recycle loop design with pro/ii - wonderware...
TRANSCRIPT
Mike Donahue
Technical Support
SimSci by Schneider Electric
Recycle Loop Design with PRO/II
Agenda
●Recycle Background
●Process Simulation Background
●Recycle Convergence
●Recycle Convergence Strategy
3
Recycle Background
Recycle Definition
●A recycle stream is a term denoting a process stream that returns material or enthalpy from a downstream process unit back to an upstream process unit
Recycle Loops
● Independent Loops
● Interconnected Loops
●Nested Loops
Tear Stream Definition
●A tear stream is any stream that “opens” a loop. It is a stream that PRO/II will update until two consecutive iterations are within the specified tolerance
●A tear stream is not a recycle stream
Tear Streams?
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
One Option
Selecting the sequence = Selecting the tear streams
Tear streams Calculation sequence
R1, R2 U1, (U2, U3, U4, U5, U6), U7
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
Minimum Tear Stream (MTS)
U3S1
U1 U6U2S2
U4S4S3
R1
R2S9
U5S6S5
U7
S8
S7
Tear streams Calculation sequence
S4 U1, (U4, U5, U6, U2, U3), U7
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^ Process Simulation Background
Steady State Modular Approach
●Sequential-Modular
˃ Flowsheet is decomposed (sequenced)
˃ Calculations are performed one unit at a time
˃ Iterate tear streams
˃ Most commercial steady state simulators use a sequential approach
●Simultaneous-Modular
˃ Flowsheet is developed as a collection of sub-flowsheets (SFS)
˃ Each SFS and collection of streams are solved together
Steady State
PRO/II is a Sequential Modular Simulator
●Recycles automatically handled
Recycle Definition
● Intuitive
˃ Clear / understandable error messages
˃ Problems localized to individual unit operations / recycles
●Robust
˃ The resolution is divided-up into several subsets that are treated sequentially
˃ This facilitates rigorous convergence, even in presence of extremely complex modules that are treated in an autonomous way
●Good heuristics for initialization and convergence
˃ No over-specifications (inconsistencies)
˃ Recycles estimates not required
˃ Recycle blocks not required
Sequential Solver Challenges
●The main challenge with a SMA
˃ Inefficient sequencing
˃ Inefficient recycles
●The combination of these issues lead to potentially long calculation times
Sequential Modular Approach (SMA)
Sequential Solvers
●Computation Time – Multiple passes are typically required to solve the flowsheet
~ 1,000
4 hours / 500
~ 30 seconds
~ 50% increase in speed
~ 500 increase in computing power
Sequencing Challenges
●How many tear streams?
●What order should we converge the units (partitioning)?
●Convergence Method?
●Many publications address tear stream determination and partitioning:
Sargent and Westerberg 1964
Forder and Hutchison 1969
Barkley and Motard 1972
Motard and Westerberg 1979
Gunderson and Hertzberg 1982
Lakshminarayanan and Rao 1991
PRO/II Sequencing Algorithms
●Minimum Tear Stream Algorithm (SimSci Method)
˃ Default
˃ Uses improved algorithms based on Motard and Westerberg
˃ Improved by SimSci
●Alternate Method (Process Method)
˃ Determines the sequence based partially on the input order
●Explicitly Defined by User
PRO/II Sequencing Algorithms
● If there are no recycle streams in your flowsheet, the SimSci sequence algorithm will determine the correct calculation sequence automatically
● If the flowsheet has recycle streams:
˃ First, the sequence algorithm is driven by reducing the number of tear streams in your flowsheet
˃ Secondly, the sequence algorithm is driven by the recycle stream estimates provided by you
●We recommend that you always provide a recycle stream estimate for each recycle loop
●These estimates will cause the calculation sequence algorithm to select the recycle streams as tear streams
PRO/II Sequencing Algorithms
●Controllers / Optimizers
˃ Single variable controllers which affect units within loops will be included in the loops
˃ Multi-variable controllers and optimizers will not be included in the affected loop
Be careful here – you may want to employ a user defined sequence
PRO/II Sequencing Algorithms
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Recycle Convergence
Convergence
●A flowsheet has converged when the stream values (material, temperature, and pressure) stop changing within the degree of tolerance for two successive loop iterations
Convergence
●Default is to converge all streams in the loop
●Optionally can choose to converge only tear streams
Tear Stream Identification
● Identify the tear streams
Recycle Tolerance
Tolerance
●Default Criteria
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All 3 must be met
Acceleration Methods
Acceleration Methods
●Direct-substitution
˃ Default method for recycle convergence in PRO/II. Last computed values for the tear streams are used for the next trial solution of the recycle loop.
˃ Generally stable
˃ Potentially slow
●Wegstein
˃ Provides rapid solution of recycles using an acceleration factor based on the convergence characteristics shown by previous iterations
˃ Note: This method does not work well when multiple recycle streams are interacting
●Broyden acceleration
˃ Based on the "Householder" method, which allows for rapid, stable solution of recycle loops
Acceleration Methods
User-Specified Recycle Loops
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Recycle Convergence Strategy
Recycle Challenges
● In closed loops (no purge), the recycle stream has the potential to do one of two things:
a) Build up
b) Deplete to zero
Unless the makeup rate is exactly equal to consumption + the other losses
●Consumption is known (typically) – what are the other losses?
●Major Challenges:
˃ Losses from the recycle components are usually insensitive to the recycle amount
˃ Small variations in makeup result in large recycle changes
˃ A large number of iterations are required to adapt to a small change in makeup
Recycle Strategy
Solution
1) Reference Stream to “Break the Recycle”
2) Use a Calculator / Controller / Splitter Specification
Recycle Strategy
Recycle Strategy
Recycle Strategy
● Identify the tear streams
Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
Recycle Strategy
<
Unit Tolerances Recycle Tolerances
Recycle Strategy
Recycle Strategy
Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
●Set appropriate tolerance (mass balance)
Recycle Strategy
Iterations vs. Tolerance Recycle Methane
Simulation time for 318 iterations – 38 seconds
Recycle Strategy
● Identify the tear streams
●Avoid complex operations when possible (move to outside loop with stream references)
●Always have tighter tolerances on internal loop operations than on recycle
●Avoid thermal recycles
●Set appropriate tolerance (mass balance)
●Use acceleration
Acceleration Methods
●Minimize controllers (recycle streams) with stream splitters
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
Recycle Strategy
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
●When using Controllers (use control)
Recycle Strategy
●Minimize controllers (recycle streams) with stream splitters
●Examine message history
●Supply recycle estimates
● Investigate Sequencing
●When using Controllers (use control)
●Use reference streams to redefine the tearing process and eliminate thermal recycles
Recycle Strategy
●Try not to spend too much effort (time) initially designing recycle loops
●PRO/II is extremely robust at solving complex loops (out-of-the-box)