Introduction to SuperPro Designer for
Batch Processing Modelling
Session outline Getting started SuperPro Designer (SPD) interface Flowsheet drawing and editing Unit procedures initialisation Simulation execution & result checking
Getting started
Process Operation Mode
Process operation mode :
BATCH
vs
CONTINUOUS
Default annual operating time
SuperPro Designer Interface
Maximise the flowsheet
SuperPro Designer Interface
Horizontal drawing size : 2 pages
Some common icons
Start a new worksheet
Open an existing worksheet
Cut / Copy / Paste
Select mode
Connect mode-stream connection
Toolbar for drawing
Solve-Run the simulation
Main unit procedure in SPD Vessel Procedure
Reactor
Seed Reactor
Fermentor
Seed Fermentor
Air-lift Fermentor
Continuous Reaction (Stoichiometric, kinetic, equilibrium)
CSTR
PFR
Fermentor
Seed Fermentor
Environmental (aerobic,
anaerobic, UV radiation)
Filtration
Microfiltration
Ultrafiltration
RO
Diafiltration
Baghouse
Air Filtration
Plate & Frame
Rotary vacuum
Distillation
Flash
Batch
Continuous
Extraction Distillation
Mixer-Settler
Differential
Centrifugal
Absorption
Homogenization
High pressure
Bead milling
Nano milling
Sedimentation
Decanting
Clarification
Thickening
Oil Separation
Flotation
Unit Procedure in SPD
Biochemical case studyBiochemical case study
Component registration View component properties
Biochemical Case Study
Case Study 1
A batch reactor is utilised to produce component C from reactant A and B:
Component C is later separated from A and B by a batch plate &frame filter
Solvent used : Heptane (soluble for A and B but insoluble for C)
Task to be performed : Mass and energy balances Process Scheduling
A + B C
Component registration
Component Database
Nitrogen, N2 Default
Oxygen, O2 Default
Water, H2O Default
Heptane, C7H16 DesignerA New (user define)B New (user define)C New (used define)
Component registration
Databanks in SuperPro
Default component
Component registration
Newly added
Referencecomponent
View component properties
Editing component properties
Component MW Price Value ($/kg)
A 150 Purchase 10
B 25 Purchase 15
C 175 Selling 200
Let’s do changes before we proceed
Time to save your work
Reminder…Reminder…
Always remember to save your work!
Flowsheet drawing and editing
Locating the unit procedures
Stream connection
Editing the flowsheet
Unit Procedures
Looking for help (F1)
Unit Procedures
Adding a process stream
Single click
Connect-modeStream connection
Select mode
(tip: Press ESC button to terminate the stream drawing)
Deleting a stream
Single left click on the stream/unit (turn into read) & press DELETE (on keyboard)
Make sure the cursor is in “Select Mode” (ESC button)
Completing the flowsheetCompleting the flowsheet
Single click
Single click
Double click
Let’s draw our flowsheet Let’s draw our flowsheet before we proceed further……before we proceed further……
Editing a stream elbow
Make sure the cursor is in “Select Mode” (Esc button)
Stream elbow
Make sure the cursor is in “Select Mode” (ESC button)
Editing tag name of the streamEditing tag name of the stream
Changing the Stream ID
Stream ID Change ID to S-101 HeptaneS-102 AS-103 BS-104 EmissionS-105 Rxt outS-106 Wash inS-107 CS-108 B+ HeptaneS-109 Wash out
Let’s do changes before we proceed
Editing the style of a stream
Change Stream thickness: 2ptChange stream colour: brown
Changing the stream title and style
Stream Colour Thickness
Heptane Brown 2 pointsA Brown 2 pointsB Brown 2 pointsEmission Green 1 pointsRxt out Brown 2 pointsWash in Blue 1 pointsC Brown 2 pointsB + Heptane Brown 2 pontsWash out Blue 1 points
(Q: is there a faster way to do so?)
Same style
Pickup style from “Heptane”
Apply style to another streamApply style to another stream
Press Ctrl button to select multiple streams
Complete the style editing for Complete the style editing for the rest of the streams…the rest of the streams…
Editing the style of the iconEditing the style of the icon
Apply the same pick-up & apply to change the style of the filter
Icon colour : blueDescription tag text;Font 10, bold, maroon
Adding a title to the case study
Text modeThis is too small
Change your font here
Save your work
Save file (s)
Initialising a Unit ProcedureInitialising a Unit Procedure
What a Unit Procedure? Initialising an Operation
What is a Unit Procedure?What is a Unit Procedure?
