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Dynamic Simulation and Chemical Engineering

dynamic simulation

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253 views

Dynamic Simulation and Chemical Engineering

dynamic simulation

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hassan
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Dynamic

Simulation
and
Chemical
Engineering

Based on the presentation in the 3rd Pan-Hellenic


Chemical Engineering Conference. 31 May - 2 June
2001.

DOCUMENT HISTORY
This document is based on the presentation of Kyriakopoulou, D., Poulou, S. and Athanassiou, V. in the 3rd Pan-Hellenic Chemical Engineering Conference. 31 May - 2 June
2001.
For comments on this document please contact Dr. Vassilis Harismiadis
([email protected]).

OWNERSHIP
This document, the concepts, ideas, designs and commercial offers included therein are
the sole property of Hyperion Systems Engineering Ltd.
Copyright 2006, Hyperion Systems Engineering, All rights reserved

Dynamic Simulation and Chemical Engineering

1 SUMMARY
In dynamic simulation, natural and chemical phenomena are expressed with algebraic and
differential equations based on engineering principles. The mathematical models created
are used for analysing how process behaviour varies with time. For the typical case of a
process industry, we describe/model the plant subunits and their regulatory control. The
relevant equations are solved repeatedly in the time domain and the values of temperature, pressure, flow and composition as well as the valve openings and the process control
system output are calculated at every point of interest. Thus, the interactions between the
process subunits can become obvious. Further, the process reaction to disturbances (such
as feed variation, instruments failure or change of operation strategy) can be fully investigated.

2 INTRODUCTION
Many of the operations in the Process Industry are naturally dynamic, such as the start-up
and shutdown of a unit, the changeover from one product to another, the operation of
batch reactors or adsorption/regeneration trains etc. Actually, it is practically impossible for
a process unit to operate under strictly constant conditions (steady state). On the other
hand, the industrial process units are becoming increasingly complex with applications of
new technologies that include thermal integration, modern process design and advanced
process control systems. The units are required to operate non-stop for longer periods of
time at optimal conditions. The need for flexibility, regarding processes or equipment, continuously increases. It is, further, well known that big and fast changes in the plant operating conditions should be avoided, since the effects of moving from one operational region
to another can be unanticipated and possibly dangerous. Thus, one need to be aware of
the danger zones and when these occur.
In brief, the behaviour of the process unit on the whole is not a simple sum of the plants
subunits actions. Safety, environmental, and economic factors highlight the importance of
understanding the design and operating of the plant, as well as the sufficient training of the
plant personnel at a time of an ever-increasing worldwide need for highly qualified and capable operators. Dynamic simulation is the only economically effective solution to these
needs, since it yields a lot more information than what traditional steady state simulation
offers. This is because dynamic simulation allows us to study a plants behaviour in a wide

Dynamic Simulation and Chemical Engineering

range of operation conditions, like during start-up or shutdown. Further, it can incorporate
algorithms describing the process unit safety or regulatory control philosophy. Thus, it is
possible to use a dynamic model for the investigation and improved understanding of the
unit's behaviour based on design or operational data.

3 APPLICATIONS OF DYNAMIC SIMULATION


The dynamic simulation applications in the process industry can be used for a variety of
purposes. These include the following.

3.1

Operator Training Systems

In todays world, where


the developed regions
face massive retirements
of their work force and
where the regions indevelopment face a skills
shortage, dynamic process models integrated
with the plants Distributed Control Systems
(DCS) can be used to
capture, maintain and develop existing operating
skills. Among others, a
fully deployed operator
training system can be
used to:
Offer plant operators an improved understanding of the unit operation and handling.
Familiarize the operators to the process design and the control systems, while emphasizing the interactions between the two.
Demonstrate the use and explain the advantages of advanced process control.
Control and verify the operators actions.
Practice without the presence of an instructor (stand-alone tool).

3.2

Operation Optimisation

A dynamic model of a process unit can be use to optimise operations. Some typical examples are:
Creating, testing and verifying procedures for the safe start-up and shutdown of the
process or for the minimisation of time that plant equipment stays out of operation.

Dynamic Simulation and Chemical Engineering

Finding ways to move the plant operation to equally feasible and safe but more profitable conditions.
Addition of new process lines, before or after start up, for improved plant controllability
during transients.

3.3

Modification of Process and Control System Design

The process design can be relatively easily modified and troubleshot with a dynamic simulator.
Technical assessment of alternative design solutions.
Dynamic studies: Analysis of
controllability, de-bottlenecking,
depressurising, feed differentiation effects etc.
Determination of characteristic
equipment parameters (instrument minimum sampling time or
permissible noise levels, controller tuning parameters, control
valves characteristics etc.)
Compressor performance verification and avoiding compressor
surge.
Effects to plant controllability
due to equipment modifications.

3.4

Investigation of Operational Issues

Rapid assessment of
alternative solutions to
what-if scenarios.
Achievement of optimal
plant conditions, after
an
unanticipated
change.
Incident investigation
and procedures for future prevention.
Estimation of functional
parameters for instrumentation.

Dynamic Simulation and Chemical Engineering

3.5

Safety and Environmental Issues

Exhaustive testing of plant


procedures and detection of
unfavourable conditions (e.g.
explosive/toxic mixtures, formation and deposition of hydrates etc.) due to transients or
malfunctions.
Verification of depressurising
procedures.
Verification of DCS and emergency shutdown system control loops and sequences.

4 REFERENCES
[1]
[2]
[3]

Nisenfeld A. E., 1982. Principles of Operation and Control, ISA, Monograph Series 3.
AspenTech Modelling Philosophy, 1998. AspenTech Ltd.
Gas Injection Plant, 1997. SAST Ltd.

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1, Century Court, Tolpits Lane, Watford, WD18 9PT, UK


Tel: +44.1923.65200, Fax: +44.1923.816456
e-mail: [email protected]
web site: www.bronermetals.com
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e-mail: [email protected]
Web site: www.hyperion.com.cy
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