Conceptual Demo Guide

2013 Aspen Technology, Inc.
All rights reserved

Conceptual Solids Models
in Aspen Plus V8.4
Guide to the Demo
Aspen Technology
Burlington, MA
2013

2013 Aspen Technology, Inc. All rights reserved |

2
Conceptual models ease learning experience for new solids
users such as process engineers
Not necessary to have in-depth knowledge of particle
technology or the specific apparatus

More experienced solids users can use conceptual models to
sketch the solids processing section before adding more
details (if necessary)
Conceptual model can be changed to a more rigorous model
without reconnecting streams

Conceptual models allow for better collaboration between
process engineers and particle scientists
Process engineer can include solids sections in the overall
flowsheet using conceptual solids models
Particle scientist can work with the process engineer to make
the model more rigorous if necessary


3
Conceptual solids models enable everybody to
model solids without being a solids expert

Conceptual
(process engineer)
Rigorous Equipment Model
(solids expert)
3 parameters to
define a decanter

4
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

5
Example:
Aspen Plus Model Bisphenol A (BPA) Production
Demo Focus: BPA
Purification Section
Large, mostly fluid process
Includes several solids unit operations and a purification
section at the end of the process

6
BPA Purification Section of the Process
BPA is crystallized in
toluene to remove residual
phenol. The BPA crystals
are dried with nitrogen to
remove toluene. The final
product is melted and sent
to a heated storage tank

7
Open the file Conceptual Model Example
Isolated purification
section from the
larger BPA Process

8
Conceptual Modeling Example
Dryer is
described by a
rigorous model
Optimizer is used to
adjust the nitrogen
flow to reach a purity
of 99.9%
Conceptual
model is used for
the centrifuge

9
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 on
particles settling velocity and a given separation sharpness


10
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 separation
based on settling velocity
Tip: Change the scale of
the X-axis to log to get a
better resolution

11
Calculation Results
Custom tables shows
Necessary dry gas flow
rate (determine by the
optimizer)
Power and utility costs
for the blower (K505)
Duty and utility costs
for the nitrogen heater
(E504)
Duty and utility costs
for the exhaust heater
(E503)
Total process utility cost
Total process utility cost in the base case are 32.30 $/hr
(~283.5 K$/HR)

12
Objective
Goals
Necessary dry gas flow rate (determine by the optimizer)
BPA must by purified
reduce energy demand for the dryer and with this the
process 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 the
solids stream leaving the centrifuge on the utility costs


13
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 click
OK
1
2
3
Position vary input form on
the left of your screen
4
Open input form of centrifuge S502 and position
the form right on the screen
5
Use right click and new vertical tab.

14
6
drag & drop
Drag and drop the
fraction of liquid to
liquid outlet to the
manipulated
variable section
7
Vary fraction of
liquid to liquid
outlet from 0.4 to
0.6 (10 points)

Vary

15
8
drag & drop
Drag and drop variables from the
custom table into the measured
variables 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

16
Run & Review Sensitivity Results
Run the model and
review the results

Reduced outlet solids
moisture content from
the centrifuge leads to
reduced utility costs for
the heaters and the
blower (conceptual
model predicts a linear
relationship)


17
Objective: Gain further
understanding of how the
operating conditions of the
decanter influences the
utility costs of the process
Solution:
Convert the model to
rigorous
Conduct a sensitivity
study using the rigorous
model of the decanter
Reduce Energy Costs

18
Switch to Equipment Model
Switch the centrifuge (block S502) to the equipment model
Not necessary to reconnect streams
Select decanter
equipment model

19
Select classification and deliquoring model
(already pre-defined in the example)

20
Enter model and geometry
parameter (already pre-
defined in the example)

21
Hide Sensitivity
Hide sensitivity case
Only deactivating the sensitivity case will lead to an error during
input translation since the varied variable is no longer exists
Want to reuse the sensitivity case later on

22
Run Simulation with the rigorous model
Run simulation and review separation efficiency curve if S502
Tip: Change the scale of
the X-axis to log to get a
better resolution

23
Comparison of Results from Conceptual and
Equipment 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

24
Change Sensitivity Case
Reveal the defined sensitivity task
Use sensitivity analysis to determine how the rpm of the
decanter influence the utility costs of the process
1

25
Change Sensitivity Case
2
Open sensitivity
input form
3
Position vary input form on the left of
your screen and delete defined variable
4
Open input form of centrifuge S502 and position the
form right on the screen

26
5
drag & drop
Drag and drop the
drum rotary speed
to the manipulated
variable section
6
Vary drum rotary
speed from 300 to
1200 rpm (5 points)

Remark: No need to make further
changes to the sensitivity case, since
measured variables etc. have been
defined already earlier


27
Sensitivity Case - Results
Run Model &
Review results

Increased rotary speed
of the decanter leads
to reduced utility costs
for the heaters and the
blower (equipment
model predicts a non-
linear relationship)


28
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

29
Summary
Use conceptual models to
gain an understanding of
which unit operations have
the largest impact on the
energy demand and utility
costs of a larger process
Convert those units from
conceptual to equipment
models to further investigate
how design or operating
conditions affect energy
demands.
Demo Focus: BPA Purification Section

Conceptual Demo Guide

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