REFFIPLANTreffiplant.com/files/REFFIPLANT_Training_Course.pdf · Calculator blocks (Fortran, Excel)...
Transcript of REFFIPLANTreffiplant.com/files/REFFIPLANT_Training_Course.pdf · Calculator blocks (Fortran, Excel)...
Valentina Colla and Ismael MatinoScuola Superiore Sant’ Anna - TeCIP Institute (Italy)
REFFIPLANT
TRAINING COURSE ON THE TOOLS FOR TOTAL SITE
ANALYSIS
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Introduction
StringentEnvironmentalRegulations
CarefulResourcesManagement
• Process Integration solutions (e.g. water blow downs recovery, recycle of solid by-products fractions, etc.)
Environmentaland EconomicAdvantages• Decrease of waste
generation and disposal
• Reduction of freshwaterintake and emissions
• Increase in profits
SustainableSteel Production
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Methodological Approach (1)
Process Analysis
Identification of potential PI solution
and Technological Improvement
Literature Analysis
Modelling &
Simulation
Optimization & Economical
Analysis
Design and On-line
Application
Data Collection&
Analysis
REFFIPLANT
Training course on the tools for total site analysis
Methodological Approach (2)
ConventionalProcess
InvestigationTechniques
• Theoretical studies
• Pinch Analyses
• ExperimentalCampaign
ProcessSimulation
• Assessment of non-conventionalscenarios difficult to evaluate or test
DetailedAnalyses
• taking into account all the relevantaspects for assessing the viability of industrial process modification
REFFIPLANT
Training course on the tools for total site analysis
Modelling & simulation
Process simulations are possible by developing suitable process models.
Ad-hoc developed software
MS Excel®
Specialized
commercial
simulation
software
First level of
detail
Third level of detail
Second level of detail
First level of detail
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationMS Excel - First level of detail
Theoretical or empirical
based models
Simplified representation of
• Unit operations
• Resources user
• Treatments
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationMS Excel - First level of detail
Applications
• Stand-alone to predict main properties of output streams
• Stand-alone for preliminary investigations on the behavior of a
specific unit operation
• Grouped in libraries to be jointly exploited to simulate treatment
arrangements
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationAd-hoc developed software – Second Level of detail
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int - Applications
The Water-int software is based
on linear optimisation framework
and hence it does not consider
complex ionic interactions between
different contaminants.
Allows preliminary studies of
simulation and optimization of the
structure of an industrial water
network
Suggests possible network
modifications or arrangements
for economic and
environmental advantages
REFFIPLANT
Training course on the tools for total site analysis
In the next slides some guidelines to use Water-Int
Modelling & SimulationWATER-Int – User Interface
Network Design Environment Main Interface
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Translate a process in a Water-int model
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Modelling phase - Contaminant Data
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int - Modelling phase - Source Water Data
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Modelling phase - Process Data
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Modelling phase - Treatment Data
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Modelling phase - Treatment Data
Treatment type
Generic tab
Clarifier
Active sludge
Belt Filter
Sand Filter
Reverse Osmosys
Oil separator
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Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Modelling phase - Other Features
The editor is used to specify
piping information
(distance and cost law)
between any given units.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Simulation & Optimization
The editor allows calculation
options and optimization objectives
to be set.
Analysis class:
• Reuse
• Regeneration Reuse
• Regeneration Recycle
Objective type:
• Minimum Source water Flowrate
• Minimum Treatment Flowrate
• Minimum Operating Cost
• Minimum Total Cost
Multiple objective:
Generation of a “Pareto front”
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationWATER-Int – Guidelines for Non-Linear Optimisation problems
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND
Exploits real or simulated data (by Excel-based models) in its
computations starting from a superstructure model
Equations are generated within the program and exported to an
optimization file in standard format (MPS)
Allows optimization of solid streams through Mixed-Integer Linear
Programming comparing all the considered configurations
REFFIPLANT
Training course on the tools for total site analysis
In the next slides some guidelines to use reMIND
Modelling & SimulationreMIND – User Interface
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Model Development
You develop a model through connections between:
• nodes process or ingoing resource
• branches flows
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Nodes
The definition of a node can be made by
Functions that can be add use “drag and drop”
The properties of a Function are in the
Properties tab of the node
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Functions
Boundary: defines a bound on ingoing or outgoing resource from a node on a specific time step, uses resources to
generate the bound.
BoundaryTOP: works in the same way as the Boundary function but is used to set a boundary on the sum of all time
steps.
Destination: defines the end of a node in the model and works as a sink for the ingoing resource(s).
