Process Simulation Tools for Effective Design and Optimization

Process Simulation and
Design
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HEATX
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V-203
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COND
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STEAM
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Introduction
Dr. Naveed Ramzan
Education
B.Sc. Chemical Engineering (1999, UET Lahore)
M.Sc. Chemical Engineering (2003, UET Lahore)
Ph.D. Chemical Engineering (2007, BTU Cottbus, Germany)
Experience
Chairman, Chemical Engineering (2016Present, UET Lahore)
Campus Coordinator, Faisalabad Campus (20132016, UET
Lahore)
Professor (2011Present, UET Lahore)
NEBOSH Approved Tutor
OHSAS 18001:2007 Lead Auditor (IRCA UK)
Resource Person CPD Training for PEC
Resource Person SBS
Dr. Muhammad Faheem
Education
B.Sc. Chemical Engineering (2007, UET Lahore)
M.Sc. Chemical Engineering (2009, UET Lahore)
Ph.D. Chemical Engineering (2014, USC Columbia, USA)
Experience
Lecturer (20072009, UET Lahore)
Research Assistant (20092014, USC Columbia, USA)
Assistant Professor (2014Present, UET Lahore)
Role of Simulation in
Process Design
Simulation
Process Simulation and Design
Modeling and Simulation

1: What is Modeling
Description of any complete system in
mathematical terms is called a mathematical
model
2: What is Simulation
Solving the modeling equations
numerically or analytically
either
Process Simulation
Simulation is a process of designing an
operational model of system and conducting
experiments with this model for the purpose either
of understanding the behaviour of the system or of
evaluating
alternative
strategies
for
the
development or operation of the system.It has to
be able to reproduce selected aspects of the
behaviour of the system modelled to an accepted
degree of accuracy. (Thome, 1993)
Simulation and Modeling Problem in

Process Engineering
Nano
Molecular
Processes,
Active sites
Micro
Bubbles,
Drops,
Particles,
Eddies
Meso
Reactors,
Columns,
Exchangers,
Pumps,
Compressors,
...
Macro
Production
Plants,
Petrochemical
Complexes
Mega
Environment,
Atmosphere
Oceans
Soils
Lit.: Charpentier, J.-C.; Trambouze, P.: Process Engineering and problems encountered
by chemical and related Industries in the near future. Revolution or cointinuity?
Chemical Enginering and Processing 37(1998) 559-565
Simulation and Modeling Problem in

Process Engineering
10
Why Process Simulation
Simulation as core activity in Research & Development, Design & Operation

11
Process Simulation Applications in Chemical

Process Industries
Chemical Process
Industries
Applications
Oil & Gas
Offshore exploration, Gas processing, Pipeline

transport, Surface Treatment etc.
Refining
Petrochemicals
Gasoline and Fuels

Hydrocarbon based chemicals, Methanol ,
Monomers
Intermediates, Solvents, Detergents, Dyes etc
Ammonia, Sulphuric acid, Fertilizers
Pharmaceuticals, Cosmetics
Food and Bioproducts
Steel, Aluminium, Copper etc
Polyethylene, PVC, Polystyrene, Fibers etc
Paper pulp
Power plants, Coal Gasification
Water Treatment, Safety
Water cleaning etc.
Basic Organic Chemicals

Inorganic Chemicals
Fine Chemicals
Biotechnology
Metallurgy
Polymers
Paper and Wood
Energy
Nuclear Industry
Environment
12
Process Simulation Tools

Simulations tools can help to resolve several of these
problems, with low cost, high reliability and normally in less
time. Otherwise these tools can help to the process engineer
to understand what happen, and what are the problematic
points in the whole process, or in a particular equipment.
These tools can be classified in three groups depending on
the problem that are going to be resolved:
Process Simulation tools.
A computational fluid dynamics (CFD) tools.
Other particular simulation software.
13
Process Simulation Tools

