Minimize Energy in a BPA Process Webinar_V2_FINAL

8/10/2019 Minimize Energy in a BPA Process Webinar_V2_FINAL

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2013 Aspen Technology, Inc. All rights reserved | 2

Agenda

Introduction

BPA Process Overview

Demonstration

Key Take-Away Points

Questions & Discussion


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Ongoing Series of Technical WebinarsEngineering webinars for education and best practices

RECENT WEBINARS:

Modeling Fluidized Beds and Pneumatic Conveying (Technical)-September 2013

Modeling Solids Dryers and Granulators with Aspen Plus V8(Technical)- April 2013

Model Solids Processes Easily with Aspen Plus (Technical)-January 2013

UPCOMING WEBINARS OF INTEREST:

Webinar with Bilington Process Technology: Integrate PipelineDesign and Gas Production System Models with Aspen HYSYS-November 12, 2013

Solids Webinar: Topic TBD- February 22, 2014


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BasicEngineering

SafetyAnalysisAspen HYSYS

&Aspen Plus

aspenONE EngineeringBest-in-class engineering solutions in an integrated workflow

Operationsand Planning

Support

ProcessDevelopment

ConceptualEngineering

Equipment

Design

EconomicEvaluation


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Agenda

Introduction


Demonstration




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The Challenge

Designing a new BPA Process Is it energy efficient? What operating costs can I expect? How can I reduce drying energy cost?


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Aspen Plus model of the BPA Process

Basis: SRI Process Economics Program Report #224,Strategic Business Units for Polycarbonate and Epoxy Resins

Demo Focus



BPA(s)

CentrifugeS502

ProductCrystallizerS501

Melting VesselV502

BPADryerS503

E504

E503

N2

N2

Toluene

Phenol

Recycle

H2OToluene

Toluene

PhenolfromC303C302

BPA fromC202

BPA is crystallized again intoluene to remove residualphenol. The BPA crystalsare dried with N2 toremove toluene. The finalproduct is melted and sentto a heated storage tank

BPA Purification



Agenda

Introduction


Demonstration





Demonstration: What You Will See

SolidsProcess

Modeling

ActivatedEconomic

Analysis

ActivatedEnergy

Analysis



Activated Economic Analysis

This is the new Activated Analysis panel in Aspen

Plus v8.2. It enables quick relative cost analysisand energy analysis.

Under the hood, Aspen Plus uses AspenTechsproven cost modeling technology to rigorouslyevaluate capital and operating costs.

The cost estimates can be handed overelectronically to an estimator to do a more detailedanalysis using Aspen Capital Cost Estimator.



Operating Cost Estimates

The Process Utility feature in Aspen Plus lets you specify the cost of each type ofutility (steam, hot oil, etc.). You assign the utilities to the operations that requireheating and cooling. Aspen Plus calculates the new utility cost and the carbonequivalents (greenhouse gas).



Activated Costing - Stream Prices

You can enter the product selling price and raw material cosfeed and product stream.

We can enter a negative price to address waste water proce


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Activated CostingEquipment Specifications

You can enter equipment details, such asmaterials of construction, to get a moreaccurate cost estimate.


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BPA(s)

CentrifugeS502

CrystallizerS501

Melting VesselV502

BPADryerS503

E504

E503

N2

N2

Toluene

PhenolRecycle

H2OToluene

Toluene

Phenol

fromC303

C302

BPA

Increaserotationrate here

Lessresidualmoisture

Lowerflow rate

LessSteam

LessCooling

Optimizing Drying


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Results Changes in Rotation Rate


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Dryer Optimization Results

Centrifuge Rotation Residual Moisture Gas to Dryer Blower Power

Gas Heater Duty Condenser Duty Operating CostDryer Size Blower Size Gas Heater Size Condenser Size

Capital Cost


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Economics Before & After Centrifuge Change

Payout Period reduced from 16.3 to 15.9 years

Capital Cost Reduced by $ 510,400 (1%)Utility Costs Reduced by $ 452,000 (4%)


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The Solids Models Report Particle Sizes

You can switch between mass fractionplot and cumulative mass fraction plots


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Activated Energy Analysis


uses pinch theory find theenergy efficiency limits.