In the batch modeling mode, a Unit Procedure may consists of various Operations:
Reactor procedure: feed charge, reaction, product withdraw, etc
Filtration procedure: filtration, cake wash, CIP, etc
In continuous modeling mode, a Unit Procedure= Unit Operation
Hierarchy in batch modelingHierarchy in batch modeling
Operation(s) level
Procedure(s) level
Entire plant
The same for continuous process modeling
Function of each unit procedureFunction of each unit procedureVessel Procedure (P-1):Acts as a batch reactor to carry out reaction: A + B CHeptane is used to dissolve components A & B, to aid separation in P-2Plate and Frame Filtration (P-2):Component C is not dissolved in heptane, hence is filtered out by the filter clothHeptane is used to wash out the trapped heptane ( and also the dissolved A & B) from the filter cake
Stream specificationStream specification
Click to insert Heptane here
Heptane flow =800 kg/batch
Ingredient flow
T, P = default
Set spec for Stream A & BSet spec for Stream A & B
Stream ID ComponentAmount
(kg/batch)Temperature
Pressure
Heptane
A
B
Heptane
A
B
800
50
40Default
Working sessionDo not forget to save your work !!!
A question to ponder…A question to ponder…
Q: Why do we only specify the inlet stream?
Sequential modular approach Sequential modular approach
Individual equipment blocks may require iterative solution algorithms
Overall process solution is sequential & not iterative
(Turton et al., 1998)
Adding operations to P-1Adding operations to P-1
3 Charge operation (to charge A, B and heptane respectively)1 React (Stoichiometric) operation (for reaction to be carried out)1 Transfer Out operation (to deliver product to next unit)
Adding operations to P-1Adding operations to P-1
Add new operation before the currently selected operation
Add new operation at the end of the list
Initialising operations in P-1Initialising operations in P-1
Initialising CHARGE-1Initialising CHARGE-1
Vol. flowrate=100 L/min
Setup time = 5 min
800 kg heptane
Emission calculation(next slide…)
Emission calculationEmission calculation
Click to perform emission calculation
OK, next operation (CHARGE-2)
OK, previous Operation (none)
Previous operation (same tab –none)
Next operation (same tab)
Go to selected operation
Initialising CHARGE operationInitialising CHARGE operationOperation Operating condition Emission
CHARGE-1 Charge 800kg/batch of heptane using stream “Heptane”Setup time= 5 minProcess time : 100L/min
Perform heptane emission on this stream
CHARGE-2 Charge 50 kg/batch of A (limiting component) using Stream “A”Setup time = 5minProcess time: calculated based on 20 kg/min
Nil
CHARGE-3 Charge 40/kg batch of B using Stream “B” (B is in excess)Setup time = 5 minProcess time : calculated based on 20 kg/min
Please complete the initialisation of CHARGE-2 & CHARGE-3
Initialising REACT-1 & TRANSFER-OUT-1
Operation Operating condition Volumes Reaction
REACT-1 Final temp = 50 °CHeat transfer agent:
steamProcess time = 6 hourLeave other values as
defaults
Max Allowable working/ vessel
volume: 80 %
Extent of reaction = 95 %
Reaction stoichiometry
A + B C
TRANSFER-OUT-1
Using stream “Rxt out”
Duration: same as Cloth Filtration in P-2 (using
Master-Slave Relationship)
Nil
Initilising REACT-1 in P-1Initilising REACT-1 in P-1
SteamProcess time
= 6 h
Final temp = 50 °C
Max allowable volume = 80 %
Initialising REACT-1 in P-1Initialising REACT-1 in P-1
Reaction extent = 95 %
Edit reaction stoichiometry
Rename reaction
Add reaction(s)
Delete stoichiometry (when needed)
Molar stoichiometry
OK, next operation (Transfer-out)
Transfer out stream
Click here to selectMaster-and-Slave to calculate duration
To quit Vessel Procedure
Select the MasterProcedure
Select the Master Operation in
Master Procedure
Initialising Transfer OutInitialising Transfer Out
Master-Slave RelationshipMaster-Slave Relationship
Slave
Master
Master operation – processing step that control the duration of another operation (slave)When simulation is executed, duration calculation for the slave operation will be bypassed (note: M&E balances affected), until the master operation is metBoth master and slave operation may exist in the same procedure or in another procedure
