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Introduction to SuperPro Designer for Batch Processing Modelling

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Presentation on theme: "Introduction to SuperPro Designer for Batch Processing Modelling"— Presentation transcript:

1 Introduction to SuperPro Designer for Batch Processing Modelling

2 Session outline Getting started SuperPro Designer (SPD) interface
Flowsheet drawing and editing Unit procedures initialisation Simulation execution & result checking

3 Getting started

4 Process Operation Mode
BATCH vs CONTINUOUS Default annual operating time

5 SuperPro Designer Interface
Maximise the flowsheet

6 SuperPro Designer Interface
Horizontal drawing size : 2 pages

7 Some common icons Solve-Run the simulation Cut / Copy / Paste
Select mode Open an existing worksheet Connect mode-stream connection Start a new worksheet Toolbar for drawing

8 Main unit procedure in SPD
Distillation Flash Batch Continuous Extraction Distillation Mixer-Settler Differential Centrifugal Absorption Homogenization High pressure Bead milling Nano milling Sedimentation Decanting Clarification Thickening Oil Separation Flotation Filtration Microfiltration Ultrafiltration RO Diafiltration Baghouse Air Filtration Plate & Frame Rotary vacuum Vessel Procedure Reactor Seed Reactor Fermentor Seed Fermentor Air-lift Fermentor Continuous Reaction (Stoichiometric, kinetic, equilibrium) CSTR PFR Environmental (aerobic, anaerobic, UV radiation)

9 Unit Procedure in SPD

10 Biochemical case study
Component registration View component properties

11 Biochemical Case Study

12 Case Study 1 A batch reactor is utilised to produce component C from reactant A and B: Component C is later separated from A and B by a batch plate &frame filter Solvent used : Heptane (soluble for A and B but insoluble for C) Task to be performed : Mass and energy balances Process Scheduling A + B C

13 Component registration
Component Database Nitrogen, N2 Default Oxygen, O2 Default Water, H2O Default Heptane, C7H Designer A New (user define) B New (user define) C New (used define)

14 Component registration
Databanks in SuperPro Default component

15 Component registration
Newly added Reference component

16 View component properties

17 Editing component properties
Component MW Price Value ($/kg) A Purchase 10 B Purchase 15 C Selling Let’s do changes before we proceed

18 Time to save your work

19 Always remember to save your work!
Reminder… Always remember to save your work!

20 Flowsheet drawing and editing
Locating the unit procedures Stream connection Editing the flowsheet

21 Unit Procedures

22 Looking for help (F1)

23 Unit Procedures

24 Adding a process stream
Select mode Connect-mode Stream connection Single click (tip: Press ESC button to terminate the stream drawing)

25 Deleting a stream Make sure the cursor is in
“Select Mode” (ESC button) Single left click on the stream/unit (turn into read) & press DELETE (on keyboard)

26 Completing the flowsheet
Double click Single click Single click

27 Let’s draw our flowsheet before we proceed further……

28 Editing a stream elbow Make sure the cursor is in
Make sure the cursor is in “Select Mode” (Esc button) Make sure the cursor is in “Select Mode” (ESC button) Stream elbow

29

30 Editing tag name of the stream

31 Changing the Stream ID Stream ID Change ID to S-101 Heptane S-102 A
S B S Emission S Rxt out S Wash in S C S B+ Heptane S Wash out Let’s do changes before we proceed

32 Editing the style of a stream
Change Stream thickness: 2pt Change stream colour: brown

33 Changing the stream title and style
Stream Colour Thickness Heptane Brown 2 points A Brown 2 points B Brown 2 points Emission Green 1 points Rxt out Brown 2 points Wash in Blue 1 points C Brown 2 points B + Heptane Brown 2 ponts Wash out Blue 1 points Same style (Q: is there a faster way to do so?)

