Introduction of Process Modelling and Simulation of Batch Process PTT 303/2 PROCESS MODELLING AND SIMULATION SEM 1 (2013/2014)

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

IDEA GENERATION Project Screening, Strategic Planning PROCESS DEVELOPMENT Evaluation of Alternatives Common Language of Communication FACILITY DESIGN Equipment & Utility Sizing and Design MANUFACTURING On-Going Optimization, Debottlenecking Production Scheduling, Capacity Analysis Development Groups Process Engineering Corporate Environmental Tech Transfer Manufacturing The Role of Process Simulation and Scheduling Tools in Product Development and Commercialization

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

Commercial process simulators Oil, Gas & Petrochemicals Oleo Chemicals Specialty Chemicals Aspen Plus HYSYS Provision Design II SuperPro SS Simulation Dynamic Simulation Batch Solids Pinch Phys Prop Sizing & Costing Economics Rating Sensitivity Analysis Optimization

SuperPro Designer (SPD) Water Purification Wastewater Treatment Air Pollution Control BioPro Designer SuperPro Designer BatchPro DesignerEnviroPro Designer Biotechnology Bio-Fuels Fine Chemicals Pharmaceuticals Food Processing Mineral Processing SchedulePro Scheduling and Debottlenecking 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

Double-Click Detailed Modeling using Unit Procedures and Operations

Operations Gantt Chart

Equipment Occupancy Chart

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? Scheduling Questions

Resource Demand Chart

Labor Demand Chart

Cost Breakdown Raw materials $0.88/g 39.6% Facility $0.54/g 24.4% Consumables $0.65/g 29.1%

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? Cost Analysis Questions

Environmental Impact Report

Bottleneck identification

How much product can I make in this plant? What limits the current production level? What is the capital investment for increasing production? Debottlenecking Questions

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