A-Introduction & Thermodynamics 2012

Steady State Seminar
Introductory Presentation John Edwards, P&I Design Ltd 2012
www.chemstations.com
Engineering advanced Engineering advanced
CRYOGENIC BATCH REACTOR TYPICAL PROCESSES OPTIMISATION
www.chemstations.net www.chemstations.co
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR PROCESS DEVELOPMENT OPTIMISATION
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CRYOGENIC BATCH REACTOR DESIGN SEQUENCE OPTIMISATION
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR CAUTIONARY STORY OPTIMISATION
Modelling requires engineering judgement Rules of thumb (heuristics) used in initial simulations Modelling enables the engineer to make mistakes faster Simulation sometimes will give a result different to intuition > check Plant problems should be reproducible in simulation Always verify results with independent calculation>rules of thumb Some of seminar cases have taken days to develop Modelling can be frustrating > one incorrect parameter is all it takes
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CRYOGENIC BATCH REACTOR IMPACT OF DESIGN ERRORS OPTIMISATION
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CRYOGENIC BATCH REACTOR SIMULATION PRINCIPLES OPTIMISATION
Steady State
Based on direct substitution of variable each iteration and speed up principles
Models plant behaviour using continuous, time interval based, steady state estimates Requires least effort to set up and calibrate the flowsheet Ideal for economic analysis and process optimization
Dynamic
Based on real time or speed up dynamics
Real plant and equipment performance, retention times and control systems Requires more information and more difficult to set up Ideal for troubleshooting, control loop tuning and real time study
www.chemstations.net www.chemstations.com
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR SIMULATION PRINCIPLES OPTIMISATION
Process Unit / Total Plant Feeds Recycles Products
Batch Cycle Time, Volume Scale Continuous Steady State Varying Throughput Continuous Dynamic Start up, Shutdown, Feed Change , Composition Change
Dynamic simulation is series of steady state cases
www.chemcad.co.uk
CHEMCAD SIMULATION SOFTWARE
CHEMCAD
Steady State
CC-BATCH
Batch Distillation
CC-Dynamics
Physical Properties Database

SAFETYNET
Relief-Piping Dynamics
FLASH
Reactors-Columns SIMULATION SUITE Heat Exchangers Relief-Piping
CC-THERM
CHEMCAD SOFTWARE
www.chemstations.com
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR CHEMCAD PROCESS SIMULATOR OPTIMISATION

Graphical Representation of Process Unit Operation Symbols contain Math models Stream Connections with P-T-x Composition Mass & Energy Balances with Recycle Equipment Sizing
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CRYOGENIC BATCH REACTOR CHEMCAD INTERFACES OPTIMISATION
Microsoft Word Microsoft WordPad Microsoft Excel OPC-OLE for process control VBA/VSTA
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CRYOGENIC BATCH REACTOR CHEMCAD REPORT FORMATS OPTIMISATION
Reporting in Excel allows for data manipulation
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR CHEMCAD EQUIPMENT SIZING OPTIMISATION
Pipe networks Pump sizing Ventilation systems Relief devices Packed & plate towers Orifice plates, restriction orifice plates Control valves Shell and tube & plate heat exchangers Air cooled heat exchangers Plate heat exchangers Pipe in pipe heat exchanger Tank Sizing
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CRYOGENIC BATCH REACTOR REALITY IN SIMULATION OPTIMISATION
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CRYOGENIC BATCH REACTOR INTRODUCTORY SESSION OBJECTIVES OPTIMISATION
Steady state simulation principles Modelling procedure Draw flowsheets Manipulate text and lines Specify units Specify components Plot component properties User component for aqueous mixtures Introduce CHEMCAD sizing features Introduce Data Map facility
www.chemcad.co.uk
MODELLING PROCEDURE
Engineering advanced
Draw Flowsheet
Select Thermodynamics Specify Feed Streams Run Simulation Analyze Results Final PFD Report
Set Engineering Units

