Process simulation—batch recipes

Figure 4.27 BATCH PLUS simulation for Example 45. (a) Operations recipe for the process-BATCH PLUS output, (b) Last three columns of stream table (for the complete table, see ASPEN —> TutoM — Batch Process Simulation — tPA Manufacture on the CD-ROM. (c) Mixing Tank report (fa Fermenter 1 and 2 reports, see the CD-ROM), (d) 3-batch Gantt chart.

To examine the performance of this recipe, it is helpful to use a batch distillation program is a process simulator, such as BATCHFRAC by Aspen Technology, Inc. (Boston et al., 1981). Then, a... 

A substantial number of chemical, food, pharmaceutical and metallurgical industry rely on batch-wise production processes. The dynamic and complicated character of the recipe steps and the equipment can lead the process to reach unsafe conditions. The accurate and appropriate modeling of the batch process and the recipe is the focus of this research. In particular, the goal of this paper is to present the modeling for simulation and optimization of safety constraints related to a polymer batch process. 

Batch Plus (now called Aspen Batch Process Developer), a recipe-driven simulator that targeted batch pharmaceutical processes. Around the same time, Intelligen (Scotch Plains, NJ) introduced SuperPro Designer. The initial focus of SuperPro Designer was on bioprocessing. Over the years, its scope has been expanded to support modeling of fine chemicals, pharmaceuticals, food processing, consumer products, and other types of batch/semi-continuous processes. 

Scheduling and cycle time analysis in the context of a simulator is fuUy process-driven and the impact of process changes can be analyzed in a matter of seconds. For instance, the impact of an increase in batch size (which affects the dmration of charge, transfer, filtration, distillation, and other scale-dependent operations) on the recipe cycle time and the maximmn nmnber of batches can be seen immediately. Due to the many interacting factors involved with even a relatively simple process, simulation tools that allow users to describe their processes in detail, and to quickly perform what-if analyses, can be extremely useful. 

In co-operation with a German chemical company, a recipe-driven batch process was modelled and simulated using PPSiM. In the simulation study, different pipeless plant scenarios were tested and evaluated. The plant under consideration produces a set of consumer care products. 

Fritz, M., Liefeldt, A. and Engell, S. (1999) Recipe-driven batch processes Event handling in hybrid system simulation. Proceedings of 1999 IEEE International Symposium on Computer Aided Control System Design (CACSD 99), Hawaii, USA, pp. 138-143. 

The resulting optimization problem is solved using ILOG CPLEX [4], which generates a schedule for all major process steps, as well as the main material requirements for the production (optimal recipe definition for each batch). The schedule obtained is furthermore passed on to a crane movement simulation module, which... 

Verify correct operation of process sequences during water simulations tune control loops. Ensure all process paths are tested, including any emergency stop and hold conditions. Verify correct operation of any recipe management and batch data recording during these tests. 

As in the steady-state simulation of continuous processes, it is convenient to convert from a process flowsheet to a simulation flowsheet. To accomplish this, it is helpful to be familiar with the library of models (or procedures) and operations provided by the simulator. For example, when using SUPERPRO DESIGNER to simulate two fermentation reactors in series, the process flowsheet in Figure 4.25a is replaced by the simulation flowsheet in Figure 4.25b. In BATCH PLUS, however, this conversion is accomplished without drawing the simulation flowsheet, since the latter is generated automatically on the basis of the recipe specifications for each equipment item. 

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