M9 Part1 Tier1

TIER 1 STEADY STATE SIMULATION PIECE
PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 1

Process Integration for Environmental
Control in Engineering Curricula (PIECE)
Program for North American Mobility
in Higher Education (NAMP)
Understand and simulate processes in steady state.

Solve technical and economic problems more
quickly, efficiently and successfully.
Propose
This module has been developed
to help the students:
Statement of intent
The student will.

Review basic concepts used in steady state
simulation.

Understand the purpose of steady state
simulation.

Develop models of a processes in steady state.

Simulate processes with help of computer
simulators.
Contents
This module is divided in 3 tiers

Tier 1.
Introduction to simulation tool.

Tier 2.
How to use computer tool.

Tier 3.
How to apply in real world.
1. Basic concepts.

2. Steady state simulation in a process integration
context.

3. Steady state simulation in a broader context.
Tier 1 is divided in 3 sections
Contents
Show the basic concepts of steady state simulation.

Improve process simulation skills.

Create your own simulation flowsheets.

Recognize why simulation is useful in the process
industries.
Basic concepts
Statement of intent
Basic Concepts
Steady state.
Models and simulation.
Creating models.
Unit efficiencies.
Stream components.
Units.
Performing a steady state simulation study.
Contents
By steady state we mean, in most systems, the
conditions when nothing is changing with time.

Mathematically this corresponds to having all time
derivatives equal to zero, or to allowing time to
become very large (go to infinity).
Steady State
Steady state
Steady State
The design of process systems requires both:
Steady state model.
Dynamic models.

One use for the steady state models is in determining
the possible region of steady state operation for a
process that can be limited by constraints such as
safety, product quality, and equipment performance.
Steady state
Model
A model is an abstraction of a process operation used
to build, change, improve or control a process.
Uses of a model:
Equipment design, sizing and selection.
Comparison of possible configurations.
Evaluation of process performance against limits
(e.g. Concentrations, effluent discharge rates).
De-bottlenecking and optimization.
Control strategy development and evaluation.
Models & simulation
Model
The model is an abstraction of the real word
Models vary by:
Phenomena represented (energy, classifications
phase change).
Level of detail and granularity
Assumptions (perfect mixing, zero heat loss).
Kind of input required
Functions performed (constraint satisfaction,
optimization).
Nature of output generated
Models & simulation
Models vary by purpose and category
Purpose
Operator training simulator.
Control strategy evaluation.
Investment justification (e.g. new equipment
purchase).
Other
Category
Physical (e.g. mimic panel) vs. Mathematical.
Qualitative vs. Quantitative.
Empirical vs. First principle based.
Steady state vs. Dynamic state.
Models & simulation
Physical Model
From a balance:
Mathematical Model
{ } { } { } { } { } on accumulati n consumptio production out in = +
Models & simulation
Quantitative
Using non numeric
descriptors.

Fuzzy, logic.
Expert system.
Turn an alarm on.
Qualitative
Using numbers, and
quantifying the
magnitude of the
response.
Models & simulation
Empirical
Derived from observation.
Often simple.
May or may not have
theoretical foundation.
Valid only within range of
observation.
First principle based
Derived from fundamental
physical laws.

Most reliable, but we often
dont have them.
Models & simulation
Steady State
Snapshot of a unit operation or
plant
Movie of plant operation

Balance at equilibrium condition Time dependent results

Equilibrium results for all unit
operations
Equilibrium conditions not assumed
for all units
Equipment sizes, in general not
needed
Equipment sizes needed

Amount of information required:
small to medium
Amount of information required:
medium to large
Dynamic
Models & simulation
Requirements of a good model
Accuracy: close enough to the target. It is required in
quantitative and qualitative models.

Validity: we must consider the range of the model. The model
must have a solid foundation or justification.

Right level of complexity: models can be simple, usually
macroscopic, or detailed, usually microscopic. The detail level
of phenomena should be considered. Easy to understand.

