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

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 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