REFFIPLANT Training Course PDF

REFFIPLANT
TRAINING COURSE ON THE TOOLS FOR TOTAL SITE

ANALYSIS
Valentina Colla and Ismael Matino

Scuola Superiore Sant Anna - TeCIP Institute (Italy)
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

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Introduction
Sustainable
Steel
Environmental Production
and
Careful Economic
Resources Advantages
Management Decrease of waste
Stringent generation and disposal
Environmental Process Integration Reduction of freshwater
solutions (e.g. water intake and emissions
Regulations blow downs recovery, Increase in profits
recycle of solid by-
products fractions, etc.)
REFFIPLANT
Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Methodological Approach (1)
Process
Analysis
Identification of
potential PI solution
and Technological
Improvement
Literature
Analysis
Data Collection
&
Modelling
& Analysis
Simulation
Optimization
& Economical
Analysis
Design and
On-line
Application
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Methodological Approach (2)
Conventional
Process Process Detailed
Investigation Simulation Analyses
Techniques taking into account
all the relevant
Assessment of non- aspects for
Theoretical studies conventional assessing the
Pinch Analyses scenarios difficult to viability of industrial
Experimental
evaluate or test process modification
Campaign
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Modelling & simulation
Process simulations are possible by developing suitable process models.
Specialized Third level of detail

commercial
simulation
software
Ad-hoc Second level of detail

developed
software
First level of
First level of
detail
detail
MS Excel
REFFIPLANT
Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
MS Excel - First level of detail
Theoretical or empirical
based models
Simplified representation of
Unit operations
Resources user
Treatments
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MS 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
Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Ad-hoc developed software Second Level of detail
REFFIPLANT
Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
WATER-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
In the next slides some guidelines to use Water-Int

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WATER-Int User Interface
Network Design Environment

Main Interface
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WATER-Int Translate a process in a Water-int model
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WATER-Int Modelling phase - Contaminant Data
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WATER-Int - Modelling phase - Source Water Data
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WATER-Int Modelling phase - Process Data
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WATER-Int Modelling phase - Treatment Data
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WATER-Int Modelling phase - Treatment Data
Treatment type
Generic tab
Clarifier
Active sludge
Belt Filter
Sand Filter
Reverse Osmosys
Oil separator
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WATER-Int Modelling phase - Other Features
The editor is used to specify

piping information
(distance and cost law)
between any given units.
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WATER-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
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WATER-Int Guidelines for Non-Linear Optimisation problems
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Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
reMIND
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
In the next slides some guidelines to use reMIND

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reMIND User Interface
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reMIND Model Development
You develop a model through connections between:
nodes process or ingoing resource
branches flows
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reMIND 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
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reMIND 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.
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reMIND 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.
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reMIND Objective Function
The objective function is defined as:
c
N T M
min k1n k 2 n x
m ,t , n m ,t
n 1 t 1 m 1
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.
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reMIND 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
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reMIND 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
reMIND Optimization
The MPS file can be opened by an optimization tool such as CPLEX,

lp_solve or gnuwin32.
Optimization study can be finalized.
REFFIPLANT
Contents
Introduction

Microsoft Excel
WATER-Int
reMIND
Aspen Plus
REFFIPLANT
Specialized 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
In the next slides some guidelines to use Aspen Plus Some of the figures referers to
Reffiplant simulated case studies
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Aspen Plus - Applications
Rigorous Electrolyte Simulation
Solids Handling
Petroleum Handling
Air Separation
Chemical Processes
Gas Processing
Metallurgy
Pharmaceutical
Polymers
Others
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Aspen Plus - Functions
Design specifications
Sensitivity analysis
Calculator blocks (Fortran, Excel)
Unit operation model
Data Regression
Data Fit
Optimization
User Routines
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Aspen Plus User Interface
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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)
Basic input
2) Specify thermodynamic models to represent the
physical properties of the components and Setup
mixtures in the process Components

3) Define the process flowsheet (unit operations,
Properties
streams to and from the unit operations, ..)
4) Specify the component flow rates and the Streams
thermodynamic conditions (temperature, pressure, Blocks

etc.) of feed streams
5) Specify the operating conditions for the unit
operation models
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Properties / Components / Specification / Selection / Find
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If you need to model solid and fluid streams you have to define the stream class
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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)
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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.
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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.
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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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3) Define the process flowsheet
In the Main Flowsheet choose your equipments (blocks) from the Model Palette.
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Blocks: Unit Operation Model Types

Mixers/Splitters
Separators
Heat Exchangers
Columns
Reactors
Pressure Changers
Manipulators
Solids
User Models
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Blocks: Mixers/Splitters
Model Description Purpose Use

Mixer Stream mixer Combine multiple Mixing tees, stream mixing
streams into one operations, adding heat
stream streams, adding work streams
FSplit Stream splitter Split stream flows Stream splitters, bleed valves
SSplit Substream splitter Split substream flows Solid stream splitters, bleed
valves
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Blocks: Separators

