SAJJAD KHUDHUR ABBASCeo , Founder & Head of SHacademyChemical Engineering , Al-Muthanna University, IraqOil & Gas Safety and Health Professional – OSHACADEMYTrainer of Trainers (TOT) - Canadian Center of Human Development

Episode 51 : Integrated Process Simulation

Integration: Introduction

Why Integration ?

* Consider aspects of control, environmental impact, energy, etc., early

during process design

* Prevent potential problems rather than cure (which may not be possible)

Definition of Integration

Integration

Off-line

Tools

On-line

Process

Simultaneously solve more than one problem, or, simultaneously perform more than one operation !

Process Integration is about Operation/Control !

Difference Between Process & Tools Integration

Tools Integration

* Combines tools/algorithms in order to determine optimal conditions of operation

& design subject to constraints

Process Integration

Links more than one operation and/or equipment together in order to achieve an integrated condition of operation & design

Difference Between Process & Tools Integration

Example: Heat Integration

Tools Integration- Determine the heating/cooling demands and the

optimal distribution

Process Integration - Supply the individual heating/cooling demands

based on optimal network (connection)

Tools Integration: ExampleIntegrated synthesis, design and control: Separation

of an azeotropic mixture

Solve the following steps in an integrated manner* Mixture analysis

* Use solvents or external agents ?* Analyze phase boundaries and distillation

boundaries* Configure/design the separation sequence

* Validate separation by simulation* Design & verify process operation/control

Tools Integration: ExampleOptimal design and control of a process: Determine energy efficient and “clean” condition of operation

Solve the following steps in an integrated manner* Process (flowsheet) analysis (control,

environmental impact, energy used)* Solvents or external agents used?

* Define feasibility (control, energy, environment) regions

*Reconfigure/design the process flowsheet

*Validate process operation by simulation (open-loop and closed-loop)

Tools Integration : RequirementsNo recycle of information flow - Integration possible ?

problem 1 problem 2

Recycle of information flow - Integration possible ?problem 1 problem 2

Direction of Information flow

Tools Integration: General Framework

Outline

* Basis for integration

* Integration of synthesis, design & operation

* Tools needed (models, properties, algorithms (synthesis, design, ..), simulation engine, etc.)

* Integration approach

* Aspects of models-properties

Tools Integration: Basis for Integration

* What are common (information) between various problems (tools) to be integrated ?

* Can the same tools supply the common information ?

* How can various tools share the common information ?

Tools Integration: Basis for Integration

design control

synthesis

To consider aspects of synthesis, design and control simultaneously, it is necessary to determine what is “common” information to the three problems.

Intensive variables such as T, P, x are “common” but have different “functions”

Tools Integration: Basis for Integration

To consider aspects of synthesis, design and control simultaneously, it is necessary to determine what is “common” information to the three problems.

Intensive variables such as T, P, x are “common” but have different “functions”

Stream Summary from

Simulation Engine

design control

synthesis

Functions of Intensive Variables T, P, x Synthesis: Determine effects of T, P, x on the process

model (properties) to generate the process flowsheet/configuration

Design: Determine T, P, x such that the process satisfies the specified objectives

Control: Determine the sensitivities of T, P, x in order to design the control systemEnergy: Determine H(T, P, x) to compute the

energy requirementsEnvironmental Impact: Identify

environmental problems through xEconomy: Cost of operation,

equipment are functions of T, P, x

INTEGRATION OF TOOLS/METHODS

Intensive variables T, P, x

Extensive variables& properties

Process Models (constraints)

Problems

(synthesis, design, control, analysis)

Tools Integration: Tools Needed

* Models (Properties, process, …)

* Algorithms (synthesis, design, control, …)

* Simulation engine

* Storage of knowledge (information)

* Numerical methods (solvers)

* Process analysis

Hierarchical Approach: Example

Separation system

Level mReactor

Level nReactor

Level pFlash DistillationReactor

At every level perform integrated design & control analysis !

Extractive separation of azeotropic mixtures: Separation of acetone-chloroform

Problem Definition: Determine Optimal Flowshet* Define Optimal (energy, environment, operation)

* VLE-phase diagram & azeotrope verification

* Selection of extractive agent* Configuration of extractive distillation system

* Evaluation of alternatives (by simulation)* Determine optimal flowsheet

Level 1

Levels 2 …N

A Hierarchical Approach: Problem Decomposition

Level 1

Level 2

Level 3

Level NEach level solves an integrated problem. Complexity of problem increases with

Computer Aided Process Engineering - Lecture 5 (R. Gani)

19SIMULATION ENGINE

MANAGER

AE / ODE / DAE

PDE

LP / NLP

MILP / MINLP

Solver Library

Rigorous

Linear

Regression

Model Analysis

FlowsheetComponents / Reactions Measure units Constitutive models What to solveMethod of solution Set/initialize variables Output (detail/form)

PROBLEM DEFINITIONADD TO THE SYSTEM TOOLBOX

DATABANKS LIBRARIES

Models(Model development)

Components(Property prediction)

Reactions

Process synthesis/equipment design/control

Utilities (model selection, properties)

INFORMATION STORRAGE

Agents (solvent design/selection)

Analysis & assessment

Model Equations

Model equations

Model equations

Constitutive relations

Model Adaptation

Rigorous

Linear

Regression

RHS

Thanks for Watching Please follow me / SAJJAD KHUDHUR ABBAS