Source: defines the resource and assigns this to the outgoing flows, usually in each starting node of the model. All
source functions are part of the defined objectives for the model.
Flow dependency: can be used to define the relation between two resources ingoing, outgoing or a transformation
from ingoing to outgoing.
Flow relation: can be used to define a distribution between different ingoing or outgoing flows of the same resource. By
using integers non-linear relations between flows of different resources can be depicted.
Investment cost: can be use to model an investment of equipment based on flows out or in to the model
Function editor: in this it is possible to define the model more flexible. The modelling includes the potential to define
float variables (Flt) and integer variables (Int). Thereby allowing for the possibility to generate most of the pre-defined
equation types.
Others: Flow, Storage, Batch and Logical equations.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Branches
Each branch (flow) can be added using and it is assigned to a resource.
The resource can be material, economic or environmental related and refers to something
that is consumed.
Resources are used by some of the Functions to create the equations.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Objective Function
The objective function is defined as:
M
m
tmntm
T
t
N
n
nn xckk1
,,,
11
21min
xm,t is the flow m for the time step t.
cm,t,n is the coefficient for flow m of objective type n in time step t.
k1n is a coefficient making it possible to normalize each objective function n,
k2n is a coefficient making it possible to weight the objectives.
The k1n and k2n coefficients also provide the possibility to exclude any objectives from the optimisation by setting them to zero.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Other Features
Timesteps
The timesteps are used to make different parameters in a model
vary over time.
Each time step level divides the level above in a certain number of
parts
The highest level is the TOP level
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Exporting model in MPS file
The final step is to export the
developed model into a MPS file
format that can be read by most
optimization tool.
When selecting this option if no
information is missing, equations will
be generated for all flows, nodes and
functions in the model.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationreMIND – Optimization
The MPS file can be opened by an optimization tool such as CPLEX,
lp_solve or gnuwin32.
Optimization study can be finalized.
REFFIPLANT
Training course on the tools for total site analysis
Contents
Introduction
Methodological Approach
Modelling & Simulation Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Training course on the tools for total site analysis
In the next slides some guidelines to use Aspen Plus Some of the figures referers to
Reffiplant simulated case studies
Modelling & SimulationSpecialized commercial simulation software - Third level of detail
Complex simulations of water
networks or solid streams
treatment processes
considering all the features
that in a real plant are
normally monitored
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationAspen Plus - Applications
Rigorous Electrolyte Simulation
Solids Handling
Petroleum Handling
Air Separation
Chemical Processes
Gas Processing
Metallurgy
Pharmaceutical
Polymers
Others
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Training course on the tools for total site analysis
Modelling & SimulationAspen Plus - Functions
Design specifications
Sensitivity analysis
Calculator blocks (Fortran, Excel)
Unit operation model
Data Regression
Data Fit
Optimization
User Routines
REFFIPLANT
Training course on the tools for total site analysis
Modelling & SimulationAspen Plus – User Interface
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
1) Specify the chemical components in the process
(you can define them if not present in databanks)
2) Specify thermodynamic models to represent the
physical properties of the components and
mixtures in the process
3) Define the process flowsheet (unit operations,
streams to and from the unit operations, ..)
4) Specify the component flow rates and the
thermodynamic conditions (temperature, pressure,
etc.) of feed streams
5) Specify the operating conditions for the unit
operation models
Basic input
Setup
Components
Properties
Streams
Blocks
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
1) Specify the chemical components in the process
Properties / Components / Specification / Selection / Find
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Training course on the tools for total site analysis
If you need to model solid and fluid streams you have to define the stream class
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
1) Specify the chemical components in the process
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
1) Specify the chemical components in the process
If a chemical species is not present in the Aspen Plus
databank, you can specify it with its main properties
(e.g. molecular weight, critical parameters, heat of
formation, chemical structure, etc.)
If a complex mixture (e.g. oil) have to inserted you can
create it as a mixture of pseudocomponents starting
from mixture main parameters (e.g. Distillation curve)
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
1) Specify the chemical components in the process
If a rigorous treatment of electrolytes is needed with the
Aspen Plus electrolyte capabilities, you can model:
• Sour water solutions.
• Aqueous amines for gas sweetening.
• Aqueous acids or bases.
• Salt solutions
Aspen Plus generates all possible ionic and salt species
and reactions:
<===> Denotes ionic equilibrium or salt precipitation.
---> Denotes complete dissociation.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
2) Specify thermodynamic models to represent the physical properties of the
components and mixtures in the process
Property method: to calculate properties such as K-
values, enthalpy and density.
The Base method list contains various property methods
built into Aspen Plus. The specific methods in the list
depend on the chosen Process type.
