located in the top right-hand corner of the flowsheet, as shown in Figure 7.9.
Users can access the Help Topics section of this menu and search for more specific
information on the many types of operations.
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8.0 Schedule Process
After the process has been specified with unit procedures, streams, and operations, it is
necessary to begin scheduling the process. To begin scheduling the first unit procedure,
right-click on the unit procedure and select:
This menu lists the unit operations that are present in the unit procedure in the order that
they were added to the procedure. If the operations are not in the desired sequence, refer
to Section 7.1 for information on how to change the order of the operations.
Note: Scheduling is only necessary for batch processes. Continuous processes require no
scheduling information in order for the procedure to run.
Once the order of the operations has been verified, the scheduling process can begin. The
user should choose the first operation in the unit procedure and they will arrive at a
screen similar to Figure 8.2.
1) Click on Oper. Cond’s tab. Note: The Oper. Cond’s tab will automatically
appear on top when the Unit Operation Properties window is opened.
2) Specify setup time.
3) Specify process time (three methods: user specified, simulation calculated,
master-slave relationship).
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Figure 8.2: Operation Duration Conditions
To continue directly to the next operation for the unit procedure, select:
OK>>
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8.1.1 User Specified
If the process time for a particular operation is known, the user may provide the time
numerically by choosing the Set by User option as seen in Figure 8.3. In the box next to
the Set by User option, the user may enter the desired time value and select the
appropriate corresponding units.
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Figure 8.3: Operation Duration: Master-Slave Relationship
Once the user chooses the Setup… button, a screen similar to Figure 8.4 will appear.
The Slave Operation at the top of Figure 8.4 should be verified as the operation that the
user is currently scheduling. The user must then specify the Master Procedure. The
master procedure can be specified as either the same as the slave operation’s procedure,
or as another procedure in the process.
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Figure 8.4: Master-Slave Relationship – Master Procedure Setup
Once the master procedure is chosen, the Master Operation can be specified. This is
done by choosing to match a single operation or to match a sequence of operations.
Choosing to match a single operation will specify to SuperPro® that the slave operation
should take the same amount of time as the master operation, while choosing to match a
sequence of operations will specify that the slave operation should take the same amount
of time as a group of operations in sequence.
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Figure 8.5: Master-Slave Relationship – Master Single Operation Setup
When matching a sequence of operations, the user should specify which operation the
master sequence should start with and which operation it should finish with (i.e., the
beginning of the slave operation should start at the same time as the master operation that
is chosen in the Starting With box, and the slave operation should end at the same time
as the master operation that is in the Ending With box). As indicated by Figure 8.5, the
master operations are chosen by clicking on the down arrow next to the corresponding
box.
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Figure 8.6: Master-Slave Relationship – Master Sequence Operation Setup
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Figure 8.7: Scheduling Overview Screen
The next task in the scheduling process is to indicate when each operation should start.
This can be done in the Start Time section of the scheduling screen (see Figure 8.8). If
the starting time of the operation is known, the user can indicate a start time shift. If the
starting time is not known, a scheduling relationship can be used to determine when the
operation will begin. The four scheduling relationships are:
Note: When using a scheduling relationship, remember that indicating a start time shift
will cause a shift from the beginning of the relationship time specification.
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Figure 8.8: Scheduling Overview Screen – Start Time Information
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8.2.2 Using the “Previous Operation in the Same
Procedure” Relationship
The start time of an operation can also be scheduled according to the start or end time of
another operation in the same unit procedure. This is done by choosing the circle next to
Relative to Previous Operation in the Procedure, and choosing the desired operation
for comparison. Then it must be specified whether the operation should begin at the start
or the end of the previous operation.
Note: If the user is specifying the first operation in the unit procedure, this start time
scheduling option is not available, as seen in Figure 8.8.
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Figure 8.9: Start Time Relationship – Relative to Another Operation in this Procedure
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Figure 8.10: Start Time Relationship – Relative to Another Operation in Another Procedure
Once the start time and the duration time have been completely specified according to the
procedures above, scheduling for the operation in the unit procedure is complete. This
process should be repeated for all of the operations in each unit procedure. When the
scheduling process is finished, the simulation should run to completion without any
scheduling errors. Scheduling errors for specific operations can be corrected by ensuring
proper scheduling according to the above procedures.
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8.3 Process Schedule Information
Once the scheduling process is complete and the simulation runs without errors, the user
can view the scheduling information for the process by selecting:
Selecting this option will bring up a screen similar to Figure 8.12. This figure is an
overview of all the scheduling information for the process. It indicates the total time to
complete a batch, the number of batches that can be made in a year, the amount of time
the process will be running through out the year, and the longest procedure and
bottleneck of the process. The number of batches per year can be user specified by
clicking on the circle in front of Set by User, in the number of batches per year section.
If there are changes made to the scheduling process after this screen is viewed, click on
Update Sched. Outputs to update this scheduling summary.