Computational efficiency: the models should be calculable using
reasonable amounts of time and computing resources.
Models & simulation
Simulation
Predicts the behavior of a plant by solving the
mathematical relationships that describe the behavior
of the plants constituent components.

Involves performing a series of experiments with a
process model.
Models & simulation
Importance of steady state simulation
Better understanding of the process.
Consistent set of typical mill data.
Objective comparative evaluation of options for return
on investment etc.
Identification of bottlenecks, instabilities, etc.
Ability to perform many experiments cheaply once
model built.
Avoidance of ineffective solutions.
Models & simulation
Constructing a model
When we try to represent a phenomena, to predict
future conditions, or to know how the process will
behave in certain situation, it is common to use
mathematical expressions.
} } }
+ =
V
V
S V
dV B dS n F dV b
dt
d
Models & simulation
Constitutive relations
Relate the diffusive flux of a certain quantity with the local
properties of the material and with the transport driving
force.
Express the movement of a certain quantity in the
decreasing gradient direction of the quantity.
Creating models
Constitutive relations
Fouriers law:
Ficks first law:
) ( CpT q oV =
Cp
k
o =
A AB A
C J V = D
Thermal diffusion
Mass diffusion
AB
D
Newtons law:
v t V =
= v
Kinematic viscosity
Creating models
Variation Equations
Conservation Equations or Equations of change
Those relate the accumulation of a quantity with the rate
of entrance or formation of the same quantity in a
specific volume. Those are based in fundamental
principles and have universal description.
Creating models
Conservation of mass
consumed
mass
of rate
produced
mass
of rate
out
mass
of rate
in
mass
of rate
on accumulati
mass
of rate
In a differential element:
It is common practice to express the balance in a
differential element, and convert the equation to a
differential form.
Creating models
Conservation of mass
) ( v
V =
c
c
t
For a pure component:
R N
t
C
i
i
+ V =
c
c
i i i
J v C N + =
reaction chemical a in n Consumptio or Production R
Conservation of
chemical species:
Note: steady state no change in the time.
0 =
c
c
t
Creating models
Conservation of energy
Note: steady state no change in the time.
0 =
c
c
t
V P
H T v C + V = V q
Where H
V
is rate of heat generated by external source
(electricity, compression, chemical reactions, etc.).
energy kinetic
internal of
on accumulati
of rate
s surrouding on
system by done
work of rate net
conduction
by addition
heat of rate net
convection by out
energy kinetic and
internal of rate
convection by in
energy kinetic and
internal of rate
Creating models
Unit efficiencies
An engineer may define energy efficiency in a very
restrictive equipment sense. Energy efficiency has
been used to describe what actually may be
conservation.

Energy efficiency in a more subjective sense may refer
to the relative economy with which energy inputs are
used to provide services.
Q
W
= c
Unit efficiencies
Typical Efficiencies Values
Compressors c = 0.8
Motor c = 0.9
Turbine c = 0.8
Pump c = 0.5
Unit efficiencies
Stream Components
Ideal gas law and equations of state.
Solubility relations (solid in liquid and gas in liquid).
Reaction stoichiometry and equilibrium.
Simple vapor/liquid relationships such as Raouts law.
Overall stream flows and components are
calculated based on physical and chemical
properties such as:
Stream components
Conversion of stream components
Mechanical work.
A
B
C
A
B
A B
Via chemical reaction.
Heat.
Stream components
Engineering Units
The official international system of units is the SI . But
older systems, particularly the centimeter gram
second (cgs) and foot pound second (fps), are
still in use.
It was originated in France, in 1790 by the French
Academy of Science.
The units should be based on unvarying quantities in
nature.
Multiples of units should be decimal.
The base units should be used to derive other units.
Units
Engineering Units
Units
Steady state model derivation.

Calculation order.

Recycle streams.

Convergence and iteration.

Recycle convergence methods.