Working sessionLet’s try before we proceed further…
Initialising operation for P-2Initialising operation for P-2
Cloth Filtration operation (by default, to filter product C)
Cake Wash operation (to wash out left over trapped A & B in filter cake)
Transfer Out operation (to deliver product)
Adding operations to P-2Adding operations to P-2
Initialising operations for P-2Initialising operations for P-2
Initialising FILTER-1Initialising FILTER-1Operation Operating condition Scheduling
FILTER-1 Particulate component removal: 95% C (assuming that A & B are completely soluble in Heptane & C is virtually insoluble).LOD (loss on drying) = 35% (this value cause a portion of heptane & any soluble component to be held in the wet cake 65% is insoluble C).Filtrate stream: “B + Heptane”
By default, first operation of any batch unit procedure is scheduled to start at the beginning of the batchStart time: relative to the START of TRANSFER-OUT-1 operation in P-1 procedure
Initialising FILTER-1Initialising FILTER-1Scheduling
C = 95% removal
LOD = 35%
Filtrate
By default
Filtration will only start when product is
transferred out from P1
Initialising CAKE-WASH-1 & Initialising CAKE-WASH-1 & TRANSFER-OUT-1TRANSFER-OUT-1
Operation Operation condition
CAKE-WASH-1
Wash In stream: “Wash in”Wash Out stream: “Wash out”Wash solvent: heptane (click on “Composition”, select “Auto-adjust”, the program will estimate a value automatically)Wash time: 30 minutesWash type: slurry (Note: A “slurry” wash will essentially dilute the soluble components trapped in the cake and remove most of them in the wash stream, whereas a “displacement” wash will remove the soluble components form the cake in a plug-flow fashion.)
TRANSFER-OUT-1
Transfer out using stream “C”Duration: calculated based on 10kg/min
Working sessionWorking sessionRemember to save your file !
Simulating a flowsheetSimulating a flowsheetExecute the simulation
Viewing the results
Simulating a process:1. Menu bar: Task/ Solve M&E balances2. Press “Ctrl 3”3. Solve icon in menu bar4. Press “F9”
Result viewingResult viewing
1. Calculated output variables for each oeration can be viewed by revisiting the corresponding Operation Data dialog windows
2. To see the calculated equipment sizes, right click on the unit procedure icon & choose the Equipment Data… option
3. The contents of a piece of equipment as a function of time can be viewed by right clicking on a unit procedure and selecting Equipment Contents or Operation Sequence
4. The calculated flowrates and compositions of intermediate & output streams can be viewed by in the Simulation Data dialog windows of each stream
Result viewingResult viewing
5. A list of reports can be viewed in Reports: Stream Reports (SR) Economic Evaluation Report (EER) Itemized Cost Report (ICR) Cash Flow Report (CFR) Throughput Analysis Report (THR) Environmental Impact Assessment Report (EIR) Emission Reports (EMS) Input Data Report (EDR) Equipment Report (EQR)
Let’s visit the one by one…Let’s visit the one by one…
Equipment operation dataEquipment operation data
Calculated heptane emission: 0.028%
Equipment dataEquipment data
Calculated vessel volume: 1628 L
Equipment contentEquipment content
Stream simulation dataStream simulation data
Generating a stream reportGenerating a stream report
Check your scheduling resultsCheck your scheduling results
Reaction A B C
MW
Initial content, miO (kg)
Initial mol, niO (kg-mol)
X= 95% (based on A)
Current mol, n (kg-mol)
Current content, m (kg)
nAO-nAOX nBO-nBOX
-
-
nAOX
+
Check your scheduling resultCheck your scheduling result
Heptane charge =____kg/batch (stream specification)
Volumetric flowrate=___L/min (in Operation Data/CHARGE-1)
Task: Find out the density of the heptane stream
from your simulation sheet Verify the heptane charging duration
calculated by SPD heptane
Do not just take the computer’s word as it is, please check your results accordingly!!!
Remember the GIGO principle