Objectives of Process Simulation Tools:
Optimizing the design and performance of product assets
Increasing throughput and yield, improving quality, and
reducing energy costs
Responding more quickly to unexpected events or
changes in customer demand
Managing the profitability of operations in real-time.
14
Types of Process Simulation Tools

In process engineering two types of simulations tools are
used:
Steady-State Simulators:
Or Static simulators.
Typically used in process design, they simulate the
process at steady state conditions, usually at the design
operating conditions. In this kind of tools Time is not a
variable.
Dynamic models: consider time as a variable and
simulate the process over a period of time. A dynamic
simulation can be used to estimate or illustrate the
response, over time, to a change in the process.
15
Steady State Process Simulation Tools

The steady state simulation tool produce a static simulation,
which typically used in process design, to simulate the
process at steady state conditions, usually at the design
operating conditions. This simulator dont use Time as
variable.
These simulation tools allow the engineer to do easily and

strictly mass balance and energy balance for a high variety of
chemical and petrochemical processes. Equipment and
instrument design, plant design, capital costs, and technical
evaluations are all dependent on such calculations.
16
Steady State Process Simulation Tools

All of this tools contains:
A Physical and chemical properties Data Base for several
elements and compounds, and different methods to calculate the
properties of mix.
A Drawing tool, which can help to produce the Process Flow
Diagrams (PFD).
A Pre-modelled unit operation; like abortion columns, heaters,
reactors, etc.
There are several different software for the steady state process
simulation as:
- Pro-II
- Aspen plus
- Winsim
- Chemcad
- Others
17
Methodological levels in Steady State

Process Simulation
18
Dynamic Process Simulation Tools

Dynamic simulation tools consider time as a variable and
simulate the process over a period of time. A dynamic
simulation can be used to estimate or illustrate the response,
over time, to a change in the process.
This technology is commonly used for design and revamp
studies, operator training, testing of DCS configurations and
the development of operating procedures.
Several of the steady state software tools have an especial
module to produce the dynamic simulation of the process. For
example Aspen Dynamics
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Process Simulation Targets

Process Simulation
Debottlenecking
Steady State Simulation
Optimization,design etc.
Revamping
Heat integration etc.
Operation
Sensitivity, maintenance
Process Control
Real time optimization
Dynamic Simulation
Start up, Shut down, safety
Operation
Disturbance Simulation
Operational failures
Operator Training
Safety examinations, design

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Process Design & Simulation

Commercial Softwares
21
Computational Fluid Dynamic (CFD) Tools

Computational Fluid Dynamics involves the analysis,
simulation and study of fluid, heat and mass transfer;
chemical reactions and associated engineering phenomena
by solving mathematical and numerical equations through
computerbased simulation.
CFD is based on finite elements calculations. The simulation
software divides the 3D surface in discrete cells creating a
mesh. The software creates and calculates the Navier
Stokes equations for every cell within the mesh starting from
defined boundary conditions. It is possible to define
calculation objectives, for instance pressure, temperature,
and flow velocity, at selected sites of the simulated volume.
22
Computational Fluid Dynamic (CFD) Tools

The following analyses can be performed:
2D and 3D analysis of Newtonian fluids
External and internal flows
Steady-state and transient-state flows
Compressible and non-compressible flows
Laminar, turbulent and transitional flow regimes
Flows with vortex
There are several different CFD
Multicomponent flows
Heat transference effects software as:
Gravitational effects.
- Comsol
- Fluent
- Ansys
- Floworks
- Flow Science
23
Required Competency
24
Impact on Chemical Process Industry
25
Design and Analysis through process simulation
Divider
Mixer
Reactor
Separator
A Chemical Plant is our real world
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Main steps of process simulation

Develop
process
model
Divider
Define
problem
Mixer
Reactor
Separator
Collect
additional
data
Analyze
results
Chemical Plant
Solve model
equation
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Problem definition
What information do we need?
Divider
Mixer
Reactor
Separator
Stream
data
Chemical Plant
Mixture
Compounds
Unit
Operations
Process
flowsheet
Known
data
Equipment
data
Operating
data
28
Problem definition
What do we need to define?
Divider
Mixer
Reactor
Separator
Unit
models
Chemical Plant
Mixture
Compounds
Unit
Operations
Process
flowsheet
Library
Thermomodels
Method of
solution
29
AspenTech Products & Aspen Plus

