Download - Episode 51 : Integrated Process Simulation
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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
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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)
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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 !
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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
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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)
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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
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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)
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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
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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
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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 ?
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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”
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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
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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
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INTEGRATION OF TOOLS/METHODS
Intensive variables T, P, x
Extensive variables& properties
Process Models (constraints)
Problems
(synthesis, design, control, analysis)
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Tools Integration: Tools Needed
* Models (Properties, process, …)
* Algorithms (synthesis, design, control, …)
* Simulation engine
* Storage of knowledge (information)
* Numerical methods (solvers)
* Process analysis
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Hierarchical Approach: Example
Separation system
Level mReactor
Level nReactor
Level pFlash DistillationReactor
At every level perform integrated design & control analysis !
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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
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A Hierarchical Approach: Problem Decomposition
Level 1
Level 2
Level 3
Level NEach level solves an integrated problem. Complexity of problem increases with
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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
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