Introduction to Process Simulation of Plant Design

8/11/2019 Introduction to Process Simulation of Plant Design

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@ dr zain, pse-fkkksa, UTM Page PS-1Intro to Process Simulation

Introduction to Computer Aided

Process Simulation


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Objectives

At the end of the course participants will be able to:

1. Create a process flowsheet.

2. Simulate an equipment and a process flowsheet.3. Analyse and operate with simulation results.

4. Troubleshoot simulation problems.

.for continuous and batchprocess systems.


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A Refinery Flowsheet


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Tutorial 5: Results


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Intuitive User Interface


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Double-Click

Detailed Modeling using UnitProcedures and Operations


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What is Process Simulation?

Building a Process Model

Predicting how a process would actually behave

Performing an experiment (on computer)

Incentives:

Highly Cost EffectiveReasonably Accurate

Proactive Approach

Q: What does the word simulate mean?


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Why Perform Process Simulation?

Some State-Of-The-Art Features: Material and Energy Balances

What if Scenario Case Study, Sensitivity

Analysis

Equipment Sizing and Costing

Equipment (Performance) Rating

Equipment & Process Optimisation

Dynamic Simulation & Optimisation


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Some Commercial Simulators

Aspen Plus and Derivatives

Hysis

PRO II with Provision

Design II

Super Pro Designer (Batch Process)

.and other in house simulators

C: We have the first five packages mentioned!

Q: Which one are you familiar with?


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Aspen Plus

Hysis

Provision

Oil, Gas &

Petrochemicals

Continuous Processes

Design IISpecialty Chemicals

Oleo Chemicals

SS Simulation

Optimisation

Sensitivity Analysis

Dynamic Simulation

Rating

Phys Prop

Batch

Pinch

Economics

Sizing & Costing

Solids

C: We have all the packages mentioned!

Q: Which one are you familiar with?


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Water Purification

Wastewater Treatment

Air Pollution Control

BioPro Designer

SuperPro Designer

BatchPro Designer

EnviroPro Designer

Biotechnology

Food Processing

Synthetic

Pharmaceuticals

Specialty Chemicals

AgriChemicals

Established by Intelligen, Inc. (early 90s)

Batch Processes


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The Problem

Design a Process to Recover Methanefrom a Gas Stream (i.e. Build a

Process Model to Recover Methane)


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The Data

Comp Mole % Comp Mole %

Nitrogen 7.91 n-butane 2.44

Methane 73.05 i-pentane 0.69

Ethane 7.68 Pentane 0.82

Propone 5.69 Hexane 0.42

i-butane 0.99 Heptane 0.31

A (typical) gas stream to be processed:

Flowrate 8.0 m3/hr

Temperature 120 F

Pressure 602.7 psia


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The Onion Model (Smith, 1995)

Reactor

Separation &

recycle

Heat exchange

network

Utilities


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Process Synthesis-Design Cycle

Process Synthesis

Process Simulation

parameter

optimisation

Process Flowsheetingstructural optimisation

Optimised Design

Material and Energy Balances

(manual & simulation)

Q: Why manual calculations?

Existing

Plant

domain


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S1 S2

S3 S4

S5

S6

S7

S10

S9

E1 E2

F1 T1

EX1

C1

V1

S8

FLASH

DEMETHANIZ

ER

COMPRESSOR

EXPANDER

CHILLERGAS-GAS

EXCHANGER

Expander Plant Flowsheet

..after structural optimisation)


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How to Simulate a Process

Flowsheet: A Birds Eye View


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A Completed Flowsheet


S1 S2

S3 S4

S5

S6

S7

S10

S9

E1 E2

F1T1

EX1

C1

V1

S8

FLASH

DEMETHANIZE

R

COMPRESSOR

EXPANDER

CHILLERGAS-GAS

EXCHANGER


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Process Simulation Steps

1. Draw Flowsheet2. Define Components

3. Select Thermodynamic Option

4. Define Feed Streams5. Provide Process Conditions

6. Run Simulation, and

dont just take the computers word for it

check the results!!!