Note: Clicking the Modify property models you can
create a custom property method that starts out identical
to the chosen base method but may be modified
according to your needs.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
2) Specify thermodynamic models to represent the physical properties of the
components and mixtures in the process
How to choose the property method
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Unit Operation Model Types
Mixers/Splitters
Separators
Heat Exchangers
Columns
Reactors
Pressure Changers
Manipulators
Solids
User Models
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Mixers/Splitters
Model Description Purpose Use
Mixer Stream mixer Combine multiplestreams into onestream
Mixing tees, stream mixingoperations, adding heatstreams, adding work streams
FSplit Stream splitter Split stream flows Stream splitters, bleed valves
SSplit Substream splitter Split substream flows Solid stream splitters, bleedvalves
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Separators
Model Description Purpose Use
Flash2 Two-outlet flash Determine thermal
and phase conditions
Flashes, evaporators, knockout
drums, single stage separators,
free water separations
Flash3 Three-outlet
flash
Determine thermal
and phase conditions
Decanters, single stage separators
with two liquid phases
Decanter Liquid-liquid
decanter
Determine thermal
and phase conditions
Decanters, single stage separators
with two liquid phases and no vapor
phase
Sep Multi-outlet
component
separator
Separate inlet stream
components into any
number of outlet
streams
Component separation operations
such as distillation and absorption,
when the details of the separation are
unknown or unimportant
Sep2 Two-outlet
component
separator
Separate inlet stream
components into two
outlet streams
Component separation operations
such as distillation and absorption,
when the details of the separation are
unknown or unimportant
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Heat exchangers
Model Description Purpose Use
Heater Heater or cooler Determines thermal and
phase conditions
Heaters, coolers, valves. Pumps and
compressors when work-related results are not
needed.
HeatX Two-stream heat
exchanger
Exchange heat between two
streams
Two-stream heat exchangers. Rating shell and
tube heat exchangers when geometry is known.
MHeatX Multistream heat
exchanger
Exchange heat between any
number of streams
Multiple hot and cold stream heat exchangers.
Two-stream heat exchangers. LNG
exchangers.
Hetran* Interface to B-JAC
Hetran program
Design and simulate shell and
tube heat exchangers
Shell and tube heat exchangers with a wide
variety of configurations.
Aerotran* Interface to B-JAC
Aerotran program
Design and simulate air-
cooled heat exchangers
Air-cooled heat exchangers with a wide variety
of configurations. Model economizers and the
convection section of fired heaters.
HXFlux Heat transfer
calculation model
Models convective heat
transfer between a heat sink
and a heat source.
Determines the log-mean temperature
difference, using either the rigorous or the
approximate method.
HTRIIST* Interface to the IST
heat exchanger
program from HTRI.
Design and simulate shell and
tube heat exchangers
Shell and tube heat exchangers with a wide
variety of configurations, including kettle
boilers.
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Columns (short cut)
Model Description Purpose Use
DSTWU Shortcut distillationdesign
Determine minimum RR,minimum stages, and eitheractual RR or actual stagesby Winn-Underwood-Gilliland method.
Columns with one feed andtwo product streams
Distl Shortcut distillationrating
Determine separationbased on RR, stages, andD:F ratio using Edmistermethod.
Columns with one feed andtwo product streams
SCFrac Shortcut distillationfor petroleumfractionation
Determine productcomposition and flow,stages per section, dutyusing fractionation indices.
Complex columns, such ascrude units and vacuumtowers
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Columns (rigorous)
Model Description Purpose Use
RadFrac Rigorousfractionation
Rigorous rating and design for singlecolumns
Distillation, absorbers, strippers,extractive and azeotropic distillation,reactive distillation
MultiFrac Rigorousfractionation forcomplex columns
Rigorous rating and design formultiple columns of any complexity
Heat integrated columns, air separators,absorber/stripper combinations, ethyleneprimary fractionator/quench towercombinations, petroleum refining
PetroFrac Petroleum refiningfractionation
Rigorous rating and design forpetroleum refining applications
Preflash tower, atmospheric crude unit,vacuum unit, catalytic cracker or cokerfractionator, vacuum lube fractionator,ethylene fractionator and quench towers
BatchFrac*+ Rigorous batchdistillation
Rigorous rating calculations forsingle batch columns
Ordinary azeotropic batch distillation, 3-phase, and reactive batch distillation
RateFrac* Rate-baseddistillation
Rigorous rating and design for singleand multiple columns. Based onnonequilibrium calculations
Distillation columns, absorbers, strippers,reactive systems, heat integrated units,petroleum applications
Extract Liquid-liquidextraction
Rigorous rating for liquid-liquidextraction columns
Liquid-liquid extraction
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Reactors
Model Description Purpose Use
RStoic Stoichiometricreactor
Stoichiometric reactor withspecified reaction extent orconversion
Reactors where the kinetics are unknown orunimportant but stoichiometry and extent areknown
RYield Yield reactor Reactor with specified yield Reactors where the stoichiometry and kineticsare unknown or unimportant but yielddistribution is known
REquil Equilibrium reactor Chemical and phaseequilibrium bystoichiometric calculations
Single- and two-phase chemical equilibriumand simultaneous phase equilibrium
RGibbs Equilibrium reactor Chemical and phaseequilibrium by Gibbsenergy minimization
Chemical and/or simultaneous phase andchemical equilibrium. Includes solid phaseequilibrium.