The energy efficiency of yourprocess is rated againstthese limits.

You can run an optimizationto find alternatives. In thisexample


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The system identifies five options to place the new exchanger.Note the first four options all involve the C303 condenser.The first option, involving C302 reboiler, offers the best advantage


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Activated Energy Analysis Utilities

Click Saving Potentials on the ribbon to see the utility analysis

These results suggest several options to consider:(1) Replace tower cooling water (TCW) with less expensive air cooling(2) Opportunity to reduce refrigeration and steam costs


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Energy Analysis Recommendation

C303 C302

Energy analyzer suggests adding an exchanger upstream of C303

condenser and upstream of C302 reboiler.This could make the process hard to control, however.Instead, we can use C303 condenser to generate steam which can beused in the C302 reboiler


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Switch C303 Condenser Utility from CoolingWater to Low Pressure Steam Generation

Payout Period about equal

Capital Cost Increased by $ 1.6 million (3%)Utility Costs Reduced by $ 322,000/year (20%)


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Agenda

Introduction


Demonstration




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Demonstration: Key Take-Away Points

NewAspen Plus

EnablesModeling of

Processes withSolids

ActivatedEconomic

Analysis Leadsto Better

DecisionsBased on

Rigorous CostEstimates

ActivatedEnergy

Analysis RatesProcess

EnergyEfficiency and

IdentifiesImprovements

l 8 O i i i i h


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Aspen Plus V8 - Optimizing Processes withSolids and Fluids Made Easy

Sample

Templates

Online

Training

Visualize PSD

Comprehensive SolidsModel Library

Optimize Entire Process

VisualizeSeparation Curves

Economics

for Solids


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Comprehensive Solids Model Library

Design Philosophy:One unit operation model can represent many different types of equipmentat various levels of fidelity from conceptualdetailed

17 blocksrepresentover 70types ofequipment

A Pl S lid M d li


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Aspen Plus Solids Modeling- Description of Disperse Solids

Aspen Plus allows for detailed description of disperse solids

Different particle types (sub streams)

Each particle type is described by

Distributed Properties Composition

Particle size

Scalar values per particle type (sub stream)

Moisture content(s)


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Agenda

Introduction


Demonstration




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What Next?

Get more information now Call your AspenTech account manager or

Call Aspen Telesales Direct:

USA: +1-855-882-7736

EUROPE & MIDDLE EAST: +44-1189-226400

ASIA/PACIFIC and INDIA: +65-6395-3900

Or email us at [email protected]

Contact info for todays presenter and hosts David Tremblay [email protected]

Claus Reimers [email protected]

Ron Beck [email protected]

Jen [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Get Started with Solids Modeling in Aspen Plus

Learning Resources are Available

Presentations, videos, and getting started resourcesavailable at: www.aspentech.com/products/solids-aspen-plus.aspx

Computer Based Training: Getting Started with SolidModeling in Aspen Plus V8

Videos also available at:www.youtube.com/user/aspentechnologyinc

Demos available in aspenONE Exchange and the Support

Center (support.aspentech.com)
http://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.youtube.com/user/aspentechnologyinchttp://www.youtube.com/user/aspentechnologyinchttp://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.aspentech.com/products/solids-aspen-plus.aspxhttp://www.aspentech.com/products/solids-aspen-plus.aspx


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Self Guided Examples

Get up to speed easily by using 14 New Self Guided Examples

Consist of example files and detailed step-by-step slides Included in the Support Center (http://support.aspentech.com)

and accessible via aspenONE Exchange

Search Solids,

Granulation, Dryers etc.sort by date
http://support.aspentech.com/http://support.aspentech.com/http://support.aspentech.com/


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Want more help?

http://training.aspentech.com

Consider a training class from AspenTech
http://training.aspentech.com/http://training.aspentech.com/http://training.aspentech.com/


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Questions

Minimize Energy in a BPA Process Webinar_V2_FINAL

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