design project steps 20 july 2007 - lecture 2

8/10/2019 Design Project Steps 20 July 2007 - Lecture 2

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Copyright@FKKKSA, UTM Computer-Aided Process Simulation Project Intro to PD - 1

PSE

Process,Process,

Product DesignProduct Design& Process Creation& Process Creation

PSE


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PSE

ZainuddinZainuddin Abdul Manan, PhDAbdul Manan, PhDAssociate Professor and Head,Associate Professor and Head,Dept of Chemical Engineering, UTMDept of Chemical Engineering, UTM

Dr. Zainuddin Abdul Manan holds a BSc degreein Chemical Engineering from University ofHouston, USA, a master degree in ProcessIntegration from Centre for ProcessIntegration, UMIST, Manchester, and PhD inChemical Engineering from the University ofEdinburgh, Scotland. He has worked as aproduction engineer with Hume Industries.

[email protected]:07-5535512

His research interests include Process Systems Design and ProcessImprovement with emphasis on efficient energy utilisation and wasteminimisation (cleaner production). He has ten years research and consultancyexperience in the area of process design, process improvement, energyconservation and cleaner production; having completed over 30 research andconsultancy projects involving petrochemicals, fine chemicals, pulp and paperand food production industries in Malaysia and abroad. He is also anexperienced instructor for professional courses related to chemical andprocess engineering, having taught over 250 companies nationwide.


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PSELearning OutcomesLearning Outcomes

After studying this topic, participants should:

Recognise the significance of design project for chemical/processengineers

Be able to describe the life cycle of a chemical process and identify theactivities associated with it

Have an appreciation of the key steps in carrying out a product and / orprocess design.

Be knowledgeable about the kinds of design decisions that challengeproduct and process design teams

Be familiar with the key roles of a chemical/process engineerBe aware of the various techniques and steps involve during processcreation


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PSE

Process Design whose job? Design project in the context of a chemical

process engineers role

Process Design Definition Process Design Procedure Process Design Activities Process Life Cycle Levels of Design Accuracy

Intro to Process Design


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PSE One day in a job interviewOne day in a job interview

...

...

What is your

field of study?ChemicalEngineering!

Then, our

chemistry lab might be the best place for you ?Oh no!

Not again...

ThemanagerThe

freshgrad


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PSE Chemical/ProcessChemical/ProcessEngineeringEngineering

..is the field of study

that involves the processof converting resourcesinto value-added products


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PSE A design project A design project A design project A design project A design project A design project A design project A design project

Survey/feasibility studies

Project teamProject structure/planning (milestone)Process and Product Design

DesiredProducts

PROCESS ?

Raw materials?

Process Structure


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PSE

Methane

Ammonia

Methanol

EthyleneOxide

ChloralkaliPlant

Ethane

Propane

Ammonia

MTBE

UreaFormadehyde

Ammonia Urea

Ammonium Nitrate

Ammonium Phosphate

Polyvinyl Chloride

Titanium Dioxide

Silicones

Polyethylene LDPE

Glycol

Surfactant

Polypropylene

Acrylics

Acrylonitrile

Caprolactam Terephthalic Acid

Polystyrene

ABS, SAN

MTBE

Unsaturated Esters

Butane

Benzene

e.g. End Uses ofFractionated Raw

Natural Gas

Middle Distillates


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PSE

E.g. Naphtha Utilisation For Petrochemicals (1/2)

Cl2

EDC/VCM Polyvinyl Chloride

LDPE Acetic Acid

Vinyl Acetate Polyvinyl AcetateLLDPE/HDPE

Ethylene O2 H2O PTA Polyester Polyethylene

Ethylene Oxide Ethylene Glycol Chips Terephthalate

Benzene (PET)