Granularity model.
Performing a Steady State simulation Study
Performing a SS simulation study
Steady state model derivation
1.- Define Goals.
a) Specific design decisions.
b) Numerical values.
c) Functional relationships.
d) Required accuracy.
2.- Prepare information.
a) Sketch process and identify system.
b) Identify variables of interest.
c) State assumptions and data.
3.- Formulate model.
a) Conservation balances.
b) Constitutive equations.
c) Rationalize (combine equations and collect terms).
d) Check degrees of freedom.
e) Dimensionless groups (Pr, Nu, Re, etc.).
4.- Determine solution.
a) Analytical.
b) Numerical.
5.- Analyze results
a) Check results for correctness
Limiting and approximate answers
Accuracy of numerical method

b) Interpret results
Plot solution
Relate results to data and assumptions
Evaluate sensitivity
Answer what if questions
-1
-0.5
0
0.5
1
0 1 2 3 4 5 6 7 8 9 10
6.- Validate model.

a) Select key values for validation.
b) Compare with experimental results.
Calculation Order
In most process simulators, the units are computed
(simulated) one at a time. The calculation order is
automatically computed to be consistent with the flow of
information in the simulation flowsheet, where the
information flow depends on the specifications for the
chemical process.
1 2 3 4
Recycle Flows
A simulation flowsheet usually contains information
recycle loops. That is, cycles for which too few
streams variables are known to permit the equation for
each unit to be solved independently.
1 2 3 4
For these processes, a solution technique is needed
to solve the equations for all the units in the recycle
loop.
Solution technique
Consist in guessing a value for the recycle stream. This
value is generally not going to equal the calculated
value, this represent another problem which is solved
by iteration.
Calculation
Initial guessing
values
New values from
The calculation
Iteration
Convergence units use convergence subroutines to
compare the newly computed variables (in the feed
stream to the convergence unit) with guessed values
(in the product stream from the convergence unit) and
to compute new guess values when the two streams
are not identical to within convergence tolerances.
This procedure is call iteration. It involves re
calculating the flowsheet.
Convergence
Is the process to compare the guessed value with the
computed value, until find a value within the tolerance
range.
Guess value calculated value < Tolerance
Guess value
Yes
No
Convergence
When the criteria is achieve, the solution is found, and
is time to stop the iteration.
Convergence
Initialize each unit
Convergence?
Start
t = 0, k = 0 Guess torn streams
no
Stop
k = k + 1
Xij yij
e x
j i
s
+ j i, , 1
y -
no
Recycle convergence methods
Where is the vector of guesses for n recycle (tear)
variables and is the vector of the recycle variable
computed from the guesses after one pass through
the simulation units in the recycle loop. Clearly, the
objective of the convergence unit is to adjust so as to
drive toward zero.
* *
) ( x x f y =
*
x
) (
*
x f
Successive substitution as the basic and
obvious method
Also call direct iteration. In this method the new guess
for x is simply made equal to f(x
*
).
x
0
*
x
1
*
Locus of
Iterates
When the slope of the locus of
iterates (f(x),x) is close to unity, a
large number of iterations may be
required before convergence
occurs
Other convergence methods
When the method of successive substitutions requires a
large number of iterations, another methods are used
to accelerate convergence:

Wegsteins method.
Newton Raphson method.
Broydens quasi Newton method.
The dominant eigenvalue method.
Wegsteins method
In this method, the two previous
iterates of f(x
*
) and x
*
are
extrapolated linearly to obtain
the next value of x as the point
of intersection.
x
0
*
x
1
*
Locus of
Iterates
Granularity of modeling
With the advance in technology, it is possible to
combine on a single computer the full capability of a
high fidelity simulation models.

