PTT 303/2 PROCESS MODELLING AND SIMULATION

SEM 1 (2013/2014)

Introduction of Process Modelling and

Simulation of Batch Process
 Subject covered
 Modeling and optimization of batch and
continuous processes
 Batch Process Scheduling
 Resources and inventory tracking
Cost analysis & project economic evaluation
 Throughput Analysis & Debottlenecking
 What is “Process Simulation”?
Q: What does the word “simulate” mean?

Building a process model

 Predicting how a process would actually
behave
 Performing an experiment (on computer)

Incentives:
 Highly cost effective
 Reasonably accurate
 Proactive approach
Sequential modular approach
Individual equipment blocks may require
iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

Sequential modular approach
 Objectives of simulation

• Raw Materials
• Labor Process Batch Batch
• Utilities Throughput

Size / Cycle Time
Product(s)
• Capital Expenses

Waste
 Commercial process simulators
SS Simulation

Aspen Plus Dynamic Simulation

Batch
Oil, Gas &
Petrochemicals HYSYS Solids

Pinch
Oleo Chemicals Provision
Phys Prop

Sizing & Costing

Specialty Chemicals Design II
Economics
SuperPro
Rating

Sensitivity Analysis

Optimization
SuperPro Designer (SPD)

SuperPro Designer
Biotechnology
BioPro Designer Bio-Fuels

Fine Chemicals
Pharmaceuticals
BatchPro Designer Food Processing
Mineral Processing

Water Purification
Wastewater Treatment
EnviroPro Designer Air Pollution Control

Scheduling and Debottlenecking

SchedulePro of Multi-Product Facilities
 Available tools
• Intuitive user interface
• Wide variety of unit operation models
• Databases for components and mixtures
• M&E Balances of Integrated Processes
• Equipment Sizing and Costing
• Project Economic Evaluation
• Process Scheduling & Cycle Time Analysis
• Throughput Analysis & Debottlenecking
• Environmental Impact
• Detailed Reports and Charts for the Above
User Interface of SuperPro Designer
Detailed Modeling using Unit Procedures and Operations

Double-Click
Operations Gantt Chart
Equipment Occupancy Chart
 Scheduling Questions

• How can I schedule production during the next 6-18 months?

• How can I schedule operations in an R&D facility?

• How to adjust scheduling if priorities change?

• Can I fit a new product into my facility?

Resource Demand Chart
Labor Demand Chart
 Cost Breakdown

Consumables Raw materials

$0.65/g $0.88/g
29.1% 39.6%
Raw Materials
Equipment
Labor
Consumables
Lab/QC/QA
Waste Trtm/Disp
Utilities

Facility
$0.54/g
24.4%
 Cost Analysis Questions

• What is the required capital investment for a new plant?

• How much would it cost to make a kilo of product?

• Which process is better for making this product? A or B?

• How can I reduce the operating cost of a process?

 Environmental
Stream Dialog – Env. Impact Report
Properties Tab

INTELLIGEN, INC.
Bottleneck identification
 Debottlenecking Questions

• How much product can I make in this plant?

• What limits the current production level?

• What is the capital investment for increasing production?

 Course overview
• Lab 1
 Overview of process simulation
 Flowsheet development
• Lab 2
 Unit procedures initialisation
• Lab 3
 Process scheduling
 Resource & inventory tracking
• Lab 4
 Equipment rating
 Project economic evaluation
• Lab 5 – Biochemical case study
• Lab 6 – Throughput analysis & debottlenecking strategies