Ethylbenzene Styrene Polystyrene

Naphtha H2O O2Cracker Ethyl Alcohol Ethyl Aldehyde Acetic Acid

Polypropylene

H2O O2 HCN

Propylene Isopropanol Acetone Methyl Methacrylate Polymethylmethacrylate

Benzene Isopropylbenz O2 Cumene Hydroperoxide Cleavage Phenol /

(Cumene) (CHP) Acetone


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E.g. Naphtha Utilisation For Petrochemicals (2/2)O2

(By Products) n - Butane Acetic Acid

Acrylonitrile

Butene - 1

Mixed C 4Butadiene Polybutadiene (Synthetic Butadiene Rubber)

H2

HMDA Nylon 6,6

Adiponitrile

Nylon 6

Butene - 2 Isobutene Polybutene

MTBE (ABS)

Naphtha

Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6

C2Benzene Ethylbenzene Styrene Polystyrene

Pyrolysis C3 O2Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam

Acetic Acid EGPara - xylene Pure Terephthalic Acid (PTA) Polyester Fiber

Fuel Oil

Fuel Gas

Caprolactam


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(Seider et al. , 2004)

Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle A Bird A Bird A Bird A Bird A Bird A Bird A Bird A Bird s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View


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PSE

Process DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess Design Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level

Steps in the design of a chemical process:1. Project Conception

2. Process Synthesis/Creation

3. Equipment Design4. Economic Analysis

5. Optimisation

(Ulrich, 1984)


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PSE

Process DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess Design ProcessProcessProcessProcessProcessProcessProcessProcessSynthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation

Process Simulation

parameteroptimisation

Optimised Design

Material and Energy Balances(manual & simulation)

Process Synthesis/

Flowsheeting

Process Modelling/Analysis

(Manan, 2001)

structural optimisation


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Copyright@FKKKSA, UTM Process Design Intro to PD - 18

PSE

Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details)


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PSE

Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design


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PSE

Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation


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PSE

Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation

Layout and3-D Modelling

Construction

Startup andCommissioning

Plant Operation

Debottlenecking

Decommisioning


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PSE What aWhat a Chemical ProcessChemical ProcessEngineer Engineer * Does for a Living* Does for a Living

1. Process Design2. Process Development3. Construction4. Manufacturing/Operation5. Technical Sales6. Research

*A person whose job is related to the process of transforming materialsinto value-added products


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PSE2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development

Design

Construction Operation - testing

- reaction & catalyst- process conditions- process control scheme- materials of construction

Pilot Plant(10 kg/hr)Chemical

Lab(10g)

CommercialScale

(100 tonne/hr)


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PSE

3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning- -- - - -- - Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth

Chemical Engineers:

Ascertain that equipment operates correctly? Are involved in plant commissioning, start up Identify any problems with process and equipment Specify redesign requirements (as required)


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PSE4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production

ChemicalEngineer

Troubleshooting

SupervisionQuality ControlDebottlenecking

Energy ConservationRaw material conservationPollution controlProcess control

RoutineOperation

Process

Improvement


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PSE

5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales

Chemical Engineer

Provide process and product recommendations Provide advice on development of new process & products Networking with experts from other fields in solving

process/equipment problems to meet customer needs


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PSE 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research

Chemical engineers:

Cooperate with chemist, scientists andengineers from other fields to producenew products

Develop new processing techniques

Improve & optimise process operations

Design new equipment or improve the

existing ones


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PSE

Have you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as a chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer ? ?? ? ? ?? ?

Please take about 10 minutes to recollect a challenging task that you haveperformed in your company, related to one of the six areas that a chemicalengineer may work in - i.e. process design, process development,construction, manufacturing*, sales and research .

Please share with us your particular experience by writing it down briefly ona piece of paper. Please include your name if you dont mind.

*manufacturing may involve process (product and quality) monitoring ,troubleshooting, improvement and debottlenecking .