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Figure 8.12: Recipe Scheduling Information Data
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Figure 8.13: The Gantt Charts Menu
• Operations GC
• Equipment GC
• Operations GC (Multiple Batches)
• Equipment GC (Multiple Batches)
The Operations Gantt Chart displays the time involved in each operation, segmented
by the unit procedures in which the operations take place. The Operations Gantt Chart
for multiple batches contains the same information, but includes more than one batch run.
The Equipment Gantt Chart displays the time involved in each operation, segmented by
both the unit procedures and the equipment in which the operations take place.
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Figure 9.1: Operation Data Command Screen
Once the first operation is selected, the user will see a screen similar to Figure 9.2 and
should click on the Labor, etc. tab at the top of the screen.
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Figure 9.2: Operation Conditions Main Screen
Once the labor window is open, the user should first choose the type of operator for the
operation. To access a list of the available types of operators, click on the word
“Operator” to make a down arrow appear and then click the down arrow next to it. The
list of available operator types is shown below in Figure 9.3. The type of operator chosen
should be decided by the type of operation. If the user prefers a more generalized labor
assessment, the general operator can be used instead of a more specific one.
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Figure 9.3: Operation Operator Specifications
Next, the user should specify the value of the operator in Labor-hrs/hr or Labor-hrs/cycle
by clicking on the corresponding box and the downward arrow associated with it (see
Figure 9.4).
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Figure 9.4: Operation Labor Units Specification
Once the operator and units are determined, the number of operators can be changed by
clicking on the Add Labor or Delete Labor buttons (see Figure 9.5).
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Figure 9.5: Operation Add/Delete Labor
1) Component Costs
2) Stream Costs
3) Equipment costs
4) Labor & Utility costs
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The following sections will describe how to determine each of these costs using
SuperPro® and how to use SuperPro® to perform an economic evaluation of the process.
Selecting properties will bring up the Component Properties interface, which will look
similar to Figure 10.2. To input economic information such as purchasing price, selling
price, or waste treatment cost, the Economics tab must be selected, as is done in the
following figure.
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Figure 10.2: Component Economic Properties Interface
1) If the component is a reactant, the user should specify the purchasing cost of the
component.
2) If the component is a product, the user should specify the selling price of the
component.
3) If the component is a waste product or byproduct, the user should specify the
waste treatment or disposal cost.
These costs can be specified by clicking on the box next to the corresponding cost
description, as shown above in Figure 10.2. Then the known values from suppliers or
other sources can be entered into the appropriate space. There is also space available to
specify the supplier from whom the component is purchased and any comments regarding
the component.
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10.2 Stream Costs
When determining the costs of streams, the first thing that needs to be evaluated is the
economic classification of the stream. Each stream can be designated as Revenue, Raw
Material, or Waste and then specified with revenue or cost values. Figure 10.3 is the
command interface for bringing up the revenue, raw material, and waste stream
information. To get to the information screen, select:
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stream is the desired product or a particular component in the stream is the desired
product. If a particular component of the product stream is the desired product, click on
the down arrow next to the corresponding box and select that component.
Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface
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• Revenue
• Solid Waste
• Liquid Waste
• Emissions
All of the output streams are listed on the left side of the Specifying Output Stream
Classifications interface. To specify the classification of the stream, the user should click
on the down arrow next to the corresponding box in the classification column of the table.
Then the unit cost of treatment/disposal or selling price of the stream can be specified in
the third column. Some streams may be automatically determined by SuperPro®, but
most will need to be set by the user. Finally, once the streams have been classified and
quantified, they can be marked as hazardous if applicable, using the fifth column in
Figure 10.5.
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10.2.3 Input Stream Classification
Specifying the input streams is done in much the same way as the output streams. In the
case of input streams there are only two possible classifications for the streams: Revenue
and Raw Material. Again, all the input streams are listed on the left hand side of the table
at the bottom of Figure 10.6, the streams are classified by clicking the down arrow in the
corresponding box in the classification column. However, for input streams, most of the
costs associated with the streams are obtained from component cost information, which
has already been entered. The values in the purchasing price/processing fee column may
be altered by clicking on the box and entering the desired value.
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10.3 Equipment Costs
The next area of cost specification is for the equipment in the process. To specify the
economic information for equipment, right-click on the piece of equipment and select:
Equipment Data
Choosing this command will bring up a screen similar to Figure 10.8. On this screen, the
purchase cost tab should be selected so the equipment economics can be viewed and
further specified if necessary. In most cases, SuperPro® will indicate a equipment cost
based on user specified size and capacity that was discussed in Chapter 5. The cost that
is specified is adjusted for the year 2004, but can be altered by clicking on the box and
entering the desired value.
130
Figure 10.8: Equipment Purchase Cost Information
Labor costs are determined from the labor information input in Chapter 9 of this manual.
However, the utility costs can be specified by selecting the Labor, etc. tab on the
operation conditions interface as shown below in Figure 10.9. In the bottom section of
the interface, each utility is given prices which are determined by SuperPro® according
to the national average cost. These prices are displayed in gray boxes and can’t be edited
by the user.
131
In order for SuperPro® to accurately determine the utility costs of the process, it is
necessary to input the rate at which the utilities are being used. To do this, click the box
next to Rate, for each utility, and enter the desired value.