Flash2 Two-outlet flash Determine thermal Flashes, evaporators, knockout
and phase conditions drums, single stage separators,
free water separations
Flash3 Three-outlet Determine thermal Decanters, single stage separators
flash and phase conditions with two liquid phases
Decanter Liquid-liquid Determine thermal Decanters, single stage separators
decanter and phase conditions with two liquid phases and no vapor
phase
Sep Multi-outlet Separate inlet stream Component separation operations
component components into any such as distillation and absorption,
separator number of outlet when the details of the separation are
streams unknown or unimportant
Sep2 Two-outlet Separate inlet stream Component separation operations
component components into two such as distillation and absorption,
separator outlet streams when the details of the separation are
unknown or unimportant
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Blocks: Heat exchangers

Heater Heater or cooler Determines thermal and Heaters, coolers, valves. Pumps and
phase conditions compressors when work-related results are not
needed.
HeatX Two-stream heat Exchange heat between two Two-stream heat exchangers. Rating shell and
exchanger streams tube heat exchangers when geometry is known.
MHeatX Multistream heat Exchange heat between any Multiple hot and cold stream heat exchangers.
exchanger number of streams Two-stream heat exchangers. LNG
exchangers.
Hetran* Interface to B-JAC Design and simulate shell and Shell and tube heat exchangers with a wide
Hetran program tube heat exchangers variety of configurations.
Aerotran* Interface to B-JAC Design and simulate air- Air-cooled heat exchangers with a wide variety
Aerotran program cooled heat exchangers of configurations. Model economizers and the
convection section of fired heaters.
HXFlux Heat transfer Models convective heat Determines the log-mean temperature
calculation model transfer between a heat sink difference, using either the rigorous or the
and a heat source. approximate method.
HTRIIST* Interface to the IST Design and simulate shell and Shell and tube heat exchangers with a wide
heat exchanger tube heat exchangers variety of configurations, including kettle
program from HTRI. boilers.
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Blocks: Columns (short cut)

DSTWU Shortcut distillation Determine minimum RR, Columns with one feed and
design minimum stages, and either two product streams
actual RR or actual stages
by Winn-Underwood-
Gilliland method.
Distl Shortcut distillation Determine separation Columns with one feed and
rating based on RR, stages, and two product streams
D:F ratio using Edmister
method.
SCFrac Shortcut distillation Determine product Complex columns, such as
for petroleum composition and flow, crude units and vacuum
fractionation stages per section, duty towers
using fractionation indices.
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Blocks: Columns (rigorous)

RadFrac Rigorous Rigorous rating and design for single Distillation, absorbers, strippers,
fractionation columns extractive and azeotropic distillation,
reactive distillation
MultiFrac Rigorous Rigorous rating and design for Heat integrated columns, air separators,
fractionation for multiple columns of any complexity absorber/stripper combinations, ethylene
complex columns primary fractionator/quench tower
combinations, petroleum refining
PetroFrac Petroleum refining Rigorous rating and design for Preflash tower, atmospheric crude unit,
fractionation petroleum refining applications vacuum unit, catalytic cracker or coker
fractionator, vacuum lube fractionator,
ethylene fractionator and quench towers
BatchFrac*+ Rigorous batch Rigorous rating calculations for Ordinary azeotropic batch distillation,
distillation single batch columns 3-phase, and reactive batch distillation
RateFrac* Rate-based Rigorous rating and design for single Distillation columns, absorbers, strippers,
distillation and multiple columns. Based on reactive systems, heat integrated units,
nonequilibrium calculations petroleum applications
Extract Liquid-liquid Rigorous rating for liquid-liquid Liquid-liquid extraction
extraction extraction columns
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Blocks: Reactors
RStoic Stoichiometric Stoichiometric reactor with Reactors where the kinetics are unknown or
reactor specified reaction extent or unimportant but stoichiometry and extent are
conversion known
RYield Yield reactor Reactor with specified yield Reactors where the stoichiometry and kinetics
are unknown or unimportant but yield
distribution is known
REquil Equilibrium reactor Chemical and phase Single- and two-phase chemical equilibrium
equilibrium by and simultaneous phase equilibrium
stoichiometric calculations
RGibbs Equilibrium reactor Chemical and phase Chemical and/or simultaneous phase and
equilibrium by Gibbs chemical equilibrium. Includes solid phase
energy minimization equilibrium.
RCSTR Continuous stirred Continuous stirred tank One, two, or three-phase stirred tank reactors
tank reactor reactor with kinetics reactions in the vapor or liquid
RPlug Plug flow reactor Plug flow reactor One, two, or three-phase plug flow reactors with
kinetic reactions in any phase. Plug flow
reactions with external coolant.
RBatch Batch reactor Batch or semi-batch Batch and semi-batch reactors where the
reactor reaction kinetics are known
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Blocks: Pressure Changers