High fidelity process simulation is commonly used by
many industries in the design of a process.
Is the level of detail taken into account in a simulation.
Comparing
Coarse vs. Fine models
Coarse:
Bleaching tower
Kx
z
x
D
z
x
v
c
c
=
c
c
2
2
A coarse model represent the equipment with few
detail.
Fine model
Bleaching tower
i i o
V L L + =
mi
mi
i
mo
mo
o
C
C
L
C
C
L
=
1 1
0 =
r
t
K K
c
i o
i j i i j i o j o
Y V X L X L
, , ,
+ =
Liquors
Fibers
Chromophores
Chemicals
PFR
CSTR
CSTR
The same equipment is divided in 3, and the substances into
account are more than just an approximation.
Kx x D x v V = V
2
More than 1 direction
Benefits
The detail level is low

The time involve is less

The solution effort is few

The solution is approximated
The detail level is big

Time require is big

The solution effort is big

The solution is exact

Coarse Models

Fine Models


Steady state simulation in a process
integration context
Recognize the components in a simulation flowsheet.
Check the procedure to create a process.
What is the importance of the computer.
What can we obtain as a result of a simulation.
Statement of intent
Steady state simulation in a process
integration context
Process flowsheets.
Simulation flowsheets.
Process synthesis methodologies.
Minimal time and expense.
Computer based process.
Data reconciliation.
Process insights resulting from simulation.
Table of content
Process flowsheets
Process flowsheets are the language of chemical
processes. Like a work of art, they describe an
existing process or a hypothetical process in
sufficient detail to convey the essential features.
Process flowsheets
Process flowsheet
A process flowsheet is a collection of icons to represent
process units and arcs to represent the flow of
materials to and from the units.
Fresh Feed
Steam
Heater
Reactor
Flash
Distillation
Product
Process flowsheets
Simulation
The analysis of a
simulation, is the tool
chemical engineers use
to interpret process
flowsheets, to locate
malfunctions, and to
predict the performance
of the process.
Simulation flowsheets
Simulation Flowsheet
A simulation flowsheet, on the other hand, is a collection
of simulation units, each representing a computer
program (subroutine or model) that simulates a process
unit, and arcs to represent the flow of information
among the simulation units.
Mixer
Heater
Reactor
Flash
Column
Mathematical
Convergence
Unit
Simulation flowsheets
Process synthesis methodologies
Total enumeration of an explicit space: is the most
obvious. Here we generate and evaluate every
alternative design. We locate the better alternative by
directly comparing the evaluations.

Evolutionary methods: follow from the generation of
a good base case design. Designers can then make
many small changes, a few at a time, to improve the
design incrementally.

Structured Decision Making: following a plan that
contains all the alternatives.
Design to target: these have been especially useful
in designing heat recovery and reactor networks. The
utility requirements become the targets for the
design.

Problem abstraction: Here the search for better
design alternatives begins by formulating a less
detailed problem statement and attempting to solve
this more abstract problem first.
Minimal time
Fresh Feed
Steam
Heater
Reactor
Flash
Distillation
Product
Change in
Heat Duty
Change in
Reactor Properties
Change in
Column Properties
Change
composition
In feed
With a simulation, you can simulate one day of process
operation in just seconds, and make as many
changes as you want.
Minimal time and expense
Minimal expense
Simulated learning experiences are much less costly
than making real mistakes in the real plant.
Is easy to model the process with different kind of
equipment without having to invest in it.
Minimal time and expense
Computer Based process representation
which can be re - used
Most of the times, there are already models which can
be adapted to the process under study, with minimal
changes. This minimizes the time needed to set up
complicated equations.
Re-using models is much easier than building new ones,
specially if the process is being modeled for the first
time.
Computer based process
Data reconciliation
Data reconciliation is a technique for improving the
quality of measured plant data. These
measurements are inherently inaccurate due to
instrument failures, limitations of measurement
techniques, etc.

As a result, data are obtained that violate mass and
energy balance constraints of describe a physically
infeasible process.
Data reconciliation
How Data reconciliation works
t
F
Reconciling
errors
Find a set of data that:

Constitutes some kind
of best fit (least
squares) to the
observed data.