132
Tasks >> Perform Economic Calculations
Note that choosing this command does not bring up any additional interfaces. Instead,
SuperPro® does the calculations internally and the user can then generate the economic
evaluation report. To access this report, select:
133
Figure 10.11: Generating Economic Evaluation Report Interface
Performing this command will bring up the screen below, which requires the user to save
the economic evaluation report as a file. This file can be opened in WordPad or Notepad.
134
After the Economic Evaluation Report has been saved, the file can be opened and
viewed. To view the Economic Evaluation report, select:
as shown in figure 10.13. This command will bring up all the economic information for
the process including total revenue and payback period.
135
11.0 Perform Emissions and Environmental Impact
Assessment
Prior to performing an emissions and environmental impact assessment in SuperPro®,
the environmental properties of each pure and stock component must be registered within
SuperPro® designer. Various classifications exist for both emission and environmental
impact reporting. The following sections will describe the necessary steps to define
emissions and environmental properties, generate the emissions and environmental
impact reports and understand the resulting reports.
Figure 11.1: Selecting the component or stock mixture for registering emissions and environmental
classifications
136
Note: To access the Component Registration window for a Stock Mixture, select:
After the Component Registration window is open, click on the number beside the
component of choice to highlight the component and click the Properties button to
access the Pure Components Properties window:
The following sections will assist the user in determining which classifications to specify.
137
11.1.1 Defining Emissions Pollutant Categories
SuperPro® allows for the specification of eight major air pollutant classes in addition to
up to five other user defined categories. The following information will help the user
decide which emissions classifications to select.
Based on the New Jersey Department of Environmental Protection, raw materials and air
pollutants can be categorized into specific pollutant categories. These categories do not
include the air distillates described in the New Jersey Department of Environmental
Protection Amendment NJAC 7:27-8.1. Some materials may fit into more than one
category and should be categorized twice if there is any uncertainty. The current version
of SuperPro® will not allow the user to categorize components into more than one
category, but future versions plan to allow the user to specify as such.
Note: Additional categories are available if needed for state regulations. For information
on how to specify additional categories, refer to Section 11.1.1A.
The following table presents the major categories of emissions based on information
given by SuperPro®.
138
VCM A. Vinyl Chloride Monomer
TVOS B. Materials which are toxic volatile
organic substances listed in the NJAC
Category II
7:27-17 Table 1
EVOS C. Materials which are exempt volatile
Total VOC
organic substances listed in the NJAC
(Volatile Organic
7:27-16.1 (See Error! Reference source
Compound):
not found.)
materials which
HAP-VOC D. Hazardous Air Pollutants listed in
could not be
Note 10 except VCM (See Error!
detected under NJ
Reference source not found.)
Air Test Method 3
Other VOC E. Volatile Organic Compounds which
are not included in the above sub-
categories
Category III HAP-ACID A. Hazardous Air Pollutants (See Error!
Reference source not found.)
Acid Gases:
materials that are
acid gases and may
or may not be
B. Acid Gases which are not included in
detected as a
sub-category A, including but not limited
particulate using ACID
NJ Air Test to F2, SO3, and H2S
Method 1 or as
VOC using
Method 3
CO
NOx A. Nitrogen Oxides: including N2O, NO,
Category VI
N2O3, N2O4, NO2, N2O5, N3O4, and NO3
NOx (See Error! Reference source not
found.)
Category VII SO2 A. Sulfur Dioxide
139
Note 1:
For the purpose of SuperPro® simulation, the above categories will be used to
characterize all air pollutants and raw materials. Substances that cannot be fit into the
above categories and subcategories, may be listed individually or included in a user-
defined category (see Section 4.1.4B).
Note 2:
The biological subcategory includes infectious substances that require practices, safety
equipment, and facilities that represent a Biosafety Level 2 or higher as denoted by the
Biosafety in Biomedical and Microbiological Laboratories Report in Section III.
Note 3:
The Dioxin subcategory includes the following isomers of chlorinated dibenzo-p-dioxin
(CDDs) and CAS Number
-a unique numeric identifier that designates one substance
Charge
- a method for adding an input to the unit
• 2,3,7,8-TCDD
• 1,2,3,7,8-PeCDD
• 1,2,3,4,7,8-HxCDD
• 1,2,3,7,8,9-HxCDD
• 1,2,3,6,7,8-HxCDD
• 1,2,3,4,6,7,8-HpCDD
• 2,3,7,8-TCDF
• 1,2,3,7,8-PeCDF
• 2,3,4,7,8-PECDF
• 1,2,3,4,7,8-HxCDF
• 1,2,3,7,8,9-HxCDF
• 1,2,3,6,7,8-HxCDF
• 2,3,4,6,7,8-HxCDF
• 1,2,3,4,6,7,8-HpCDF
• 1,2,3,4,7,8,9-HpCDF
For more information about Dioxin compounds see Error! Reference source not
found..