RCSTR Continuous stirredtank reactor
Continuous stirred tankreactor
One, two, or three-phase stirred tank reactorswith kinetics reactions in the vapor or liquid
RPlug Plug flow reactor Plug flow reactor One, two, or three-phase plug flow reactors withkinetic reactions in any phase. Plug flowreactions with external coolant.
RBatch Batch reactor Batch or semi-batchreactor
Batch and semi-batch reactors where thereaction kinetics are known
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Pressure Changers
Model Description Purpose Use
Pump Pump orhydraulicturbine
Change stream pressure whenthe pressure, power requirementor performance curve is known
Pumps and hydraulic turbines
Compr Compressor orturbine
Change stream pressure whenthe pressure, power requirementor performance curve is known
Polytropic compressors, polytropicpositive displacementcompressors, isentropiccompressors, isentropic turbines.
MCompr Multi-stagecompressor orturbine
Change stream pressure acrossmultiple stages with intercoolers.Allows for liquid knockoutstreams from intercoolers
Multistage polytropic compressors,polytropic positive compressors,isentropic compressors, isentropicturbines.
Valve Control valve Determine pressure drop orvalve coefficient (CV)
Multi-phase, adiabatic flow in ball,globe and butterfly valves
Pipe Single-segmentpipe
Determine pressure drop andheat transfer in single-segmentpipe or annular space
Multi-phase, one dimensional,steady-state and fully developedpipeline flow with fittings
Pipeline Multi-segmentpipe
Determine pressure drop andheat transfer in multi-segmentpipe or annular space
Multi-phase, one dimensional,steady-state and fully developedpipeline flow
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Manipulators
Model Description Purpose Use
Mult Stream multiplier Multiply stream flows by
a user supplied factor
Multiply streams for scale-up or
scale-down
Dupl Stream
duplicator
Copy a stream to any
number of outlets
Duplicate streams to look at
different scenarios in the same
flowsheet
ClChng Stream class
changer
Change stream class Link sections or blocks that use
different stream classes
Selector Stream selector Switch between different
inlet streams.
Test different flowsheet senarios
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: Solids
Model Description Uses
Crystallizer Continuous Crystallizer Mixed suspension, mixed product removal (MSMPR)crystallizeer used for the production of a single solid product
Crusher Crushers Gyratory/jaw crusher, cage mill breaker, and single ormultiple roll crushers
Screen Screens Solids-solids separation using screens
FabFl Fabric filters Gas-solids separation using fabric filters
Cyclone Cyclones Gas-solids separation using cyclones
VScrub Venturi scrubbers Gas-solids separation using venturi scrubbers
ESP Dry electrostatic precipitators Gas-solids separation using dry electrostatic precipitators
HyCyc Hydrocyclones Liquid-solids separation using hydrocyclones
CFuge Centrifuge filters Liquid-solids separation using centrifuge filters
Filter Rotary vacuum filters Liquid-solids separation using continuous rotary vacuumfilters
SWash Single-stage solids washer Single-stage solids washer
CCD Counter-current decanter Multistage washer or a counter-current decanter
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
Blocks: User Models
Proprietary models or 3-rd party software can be included in an Aspen Plus flowsheet
using a User2 unit operation block.
Excel Workbooks or Fortran code can be used to define the User2 unit operation
model.
User-defined names can be associated with variables.
Variables can be dimensioned based on other input specifications (for example,
number of components).
Aspen Plus helper functions eliminate the need to know the internal data structure to
retrieve variables.
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
3) Define the process flowsheet
Now you have to add the connections with the material stream.
When you click on Material you can view
the whole places where it is possible to
attach material streams to the equipment.
