Flow-sheeting simulation programs

A future goal for the integration of graphics and process design simulators is to be able to use an interactive graphics program to prepare the input to the process simulator. This capabiHty would allow tme on-line process modification, flow-sheet optimization, and process optimization, and is likely to be one of the key developments in this field in the 1990s (99). 

A process-simulation program almost always contains a physical property service, because the quaflty of process design ultimately depends on the way in which the laws of physics and chemistry are appfled to the problem. Accordingly, the quaflty of this service is an important consideration to the user of a flow-sheeting system. 

The simulation models of the flow-sheeting system must make frequent requests for properties at specific temperatures, pressures, and compositions. Computer-program calls for such data are usually made in a rigorously defined manner, which is independent of both the point data generation models and the particular components. These point generation routines provide the property values, using selected methods that base their calculations on a set of parameters for each component. 

A wide array of general-purpose distillation packages are available to the engineer. Some of the distillation software is stand-alone, whereas other packages are a part of a general-purpose flow sheet or process-simulation system. Because distillation is so universal, all process simulators have one or more distillation program modules for this unit operation. Often the nature of the distillation modules determines the suitabiUty of or the preference for the use of a specific simulator for an appHcation. 

Many industrial separations require a series of columns that are connected in specific ways. Some distillation programs can model such a system as a hypothetical single column with arbitrary cross-flows and connections and then carry out the distillation calculations for the modeled hypothetical column. Alternatively, such a system can be modeled as a process flow sheet using a process simulator. 

Complex flow-sheeting programs, that simulate the operation and a complete process, or individual units, have been developed by several commercial software organisations. The names of the principal packages available, and the contact address, are listed in Table 4.1. Many of the commercial programs have been made available by the proprietors to university and college departments for use in teaching, at nominal cost. 

In an equation based simulators the executive program sets up the flow-sheet and the set of equations that describe the unit operations, and then solves the equations taking data from the unit operations library and physical property data bank and the file of thermodynamic sub-routines. 

Figure 8.3-2 shows the simplified flow-sheet used in the simulation program. For plantmodelling, the solution was considered to be constituted of only CO2 and THF. The dissolved polymer and drug were neglected. Because of the low concentration of these compounds in the feed, this approximation should not have significant consequences. 

The computational architecture is a sequential modular approach with advanced features. To model a process, each equipment module is simulated by a program module. The overall process is simulated by connecting the models together in the same way as the equipment in the flow sheet. When the input streams are known then the outputs can be calculated. The entire flowsheet can be calculated "sequentially" in this manner. Advanced features are discussed below in connection with an example. 

The simulation of a multi-component system was done with the flow sheeting program Aspen+. An external routine replaced the internal Kj-calculation with a fit function through the experimental Revalues as given in figure 4. The multistage column was split into a cascade of flash modules. Each module is connected to two other... 

In the initial stages of the process design and evaluation, when only a rough, approximate, material balance is required, the use of a full simulation program is often not justified. Simpler programs, which calculate only the material balance, have been developed and these can be used as an aid to manual flow-sheeting calculations. They will be particularly useful if the process involves several recycle streams. 

The flow-sheeting program Aspen Plus is used to design the FP-FC system, which produces 100 W of electricity. The process has been modeled and simulated for a standard set of conditions shown in Table 15.3 and subsequently the process... 

In equation-based simulators, the mathematical equations that describe the physical process are entered into an equation solver that then uses appropriate techniques to solve them. In modular-based process simulators, the mathematical equations that describe the physical process are coded into modules that the user "flow sheets" together. Modular-based process simulators are preferred over equation-based simulators because it is easier for the user to "map" the real world into the virtual one, and programming and debugging of the modules are easier than analyzing sets of equations (Popovic and Bhatkar, 1997). However, equation-based simulators have proved highly successful in the field of optimum process control. Equation-based models handle instrument error and incorrect or errors from modeling simplifications better than modular-based simulators. Modular-based simulators invariably have a data reconciliation step, where the model is nm against values obtained from the instrumentation system and then a least-squares fit is performed to fit the model to the process. 

Start the Aspen program, select Aspen Plus User Interface, and when the Connect to Engine window appears, use the default Server Type Local PC. Select Pipe under the Pressure Changes tab from the Equipment Model Library and then click on the flow sheet window where you would like the piece of equipment to appear. In order to add material streams to the simulation, select the material stream from the Stream Library. When the material stream option is selected, a number of arrows will appear on each of the unit operations. Red arrows indicate a required stream and blue arrows indicate an optional stream. 

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