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PTT303 /2PROCESS MODELLING AND
SIMULATION
SEM 1 (2013/2014)
Introducton to Su!"r PRO
D"#$n"r %or &'tcProc"##n$ Mod"n$
(P'rt 2)
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STUDENT S*OULD &E A&LE TO+
DEMONSTRATE the ,"tod# o% nt'#n$ o%
o!"r'ton o% unt !roc"dur"#
SIMULATE t" -o.#""t o% o!roc"## !roducton!'nt
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SESSION OUTLINE
Unit procedures initialisation
Simulation execution & result checking
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INITIALISING A UNIT
PROCEDURE
What aUnit Procedure?
Initialising anOperation
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WHAT IS A UNIT
PROCEDURE?
In the batch modeling mode, a UnitProcedure may consists of variousOperations:
Reactor procedure: feed charge, reaction,product withdraw, etc
Filtration procedure: filtration, cake wash,CIP, etc
Incontinuous modeling mode, aUnitProcedure= Unit Operation
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HIERARCHY IN BATCH MODELING
Operation(s) level
Procedure(s) level
Entire plant
The same forcontinuous
process
modeling
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FUNCTION OF EACH UNIT
PROCEDURE
Vessel Procedure (P-1): Acts as abatch reactor to
carry out reaction:
A + B CHeptane is used to dissolvecomponents A & B,
to aid separation in P-2
Plate and Frame Filtration (P-2):Component C is not dissolved in heptane, hence isfiltered outby the filter cloth
Heptane is used to wash out the trapped heptane ( and also th
dissolved A & B) from the filter cake
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STREAM SPECIFICATION
Click to insert
Heptane here
Heptane flow =
800 kg/batch
Ingredient flow
T, P = default
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SET SPEC FOR STREAM A & B
Stream ID ComponentAmount
(kg/batch)Temperature
Pressure
Heptane A
B
Heptane A
B
80050
40Default
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WORKING
SESSIONDo not forget to save your work !!!
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A QUESTION TO PONDER…
Q: Why do we only specify theinlet stream?
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ADDING OPERATIONS TO P-1
3Charge operation (to
charge A, B and
heptane respectively)1React (Stoichiometric)
operation (for reaction
to be carried out)
1Transfer Out operation (to deliver
product to next unit)
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ADDING OPERATIONS TO P-1
Add new operation
before the currently
selected operation
Add new operation
at the end of the list
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INITIALISING OPERATIONS IN P-1
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INITIALISING CHARGE-1
Vol. flowrate
=100 L/min
Setup time =
5 min
800 kg heptane
Emission calculation
(next slide…)
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EMISSION CALCULATION
lick to perform
mission calculation
OK, next operation
(CHARGE-2)
OK, previous
Operation (none)
Previous operation
(same tab –none)
Next operation
(same tab)
Go to selectedoperation
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INITIALISING CHARGE OPERATION
Operation Operating condition Emission
CHARGE- C!arge 800"g#$atc! of !eptane usingstream %Heptane&
'etup time( 5 min
)rocess time * 00+#min
)erform!eptaneemission on t!isstream
CHARGE-, C!arge 50 "g#$atc! of A limitingcomponent. using 'tream %A&
'etup time ( 5min
)rocess time* calculated $ased on ,0"g#min
/il
CHARGE- C!arge 40#"g $atc! of B using 'tream %B&B is in e1cess.
'etup time ( 5 min
)rocess time * calculated $ased on ,0"g#min
Please complete the initialisation ofCHARGE-2 & CHARGE-3
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INITIALISING REACT-1 & TRANSFER-
OUT-1
Operation Operating condition 2olumes Reaction
REAC3- inal temp ( 50 C
Heat transfer agent*steam
)rocess time ( 6 !our
+ea7e ot!er 7alues asdefaults
a1 Allo9a$le9or"ing#
7essel7olume* 80 :
E1tent of reaction( ;5 :
Reactionstoic!iometr<
A = B C
3RA/'ER-
O>3-
>sing stream %R1t out&
Duration* same as Clot!iltration in )-, using
aster-'la7eRelations!ip.
