Title

Getting Started with PROVISION and PRO/II

Course Content
Introduction Guided and Independent Exercises Simulation in Seven Steps Main Parts of a Simulation
Components Thermodynamics Streams Phase Equilibrium Calculations Unit Operations Columns

A Brief History of Simsci-Esscor

Simsci founded in Nov. 1966 by Dr. Wang

SP03 - distillation program

1974: SSI/100 - first flowsheet simulator 1979: PROCESS - keyword, batch mode 1988: PRO/II - interactive

1995: PRO/II with PROVISION

true 32-bit Windows-based application

1997: Simsci became a public company

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A Brief History of Simsci-Esscor

1998: Simsci acquired by Siebe

1999: Siebe merged w/ BTR and renamed the company - Invensys

2002: Simsci & Esscor merge Today
$5 Billion company located in UK

Diversified Engineering and Electronics group

Employs more than 30,000 people worldwide

Simsci Solution Suites

Products fall into one of five

Solution Suites
Process Engineering
PRO/II HEXTRAN VISUAL FLOW SUITE INPLANT DATACON

Oil and Gas Production

PIPEPHASE NETOPT TACITE

Dynamic Simulation
DYNSIM FSIM

On-Line Performance
ROMeo CONNOISSEUR ARPM

iFEED

COMOS FEED

TRISIM OTS

Introduction

PRO/II vs PROVISION
PRO/II is the Calculation Engine Solves Equations PROVISION Makes PRO/II Easy to Use Graphical User Interface
PRO/II 5.0+: Microsoft Windows 95 or NT
PRO/II 5.1.1+: Microsoft Windows 2000 PRO/II 5.6+: Microsoft Windows XP

SIM4ME will be very similar to PROVISION

PRO/II Capabilities & Features

Large component data bank and thermodynamics data bank
Flexible and powerful refinery capabilities Reactive and electrolyte distillation modeling Regression and data management tools

Advanced flowsheet sequencing capabilities

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PRO/II Capabilities & Features

PROVISION (GUI) 32-bit Windows-based application

Interactive execution
Graphs, tables and charts can be exported OLE functionality
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Steady State Simulator

No Time Dependent Phenomena

Exception: Depressuring Unit

Controllers & Instrumentation Are Irrelevant

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Remove Control Valves and Instrumentation

PI

TI

PI

TI

LC

LC

LC

11

Sequential-Modular Simulator

Units solved one at a time Feeds must be known Recycles automatically handled

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Desktop Environment
Menu bar
Toolbar Can easily access many of the menu functions

Color Cues Indicates required data entry

Palettes PFD Run

13

Desktop Environment

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How to Do a Simulation in PRO/II

Simulation in Seven Steps

2 Units of Measure 1

Check

Select Thermo
3
5

Provide Process Conditions

7

Build Flowsheet

Define Components

Supply Stream Data

Run & View Results

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Group Units if Desired

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Units of Measure
Common Source of Errors English is Default Default Can be Changed Globally (all Future Simulations) Can be Changed for Entire Flowsheet Can be Changed Locally Can Define Custom Set of UOM

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Components

Component Selection

Pure component from a library

User-defined component

Petroleum component

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Petroleum Components

Normal Boiling Point

Gravity Molecular Weight

At least two of three required

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Simulate a Chiller Plant in 4 Parts

Recover liquids & deliver gas to pipeline
Pipeline Gas
S18 Cooling Air

S20
C2 M2

Refrigerant
S14 S6 T1 Stabilizer

S8
C1 S2 S4 HX1 F1 S1 Inlet Gas S9 S5 F2 S10 HX2

S15

S12

S11 HX3

F3
S1

S7
S13 S17 S16 V1

S19 S3

M1

Natural Gas Liquids (NGL)

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Selecting the Thermodynamics

K-Value Calculation Methods

Ideal
Equation of State

Liquid Activity
Generalized Correlations Special Packages Electrolytes Polymers
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Selecting the Thermo Method

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Hydrocarbon Systems
Refining Processes:
Grayson-Streed: Hydrogen rich systems, Crude tower, Vacuum unit, Coker fractionator, FCC main fractionator SRK and PR: Light ends columns, Splitters, Gas recovery plants, Hydrogen rich systems (SRKM)

SOUR, GPSWATER: Sour water systems

SRKK, SRKM, SRKS, IGS: Use if H/C solubility in liquid water (VLLE) is important.