Graphical User Interface
Lesson Objectives
Aspen Tech Company Information
List of AspenTech Products
31
AspenTech Company Information
Advanced System for Process Engineering

(ASPEN)
Project conducted at the Massachusetts Institute of
Technology (MIT) in Cambridge Massachusetts,
from 1976 to 1981
Over 2000 Employees world wide
HQ in Cambridge, MA (Boston)
Offices in 35 Countries
Public held since 1994, NASDAQ
www.aspentech.com
http://support.aspentech.com
32
Products
Process Engineering
Process simulation Chemicals (10 products : AspenPlus)
Process simulation Oil&Gas (8 products : AspenHYSYS)
Process simulation Refining (11 products : Aspenadsim+)
Process simulation Batch/Pharma (8 products :Aspenproperties)
Model Deployment (3 products : AspenModelrunner)
Equipment modeling (8 products :AspenAcol+)
Basic Engineering (2 products :AspenKbase)
Economic Evaluation (3 products : Aspn Icarus Project Manager)
Advance Process Control (14 products : Aspen Apollo, Aspen IQ)
Planning & Scheduling (10 products : Aspen Advisor, Aspen MBO)
Supply & Distribution (3 products : Aspen Retail)
Production Management & Execution (16 products : Aspen 0server)
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Products
Aspen Plus
Aspen Plus is the most popular product (accounted 48%
of sales in 1995)
a steady state modeling system built around the core
technology
Properties PLUS
It is a database of chemicals properties underlying its
other products, popular with customers ~ developed inhouse modeling software
Other modules
offers to the customers ~ license separately
use with its other products to model subsystems used
in highly specialized chemicals processing application.
34
Flowsheet Simulation
35
Flowsheet Simulation
36
General Simulation Problem
37
Approaches to Flowsheet Simulation
38
Software Architecture of a SequentialModular Simulator
39
Software Architecture of an EquationOriented Simulator
40
Integrated Software System
41
Good Flowsheeting Practice
42
Why Aspen Plus?
43
Starting with Aspen Plus
The User Interface
45
FlowSheet Definition
46
47
Graphic Flowsheet Operations--Blocks
48
Graphic Flowsheet Operations-- Streams
49
Using the Mouse Button
50
Modifying Blocks and Streams
51
Exercise-I
53
54
Basic Input to Run Aspen Plus

Simulation
Aspen Plus User Interface
56
Data Browser
57
Data Browser
58
Functionality of Forms
59
Help
60
Basic Input
61
Status Indicators
62
Example
63
Setup
64
Setup Specification Form
65
Setup Run Types
66
Setup Units
67
Components
68
Component Specification Form
69
Entering Components
70
Find
71
Pure Component DataBanks
72
Pure Component DataBanks
73
Properties
74
Properties Specification Form
75
Streams
76
Streams Input Form
77
Blocks
78
Blocks
79
Starting the Run
80
Control Panel
81
Reviewing Results
82
Exercise-II
Exercise-II
84

Process Simulation Tools for Effective Design and Optimization

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Process Simulation Tools for Effective Design and Optimization

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Process Simulation and

Dr. Naveed Ramzan

Dr. Muhammad Faheem

Process Simulation and Design

Modeling and Simulation

Process Simulation and Design

Process Simulation and Design

Simulation and Modeling Problem in

Simulation and Modeling Problem in

Process Simulation and Design

Why Process Simulation

Simulation as core activity in Research & Development, Design & Operation

Process Simulation Applications in Chemical

Oil & Gas

Offshore exploration, Gas processing, Pipeline

Gasoline and Fuels

Basic Organic Chemicals

Process Simulation and Design