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INITILISING REACT-1 IN P-1
Steam
Process time
= 6 h
Final temp = 50 °C
Max allowable volume
= 80 %
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INITIALISING REACT-1 IN P-1
Reaction
extent = 95 %
Edit reactionstoichiometry
Rename reaction
Add reaction(s)
Delete
stoichiometry(when needed)
Molar
stoichiometry
OK, next operation
(Transfer-out)
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INITIALISING TRANSFER OUT
Transferout stream
Click here to select
Master-and-Slave to
calculate duration
To quit Vessel
Procedure
Select the Master
Procedure
Select the Master
Operation in
Master Procedure
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MASTER-SLAVE RELATIONSHIP
Slave
Master
Master operation – processing step that control the duration of
another operation (slave)
When simulation is executed,duration calculation for the slaveoperation will be bypassed (note:M&E balances affected), until
the master operation is met
Both master and slave operation may exist in the same procedur
or in another procedure
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WORKING
SESSIONLet’s try before we proceed further…
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INITIALISING OPERATION FOR P-2
Cloth Filtration operation(by default, to filter
product C)Cake Wash operation (towash out left over trapped
A & B in filter cake)Transfer Out operation (todeliver product)
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ADDING OPERATIONS TO P-2
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INITIALISING OPERATIONS FOR P-2
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INITIALISING FILTER-1
Operation Operating condition Scheduling
FIT!"#$ Particulate componentremo%al& ' C (assumingthat A * + are completel,
soluble in -eptane * C is%irtuall, insoluble).
OD (loss on dr,ing) 0 (this %alue cause aportion o1 heptane * an,
soluble component to beheld in the 2et cake 3is insoluble C).
Filtrate stream& 4+ 5
-eptane6
+, de1ault7 1irstoperation o1 an,batch unit
procedure isscheduled to startat the beginning o1the batch
Start time& relati%e
to the STA"T o1T"A8SF!"#O9T#$operation in P#$procedure
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INITIALISING FILTER-1
Scheduling
C = 95%removal
LOD = 35%
Filtrate
By default
Filtration will only start
when product is
transferred out from P1
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INITIALISING CAKE-WASH-1 &
TRANSFER-OUT-1
Operation Operation condition
CA?E-@A'H-
@as! n stream* %@as! in&
@as! Out stream* %@as! out&
@as! sol7ent* !eptane clic" on %Composition& select %Auto-adust& t!e program 9ill estimate a 7alue automaticall
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WORKING
SESSIONRemember to save your file !
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SIMULATING A FLOWSHEETExecute the simulation
Viewing the results
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RESULT VIEWING
1. Calculated output variables for each oeration can beviewed by revisiting the correspondingOperationData dialog windows
2. To see the calculated equipment sizes, right click on
the unit procedure icon & choose theEquipmentData… option
3. The contents of a piece of equipment as a function oftime can be viewed by right clicking on a unitprocedure and selectingEquipment Contents orOperation Sequence
4. The calculated flowrates and compositions ofintermediate & output streams can be viewed by intheSimulation Data dialog windows of each stream
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RESULT VIEWING
5. A list of reports can be viewed inReports:Stream Reports (SR)Economic Evaluation Report (EER)
Itemized Cost Report (ICR)Cash Flow Report (CFR)Throughput Analysis Report (THR)Environmental Impact Assessment Report (EIR)
Emission Reports (EMS)Input Data Report (EDR)Equipment Report (EQR)
Let’s visit the one by one…
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EQUIPMENT CONTENT
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STREAM SIMULATION DATA
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GENERATING A STREAM REPORT
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CHECK YOUR SCHEDULING
RESULTS
Reaction A B C
@
nitial content miO "g.
nitial mol niO "g-mol.
( ;5: $ased on A.
Current mol n "g-mol.
Current content m "g.
n AO-n AO nBO-nBO
-
-
n AO
+
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CHECK YOUR SCHEDULING RESULT
Heptane charge =____kg/batch (streamspecification)
Volumetric flowrate=___L/min (in OperationData/CHARGE-1)
Task: Find out the density of the heptane stream fromyour simulation sheet
Verify the heptane charging duration calculated
by SPD heptane
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DO NOT JUST TAKE
THE COMPUTER’S
WORD AS IT IS, PLEASECHECK YOUR RESULTS
ACCORDINGLY!!!REMEMBER THE GIGO PRINCIPLE