PTT 303/2 PROCESS MODELLING AND SIMULATION
SEM 1 (2013/2014)
Introduction of Process Modelling and
Simulation of Batch Process
Subject covered
 Modeling and optimization of batch and
continuous processes
 Batch Process Scheduling
 Resources and inventory tracking
Cost analysis & project economic evaluation
 Throughput Analysis & Debottlenecking
What is “Process Simulation”?
Q: What does the word “simulate” mean?
Building a process model
 Predicting how a process would actually
behave
 Performing an experiment (on computer)

Incentives:
 Highly cost effective
 Reasonably accurate
 Proactive approach
Sequential modular approach
Individual equipment blocks may require
iterative solution algorithms
Overall process solution is sequential & not iterative
(Turton et al., 1998)
Sequential modular approach
Objectives of simulation
• Raw Materials
• Labor
• Utilities
• Capital Expenses
Batch
Process

Size
Throughput
/
Batch
Cycle Time
Waste
Product(s)
Commercial process simulators
SS Simulation
Aspen Plus
Dynamic Simulation
Batch
Oil, Gas &
Petrochemicals
HYSYS
Solids
Pinch
Oleo Chemicals
Specialty Chemicals
Provision
Design II
Phys Prop
Sizing & Costing
Economics
SuperPro
Rating
Sensitivity Analysis
Optimization
SuperPro Designer (SPD)
SuperPro Designer
BioPro Designer
BatchPro Designer
EnviroPro Designer
SchedulePro
Biotechnology
Bio-Fuels
Fine Chemicals
Pharmaceuticals
Food Processing
Mineral Processing
Water Purification
Wastewater Treatment
Air Pollution Control
Scheduling and Debottlenecking
of Multi-Product Facilities
Available tools
• Intuitive user interface
• Wide variety of unit operation models
• Databases for components and mixtures
• M&E Balances of Integrated Processes
• Equipment Sizing and Costing
• Project Economic Evaluation
• Process Scheduling & Cycle Time Analysis
• Throughput Analysis & Debottlenecking
• Environmental Impact
• Detailed Reports and Charts for the Above
User Interface of SuperPro Designer
Detailed Modeling using Unit Procedures and Operations
Double-Click
Operations Gantt Chart
Equipment Occupancy Chart
Scheduling Questions
• How can I schedule production during the next 6-18 months?
• How can I schedule operations in an R&D facility?
• How to adjust scheduling if priorities change?
• Can I fit a new product into my facility?
Resource Demand Chart
Labor Demand Chart
Cost Breakdown
Consumables
$0.65/g
29.1%
Raw materials
$0.88/g
39.6%
Raw Materials
Equipment
Labor
Consumables
Lab/QC/QA
Waste Trtm/Disp
Utilities
Facility
$0.54/g
24.4%
Cost Analysis Questions
• What is the required capital investment for a new plant?
• How much would it cost to make a kilo of product?
• Which process is better for making this product? A or B?
• How can I reduce the operating cost of a process?
Environmental
Report
Stream
Dialog – Env. Impact
Properties
Tab
INTELLIGEN, INC.
Bottleneck identification
Debottlenecking Questions
• How much product can I make in this plant?
• What limits the current production level?
• What is the capital investment for increasing production?
Course overview
• Lab 1
 Overview of process simulation
 Flowsheet development
• Lab 2
 Unit procedures initialisation
• Lab 3
 Process scheduling
 Resource & inventory tracking
• Lab 4
 Equipment rating
 Project economic evaluation
• Lab 5 – Biochemical case study
• Lab 6 – Throughput analysis & debottlenecking strategies