Run Wizard Specify T & P Specify UnitOps Equipment Sizing
Select Convergence
Adjust K Set Local K Controllers & Convergence Sensitivity Analyses Sizing Reports Consider Data Maps
Select Components
Set Global Phase SLV Data Map & Execution Rule
Consider Electrolytes
Adjust H Set Local H
Optimise
SIMULATION SUITE CHEMCAD SOFTWARE

GUI Presentation
www.pidesign.co.uk
TPxy-UnitOp Plots Component PPD Plots
CRYOGENIC BATCH REACTOR CASE 2.01 TUTORIAL FLOWSHEET OPTIMISATION
SAVE!!!
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CRYOGENIC BATCH REACTOR SPECIFY ENGINEERING UNITS OPTIMISATION
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CRYOGENIC BATCH REACTOR UNIT CONVERTER OPTIMISATION
Enter data in your units Press enter to calculate then press OK
Select cell F6 Selects Unit Converter

F7 Selects Calculator
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CRYOGENIC BATCH REACTOR CONVERGENCE OPTIMISATION
DIRECT SUBSTITUTION Value replaced after each iteration WEGSTEIN ACCELERATION Value replaced after three iterations-speed up frequency 3 DOMINANT EIGEN VALUE Value replaced after four iterations-speed up frequency 4 CALCULATION STEPS / ITERATIONS Default set at forty CONVERGENCE PARAMETERS Value change on subsequent iteration Tolerance 0.001 equivalent 10-3 absolute value
CRYOGENIC BATCH REACTOR SELECT COMPONENTS OPTIMISATION
Double click or select
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR RUN THERMODYNAMIC WIZARD OPTIMISATION
Enter service fluids
Use for guidance only MUST verify against plant data

CRYOGENIC BATCH REACTOR THERMODYNAMIC WIZARD DECISION TREE OPTIMISATION

SINGLE COMP HEAVY HC MULTI
CHEMICAL SYSTEM
OTHER
CHEM<13BAR SYSTEM
Data>50%
OTHER
>70C
CHEM>13BAR TEMP K=SRK H=SRK <70C K=PSRK H=MIXH K=PR H=PR
www.chemcad.co.uk
K=VAP H=LATE
K=VAP H=SRK
NRTL,Wilson UNIQUAC
Data<50%
SPECIAL METHODS AMINE

K=AMINE H=AMINE
UNIFAC H=LATE (all)
SOUR
K=SOUR H=SRK
<7BAR
PRESS K=ESSO 90 to 200C H=LK
>7BAR
POLYMER
K=UPLM H=LATE
HCL/NH3
K=PPAQ H=SRK HTSL www.chemstations.net www.chemstations.com
K=GS (P<200BAR) H=LK
CRYOGENIC BATCH REACTOR SPECIFY THERMODYNAMICS OPTIMISATION
Use V/L/L/S for extraction & azeotropes
Check when Electrolytes
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CRYOGENIC BATCH REACTOR SPECIFY FEED STREAM OPTIMISATION
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR SPECIFY UNITOPS OPTIMISATION
Heat Exchanger 1 > Stream 2 > Vapor Fraction 1 Heat Exchanger 2 > Stream 3 > -10 deg C Pipe 5 > D = 200 mm L =50m Flash 3 > Mode 0 Inlet T&P Valve 6 > Outlet Pressure 9 bara Tower 4 > Stages 12 with Feed Stage 1 > Top Pressure 8.6 bara > Column DP 0.34 bar > Bottom mf propane 0.01
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CRYOGENIC BATCH REACTOR CASE 2.02 TUTORIAL DATA OPTIMISATION
OBJECTIVE: MINIMIZE TOLUENE & BENZENE DISCHARGE TO ATMOSPHERE
SERVICES COOLING WATER AT 85 deg F & 50 psia GLYCOL AT -60 deg F STRATEGY CONSIDER COOLING, COMPRESSION & RECYCLE
CRYOGENIC BATCH REACTOR CASE 12.01 VOC MINIMIZATION STUDY OPTIMISATION
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CRYOGENIC BATCH REACTOR THERMODYNAMIC SESSION OBJECTIVES OPTIMISATION
THERMODYNAMICS
Introduce Thermodynamic Wizard Review K Model facilities Review L Model facilities Physical Property Library Physical Property Plot facility User components User component for aqueous mixtures Introduce CHEMCAD sizing features Introduce Data Map facility
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR THERMODYNAMICS - ENTHALPY OPTIMISATION
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CRYOGENIC BATCH REACTOR THERMODYNAMICS - PHASES OPTIMISATION
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR THERMODYNAMIC WIZARD DECISION TREE OPTIMISATION