140
Note 4:
Includes the following substances:
• Methane
• Trichlorofluoromethane
• Dichlorodifluoromethane
• Chlorodifluoromethane
• Trifluoromethane
• 1,1,2-Trichloro-1,2,2-Trifluoroethane
• 1,2,-Dichloro-1,1,2,2 Tertafluoroethane
• Chloropentafluoroethane
Note 5:
Extraordinarily Toxic Gases
141
Note 6:
CO2 is NOT a VOC
Note 7:
Nitrogen Oxides include:
• N2O (nitrous oxide)
• NO (nitric oxide)
• N2O4 (dinitrogen tetroxide or nitrogen peroxide)
• NO2 (nitrogen dioxide)
• N2O5 (dinitrogen pentoxide)
• N3O4 (trinitrogen tetroxide)
• NO3 (nitrogen trioxide)
Note 8:
Includes the following chemicals:
Name CAS Number
Chlorine 7782505
Hydrogen Chloride 7647010
Hydrogen Fluoride 7664393
Note 9:
Includes the following chemicals:
Name CAS Number
Phosphine (PH3) 7803-51-2
Arsine (AsH3) 7784-42-1
Note 10:
Includes the following chemicals:
142
4-Aminobiphenyl 92671
Aniline 62533
o-Anisidine 90040
Asbestos 1332214
Benzene (including benzene from 71432
gasoline)
Benzidine 92875
Benzotrichloride 98077
Benzyl chloride 100447
Biphenyl 92524
Bis(2-ethylhexyl)phthalate (DEHP) 117817
Bis(chloromethyl)ether 542881
Bromoform 75252
1,3-Butadiene 106990
Calcium cyanamide 156627
Caprolactam 105602
Captan 133062
Carbaryl 63252
Carbon disulfide 75150
Carbon tetrachloride 56235
Carbonyl sulfide 463581
Catechol 120809
Chloramben 133904
Chlordane 57749
Chlorine 7782505
Chloroacetic acid 79118
2-Chloroacetophenone 532274
Chlorobenzene 108907
Chlorobenzilate 510156
Chloroform 67663
Chloromethyl methyl ether 107302
Chloroprene 126998
Cresols/Cresylic acid (isomers and 1319773
mixture)
o-Cresol 95487
m-Cresol 108394
p-Cresol 106445
Cumene 98828
2,4-D, salts and esters 94757
DDE 3547044
Diazomethane 334883
Dibenzofurans 132649
1,2-Dibromo-3-chloropropane 96128
Dibutylphthalate 84742
1,4-Dichlorobenzene(p) 106467
143
3,3-Dichlorobenzidene 91941
Dichloroethyl ether (Bis(2- 111444
chloroethyl)ether)
1,3-Dichloropropene 542756
Dichlorvos 62737
Diethanolamine 111422
N,N-Diethyl aniline (N,N- 121697
Dimethylaniline)
Diethyl sulfate 64675
3,3-Dimethoxybenzidine 119904
Dimethyl aminoazobenzene 60117
3,3'-Dimethyl benzidine 119937
Dimethyl carbamoyl chloride 79447
Dimethyl formamide 68122
1,1-Dimethyl hydrazine 57147
Dimethyl phthalate 131113
Dimethyl sulfate 77781
4,6-Dinitro-o-cresol, and salts 534521
2,4-Dinitrophenol 51285
2,4-Dinitrotoluene 121142
1,4-Dioxane (1,4-Diethyleneoxide) 123911
1,2-Diphenylhydrazine 122667
Epichlorohydrin (l-Chloro-2,3- 106898
epoxypropane)
1,2-Epoxybutane 106887
Ethyl acrylate 140885
Ethyl benzene 100414
Ethyl carbamate (Urethane) 51796
Ethyl chloride (Chloroethane) 75003
Ethylene dibromide 106934
(Dibromoethane)
Ethylene dichloride (1,2- 107062
Dichloroethane)
Ethylene glycol 107211
Ethylene imine (Aziridine) 151564
Ethylene oxide 75218
Ethylene thiourea 96457
Ethylidene dichloride (1,1- 75343
Dichloroethane)
Formaldehyde 50000
Heptachlor 76448
Hexachlorobenzene 118741
Hexachlorobutadiene 87683
Hexachlorocyclopentadiene 77474
Hexachloroethane 67721
144
Hexamethylene-1,6-diisocyanate 822060
Hexamethylphosphoramide 680319
Hexane 110543
Hydrazine 302012
Hydrochloric acid 7647010
Hydrogen fluoride (Hydrofluoric 7664393
acid)
Hydrogen sulfide 7783064
Hydroquinone 123319
Isophorone 78591
Lindane (all isomers) 58899
Maleic anhydride 108316
Methanol 67561
Methoxychlor 72435
Methyl bromide (Bromomethane) 74839
Methyl chloride (Chloromethane) 74873
Methyl chloroform (1,1,1- 71556
Trichloroethane)
Methyl ethyl ketone (2-Butanone) 78933
Methyl hydrazine 60344
Methyl iodide (Iodomethane) 74884
Methyl isobutyl ketone (Hexone) 108101
Methyl isocyanate 624839
Methyl methacrylate 80626
Methyl tert butyl ether 1634044
4,4-Methylene bis(2-chloroaniline) 101144
Methylene chloride 75092
(Dichloromethane)
Methylene diphenyl diisocyanate 101688
(MDI)
4,4¬-Methylenedianiline 101779
Naphthalene 91203
Nitrobenzene 98953
4-Nitrobiphenyl 92933
4-Nitrophenol 100027
2-Nitropropane 79469
N-Nitroso-N-methylurea 684935
N-Nitrosodimethylamine 62759
N-Nitrosomorpholine 59892
Parathion 56382