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PSELevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design Accuracy- -- - - -- - 11111111

Types of Design estimates

1. Order of magnitude estimate - based on similar or previous cost data;probable accuracy exceeds 40%

2. Study estimate - based on knowledge of major items of equipment; probableaccuracy up to 25%

3. Preliminary/budget authorization/scope estimate -based on sufficient datato allow the estimate be budgeted; probable accuracy within 12%4. Definitive estimate (project control estimate) based on almost complete data,

but before completion of drawings and specifications; accuracy within 6%5. Detailed estimate (contractors estimate) based on complete engineering

drawings, specifications, and site surveys; probable accuracy within 3%


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PSE

b u d g e t

a u t h o r

i z a t i o n

e s t i m a

t e

Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy

10

20

30

40

Cost for an economic estimate for a $1M to 5M plant (thousands of $)1.0 5 10 50 100 5000.5

E r r o r r a n g e

( % )

F i r m o r

c o n t r a c t o r s

e s t i m a t e

P r o

j e c t

c o n

t r o l

e s t

i m a t eOrder of

magnitudeestimate

S t u d y

e s t i m a t e

Definitive Estimate

Predesign Estimates


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PSE Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS - -- - - -- - ProcessProcessProcessProcessProcessProcessProcessProcess

Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis

Methanol is an important raw material for the production offormaldehyde, acetic acid and for gasoline blending (as fuel formotor vehicle). Several routes* exist for the production ofmethanol. Make an initial selection of the best process route +and develop a preliminary flowsheet for the production of100KMT/annum of methanol based on the process route youhave selected.

(Due: Aug 7, 2005)

*these include conventional (from the 60s and 70s) as well as modern technologies (late 90sand early 2000)

+ based on various process screening criteria


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PSE Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation

Refer to problem 4.29 (3 rd edition) of Felder and Rousseau. Perform manual mass balance calculations for the separation of

1000 tons of 30% B, 40% T and 30% X . Confirm this results using Design II simulation software*,

complete the mass balance for the separation sequence.

Compare the results among your group members* www.winsim.com

The password is:The password decodes to: Serial Number:

Type of security: Name / Location / PasswordLevel: Academic (Professional privileges)Name: University of Technology of MalaysiaLocation: Skudai, Malaysia Password for DIIW


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PSE Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont ) )) ) ) )) )

Estimate the operating conditions (temperatures and pressures)*for the two columns, assuming cooling water is to be used in a pressure drop of 0.01 bara throughout each column

* These conditions are essential to facilitate process simulation

Specify the (i) reflux ratio (ii) number of stages for eachcolumn to achieve the desired product specifications


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PSEGroup Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1- -- - - -- - A AA A A AA A

Refer to the project for the manufacture of 100KMT methanol.For the processes available on the market,(a) Find the prices for the materials having commercial value.

(b) If all the limiting reactant could be converted to product, what is the maximumattainable gross profit?(c) Using the conversion and selectivity found in the literature, adjust the

maximum gross profit attainable for each reaction. Compare the maximumgross profit and identify the reaction giving the highest maximum gross profit

(d) For the reaction that you have selected, tabulate several of the physicalproperties (as in Table 1.3, Chapter 1, Biegler) for all the species you wouldexpect in this process.

(e) Develop the hierarchy of flowsheets for this process, until the final separation

system.(f) Summarise the advantage and disadvantages of the various processesfor producing methanol. Weigh these factors and choose your processaccordingly. (Due: )


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PSESome common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology

Process flow diagram (PFD) / process flowsheet -interconnections of the individual process operations(e.g. drying, mixing, etc.) together with the quantitativevariables (e.g. P, T, flowrates and composition).

DFCY1


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PSEExample: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production

Raw materials

(C 2H 4, Cl 2)

ProcessFlowsheet?