Satisfies mass
energy balance and
other criteria.
Data reconciliation
Opportunity to do data reconciliation
This amounts to validation of the process data using
knowledge of the plant structure and the plant
measurement system
Data reconciliation
Process insights resulting from modeling
1. Identification: We can find the structure and
parameters in the model.

2. Estimation: If the internal structure of model
is known, we can find the internal states in
model.

3. Design: If the structure and internal states
of model are known, we can study the
parameters in the model.
MODEL
If the model is known, we have two uses for our model:

1. Direct: input is specified, output is studied
(simulation).

2. Inverse: output is specified, input is studied. Used
when an objective must be met (production,
composition).
Steady State
Simulation in a Broader Context
Show how to take a decision to create a process.
Know if the process is viable, in terms of stability and
economic.
Taking in count security aspects.

Statement of intent
Aspects of Process Design
Process design.
Stability and sensitivity.
Process optimization.
Economic evaluation of alternatives.
Operator training.
Table of content
Process design
The design of chemical products begins with the
identification and creation of potential opportunities
to satisfy societal needs and to generate profit. The
scope of chemical product is extremely broad. They
can be roughly classified as:

1. basic chemical products.
2. Industrial products.
3. Consumer products.
Process design
Process design
Manufacturing
Process
Natural
Resources
Basic chemical
Products
Manufacturing
Process
Basic Chemical
Process
Industrial
Products
Manufacturing
Process
Basic Chemical
Industrial Products
Consumer
Products
Process design
Motivation for design projects
1. Desires of customers for chemicals with improved
properties for many applications.

2. New inexpensive source of a raw material with new
reaction paths and methods of separation.

3. New markets are discovered.
Process design
Steps in a Process Design
1. Process Design Questions to Answer

Is the chemical structure known?
Is a process required to produce the chemicals?
Is the gross profit favorable?
Is the process still promising after further
elaboration?
Is the process and/or product feasible?
Process design
Steps in a Process Design
Create and assess primitive
problem.
Find chemicals or chemical
mixtures that have the
desired properties and
performance.
Process creation.
Development of base case.
Detailed design, equipment
sizing, and optimization.
Startup assessment.
Reliability and safety
analysis.
Written design report and
oral presentation.
Plant design, construction,
startup and operation.
2. Process Design Steps
Process design
3. Process
Design Procedure
Detailed Process Synthesis Using
Algorithmic Methods
Create and evaluate chemical reactor networks for
conversion of feed to product chemicals.
Separation trains for recovering species in multi-component
mixture.
Reactor separator recycle networks.

Locate and reduce energy usage.
Create and evaluate efficient networks of heat exchangers
with turbines for power recovery.
Networks of mass exchangers to reduce waste.
Process design
Feasible Region
The region within which the process can be operated is
called the operating window or feasible operating
region.
{ }
n
R x x g x c x FR e s = = , 0 ) ( , 0 ) (
Feasible region
g
3
=0
g
2
=0
g
1
=0
Stability and Sensitivity
Feasible Region
One can not in general say a priori how a
thermodynamic model will behave when extrapolated
beyond the region in which data were available for
determining its empirical parameters.
Stability and Sensitivity
Stability of the process
When a process is disturbed from an initial steady state, it
will, in general, respond in one of 3 ways.

a) Proceed to a steady state and remain there.
Stability and sensitivity
b) Fail to attain to steady state conditions because its
output grows indefinitely.
c) Fail to attain steady state conditions because the
process oscillates indefinitely with a constant
amplitude.
A steady state system x
s
is said to be stable if for each
possible region of radios c>0 around the steady state,
there is an initial state x
0
at t=t
0
falling within a radius
o>0 around the steady state that causes the dynamic
trajectory to stay within the region (x-x
s
)<c for all times
t>t
0
.
Steady state x
s
Region c>0
Radius o
State x
Sensitivity analysis
In many cases, it is useful to know how a chemical
process respond when a equipment parameter or
stream variable is varied, rather than running
simulation only in few parameters.