Pentachloronitrobenzene 82688
(Quintobenzene)
Pentachlorophenol 87865
Phenol 108952
p-Phenylenediamine 106503
145
Phosgene 75445
Phosphine 7803512
Phosphorus 7723140
Phthalic anhydride 85449
Polychlorinated biphenyls 1336363
(Aroclors)
1,3-Propane sultone 1120714
beta-Propiolactone 57578
Propionaldehyde 123386
Propoxur (Baygon) 114261
Propylene dichloride (1,2- 78875
Dichloropropane)
Propylene oxide 75569
1,2-Propylenimine (2-Methyl 75558
aziridine)
Quinoline 91225
Quinone 106514
Styrene 100425
Styrene oxide 96093
2,3,7,8-Tetrachlorodibenzo-p- 1746016
dioxin
1,1,2,2-Tetrachloroethane 79345
Tetrachloroethylene 127184
(Perchloroethylene)
Titanium tetrachloride 7550450
Toluene 108883
2,4-Toluene diamine 95807
2,4-Toluene diisocyanate 584849
o-Toluidine 95534
Toxaphene (chlorinated camphene) 8001352
1,2,4-Trichlorobenzene 120821
1,1,2-Trichloroethane 79005
Trichloroethylene 79016
2,4,5-Trichlorophenol 95954
2,4,6-Trichlorophenol 88062
Triethylamine 121448
Trifluralin 1582098
2,2,4-Trimethylpentane 540841
Vinyl acetate 108054
Vinyl bromide 593602
Vinyl chloride 75014
Vinylidene chloride (1,1- 75354
Dichloroethylene)
Xylenes (isomers and mixture) 1330207
o-Xylenes 95476
146
m-Xylenes 108383
p-Xylenes 106423
Antimony Compounds 0
Arsenic Compounds (inorganic 0
including arsine)
Beryllium Compounds 0
Cadmium Compounds 0
Chromium Compounds 0
Cobalt Compounds 0
Coke Oven Emissions 0
Cyanide Compounds1 0
Glycol ethers2 0
Lead Compounds 0
Manganese Compounds 0
Mercury Compounds 0
Fine mineral fibers3 0
Nickel Compounds 0
Polycylic Organic Matter4 0
Radionuclides (including radon)5 0
Selenium Compounds 0
To specify that a component has VCM emissions, click on the box next to VOC to make
the subcategory editable. After VOC has been selected, click on the circle next to
Specific to be able to choose the type of VOC. Now click on the square next to VCM.
After the square has been clicked, an X will appear in the box. Figure 11.3 depicts the
selection of VOC>>Specific>>VCM and Acid gas>>HAP-gas for glucose. To finish
and save selections, select OK.
147
Figure 11.3: Selection of VOC and Acid gas for emissions consideration
Preferences>>Emission Limits
148
Figure 11.4: Accessing the Emission Limits Window
149
Figure 11.5: Adding User-Defined Pollutant Categories
User-defined pollutant categories can be added by selecting the square to the left of the
input box (indicated by the red arrow in Figure 11.5) and typing the name of the category
in the input box.
150
The designation of solid waste, liquid waste and emission depend on the physical state of
the exiting waste stream from a unit operation. SuperPro® typically pre-selects each
component and mixture to be a solid, liquid and emission waste source. In order to
change the environmental impact classification of a component or mixture, the user must
access the Pollutant Categories window as specified in Section 11.1. In order to select
or deselect the option of reporting a component as a solid waste, liquid waste or
emissions, the user must toggle the preceding box so that desired specifications are
marked with an X and undesired specifications contain empty boxes.
The user is responsible for designating a pure component and/or mixture as a hazardous,
SARA 313 or 33/50 source of waste with the aid of the following information:
Information on both hazardous and SARA 313 reportable chemicals are accessible at the
following URL: http://www.epa.gov/tri/chemical/RY2003ChemicalList.pdf
o Benzene
o Carbon tetrachloride
o Chloroform
o Dichloromethane
o Methyl ethyl ketone
o Methyl isobutyl ketone
o Tetrachloroethylene
o Toluene
o 1,1,1-Trichloroethane
o Trichloroethylene
o Xylenes
o Cadmium and cadmium compounds
o Chromium and chromium compounds
o Cyanide compounds
o Lead and lead compounds
o Mercury and mercury compounds
o Nickel and nickel compounds
Once the appropriate hazardous material classifications have been determined, the user
inputs the selections in the same manner as was performed for defining emissions
categories.