SINGLE COMP HEAVY HC MULTI
CHEMICAL SYSTEM
OTHER
CHEM<13BAR SYSTEM
Data>50%
OTHER
>70C
CHEM>13BAR TEMP K=SRK H=SRK <70C K=PSRK H=MIXH K=PR H=PR
www.chemcad.co.uk
K=VAP H=LATE
K=VAP H=SRK
NRTL,Wilson UNIQUAC
Data<50%
SPECIAL METHODS AMINE

K=AMINE H=AMINE
UNIFAC H=LATE (all)
SOUR
K=SOUR H=SRK
<7BAR
PRESS K=ESSO 90 to 200C H=LK
>7BAR
POLYMER
K=UPLM H=LATE
HCL/NH3
K=PPAQ H=SRK HTSL www.chemstations.net www.chemstations.com
K=GS (P<200BAR) H=LK
CRYOGENIC BATCH REACTOR THERMODYNAMIC MODEL SELECTION OPTIMISATION
PHASE GAS VLE VAP ONLY SYSTEM HYDROCARBON NAT GAS
LIQUID
LIQUID SYSTEM AZEOTROPE LLE BIP MODEL LLE BIPS H=LATENT HEAT
GAS EQUATION SOAVE REDLICH KWONG(SRK)
BENEDICT WEBB RUBIN H=LEE KESSLER
IDEAL VAPOR PRESSURE

H=LATENT HEAT
PENG ROBINSON GRAYSON STEED H=LEE KESSLER NO IDEAL NRTL (5 PAR) UNIQUAC (2 PAR) UNIFAC(INCREM) H=LATENT HEAT
NRTL (5 PAR) UNIQUAC (2 PAR) UNIFAC(INCREM) YES
IDEAL VAP PRESS GAS EQUATION BIP MODEL H=LATENT HEAT

www.chemcad.co.uk
CRYOGENIC BATCH REACTOR THERMO MODEL SELECTION OPTIMISATION
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www.chemcad.co.uk
www.chemcad.co.uk
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR THERMODYNAMICS BUBBLE POINT & DEW POINT OPTIMISATION
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CRYOGENIC BATCH REACTOR LIBRARY EQUATIONS IN CHEMCAD OPTIMISATION
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CRYOGENIC BATCH REACTOR PHYSICAL PROPERTY DATA PLOTS OPTIMISATION

Heat Transfer Fluids Liquid Specific Heats
4.5
4.0
Liquid Specific Heat (kJ/kg-K)
3.5
Dowtherm A Dowtherm J Dowtherm Q Syltherm XLT 50% EtGlycol Water Therminol 55 Therminol 59 Therminol LT Transcal LT
3.0
2.5
2.0
1.5
1.0 -50 0 50 Operating Temperature (degC)

100
150
CRYOGENIC BATCH REACTOR PHYSICAL PROPERTY DATA PLOTS OPTIMISATION

Heat Transfer Fluids Liquid Viscosities
100
Dowtherm A
Liquid Viscosity (cP)
Dowtherm J 10 Dowtherm Q Syltherm XLT 50% EtGlycol Water Therminol 55 1 Therminol 59 Therminol LT Transcal LT
0.1 -100
-50
50
100
150
Operating Temperature (degC)