The sensitivity analysis permits the tabulation of output
variables at equal increments over a specified range
of parameter or variable values.
Example: Carbon monoxide and hydrogen are reacted to
form methanol.
OH CH H CO
3 2
2 +
The reaction is exothermic; consider an adiabatic
reactor. 100% of the carbon monoxide is converted.
For a fixed flow rate of carbon monoxide, it is desired
to know how the outlet temperature varies with
respect to the flow rate of hydrogen in the feed
stream.
The temperature decreases as the mole flow in feed increases.
One of the most important contributions of sensitivity
analysis is that it allows one to identify those
variables which, when changed, have the greatest
impact on the process output.
Optimization
Completely specified case.

Over-specified case.

Under-specified.
From a Mathematical point of view, chemical
engineers encounter 3 situations when solving
equations.
Process optimization
Completely specified case
N
equations
= N
variables

When the number of equations is equal to the number
of variables, then we can proceed to solve the
problem.
3x 2y + 9z = 3
6x 11y + z = 7
x 15y + 4z = 25
In this case, we have 3 equations
with 3 unknowns.
Over specified case
N
variables
<

N
equations

which is commonly referred to as the reconciliation
(data reconciliation and rectification) problem.
Many variables are determined in >1 way values
must be reconciled
Under specified case
N
variables
>

N
equations

Also called optimization problems.

The optimization is used to maximize or minimize a
specified objective function by manipulating decision
variables (feed stream, block input, or other input
variables).
Some variables are undetermined can be manipulated to
optimize the process.
Optimization
N
variables

N
equations
= N
D
The decision variable, d, is iteratively adjusted to achieve
the optimal solution to a specified objective. Some
methods commonly used are:
Successive linear programming (SLP).

Successive quadratic programming (SQP).
(used by Aspen plus, Hysys.plant)

Generalized reduced gradient (GRG).
Optimization
Any optimization problem can be represented as:
) ( min x f
0 ) ( . . = x c t s 0 ) ( s x g
n
R xe
) (x f
Is the objective function.
Is the set of m equations in n variables x. The
equality constraints
Is the set of r inequality constraints. Those bound
the feasible region of operation.
0 ) ( = x c
0 ) ( s x g
Optimize on multiple criteria
Some common objectives in optimization of an
industrial process are:

Achieve lower capital cost design.
Increase production.
Reduce unit operation cost.
Reduce environmental impact.
Reduce energy consumption.
Degrees of freedom
A degree of freedom analysis is incorporated in the
development of each subroutine that simulate a
process unit. These subroutines solve sets of
N
equations
involving N
variables
.

N
D
= N
equations

N
variables
.

Degrees of freedom are the number of input variables
you need to specify.
Quantitative comparison of alternatives
In almost every case encountered by chemical
engineer, there are several alternative methods
which can be used for any given process or
operation.
Formaldehyde production:
1. By catalytic dehydrogenation of methanol.
(By controlled oxidation of natural gas)

2. By direct reaction between CO and H
2
(under special conditions of catalyst, temperature, and pressure)
Economic evaluation of alternatives
Optimum Economic Design
If there are two or more methods for obtaining exactly
equivalent final results, the preferred method would
be the one involving the least total cost.
Alternative designs do not give final products or results
that are exactly equivalent. It then becomes
necessary to consider the quality of the product or the
operation as well as the total cost.
$
Throughout the design process, estimates of the cost
of equipment and other costs related to the capital
investment play a crucial role in selecting from
among the design alternatives.

The total capital investment (TCI).

The annual cost of manufacture (COM).
Is a one time expense for the design, construction, and
start up of a new plant or a revamp of an existing
plant.
Total capital investment
Estimation of the total capital investment
1. Order of magnitude estimate based on bench scale
laboratory experiments.

