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Conceptual Solids Modelsin Aspen Plus V8.4Guide to the Demo
Aspen Technology
Burlington, MA
2013
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Conceptual Solids Models
Conceptual models ease learning experience for new solidsusers such as process engineers
Not necessary to have in-depth knowledge of particletechnology or the specific apparatus
More experienced solids users can use conceptual models to
sketch the solids processing section before adding moredetails (if necessary)
Conceptual model can be changed to a more rigorous modelwithout reconnecting streams
Conceptual models allow for better collaboration betweenprocess engineers and particle scientists
Process engineer can include solids sections in the overallflowsheet using conceptual solids models
Particle scientist can work with the process engineer to makethe model more rigorous if necessary
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Conceptual Solids Models
Conceptual solids models enable everybody tomodel solids without being a solids expert
Conceptual(process engineer)
Rigorous Equipment Model(solids expert)
3 parameters todefine a decanter
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Conceptual Solids Models
Functionality of conceptual models Comminution/Formulation
(Crusher, Granulator, Crystallizer)
Specify outlet PSD
Solid Separators(Centrifuge, Cyclone, ESP, Scrubber etc.)
Specify Desired Split
Dryers
Specify Outlet Moisture
Crystallizer Crusher Granulator Flash 2
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Example:Aspen Plus Model Bisphenol A (BPA) Production
Demo Focus: BPAPurification Section
Large, mostly fluid process
Includes several solids unit operations and a purificationsection at the end of the process
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BPA Purification Section of the Process
BPA is crystallized intoluene to remove residualphenol. The BPA crystalsare dried with nitrogen toremove toluene. The finalproduct is melted and sentto a heated storage tank
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Open the file Conceptual Model Example
Isolated purificationsection from the
larger BPA Process
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Conceptual Modeling Example
Dryer isdescribed by a
rigorous model
Optimizer is used toadjust the nitrogen
flow to reach a purityof 99.9%
Conceptualmodel is used for
the centrifuge
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Conceptual Model of the Decanter
Open the input form of centrifuge S502
conceptual model is used for the centrifuge
split of solids and liquid is described by split factors
solids separation is modeled by a separation curve based onparticles settling velocity and a given separation sharpness
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Calculation Results
Run the example and show the results for centrifuge S502
show the separation curve (switch to log. X-axis)
model is more than just a splitter model, describes separationbased on settling velocity
Tip: Change the scale ofthe X-axis to log to get abetter resolution
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Calculation Results
Custom tables shows
Necessary dry gas flowrate (determine by theoptimizer)
Power and utility costsfor the blower (K505)
Duty and utility costsfor the nitrogen heater(E504)
Duty and utility costsfor the exhaust heater(E503)
Total process utility cost
Total process utility cost in the base case are 32.30 $/hr(~283.5 K$/HR)
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Objective
Goals
Necessary dry gas flow rate (determine by the optimizer)
BPA must by purified
reduce energy demand for the dryer and with this theprocess utility costs
Constraints Throughput must not be changed
Purity of the product must be minimum 99.9%
Idea
Investigate the influence of the moisture content from thesolids stream leaving the centrifuge on the utility costs
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Set up a Sensitivity Analysis
Create a sensitivity case to investigate the influence of the
solids outlet moisture from the centrifuge on the utility costs
Click New
Enter ID and clickOK
1
23
Position vary input form onthe left of your screen
4Open input form of centrifuge S502 and positionthe form right on the screen
5
Use right click and new vertical tab.
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Set up a Sensitivity Analysis
6
drag & drop
Drag and drop thefraction of liquid toliquid outlet to themanipulatedvariable section
7
Varyfraction ofliquid to liquid
outlet from 0.4 to0.6 (10 points)
Vary
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Set up a Sensitivity Analysis
8
drag & drop
Drag and drop variables from thecustom table into the measuredvariables are- E504 Utility cost (heater before dryer)- E503 Utility costs (heater after dryer)- E505 Power costs (blower)
Rename variables E504, E505,
Blower in the define tab
9
Select tabulated variables and
click the Fill Variables button
Define
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Run & Review Sensitivity Results
Run the model andreview the results
Reduced outlet solidsmoisture content fromthe centrifuge leads toreduced utility costs forthe heaters and the
blower (conceptualmodel predicts a linearrelationship)
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Objective: Gain furtherunderstanding of how theoperating conditions of thedecanter influences theutility costs of the process
Solution: Convert the model to
rigorous
Conduct a sensitivitystudy using the rigorous
model of the decanter
Reduce Energy Costs
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Switch to Equipment Model
Switch the centrifuge (block S502) to the equipment model
Not necessary to reconnect streams
Select decanterequipment model
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Switch to Equipment Model
Select classification and deliquoring model
(already pre-defined in the example)
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Switch to Equipment Model
Enter model and geometryparameter (already pre-defined in the example)
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Hide Sensitivity
Hide sensitivity case
Only deactivating the sensitivity case will lead to an error duringinput translation since the varied variable is no longer exists
Want to reuse the sensitivity case later on
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Run Simulation with the rigorous model
Run simulation and review separation efficiency curve if S502
Tip: Change the scale ofthe X-axis to log to get abetter resolution
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Comparison of Results from Conceptual andEquipment Model
Equipment models predicts a slightly different separation curve
(based on given geometry and operating conditions)leads to different dry gas flow and therefore slightly different utility costs
Results with equipment model
Results with conceptual model
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Change Sensitivity Case
Reveal the defined sensitivity task
Use sensitivity analysis to determine how the rpm of thedecanter influence the utility costs of the process
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Change Sensitivity Case
2Open sensitivityinput form 3
Position vary input form on the left ofyour screen and delete defined variable
4Open input form of centrifuge S502 and position theform right on the screen
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Set up a Sensitivity Analysis
5
drag & drop
Drag and drop thedrum rotary speedto the manipulatedvariable section
6
Vary drum rotaryspeed from 300 to
1200 rpm (5 points)
Remark: No need to make furtherchanges to the sensitivity case, sincemeasured variables etc. have beendefined already earlier
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Sensitivity Case - Results
Run Model &Review results
Increased rotary speedof the decanter leadsto reduced utility costsfor the heaters and theblower (equipment
model predicts a non-linear relationship)
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Dryer/Centrifuge Optimization Results
Centrifuge Rotation Residual Moisture Gas to Dryer Blower Power
Gas Heater Duty Condenser Duty Operating Cost
An increase of the centrifuge rotary speed from 300 rpm to 1200 rpm would: Decrease the solids outlet moisture by ~56% Decrease the drying agent flow by ~27% Decrease the process utility costs by ~215
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Summary
Use conceptual models togain an understanding ofwhich unit operations havethe largest impact on theenergy demand and utility
costs of a larger process Convert those units from
conceptual to equipmentmodels to further investigatehow design or operating
conditions affect energydemands.
Demo Focus: BPA Purification Section