Recycle equation oriented

The computer effort required for convergence depends on the number and complexity of the recycles ia the dowsheet, the nonlinearities ia the physical properties, and the nonlinearities ia the calculation of phase or chemical equiHbria. In sequential-modular simulators these calculations are converged one at a time, sequentially, and ia a nested manner. In equation-oriented simulators they are converged as a group and, ia the case of complex dow sheets involving nonideal mixtures, there could be significant reduction ia computer effort. 

The older modular simulation mode, on the other hand, is more common in commerical applications. Here process equations are organized within their particular unit operation. Solution methods that apply to a particular unit operation solve the unit model and pass the resulting stream information to the next unit. Thus, the unit operation represents a procedure or module in the overall flowsheet calculation. These calculations continue from unit to unit, with recycle streams in the process updated and converged with new unit information. Consequently, the flow of information in the simulation systems is often analogous to the flow of material in the actual process. Unlike equation-oriented simulators, modular simulators solve smaller sets of equations, and the solution procedure can be tailored for the particular unit operation. However, because the equations are embedded within procedures, it becomes difficult to provide problem specifications where the information flow does not parallel that of the flowsheet. The earliest modular simulators (the sequential modular type) accommodated these specifications, as well as complex recycle loops, through inefficient iterative procedures. The more recent simultaneous modular simulators now have efficient convergence capabilities for handling multiple recycles and nonconventional problem specifications in a coordinated manner. 

In the past, most simulation programs available to designers were of the sequential-modular type. They were simpler to develop than the equation-oriented programs and required only moderate computing power. The modules are processed sequentially, so essentially only the equations for a particular unit are in the computer memory at one time. Also, the process conditions, temperature, pressure, flow rate, etc., are fixed in time. With the sequential modular approach, computational difficulties can arise due to the iterative methods used to solve recycle problems and obtain convergence. A major limitation of sequential modular simulators is the inability to simulate the dynamic, time-dependent behavior of a process. 

When there are multiple recycles present, it is sometimes more effective to solve the model in a simultaneous (equation-oriented) mode rather than in a sequential modular mode. If the simulation problem allows simultaneous solution of the equation set, this can be attempted. If the process is known to contain many recycles, then the designer should anticipate convergence problems and should select a process simulation program that can be run in a simultaneous mode. 

Both sequential and simultaneous calculational sequences have been proposed for the modular approach as well as the equation-oriented approach. Either the program and/or the user must select the decision variables for recycle and provide estimates of certain stream values to make sure that covergence of the calculations occurs, especially in a process with many recycle streams. Reviews by Evans and Rosen point out many of the problems and practices pertaining to flowsheeting. 

---