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Hydrocarbon Systems
Gas Processing:
SRK and PR: All types of processing plants, cryogenic systems SRKM, PRM, and SRKS: Systems with water, methanol, and other polar components GLYCOL: Dehydration with TEG. emissions. Based on SRKM. AMINE: Natural gas sweetening. SRKK, IGS, SRKM, SRKS: Use if light gas solubility in water (VLLE) is important.
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Improved for aromatic

Chemical Systems: Activity Coefficient Methods

Non-ideal components

Low to medium pressures

Rely on binary interaction parameters missing will be close to Ideal!) (if

Missing parameters estimated from structures, azeotrope composition, mutual solubilities etc.

Used with Henrys Law for non-condensibles

VLLE with some methods

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Chemical Systems: Activity Coefficient Methods

Two Liquids?
NRTL UNIQUAC Yes Yes

Binary parameters in databank?

Yes Yes

WILSON
UNIFAC

No
Yes

No
Estimates non-ideality from structure

Other methods - see Reference Manual

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Chemical Systems: Equations of State

SRK-SIMSCI, SRKM, and PRM for polar mixtures

SRK-Hexamer for mixtures involving HF

Can model high-pressures

Also relies on binary interaction parameters

Some binary parameters in databanks for above methods

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Supplying Stream Data

Types of Streams
Product

Internal Feed

Recycle External Feed

Product

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Stream Attributes
Thermal Condition Flowrate Composition Defined by components Defined by assay data Referenced to another defined stream

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Stream Data

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Thermal Condition Data

Pressure

Temperature

Liquid Fraction or Phase

Saturated liquid at bubble point Saturated vapor at dew point Specify two of these three properties

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Feedback Controller

Satisfies a flowsheet specification by manipulating an upstream parameter Long-Distance specifications and

variables
Analogous to a process feedback controller

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Exercise: Chiller Plant - Part 3, p. 17

Add a controller

Distillation

Tray Numbering

Normally use Theoretical Trays (Stages)

Numbered from Top Down Condenser is Stage 1
Even for subcooled condenser

Reboiler is Last Stage

Thermosiphon adds 2 stages

Convert Packing to Stage:

Rule of Thumb: 2-3 feet of packing per stage
Modern structured packing could be inches, so check with the manufacturer
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Tray Efficiency
Murphree Vaporization Equilibrium yi,n = yi,n+1 + EiM (yi,n*-yi,n+1) yi = EiV Kixi Like EiV, but Ks - 1

Vapor Leaving Stage not at Dew Point

Can Lead to Mixed Phase Condenser Product Better to Use Overall Efficiencies
Theoretical / Actual trays to carry out separation Use different values in different column zones Dont forget condenser and reboiler!

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Tray Efficiency
Murphree:

yi,n = yi,n+1 + EiM (yi,n*-yi,n+1)

l

yA
100% efficient: step to equilibrium curve

75% efficient: step 3/4 to equilibrium curve

xA

xA
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Typical Overall Efficiencies (%)

Deethanizers: C3 Splitters: Crude Units:
Stripping Section Flash Zone to Gas Oil G.O. Draw to Diesel Draw Diesel Draw to Kero Draw Top Section of Column 30 30-40 40-50 45-55 55-65

60-65 95-100

Columns with reboilers and condensers:

60-80

Pumparounds eliminate trays:

20-25
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Condenser Options
Available in all algorithms Partial
Vapor overhead product

Overhead

If present, Liquid product is side draw from stage 1.