34 Pickup style from “Heptane”

35 Apply style to another stream
Press Ctrl button to select multiple streams

36 Complete the style editing for the rest of the streams…

37 Editing the style of the icon
Apply the same pick-up & apply to change the style of the filter Icon colour : blue Description tag text; Font 10, bold, maroon

38 Adding a title to the case study
Text mode This is too small Change your font here

39 Save your work Save file (s)

40 Initialising a Unit Procedure
What a Unit Procedure? Initialising an Operation

41 What is a Unit Procedure?
In the batch modeling mode, a Unit Procedure may consists of various Operations: Reactor procedure: feed charge, reaction, product withdraw, etc Filtration procedure: filtration, cake wash, CIP, etc In continuous modeling mode, a Unit Procedure= Unit Operation

42 Hierarchy in batch modeling
Entire plant Procedure(s) level The same for continuous process modeling Operation(s) level

43 Function of each unit procedure
Vessel Procedure (P-1): Acts as a batch reactor to carry out reaction: A B C Heptane is used to dissolve components A & B, to aid separation in P-2 Plate and Frame Filtration (P-2): Component C is not dissolved in heptane, hence is filtered out by the filter cloth Heptane is used to wash out the trapped heptane ( and also the dissolved A & B) from the filter cake

44 Stream specification Heptane flow = 800 kg/batch Ingredient flow
T, P = default Click to insert Heptane here

45 Set spec for Stream A & B Stream ID Component Amount (kg/batch)
Temperature Pressure Heptane A B 800 50 40 Default

46 Working session Do not forget to save your work !!!

47 A question to ponder… Q: Why do we only specify the inlet stream?

48 Sequential modular approach
Individual equipment blocks may require iterative solution algorithms Overall process solution is sequential & not iterative (Turton et al., 1998)

49 Adding operations to P-1
3 Charge operation (to charge A, B and heptane respectively) 1 React (Stoichiometric) operation (for reaction to be carried out) 1 Transfer Out operation (to deliver product to next unit)

50 Adding operations to P-1
Add new operation before the currently selected operation Add new operation at the end of the list

51 Initialising operations in P-1

52 Initialising CHARGE-1 Emission calculation (next slide…)
800 kg heptane Vol. flowrate =100 L/min Setup time = 5 min

53 Emission calculation Click to perform emission calculation
Go to selected operation OK, next operation (CHARGE-2) Previous operation (same tab –none) Next operation (same tab) OK, previous Operation (none)

54 Initialising CHARGE operation
Operating condition Emission CHARGE-1 Charge 800kg/batch of heptane using stream “Heptane” Setup time= 5 min Process time : 100L/min Perform heptane emission on this stream CHARGE-2 Charge 50 kg/batch of A (limiting component) using Stream “A” Setup time = 5min Process time: calculated based on 20 kg/min Nil CHARGE-3 Charge 40/kg batch of B using Stream “B” (B is in excess) Setup time = 5 min Process time : calculated based on 20 kg/min Please complete the initialisation of CHARGE-2 & CHARGE-3

55 Initialising REACT-1 & TRANSFER-OUT-1
Operation Operating condition Volumes Reaction REACT-1 Final temp = 50 °C Heat transfer agent: steam Process time = 6 hour Leave other values as defaults Max Allowable working/ vessel volume: 80 % Extent of reaction = 95 % Reaction stoichiometry A + B C TRANSFER-OUT-1 Using stream “Rxt out” Duration: same as Cloth Filtration in P-2 (using Master-Slave Relationship) Nil

56 Initilising REACT-1 in P-1
Final temp = 50 °C Max allowable volume = 80 % Steam Process time = 6 h

57 Initialising REACT-1 in P-1
Edit reaction stoichiometry Rename reaction Reaction extent = 95 % Add reaction(s) OK, next operation (Transfer-out) Molar stoichiometry Delete stoichiometry (when needed)

58 Initialising Transfer Out
out stream Click here to select Master-and-Slave to calculate duration Select the Master Procedure Select the Master Operation in Master Procedure To quit Vessel Procedure