2. Study estimate based on a preliminary process design.

3. Preliminary estimate based on detailed process design
studies lading to an optimized process design.

4. Definitive estimate based on a detailed plant design.
Investment justification
Objective: to evaluate the costs and benefits of
investment in process modifications.

Inputs and outputs with costs attached must be
accurately represented.
Differences between candidate solutions must be
accurately modelled.
Level of detail just enough to enable cost-benefit
calculations.
Other parts of the process can be a black box.
Direct cost
Indirect cost
Quantify cost benefit of various possibilities
When designing a greenfield plant, there are many
possibilities which can be evaluated to get the best
cost benefit ratio.
Cost sensitivity analysis
Sensitivity analysis is important in order to avoid
information overload:

It usually is best to do an initial analysis using only the
data you have, being careful about indicating where
the data is weak or you are using best guesses.
Cost sensitivity analysis
Planning should stimulate thinking, not overwhelm it
Operator training
Today, cheap computer power allows virtually any
operator to have enough capability to simulate large
flowsheets with considerable detail on the desktop.
Process flowsheet simulators now have a
sophisticated user interface, large physical properties
databanks, and many thermodynamic models.
Operator training
Running sophisticated process simulations does not
guarantee correct results. You need to understand
the thermodynamic assumptions underlying the
program and how to ensure proper application.
Operator training
The personnel using the simulators, should be trained
beforehand, and be aware of problems that may
appear.
Operator training
Operator Training simulation
Objective: to mimic response of displays to simulate
process excursion and operator inputs.
integration with physical operator console.
simplified process representation, just enough to
generate appropriate responses.
progressive series of exercises as part of system.
trainee evaluation as part of system.
Operator training
Opportunity to increase process and systems
awareness in operating personnel
A simulated process can be easily executed in a
computer, without the expense of real equipment and
without the risk of disrupting the real plants
production.

In this virtual world, computer simulations allow all
manner of extreme conditions and what if
scenarios to be tested safely.
Operator training
Develop competence in unusual, undesirable, or
dangerous process operation conditions
The only certain way to test how a proposed control
system will handle every conceivable situation is to
design it, install it, and try it out.
Operator training
Simulators avoid dangerous process operation
A simulated control system can be installed in a
simulated plant without the expense of real
equipment and without the risk of disrupting the real
plants production.
Computer simulation allow all manner of
extreme conditions and what if
scenarios to be tested safely.
Operator training
Increase comfort level with advanced
technology
A simulator trainer substitutes for the
real plant and the real control
system. If the simulation is realistic,
the trainees dont know the
difference.
Operator training
Simulation in Process Design and Operation
Before constructing a plant, or making any changes to
it, it is always desirable to know how it is going to
behave. Steady state simulation, is the tool one
use.

In this tier, the basics tools to understand a process
design, construct it and simulate it in a computer,
were shown.
Summary
Quiz
Quiz
A first pass simulation using mill data indicates that the
boiler is generating more steam than the heating value of the
fuel will provide (i.e. efficiency greater than 100 %). An
appropriate response would be:
a) Ignore the problem as insignificant.
b) Replace the boiler simulation model with one that will
give you realistic results.
c) Recommend a certificate of appreciation for outstanding
performance be presented to the boiler operating crew.
d) Double check the accuracy of the measurements and
arrange for test to be performed on the boiler fuel.
a) Inaccuracies in the process data.

b) Incompatible process specifications in different parts of
the sequential flowsheet that are fighting each other.

c) The actual process in fact never balances.

d) Unrealistic assumptions about unit efficiencies.

e) To many recycle loops.
Your simulation flowsheet is failing to converge. What would
be the most likely cause of this problem?

M9 Part1 Tier1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

M9 Part1 Tier1

Uploaded by

Copyright:

Available Formats

TIER 1 STEADY STATE SIMULATION PIECE

PAPRICAN ECOLE POLYTECHNIQUE UNIVERSIDAD DE GUANAJUATO 1

You might also like