In Keywords, two product condenser is called Mixed

Overhead

Side-draw

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Condenser Options (continued)

Bubble
Liquid product at bubble point

Fixed temperature
Sub-cooled at a specified temperature

Overhead

Delta T below bubble point

Specify degree of subcooling

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Kettle Reboilers

LN-1

Vapor in Equilibrium with Bottoms

VN

VN-1

LN-2

N-1 Bottom Tray VN LN-1 Q

BTMS BTMS

N Reboiler

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Single Pass (Once Through) Thermosiphon

Equivalent to a Kettle Reboiler Because Bottoms is in Equilibrium with VN LN-1 VN LN-1

VN Bottom Sump Reboiler Sump

BTMS Baffle

Bottom Sump
BTMS

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Circulating Thermosiphon Adds 2 Stages

Simulate as TS without Baffles
LN-2 N-2 Bottom Tray

VN-1

RV RL BTMS

VN-1

LN-2 RV

N-1 Combined Sump RL RF

Combined Sump BTMS

RF

N Reboiler

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Circulating Thermosiphon
Simulate as TS without baffle

LN-2 VN-1 RV

N-2 Bottom Tray

RL
BTMS Bottom Sump Reboiler Sump RF

VN-1

LN-2 RV

N-1 Reboiler Sump RL RF

BTMS

N Reboiler

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Preferential Thermosiphon
Simulate as TS with baffle

LN-2

RV
RL LO Bottom Reboiler Sump Sump BTMS RF VN-1 Bottom Sump Lo

N-2 Bottom Tray VN-1 LN-2

RV N-1 Reboiler Sump RF

BTMS RL

N Reboiler

Q
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All Column Algorithms are Iterative

Want to Solve f(x) = 0

Generate a Sequence of Estimates of Solution: x0, x1, x2, ... xN

When all Equations are satisfied, i.e. | f(xN) | < 0.001

xN is Regarded as the Solution

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Convergence of Newtons Method...

Good initial guess leads to solution

f(X)

x
Solution

n 1

f x

f (xn )
xn

0
x0 x1 x2 x* X
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Convergence is not guaranteed!

f(x)

0
x*

X
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Convergence is not guaranteed!

f(x)

Periodic

0
x*

X
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Convergence is not guaranteed!

But better guess fails!

f(x)

Bad guess converges

0
x*

X
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You Can Help I/O by Using DAMPING

DAMPING Reduces Iteration Step and Suppresses Oscillation

Conventional Columns: DAMP = 1.0 (default)

Columns with Steam: DAMP = 0.6 -- 0.8

Crude, Vacuum, FCC Main Fractionator

Highly Non-ideal:

DAMP = 0.4 -- 0.6

If Oscillation Persists, Use Chemdist

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Distillation Algorithm Selection

Inside/Out (I/O)
Unique Features Strengths Limitations
Side & main columns solved simultaneously. Very fast Insensitivity to initial estimates. Thermo non-ideality. NO VLLE capability. (VLWE at condenser)

CHEMDIST
Reactive Distillation. VLLE on any tray. Highly Non-Ideal Systems. No Pumparounds. Side columns solved as recycles.

SURE
Total Pumparounds. VLWE on any Tray. Water draw from any tray Generality. Slow Sensitive to initial guesses

Applicability

Hydrocarbon Systems EOS & Slightly non-ideal LACT Thermo. Interlinked columns

Non-Ideal Systems. Mechanically simple columns VLLE within column

Columns with free water or water draw on trays other than condenser. Total pumparounds or vapor bypass

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Distillation Algorithm Selection

Inside Out (I/O)
Relatively Ideal Thermodynamics Including Hydrocarbon with Water Decant (Enhanced I/O can handle water on the trays)

Incorporates Sidestrippers into column -- No recycle!

Thermosiphon Reboilers Very Forgiving of Bad Initial Estimates Fast! No VLLE

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Distillation Algorithm Selection

Chemdist
Mechanically simple columns, complex thermo

True VLLE
Azeotropic and Reactive distillation

Sidestrippers solved by recycle

No Pumparounds or Thermosiphons More sensitive to Bad Initial Estimates
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Distillation Algorithm Selection

Sure
Very General: Complex Column and Thermo
Use when I/O and Chemdist do not apply Newton Method Very sensitive to Bad Initial Estimates Side columns are solved as recycles Allows free water or water draw on trays other than condenser
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Exercise: Chiller Plant - Part 4, p. 21

Add a column and compressor

Output Options

Export via Windows Clipboard

Data in Spreadsheets Graphics

Plots
Output Files

Stream Property Tables

Unit Operation Tables Case Studies

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How can we improve this course?

Thank you for attending

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