Access Pollutant Categories window. Toggle the box for the appropriate hazard
consideration and waste consideration so that an X appears in the box. Figure 11 depicts
the selection of Is Reported in Liquid Wastes?>>Is Hazardous>>threshold value of
0.500ppm for Sodium Hydro Phosphate. To finish and save selections, select OK.
151
Figure 11.6: Selection of hazard and waste considerations.
152
11.2.1 Generation of Emissions Report (EMS)
To generate an emissions report, proceed with the following selections, also illustrated in
Figure 11.6:
Note: SuperPro® will prompt the user to designate a name and location for saving the
generated emissions report. The file type should be left at default designation, THR File
(*.ems). In addition, SuperPro®, by default, saves the file in the same directory as the
simulation file and names the emissions report by the same file name as the simulation.
If the user desires to name the file under a different name, or desires to save the file in a
different directory, SuperPro® will not be able to access the report when prompted to
generate a viewable emissions report.
153
Figure 11.8: Selection steps for generating an environmental impact report.
Note: SuperPro® will prompt the user to designate a name and location for saving the
generated emissions report. The file type should be left at default designation, EIR File
(*.eir). In addition, SuperPro®, by default, saves the file in the same directory as the
simulation file and names the emissions report by the same file name as the simulation.
If the user desires to name the file under a different name, or desires to save the file in a
different directory, SuperPro® will not be able to access the report when prompted to
generate a viewable environmental impact report.
View>>Emissions Report
154
Figure 11.9: Selection steps for viewing an emissions report.
Note: SuperPro® automatically searches the file directory containing the simulation file
for files with the same name as the simulation file, but with the appropriate extension
(.ems and .eir for emissions and environmental impact reports, respectively). If the
appropriate file is located, SuperPro® will automatically generate a text file containing
the calculated information for emissions or environmental impact.
If the user has decided to save the generated emissions and/or environmental impact
report under a different name or file directory than defaulted by SuperPro®, the
generated report may be viewed by performing the following selections:
View>>Any Report…
SuperPro® will then prompt the user to specify the directory and file to open.
155
11.4 Interpreting an Emissions and Environmental
Impact Report
Once SuperPro® has generated a viewable text file for the desired emissions and/or
environmental impact report, the user is presented with the daunting task of making sense
of the presented data.
The first section specifies the stream name, source of the stream and the destination of the
stream. The emissions specifications are presented in the 8 main categories of emissions
as well as the subclassifications for each main emission category. A comparison between
the calculated values versus the allowable values is given on a kg/h basis for each
individual stream. Figure 11.10 depicts the stream portion of the emission report.
156
The second section of the emissions report presents information on the total emissions
per batch. Again, a comparison between calculated values and allowable values is given
for further comparison. Figure 11.11 depicts the emissions report on a per batch basis.
Figure 11.11: Illustrates the per batch portion of the emissions report.
157
9. Hazardous streams
10. Pollution indices
Stream section: Each stream is described by its name, source and destination procedure
(or INPUT/OUT). A list of each stream’s environmental and aqueous properties is
included (TOC, COD, ThOD, etc.) as concentrations (in mg/l) and daily demands (kg
carbon/day or kg oxygen/day). SuperPro® denotes the beginning of the stream section
with the following title:
Overall balance section: Presents the total environmental load (increase or decrease) as
reflected by the values of TOC, COD, etc. of all streams entering and leaving the process.
Two tables are generated: 1) one presents the values either on a per hour basis (only
choice for continuous processes) or on a per batch basis (batch processes); 2) the second
table has the same numbers on a yearly basis. SuperPro® denotes the beginning of the
overall balance with the following title:
Component fate section: Presents the allocation of each chemical that either enters or is
produced by the plant facility to all waste gateways. The first column presents the
cumulative amounts of each chemical entering in any of the input streams of the plant,
and the next three columns present the amounts leaving the plant in all waste streams
(solid, liquid or gaseous). SuperPro® denotes the beginning of the component fate
section with the following title:
SARA 313 chemicals section: Presents an accurate account of all SARA 313 chemicals
entering and leaving the plant as well as their difference. SuperPro® denotes the
beginning of the SARA 313 chemical section with the following title:
33/50 chemical section: Presents an accurate account of all 33/50 chemicals entering and
leaving the plant as well as their difference. SuperPro® denotes the beginning of the
33/50 chemical section with the following title:
Solid waste section: Consists of two parts. Part 1 enumerates all streams that are
characterized as solid waste by listing their composition (weight %), flowrate (in kg/h)
and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as solid waste is
distributed in each stream. SuperPro® denotes the beginning of the solid waste section
with the following title:
158
**** SOLID WASTE Section ****
Liquid waste section: Consists of two parts. Part 1 enumerates all streams that are
characterized as liquid waste by listing their composition (weight %), flowrate (in kg/h)
and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as liquid waste
is distributed in each stream. SuperPro® denotes the beginning of the liquid waste
