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T
he process industries spend an estimated $500 billion annual- useful if they represent available data within experimental accu-
ly worldwide in conceptual design, process engineering, racy. These reference quality models suffer the disadvantage,
detailed engineering, construction, startup, plant operations, however, of not easily allowing incorporation of additional
and maintenance for chemical, refining, polymer and power plants. components into the system being modeled.
In order for chemical engineers to • Engineers frequently lack either
successfully execute these process experimental data or expertise
and product studies, they perform to develop and validate models.
process modeling and capture As a result, they often rely on
knowledge of the thermodynamic estimation techniques such as
properties and phase behavior of the group-contribution methods.
chemical systems they work with. • Engineers need databanks that
Process modeling is a key are compilations of validated
enabling technology for process experimental data and model
development and design, equip- parameters for pure compo-
ment sizing and rating, and process nent and mixture properties.
(a)
debottlenecking and optimization. Databanks and correlations of
More recently, process modeling known accuracy play key roles
has enabled offline dynamic simu- in engineering calculations.
lation for controllability studies, • The value of thermodynamic
operator training simulators, online models is especially evident in
model-based process sensors, state- “flash” calculations. Robust
estimation, look-ahead predictors, and computationally efficient
and online process control and opti- flash algorithms for a variety of
mization. Success in process mod- phase equilibrium and chemi-
eling is critically dependent upon cal equilibrium conditions are
accurate descriptions of the thermo- an integral part of the practice
dynamic properties and phase of applied thermodynamics.
behavior of the concerned chemical (b) Practicing engineers prefer
systems. A perspective is offered “simple and intuitive” thermody-
Figure 1. Modeling sulfuric acid with chemistry and
here on applied thermodynamics namic models that can be applied
Electrolyte NRTL model (Mathias et al., 2001)
from an industrial viewpoint. easily. Models that are constantly
(a) Vapor pressure of sulfuric acid and oleum
being revised, sophisticated theo-
Industry Uses Thermo- at 100°C
ries requiring expert users, models
(b) Liquid-phase compositions in saturated
dynamic Innovations with excessive computational load,
sulfuric acid and oleum at 100°C
or models requiring extensive
Industry uses a wide array of
parameterization (i.e., ternary para-
thermodynamic innovations: engineering correlations, reference
meters), have limited industrial applications.
quality models, estimation methods, databanks, and flash algorithms.
• Chemical engineers benefit most from models and correla- Thermodynamic Modeling Deliver Value in
tions that capture the dominant physical and chemical behav-
ior of chemical systems. Engineers use these correlative mod- Industrial Practice
els within a thermodynamic modeling framework to describe Example 1. A number of process licensors and manufacturers are
and validate available data and to extrapolate with reasonable concerned with designing, optimizing, and troubleshooting sulfuric
confidence outside the range of available data. acid plants. Sulfuric acid is the largest volume chemical produced,
• For commonly encountered systems such as water and steam, and certain aspects of it make the development of accurate and reli-
air, ammonia, and light hydrocarbons, comprehensive experi- able process models difficult and challenging. Figure 1a demon-
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