RED CONNECTION: necessary streams for
the equipment
BLUE CONNECTIONS: optional streams
for the equipment
Streams
Material streams
Energy streams
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
4) Specify the component flow rates and the thermodynamic conditions of feed
streams
Simulation / Streams / Stream Name / Input
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
4) Specify the component flow rates and the thermodynamic conditions of feed
streams
In the case of solids presence into the Aspen Plus
simulation environment it is need to consider:
The solid components within the simulation
distinguishing solid from fluid components.
The different ways of adding solids into simulations
(Stream Classes).
The moisture composition of those solids increase
fidelity in the definition of the bulk solid.
The particle size distribution of those solids increase
the fidelity of the description of the different bulk material
in the simulation.
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Translate a process in an Aspen Plus model
5) Specify the operating conditions for the unit operation models
Simulation / Blocks / Block Name/ Specifications
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Modelling & Simulation
Aspen Plus – Simulation
If each required data is correctly inserted you can run the simulation
Control panel shows if the simulation is completed with or without warnings (minor error)
or error.
Results can be viewed in Results tab related to Blocks and Streams
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Modelling & Simulation
Aspen Plus – Tuning & Validation
You have now to compare the model results with real data in order to validate the
model if the errors are negligible.
Tuning phase can be necessary
After validation the model can be used for scenario analyses
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Calculator Blocks
Sensitivity Analyses
Integration of Aspen Plus Model
etc.
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Calculator Blocks
Calculator Blocks allows the user to carry out flowsheet calculations using equations printed in
ad-hoc made excel spreadsheet or FORTRAN statements.
How to use the calculator block:
1. model variables to sample (import variables) or manipulate (export variables) must be
identified;
2. FORTRAN statements or Excel spreadsheet must be compiled;
3. the sequence in which the blocks are executed during flowsgeet calculations must be
specified.
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Calculator Blocks
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Sensitivity Analyses
Definition of Manipulated variable Definition of Measured variable
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Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Sensitivity Analyses
Plotting the results
REFFIPLANT
Training course on the tools for total site analysis
Modelling & Simulation
Aspen Plus – Other useful features
Integration of Aspen Plus Model
Notwithstanding the powerful simulation capabilities, in some cases it might be desirable to
exploit existing knowledge or process models developed in different simulation environments.
Aspen Plus offers a few options for interaction with external simulation environment and
software:
• Integration of Excel models into Aspen using the User2 model;
• Integration of Fortran models using the User model;
• Interaction with Excel spreadsheets through the Aspen Simulation Workbook (ASW);
• Interaction with external programs through COM interface;
• Interaction with models exported in Aspen Custom Modeler and Aspen Dynamics.
REFFIPLANT
Training course on the tools for total site analysis
Acknowledgment
This tranining course was developed within the project entitled ”REFFIPLANT
Efficient Use of Resources in Steel Plants through Process Integration”
(Contract No. RFSR-CT-2012-00039), and has received funding from the
Research Fund for Coal and Steel of the European Union, which is gratefully
acknowledged.
REFFIPLANT
Training course on the tools for total site analysis
References
1. Matino, I., Colla, V., Romaniello, L., Rosito, F., & Portulano, L. (2015, December). Simulation
techniques for an Efficient Use of Resources: An overview for the steelmaking field. In 2015
World Congress on Sustainable Technologies (WCST) (pp. 48-54). IEEE.
2. Matino, I., Colla, V., (2016). Improving Resource efficiency through a general purpose
methodological approach combining standard techniques, modelling and simulation, 2016.
3. Process Integration Limited Software, (2016) WATER-IntTM User Guide.
4. Larsson, M., Karlsson, M., Mardan, N. & Sandberg, J., (2010). Seminar ReMIND, Swerea
MEFOS.
5. Aspentech. Introduction to Flowsheet Simulation. Aspen Technology, 2000.
6. Aspentech. Aspen Plus – Getting Started Building and Running a Process Model. Aspen
Technology, November 2013.
7. Aspentech. Aspen Physical Property System 11.1. Aspen Technology, September 2001.
8. Aspentech. Aspen Plus12.1 User Guide. Aspen Technology, June 2003.
9. Aspentech. Getting Started with Solid Modeling in Aspen Plus – Training Course. Aspen One,
2012.
10. Aspen Plus V. 8.6, Help
11. Aspen Plus Getting Started Modeling Processes with Electrolytes User guide, Chapter 1
12. Aspen Plus knowledge base (solutions on support.aspentech.com website)
13. Aspen Plus User Models user guide, V 8.4
14. Aspen Simulation Workbook User Guide, V 7.1
REFFIPLANT
Training course on the tools for total site analysis
e-mail: [email protected]
thank you!
REFFIPLANT
Training course on the tools for total site analysis