Pump Pump or Change stream pressure when Pumps and hydraulic turbines
hydraulic the pressure, power requirement
turbine or performance curve is known
Compr Compressor or Change stream pressure when Polytropic compressors, polytropic
turbine the pressure, power requirement positive displacement
or performance curve is known compressors, isentropic
compressors, isentropic turbines.
MCompr Multi-stage Change stream pressure across Multistage polytropic compressors,
compressor or multiple stages with intercoolers. polytropic positive compressors,
turbine Allows for liquid knockout isentropic compressors, isentropic
streams from intercoolers turbines.
Valve Control valve Determine pressure drop or Multi-phase, adiabatic flow in ball,
valve coefficient (CV) globe and butterfly valves
Pipe Single-segment Determine pressure drop and Multi-phase, one dimensional,
pipe heat transfer in single-segment steady-state and fully developed
pipe or annular space pipeline flow with fittings
Pipeline Multi-segment Determine pressure drop and Multi-phase, one dimensional,
pipe heat transfer in multi-segment steady-state and fully developed
pipe or annular space pipeline flow
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Blocks: Manipulators

Mult Stream multiplier Multiply stream flows by Multiply streams for scale-up or
a user supplied factor scale-down
Dupl Stream Copy a stream to any Duplicate streams to look at
duplicator number of outlets different scenarios in the same
flowsheet
ClChng Stream class Change stream class Link sections or blocks that use
changer different stream classes
Selector Stream selector Switch between different Test different flowsheet senarios
inlet streams.
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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 or
multiple 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 vacuum
filters
SWash Single-stage solids washer Single-stage solids washer
CCD Counter-current decanter Multistage washer or a counter-current decanter
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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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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
Streams
attach material streams to the equipment.
RED CONNECTION: necessary streams for Material streams
the equipment
Energy streams
BLUE CONNECTIONS: optional streams
for the equipment
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4) Specify the component flow rates and the thermodynamic conditions of feed
streams
Simulation / Streams / Stream Name / Input
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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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5) Specify the operating conditions for the unit operation models
Simulation / Blocks / Block Name/ Specifications
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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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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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Aspen Plus Other useful features
Calculator Blocks
Sensitivity Analyses
Integration of Aspen Plus Model
etc.
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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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Calculator Blocks
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Definition of Manipulated variable Definition of Measured variable
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Plotting the results
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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
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
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
thank you!
e-mail: colla@sssup.it
i.matino@sssup.it
REFFIPLANT

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REFFIPLANT

TRAINING COURSE ON THE TOOLS FOR TOTAL SITE

Valentina Colla and Ismael Matino

Modelling & Simulation

Modelling & Simulation

Modelling & Simulation

Process simulations are possible by developing suitable process models.

Specialized Third level of detail

Ad-hoc Second level of detail

Modelling & Simulation

Stand-alone to predict main properties of output streams

Stand-alone for preliminary investigations on the behavior of a

Grouped in libraries to be jointly exploited to simulate treatment

Modelling & Simulation

Modelling & Simulation

The Water-int software is based

Allows preliminary studies of

Suggests possible network

In the next slides some guidelines to use Water-Int

Network Design Environment

The editor is used to specify

The editor allows calculation

Modelling & Simulation

Equations are generated within the program and exported to an

Allows optimization of solid streams through Mixed-Integer Linear

In the next slides some guidelines to use reMIND

You develop a model through connections between:

nodes process or ingoing resource

The definition of a node can be made by

The properties of a Function are in the

Others: Flow, Storage, Batch and Logical equations.

Each branch (flow) can be added using and it is assigned to a resource.

Resources are used by some of the Functions to create the equations.

The objective function is defined as:

xm,t is the flow m for the time step t.

The k1n and k2n coefficients also provide the possibility to

The timesteps are used to make different parameters in a model

The highest level is the TOP level

The final step is to export the

When selecting this option if no

The MPS file can be opened by an optimization tool such as CPLEX,

Optimization study can be finalized.

Modelling & Simulation

Complex simulations of water

Rigorous Electrolyte Simulation

Calculator blocks (Fortran, Excel)

Unit operation model

1) Specify the chemical components in the process

mixtures in the process Components

thermodynamic conditions (temperature, pressure, Blocks

1) Specify the chemical components in the process

If a chemical species is not present in the Aspen Plus

If a complex mixture (e.g. oil) have to inserted you can

1) Specify the chemical components in the process

If a rigorous treatment of electrolytes is needed with the

Aspen Plus generates all possible ionic and salt species

Property method: to calculate properties such as K-

Note: Clicking the Modify property models you can

How to choose the property method

Blocks: Unit Operation Model Types

Model Description Purpose Use

Model Description Purpose Use

Blocks: Heat exchangers