1. Chemstations Dynamic Seminar
Dynamic Behaviour of
Regular Process Operations
John E Edwards
P&I Design Ltd 1

2. CRYOGENIC BATCH REACTOR OPTIMISATION
DYNAMIC SIMULATION POWER
CRYOGENIC BATCH REACTOR OPTIMISATION
Dynamic Simulation without Control Systems
Develop dynamic simulation without control systems
Equivalent to perfect control
No special control system skills required
Easier to set up in reduced time
More effective use of the design team
Correctly applied can avoid design errors
Dynamic Simulation Basic Application
Use dynamic simulation for basic design
Time dependent parameters and hold ups
Validates preliminary design concepts
Equipment sizing
Optimize the process design
Test throughput change and shutdown
Predict system performance and transient behaviour

3. CRYOGENIC BATCH REACTOR OPTIMISATION
REGULAR PROCESS OPERATIONS
CRYOGENIC BATCH REACTOR OPTIMISATION
Typical Process Operations
Process route select
Perform batch process sequences
Material transfer from tanker to storage
Material transfer within a storage facility
Storage tank heating
Emergency relief sizing and behaviour
Dynamic vessel and agitated batch reactor
Batch distillation optimization
Batch reactor design and performance
Distillation column design and performance
Equipment failure and hazardous analysis

4. CRYOGENIC BATCH REACTOR OPTIMISATION
PROCESS ROUTING
CRYOGENIC BATCH REACTOR OPTIMISATION

5. CRYOGENIC BATCH REACTOR OPTIMISATION
ROUTE SELECT TECHNIQUE
CRYOGENIC BATCH REACTOR OPTIMISATION
RAMP and FEEDFOWARD CONTROLLER
Ramp controls the stream selection over time
Feedforward controller sets divider stream selection
Dummy stream set at zero to stop route flow

6. CRYOGENIC BATCH REACTOR OPTIMISATION
PROCESS ROUTING BENEFITS
CRYOGENIC BATCH REACTOR OPTIMISATION
Benefits
Allows the study of material transfers
Design of pump and piping systems in real situations
Batch distillation cut control

7. CRYOGENIC BATCH REACTOR OPTIMISATION
MIXING VESSEL SEQUENCE CONTROL
CRYOGENIC BATCH REACTOR OPTIMISATION
Detailed Process Operations
1. Fill tank to a preset level
2. Remove water to level through screens to retain the solid product
3. Add hot wash water and mix
4. Drain to low level again
5. Repeat steps 3 and 4
6. Refill the tank with hot water to the original level
7. Inject live steam to heat at a certain rate to a soak temperature
8. Hold for a period of time
9. Recirculate through a heat exchanger to cool the tank
10. Transfer the contents to the next step in the process

8. CRYOGENIC BATCH REACTOR OPTIMISATION
MIXING VESSEL SEQUENCE CONTROL
CRYOGENIC BATCH REACTOR OPTIMISATION

9. CRYOGENIC BATCH REACTOR OPTIMISATION
MIXING VESSEL SEQUENCE CONTROL
CRYOGENIC BATCH REACTOR OPTIMISATION

10. CRYOGENIC BATCH REACTOR OPTIMISATION
ROAD/RAIL TANKER TO STORAGE
CRYOGENIC BATCH REACTOR OPTIMISATION

11. CRYOGENIC BATCH REACTOR OPTIMISATION
ROAD/RAIL TANKER TO STORAGE
CRYOGENIC BATCH REACTOR OPTIMISATION

12. CRYOGENIC BATCH REACTOR OPTIMISATION
BITUMEN STORAGE TANK HEATING
CRYOGENIC BATCH REACTOR OPTIMISATION

13. CRYOGENIC BATCH REACTOR OPTIMISATION
BITUMEN STORAGE TANK HEATING
CRYOGENIC BATCH REACTOR OPTIMISATION

14. CRYOGENIC BATCH REACTOR OPTIMISATION
STORAGE TANKER DIURNAL EMISSION
CRYOGENIC BATCH REACTOR OPTIMISATION
Current
Run Time

15. CRYOGENIC BATCH REACTOR OPTIMISATION
ROAD/RAIL TANKER TO STORAGE
CRYOGENIC BATCH REACTOR OPTIMISATION

16. CRYOGENIC BATCH REACTOR OPTIMISATION
STORAGE TANK EMISSION PREDICTION
CRYOGENIC BATCH REACTOR OPTIMISATION
Emission Prediction
Site emission reporting is a legal requirement
Government legislation required
Simulation readily adapted to geographical conditions
Adapting operational procedures to minimise emissions
Heat inputs calculated in Excel to comply with accepted methods
Easy to apply and flexible for wide range of components and procedures

17. CRYOGENIC BATCH REACTOR OPTIMISATION
CONCLUSIONS
CRYOGENIC BATCH REACTOR OPTIMISATION
Dynamic Simulation without Control Systems
No special control system skills required
Applies standard process engineering techniques
Easier to set up in less time
Applicable to a wide range of process activities
Aids initial design development
Control systems added after finalised design