section with the following title:
Emissions section: Consists of two parts. Part 1 enumerates all streams that are
characterized as emissions by listing their composition (weight %), flowrate (in kg/h) and
annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as emissions is
distributed in each stream. SuperPro® denotes the beginning of the emissions section
with the following title:
Hazardous streams section: Reports the hazardous streams. The format of this section is
similar to those of waste streams. SuperPro® denotes the beginning of the hazardous
streams section with the following title:
Pollution indices stream: Presents certain ratios that are indicative of the environmental
kindness (or lack thereof) of a design case. The first index presented applies to processes
that have a main revenue stream (e.g. manufacturing facilities with a main product
stream). It reports the ratio of total amount of waste (solid, liquid and emissions)
produced per kg of main revenue stream processed. The next three indices are similar but
report each of the three separate categories of wastes instead. The next four indices apply
to processing plants that employ raw materials. It reports the ratio of total, solid, liquid
and gaseous waste produced per kg of raw material utilized. SuperPro® denotes the
beginning of the emissions section with the following title:
159
Glossary
33/50 EPA Program
-targeted 17 priority chemicals and set as its goal a 33% reduction in releases and
transfers of these chemicals by 1992 and a 50% reduction by 1995, measured against
a 1988 baseline
-sought to foster a pollution prevention ethic, encouraging companies to focus on
reducing releases of chemicals rather than treating and disposing of wastes
Acentric Factor
Agitate
- used to disturb the system as a method of mixing
Batch
-(cyclical) mode where there is a dead time (or ‘off time’)
Biomass
-any plant derived organic matter available on a renewable basis
BOD5
-amount of dissolved oxygen consumed in five days by biological processes breaking
down organic matter
BOD5/BODu
-ratio of the five-day BOD to the ultimate BOD value
BODu/COD
-ratio of the ultimate biochemical oxygen demand to the COD of the component
Bulk Stream
-bulk streams have flow rates such as kg/h or kg/batch, where the amount of medium
in the stream is apparent in the value of the flow rate.
CaCO3
-calcium carbonate; can be used as a dehydrohalogenating agent
160
CAS Number
Charge
- a method for adding an input to the unit
-a family of chemicals that contain one to eight chlorine atoms attached to the carbon
atoms of the parent chemical, dibenzofuran
Clean-in-Place (CIP)
-used for cleaning processes using a cleaning agent
Component
-can be a pure constituent in a stream or a stock mixture. Some components can be
broken down into Ingredient
. For example, air is a component that can be broken down into nitrogen and oxygen.
Compressibility Factor
- Z; corrects the gas density for deviations from the ideal gas law
Connect Mode
-mode entered after clicking the Connect Mode button. Allows user to draw several
streams in a row.
Continuous
-procedures carried out continuously (i.e. they are ‘on’ all the time
Discrete Stream
-discrete streams have flow rates such as vials/batch or bottles/batch, where each vial
contains a particular mass or volume, making it possible to calculate the amount of
medium in the stream.
161
EIR Report: Environmental Impact Report
-presents information that describes the effects of the process output streams on the
environment
-contains a detailed tabulation of all chemicals that are regulated by the EPA or
denoted as hazardous by the user
Enthalpy of Formation
-the enthalpy change associated with the formation of a compound from its
constituent elements
Heat Capacity
-the amount of heat required to change its temperature by one degree, and has units of
energy per degree
Heat of Vaporization
-the energy required to change a gram of a liquid into the gaseous state at the boiling
point is called the "heat of vaporization"
Henry’s Constant
-the ratio of the aqueous-phase concentration
of a chemical to its equilibrium partial pressure in the gas phase
Ingredient
Input Stream
-a stream that carries material into a unit procedure. Components and flowrates for
an input stream are usually set by the user. The exception is when the Pull-In
operation is used.
162
163
Intermediate Stream
-a stream that carries material out of a unit procedure and into a different unit
procedure. Components and flowrates for an intermediate stream are usually
calculated by SuperPro®. The exception is when the Pull-Out operation is used.
Kmaxo
-maximum biodegradation rate constant
Ks
-half-saturation constant
Log10 (octanol/water)
-used to indicate the hydrophobicity of a component
-helps determine a component’s tendency to become sludge
Master-Slave Relationship
- relationship formed between two operation to determine the duration time of the
slave piece of equipment based on the duration time of the master operation
Mixed Mode
-a combination of both a (cyclical) mode where there is a dead time (or ‘off time’)
and procedures carried out continuously
Molecular Weight
-the sum of the weights of the atoms of which it is made
Operation
-represents the simplest physico-chemical transformation step that can be modeled
from simply charging data to a reaction
-individual operations can be strung together to allow for more than one operation to
occur in one unit procedure
Process Time
- time it takes for a piece of equipment to run all the way through its part of the
process
164
Pull-In
- allows the user to take in a material without directly knowing the amount of material
needed
Pull-Out
- allows the user to take out a material without directly knowing the amount of
material needed
SARA 313
-the vapor pressure associated with a saturated vapor (one which cannot contain more
liquid molecules)
Select Mode
-typical mode while in SuperPro® in which streams and operations can be clicked on
and selected.
Selling Price
-cost associated with the activities of the marketing and sales department. Their
values are zero by default, assumes this cost is zero.