59 Master-Slave Relationship
Master operation – processing step that control the duration of another operation (slave) When simulation is executed, duration calculation for the slave operation will be bypassed (note: M&E balances affected), until the master operation is met Both master and slave operation may exist in the same procedure or in another procedure

60 Working session Let’s try before we proceed further…

61 Initialising operation for P-2
Cloth Filtration operation (by default, to filter product C) Cake Wash operation (to wash out left over trapped A & B in filter cake) Transfer Out operation (to deliver product)

62 Adding operations to P-2

63 Initialising operations for P-2

64 Initialising FILTER-1 Operation Operating condition Scheduling
Particulate component removal: 95% C (assuming that A & B are completely soluble in Heptane & C is virtually insoluble). LOD (loss on drying) = 35% (this value cause a portion of heptane & any soluble component to be held in the wet cake % is insoluble C). Filtrate stream: “B + Heptane” By default, first operation of any batch unit procedure is scheduled to start at the beginning of the batch Start time: relative to the START of TRANSFER-OUT-1 operation in P-1 procedure

65 Filtration will only start
Initialising FILTER-1 Scheduling By default C = 95% removal Filtration will only start when product is transferred out from P1 LOD = 35% Filtrate

66 Initialising CAKE-WASH-1 & TRANSFER-OUT-1
Operation Operation condition CAKE-WASH-1 Wash In stream: “Wash in” Wash Out stream: “Wash out” Wash solvent: heptane (click on “Composition”, select “Auto-adjust”, the program will estimate a value automatically) Wash time: 30 minutes Wash type: slurry (Note: A “slurry” wash will essentially dilute the soluble components trapped in the cake and remove most of them in the wash stream, whereas a “displacement” wash will remove the soluble components form the cake in a plug-flow fashion.) TRANSFER-OUT-1 Transfer out using stream “C” Duration: calculated based on 10kg/min

67 Remember to save your file !
Working session Remember to save your file !

68 Simulating a flowsheet
Execute the simulation Viewing the results

69 Simulating a process: Menu bar: Task/ Solve M&E balances Press “Ctrl 3” Solve icon in menu bar Press “F9”

70 Result viewing Calculated output variables for each oeration can be viewed by revisiting the corresponding Operation Data dialog windows To see the calculated equipment sizes, right click on the unit procedure icon & choose the Equipment Data… option The contents of a piece of equipment as a function of time can be viewed by right clicking on a unit procedure and selecting Equipment Contents or Operation Sequence The calculated flowrates and compositions of intermediate & output streams can be viewed by in the Simulation Data dialog windows of each stream

71 Let’s visit the one by one…
Result viewing 5. A list of reports can be viewed in Reports: Stream Reports (SR) Economic Evaluation Report (EER) Itemized Cost Report (ICR) Cash Flow Report (CFR) Throughput Analysis Report (THR) Environmental Impact Assessment Report (EIR) Emission Reports (EMS) Input Data Report (EDR) Equipment Report (EQR) Let’s visit the one by one…

72 Equipment operation data
Calculated heptane emission: 0.028%

73 Equipment data Calculated vessel volume: 1628 L

74 Equipment content

75 Stream simulation data

76 Generating a stream report

77 Check your scheduling results
Reaction A B C MW Initial content, miO (kg) Initial mol, niO (kg-mol) X= 95% (based on A) Current mol, n (kg-mol) Current content, m (kg) nAO-nAOX nBO-nBOX - nAOX +

78 Check your scheduling result
Heptane charge =____kg/batch (stream specification) Volumetric flowrate=___L/min (in Operation Data/CHARGE-1) Task: Find out the density of the heptane stream from your simulation sheet Verify the heptane charging duration calculated by SPD heptane

79 Do not just take the computer’s word as it is, please check your results accordingly!!! Remember the GIGO principle


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