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CRYOGENIC BATCH REACTOR TPxy & ACTIVITY COEFFICIENT PLOTS OPTIMISATION
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CRYOGENIC BATCH REACTOR xy RELATIVE VOLATILITY OPTIMISATION
xy Diagram System Benzene Toluene NRTL at constant pressure

1 0.9
Benzene Vpaour (y mole fraction)
0.8
Increasing
0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 0.1 0.2 0.3
760 mm Hg
0.4
0.5
0.6
0.7
25 mm Hg
0.8
0.9
Benzene Liquid (x mole fraction)

Relative Volatility = 1.0
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CRYOGENIC BATCH REACTOR CASE 4.01 FLASH FUNDAMENTALS OPTIMISATION
SET EXECUTION RULES
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CRYOGENIC BATCH REACTOR CASE 4.01 FLASH FUNDAMENTALS OPTIMISATION
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CRYOGENIC BATCH REACTOR RESIDUE CURVE MAPS OPTIMISATION

CEiP 9-p339
Low boiling node High boiling node Saddle Distillation boundary Residue curves
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CRYOGENIC BATCH REACTOR CHEMCAD RESIDUE CURVE MAPPING OPTIMISATION
www.chemcad.co.uk
CRYOGENIC BATCH REACTOR AZEOTROPE FINDERS OPTIMISATION
www.chemcad.co.uk

A-Introduction &amp; Thermodynamics 2012

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A-Introduction &amp; Thermodynamics 2012

Cargado por

Copyright:

Formatos disponibles

Steady State Seminar

Introductory Presentation John Edwards, P&I Design Ltd 2012

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR TYPICAL PROCESSES OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR PROCESS DEVELOPMENT OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR DESIGN SEQUENCE OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CAUTIONARY STORY OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR IMPACT OF DESIGN ERRORS OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR SIMULATION PRINCIPLES OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR SIMULATION PRINCIPLES OPTIMISATION

Process Unit / Total Plant Feeds Recycles Products

Dynamic simulation is series of steady state cases

CHEMCAD SIMULATION SOFTWARE

Physical Properties Database

Reactors-Columns SIMULATION SUITE Heat Exchangers Relief-Piping

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CHEMCAD PROCESS SIMULATOR OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CHEMCAD INTERFACES OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CHEMCAD REPORT FORMATS OPTIMISATION

Reporting in Excel allows for data manipulation

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CHEMCAD EQUIPMENT SIZING OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR REALITY IN SIMULATION OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR INTRODUCTORY SESSION OBJECTIVES OPTIMISATION

Set Engineering Units

SIMULATION SUITE CHEMCAD SOFTWARE

TPxy-UnitOp Plots Component PPD Plots

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CASE 2.01 TUTORIAL FLOWSHEET OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR SPECIFY ENGINEERING UNITS OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR UNIT CONVERTER OPTIMISATION

Enter data in your units Press enter to calculate then press OK

Select cell F6 Selects Unit Converter

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR CONVERGENCE OPTIMISATION

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR SELECT COMPONENTS OPTIMISATION

Double click or select

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR RUN THERMODYNAMIC WIZARD OPTIMISATION

Enter service fluids

Use for guidance only MUST verify against plant data

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR THERMODYNAMIC WIZARD DECISION TREE OPTIMISATION

SPECIAL METHODS AMINE

UNIFAC H=LATE (all)

K=GS (P<200BAR) H=LK

Engineering advanced Engineering advanced

CRYOGENIC BATCH REACTOR SPECIFY THERMODYNAMICS OPTIMISATION

Use V/L/L/S for extraction & azeotropes

Check when Electrolytes

A-Introduction & Thermodynamics 2012

A-Introduction & Thermodynamics 2012