PTT303 /2

PROCESS MODELLING AND

SIMULATION
SEM 1 (2013/2014)
Introduction to Super PRO
Designer for Batch
Processing Modelling
(Part 2)

STUDENT SHOULD BE ABLE TO;

DEMONSTRATE the methods of initialising of

operation of unit procedures

SIMULATE the flowsheet of bioprocess production

plant

SESSION OUTLINE
Unit

procedures initialisation
Simulation execution & result checking

INITIALISING A UNIT
PROCEDURE
What

a Unit Procedure?
Initialising an Operation

WHAT IS A UNIT
PROCEDURE?
In

the batch modeling mode, a Unit

Procedure may consists of various
Operations:
Reactor procedure: feed charge, reaction,
product withdraw, etc
Filtration procedure: filtration, cake wash,
CIP, etc
In continuous modeling mode, a Unit
Procedure= Unit Operation

HIERARCHY IN BATCH MODELING

Entire plant

Procedure(s) level

Operation(s) level

The same for

continuous
process
modeling

FUNCTION OF EACH UNIT

PROCEDURE
Vessel Procedure (P-1):
Acts as a batch reactor to
carry out reaction:
A +
B
C
Heptane is used to dissolve
components A & B,
to aid separation in P-2

Plate and Frame Filtration (P-2):

Component C is not dissolved in heptane, hence is filtered out

by the filter cloth
Heptane is used to wash out the trapped heptane ( and also the
dissolved A & B) from the filter cake

STREAM SPECIFICATION

Heptane flow =
800 kg/batch

Ingredient flow
T, P = default

Click to insert
Heptane here

SET SPEC FOR STREAM A & B

Stream ID

Component

Amount
(kg/batch)

Heptane
A
B

Heptane
A
B

800
50
40

Temperature
Pressure
Default

WORKING
SESSION
Do not forget to save your work !!!

A QUESTION TO PONDER

Q: Why do we only specify the inlet stream?

Sequential modular
approach
Individual equipment blocks may require
iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

ADDING OPERATIONS TO P-1

3 Charge operation (to
charge A, B and
heptane respectively)
1 React (Stoichiometric)
operation (for reaction
to be carried out)
1 Transfer Out
operation (to deliver
product to next unit)

ADDING OPERATIONS TO P-1

Add new operation

before the currently
selected operation
Add new operation
at the end of the list

INITIALISING OPERATIONS IN P-1

INITIALISING CHARGE-1
Emission calculation
(next slide)

800 kg heptane
Vol. flowrate
=100 L/min
Setup time =
5 min

EMISSION CALCULATION

Click to perform
emission calculation

OK, next operation

(CHARGE-2)
OK, previous
Operation (none)

Go to selected
operation
Previous operation
(same tab none)
Next operation
(same tab)

INITIALISING CHARGE OPERATION

Operation

Operating condition

CHARGE-1

Charge

CHARGE-2

Charge

CHARGE-3

800kg/batch of heptane
stream Heptane
Setup time= 5 min
Process time : 100L/min

Emission
using

50 kg/batch of A (limiting
component) using Stream A
Setup time = 5min
Process time: calculated based on 20
kg/min
Charge

40/kg batch of B using Stream B

(B is in excess)
Setup time = 5 min
Process time : calculated based on 20
kg/min

Please complete the initialisation of CHARGE-2 & CHARGE-3

Perform
heptane
emission on this
stream

Nil

INITIALISING REACT-1 & TRANSFEROUT-1

Operation

Operating condition

REACT-1

Final

temp = 50 C
Heat transfer agent:
steam
Process time = 6 hour
Leave other values as
defaults

TRANSFEROUT-1

Using stream Rxt out

Duration: same as Cloth
Filtration in P-2 (using
Master-Slave
Relationship)

Volumes

Reaction

Max
Allowable
working/
vessel
volume: 80 %

Extent of reaction
= 95 %
Reaction
stoichiometry
A + B
C

Nil

INITILISING REACT-1 IN P-1

Final temp = 50 C

Max allowable volume

= 80 %
Steam

Process time
=6h

INITIALISING REACT-1 IN P-1

Edit reaction
stoichiometry

Rename reaction
Reaction
extent = 95 %

OK, next operation

(Transfer-out)

Add reaction(s)

Delete
stoichiometry
(when needed)