Desired Product

(C 2H 3Cl)

Needed to define the state of each:1) Mass (flowrate)2) Composition3) Phase (solid, liquid, gas)4) Form (particle size, etc.)5) Temperature6) Pressure (Seider et al. , 1998)

Slide 38


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Slide 38

DFCY1 An example to differentiate process synthesis & analysisDominic Foo Chwan Yee, 6/29/2004


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PSEPossible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production

DirectChlorination Pyrolysis

242242 Cl H C Cl H C + HCl Cl H C Cl H C + 32242

Cl2113,400 lb/hr

C2H444,900 lb/hr

HCl58,300 lb/hr

C2H3Cl100,000 lb/hr

Dichloroethane


DFCY2


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PSEProcess flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD)


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DFCY2 Process synthesis is what we learn in process design courseDominic Foo Chwan Yee, 6/29/2004

DFCY3


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PSE Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach

Slide 41


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DFCY3 Process synthesis is what we learn in process design courseDominic Foo Chwan Yee, 6/29/2004


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PSETypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFD


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PSETypical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD


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Introduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer Aided

Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation

Wh ih ih iWh i P Si l iSi l iSi l iP Si l i ????


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PSEWhat isWhat isWhat isWhat isWhat isWhat isWhat isWhat is Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation ? ?? ? ? ?? ?

Building a process modelPredicting how a process would actually behavePerforming an experiment (on computer)

Incentives:Highly cost effectiveReasonably accurateProactive approach

Q: What does the word simulate mean?

h ihhh iWh iWh iWh iWh i d ld ld ld ld ld ld ld l??????


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PSEWhat is aWhat is aWhat is aWhat is aWhat is aWhat is aWhat is aWhat is a model model model model model model model model ? ?? ? ? ?? ?

A model should be as simple as possible and no simpler~ Albert Einstein

Th f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l i


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PSEThe purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation

Typical purpose is to provide stream and unitoperation size parameters for entire processincluding such things as:

Flowrates.Compositions.Temperatures.

Duties.Equipment performance.Power requirements.Physical and thermodynamic properties of streams.

Secondary purpose is to determine preliminary size& cost estimates of individual pieces of equipment.

Role of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in product


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Role of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productdevelopment &development &development &development &development &development &development &development &commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation

IDEA GENERATIONProject Screening, Strategic Planning

PROCESS DEVELOPMENTEvaluation of Alternatives

Common Language of Communication

FACILITY DESIGNEquipment & Utility Sizing and Design

MANUFACTURINGOn-Going Optimization, DebottleneckingProcess Scheduling, Production Planning

Development Groups

Development GroupsProcess EngineeringCorporate EnvironmentalManufacturing

Manufacturing(Demetri, Koulouris & Siletti, 2002)

Obj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l ti


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PSEObjectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation

PROCESS

UTILITIES

Rawmaterials By-products

Fuel

Electricity

WASTETREATMENT Wastewater

Air Solid

Products Products

(Marechal & Kalitventzeff, 1998)

S h d li g tiS h d li tiS h d li tiS h d li g tiSched ling q estionsS h d li g q tiS h d li g q tiSched ling q estions


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PSEScheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions

How can I schedule production during thenext 6-18 months?

How can I schedule operations in an R&Dfacility?How to adjust scheduling if priorities change?

Can I fit a new product into my facility?

S i l i l tS i l i l tS i l i l tS i l i l tSome commercial process simulatorsSome commercial process simulatorsSome commercial process simulatorsSome commercial process simulators


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PSESome commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators

Oil, Gas &Petrochemicals

Specialty Chemicals

Oleo Chemicals

SS Simulation

Optimisation

Sensitivity Analysis

Dynamic simulation

Rating

Physical properties

Batch operation

Pinch analysis

Economics

Sizing & costing

Solid handlingHysis/Hysim

Aspen Plus

PRO/II

SuperProDesigner

Design II forWindows

Design II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for Windows


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PSEDesign II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows

SuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro Designer


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PSESuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer

Process design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design steps


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PSEProcess design steps Process design steps Process design steps Process design steps Process design steps Process design steps Process design steps Process design steps

Synthesis

Modelling &Simulation

Evaluation

Final Design

Structural

Optimisation

ParameterOptimisation

(Smith, 1995)


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design project steps 20 july 2007 - lecture 2

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