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Draw Your Flowsheet

S1 S2 S3

S4

E2

CHILLER

FLASH

E1

GAS-GAS

EXCHANGER

Place Module One by One


Typical Simulator Worksheet


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Define Your Components

E.g. N2

METHANE

ETHANEPROPANE

I-BUTANE

BUTANE

I-PENTANE

Either enter (type) the components directly or select from list

Component Databank

S1 S2 S3

S4

S5

E2

F1

E1

Simulator


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Define Your Feed Streams

S1 S2 S3

S4

S5

E2

F1

E1

Supply stream data; i.e. flowrates, compositions,

and any two of the following

PRESSURE

TEMPERATURE

BUBBLE POINT

DEW POINT


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Sequential-Modular Approach

S1 S2 S3

S4

S5

S6

S7

S10

S9

E2

F1

T1

EX1

V1

E1

C1

A

E

C

B

D

Possible Sequence: A-B-C-D-E


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Sequential-Modular Approach

S1 S2 S3

S4

S5

S6

S7

S10

S9

E2

F1

T1

EX1

V1

E1

A

B

CD

E

C1

Possible Sequence: A-B-C-D-E


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Select Your Thermodynamics

Calculation Method

Category Method

Soave-Redlich Kwong

Peng Robinson

Ideal (normally default)

NRTL

Wilson

UNIQUAC..

For phase equilibrium and thermodynamics property calculations

(e.g. liquid-phase activity and vapour-phase fugacity coefficients, enthalpies..etc)

Equation of State

Liquid Activity

Generalized Correlations

Special Packages

Electrolyte.


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Select Your Thermodynamics

Calculation Method

Relieve everyones nightmares..Chem Eng Thermo

Gaseous Systems, e.g.

Ideal Gas EOS

Generalized EOS

SRK - Non-ideal

Peng RobinsonNon-ideal

BWRSNon-Ideal

Liquid Systems

Raoults Law - IdealWilson - Nonideal

NRTLNonideal

Van LaarNonideal

UNIFAQ - Nonideal

UNIQUAC - Nonideal

Reference: Walas, Stanley M. (1985) Phase Equipment in Chemical

Engineering. Boston: Butterworth. (TP156.E65)


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Provide Process Conditions

Nstages= 20

Xlk= 0.99

Xhk= 0.01

lk = C3H8

hk = C5H12

S1 S2

S3 S4

S5

S6

S7

S8

S10

S9

E1 E2

F1T1

EX1

C1

V1

P = 1.1 bar

V/F = 0.5

Q: Where to get all the specs from?


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And FinallyRun Your

Simulation

S6

S3 S4

S1 S2

S5

S7

S8

S9

E1 E2

F1 T1

EX1

C1

V1

S10


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A reminder before we go further

Always perform your simulation for one

equipment followed by another.

Use manual calculations (on selected unitops) to make sure the results make sense


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The not so good news is..We have just got started!

this is only the tip of the iceberg.

Aspen Plus and Derivatives

PRO II with Provision

Hysim and Hysis

Design II & Super Pro (this module).and other in house simulators


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But the good news is

If you have seen one simulator.You have seen them all


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Tutorial : Expander Plant


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Expander Plant: Flowsheet

Description

Flowsheet description:

A single stage expansion of a light hydrocarbon

stream

Firstly, feed stream is cooled through a feed chiller(X-1) & any liquid is removed with a vertical separator

(F-2).

The vapor is expanded (E-4) & liquids separated

using a second vertical separator (F-3).


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Expander Plant: Equipment

Specifications

Equipment Tag Specification

Feed chiller X-1 Temp out = -35F

Delta pressure = 10 psi

2 vertical

separator

F-2

F-4

Adiabatic flash

Delta pressure = 0

Expander E-3 Pressure out = 275 psig

Efficiency = 0.80


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Expander Plant: Feed stream &

Basic Thermodynamics Specifications

Component Lbmol/hr Specifications

Methane 6100

T = 90F

P = 980 psig

Ethane 500

Propane 200

N-Butane 100

N-Pentane 100

N-Hexane 70

Thermodynamics methods used:K-Value = API Soave

Enthalpy = API Soave

Density = Yen Woods (STD)

Feed stream specification:


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SOLUTION HAS BEEN REACHED


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The Streams Summary Results


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Thank You For Your Attention

Over to Dominic Foo


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Tutorial 3: Mixer


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Mixer: Stream data

Stream data:

Components Str1

T=25 oC

P=1 atm

Str2

T=30 oC

P=1.5 atm

Str3

T=50 oC

P=1 atmWater

Ammonia

Acetylene

Oxygen

CO2

4 kmol/hr

2 kmol/hr 3 kmol/hr

7 kmol/hr

11 kmol/hr

0.1 kmol/hr


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P PS 43I P Si l i

Mixer: results

Documents

Introduction to Process Simulation of Plant Design