Setup Time
-time it takes for the equipment to be initialized and setup
Steam-in-Place (SIP)
-used to clean processes using steam
165
Stream Elbow
-a right angle bend in a stream, changing the stream from horizontal to vertical and
vice versa.
Transfer In
-allows the user to take in a material, but unlike Pull In, requires user to specify
amount of material needed
Transfer Out
-allows the user to take out a material, but unlike Pull Out, requires user to specify
amount of material needed
Turnaround Time
-time that it takes to return a piece of equipment back to its original condition (i.e., to
prepare it for the next process, cleaning, resetting, etc.)
Unit Operation
-represents the simplest physiochemical transformation step that can be modeled in
the simulation
166
Unit Procedure
- a piece of equipment in which a sequence of modeled unit operations takes place
167
Index
# G
33/50 EPA Program................................. 25, 146, 156
H
A Heat Capacity ..................................................20, 158
Acentric Factor ................................................ 20, 156 Heat of Vaporization .......................................21, 158
Agitate ............................................................. 31, 156 Henry’s Constant .............................................20, 158
B I
Batch.......................................................... 7, 109, 156 Ingredient............................................. 30, 66, 72, 158
Biomass ..................................................... 19, 25, 156 Input Stream .................................... 61, 126, 154, 158
BOD5 ............................................................... 22, 156 Intermediate Stream................................... 61, 92, 159
Breakpoint ............................................................... 48
Bulk Conversion Factor................................... 76, 156
Bulk Stream..................................................... 60, 156
J
C K
CaCO3 ............................................................. 22, 156 Kmaxo .............................................................21, 159
CAS Number ..................................... 15, 19, 138, 157 Ks.....................................................................21, 159
Charge ....................................................... 31, 95, 157
Chlorinated dibenzofuran (CDFs) ................ 137, 157 L
Clean-in-Place ................................................. 31, 157 Labor Requirements ..............................................115
COD: Chemical Oxygen Demand ........... 21, 154, 157 Log10...............................................................22, 159
Color (see style)
Component ........................................ 11, 66, 120, 157
Component Registration.......................................... 11 M
Compressibility Factor .................................... 20, 157 Master-Slave Relationship.............................103, 159
Connect Mode ................................................. 62, 157 Mixed Mode ......................................................8, 159
Continuous ......................................... 8, 101, 154,157 Mixture Registration................................................11
Cost Mode of Operation.....................................................7
Component ....................................................... 121 Molecular Weight ............................................19, 159
Stream............................................................... 123
Equipment ........................................................ 127 N
Labor & Utility ................................................. 128 NO3-NO2..........................................................22, 159
D Normal Boiling Point.......................................19, 159
Default Physical Units............................................... 9 Normal Freezing Point.....................................19, 159
Density .................................................................... 82
Discrete Stream ............................................... 60, 157 O
DVDS/VDS ..................................................... 23, 157 Operations........................................ 7, 31, 49, 92, 159
DVSS/VSS ...................................................... 23, 157 Operation Data.......................................................101
E P
EIR: Environmental Impact Report......... 25, 148, 158 Procedure Data ........................................................42
Emissions .............................................................. 133 Process Time .................................................101, 159
Enthalpy of Formation..................................... 19, 158 Pull-in ....................................................................160
EPA: Environmental Protection Agency ........ 24, 158 Pull-Out .................................................................160
Equipment Data............................................... 44, 127 Pure Components Database ....................... 11, 20, 160
Evacuate .......................................................... 31, 158
F Q
168
TKN: Total Kjeldahl Nitrogen........................22, 161
TOC: Total Organic Carbon ................... 22, 154, 161
R TP: Total Phosphorus .....................................22, 161
Register Transfer In ................................................. 31, 95, 161
Components........................................................ 11 Transfer Out............................................... 31, 93, 161
Mixtures.............................................................. 11 TS: Total Solids ..............................................23, 161
TSS/TS: Total Suspended Solids....................23, 161
S Turnaround Time....................................... 8, 107, 161
SARA 313 ....................................... 25, 146, 153, 160
Saturation Vapor Pressure ............................... 20, 160 U
Scheduling ............................................................. 101 Unit Operation ............................. 8, 31, 101, 147, 161
Select Mode..................................................... 62, 160 Unit Procedure.........................................................31
Selling Price ............................................ 76, 121, 160
Setup Time .................................................... 102, 160
Special Components ................................................ 25 V
Steam-in-Place................................................. 31, 160 VDS/TDS: Volatile Dissolved Solids.............23, 162
Stock Mixtures Database................................. 26, 160 VSS/TSS: Volatile Suspended Solids.............23, 162
New stock mixtures ............................................ 28
Stream Elbow .................................................. 62, 161
Style
W
stream ................................................................. 84 Waste Treatment or Disposal Cost .......... 23, 122, 162
unit procedure icon ............................................. 53
X
T
Tag Y
Unit procedure.................................................... 56
Stream................................................................. 87
Temporary Connect Mode............................... 62, 161 Z
ThOD: Theoretical Oxygen Demand.............. 21, 161
169