Molar
stoichiometry

INITIALISING TRANSFER OUT

Transfer
out stream

Click here to select

Master-and-Slave to
calculate duration
To quit Vessel
Procedure

Select the Master

Procedure
Select the Master
Operation in
Master Procedure

MASTER-SLAVE RELATIONSHIP
Slave

Master

Master operation processing step that control the duration of

another operation (slave)
When simulation is executed, duration calculation for the slave
operation will be bypassed (note: M&E balances affected), until
the master operation is met
Both master and slave operation may exist in the same procedure
or in another procedure

WORKING
SESSION
Lets try before we proceed further

INITIALISING OPERATION FOR P-2

Cloth Filtration operation
(by default, to filter
product C)
Cake Wash operation (to
wash out left over trapped
A & B in filter cake)
Transfer Out operation (to
deliver product)

ADDING OPERATIONS TO P-2

INITIALISING OPERATIONS FOR P-2

INITIALISING FILTER-1
Operation
FILTER-1

Operating condition
Particulate

component
removal: 95% C (assuming
that A & B are completely
soluble in Heptane & C is
virtually insoluble).
LOD (loss on drying) =
35% (this value cause a
portion of heptane & any
soluble component to be
held in the wet cake 65%
is insoluble C).
Filtrate stream: B +
Heptane

Scheduling
By

default, first
operation of any
batch unit
procedure is
scheduled to start
at the beginning of
the batch
Start time: relative
to the START of
TRANSFER-OUT-1
operation in P-1
procedure

INITIALISING FILTER-1
Scheduling

C = 95%
removal
LOD = 35%
Filtrate

By default
Filtration will only start
when product is
transferred out from P1

INITIALISING CAKE-WASH-1 &

TRANSFER-OUT-1
Operation

Operation condition

CAKEWASH-1

Wash

TRANSFEROUT-1

Transfer

In stream: Wash in
Wash Out stream: Wash out
Wash solvent: heptane (click on Composition, select Autoadjust, the program will estimate a value automatically)
Wash time: 30 minutes
Wash type: slurry (Note: A slurry wash will essentially dilute
the soluble components trapped in the cake and remove most of
them in the wash stream, whereas a displacement wash will
remove the soluble components form the cake in a plug-flow
fashion.)
out using stream C
Duration: calculated based on 10kg/min

WORKING
SESSION
Remember to save your file !

SIMULATING A FLOWSHEET
Execute

the simulation
Viewing the results

Simulating a process:
1. Menu bar: Task/ Solve M&E balances
2. Press Ctrl 3
3. Solve icon in menu bar
4. Press F9

RESULT VIEWING
1.
2.
3.

4.

Calculated output variables for each oeration can be

viewed by revisiting the corresponding Operation
Data dialog windows
To see the calculated equipment sizes, right click on
the unit procedure icon & choose the Equipment
Data option
The contents of a piece of equipment as a function of
time can be viewed by right clicking on a unit
procedure and selecting Equipment Contents or
Operation Sequence
The calculated flowrates and compositions of
intermediate & output streams can be viewed by in
the Simulation Data dialog windows of each stream

RESULT VIEWING
5. A list of reports can be viewed in Reports:
Stream Reports (SR)
Economic Evaluation Report (EER)
Itemized Cost Report (ICR)
Cash Flow Report (CFR)
Throughput Analysis Report (THR)
Environmental Impact Assessment Report (EIR)
Emission Reports (EMS)
Input Data Report (EDR)
Equipment Report (EQR)
Lets visit the one by one

EQUIPMENT OPERATION DATA

Calculated heptane
emission: 0.028%

EQUIPMENT DATA

Calculated vessel
volume: 1628 L

EQUIPMENT CONTENT

STREAM SIMULATION DATA

GENERATING A STREAM REPORT

CHECK YOUR SCHEDULING

RESULTS
Reaction

MW
Initial content, miO (kg)
Initial mol, niO (kg-mol)
X= 95% (based on A)
Current mol, n (kg-mol) nAO-nAOX
Current content, m (kg)

C
-

nBO-nBOX

nAOX

CHECK YOUR SCHEDULING RESULT

Heptane charge =____kg/batch (stream
specification)
Volumetric flowrate=___L/min (in Operation
Data/CHARGE-1)
Task:
Find out the density of the heptane stream from
your simulation sheet
Verify the heptane charging duration calculated
by SPD heptane

DO NOT JUST TAKE

THE COMPUTERS
WORD AS IT IS, PLEASE
CHECK YOUR RESULTS
ACCORDINGLY!!!
REMEMBER THE GIGO PRINCIPLE