Model Solids Processes Easily with Aspen Plus

Ajay Lakshmanan Senior Manager, Product Development

Solids Process Modeling Webinar January 23, 2013

Hosted by: Julie Levine and Ron Beck, Product Marketing, AspenTech

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Ongoing Series of Technical Webinars

Engineering webinars for education and best practices UPCOMING WEBINARS OF INTEREST:
Mejorar la Estimacin de Costos usando Aspen Economic Evaluation Jueves 31st
The New Aspen HYSYS Applied to Hydraulics and Flow Assurance (Technical) February 5th

aspenONE Engineering V8 Release Webinar for Enterprises of All Sizes (Technical) February 6th
Optimize Carbon Capture with Rate-Based Distillation Modeling (Technical) February 20th

APAC Webinar: Optimize Utility Costs with Aspen Utilities Planner (Technical) March 7th
ALSO UPCOMING: OPTIMIZE 2013 Global Conference May 6th-8th
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aspenONE Engineering

Best-in-class engineering solutions in an integrated workflow

Common Models & Data
Support Manufacturing & Supply Chain

Aspen Simulation Workbook & Aspen Online Deployment

Aspen Petroleum Downstream & HYSYS Upstream

Conceptual Engineering

Aspen Plus Dynamics, ACM & Flare System & Energy Analyzer

Aspen Plus Aspen Plus Aspen HYSYS

Aspen Process Economic Analyzer (APEA)

Basic Engineering

Aspen Equipment Design & Rating

Aspen Basic Engineering

Aspen Capital Cost Estimator (ACCE)

Detailed Engineering

Detailed Engineering

aspenONE Integration
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Agenda
Introduction Demonstration Applications Customer Comments Questions & Discussion

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Why is Solids Modeling Important?

Specialty & Agricultural Chemical Process
Fertilizers, ChlorAlkali, pTA, Silicones
Fluid Raw Material

Reactions
(liquid/gas)

Separation
(liquid/gas)

Crystallization
(liquid/solid)

(solids/gas)

Drying

Solid Product

Fluids

Solids + Fluids

Extractive Industry Process

Mineral Raw Material

Coal, Oil Sands, Cement, Phosphates, Alumina

Grinding
(solids)

Classifying
(fluid/solid)

Reactions
(fluid/solid)

Separation
(solids/liquid /gas)

Fluid Products

Solids + Fluids

Solids + Fluids

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Modeling Processes with Solids Traditional Approach

Aspen Plus Urea Synthesis Model

SolidSim Urea Granulation Model

Two Models Manual Data Transfer Inconsistent Properties

Local Optimization
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Challenge: Optimize the Entire Process

Fluid Process Model

Solids Process Model

Optimize Entire Process

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February 29, 2012: AspenTech Announced Acquisition of SolidSim Inc.

What is SolidSim? Simulator designed for optimization of solids processes
Extensive solids model library Excellent solids process and model documentation MS Windows graphical user interface

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AspenTech and SolidSim Bringing Our Strengths Together

Physical Properties

Solids Process Modeling

Reactions & Electrolytes

Fluid Unit Operations Integrated Workflows

Solids Characterization
Solids Unit Operations Deep Expertise

Worldwide Support
University Program

Relationship with universities researching solids technology

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Aspen Plus V8.0

Sample Templates

Optimizing Processes with Solids Made Easy

Online Training Visualize PSD

Optimize Entire Process

10 Unit Operations
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Agenda
Introduction Demonstration Applications Customer Comments Questions & Discussion

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Demonstration

Profit Opportunity Major Chemicals Manufacturer

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Demonstration
Opportunity
Increase profit Unexpected demand for potassium chloride from a key client

Challenge
Can we expand production capacity?
Plant already at max capacity CAPEX projects will take time and money

Keep key customer happy

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Demonstration

Demonstration

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Demonstration Review Met unexpected demand from client Capacity expanded without additional CAPEX Key customer is happy And, lower energy costs

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Solids Characterization is Easy and Flexible Solid Components

Solid compounds are treated as unique species

Dissolved KCl

Solid (crystalline) KCl

Solid/Liquid equilibrium defined through CHEMISTRY reactions: KCL <===>KCL-S

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Solids Characterization is Easy and Flexible Solids Sub-streams

New Solids Form

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Solids Characterization is Easy and Flexible Solids Characterization Form

Select stream class. Support for multiple conventional and non conventional solids Sub stream types: MIXED contains the fluids CISOLID tracks a solid phase NCSOLID non-conventionals

Select Moisture Components

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Solids Characterization is Easy and Flexible Solids Characterization Form

New: You can define and use multiple PSD meshes within a model Example use: A different mesh for each feed stream based on lab analysis and a separate mesh for the simulation results.

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Solids Characterization is Easy and Flexible

Built-in plots
Tab for solid phase

Automatic Mesh Generation Distinct Feed Mesh

Populate PSD from distribution functions

PSD Analysis
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Solids PSD Analysis to Interpret Results

Definition of Dx Properties
D50

D10

D90

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Solids PSD Analysis to Interpret Results

PSD Characterization
Steepness index (quartile ratio) larger number implies narrow PSD
3 Sauter Mean 1 3,2 = 2 Diameter 1 (SMD) Volume specific surface area (surface area/unit volume)

Volume Mean Diameter

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4,3 =
22

4 1 3 1

New & Improved Solids Handling Operations in Aspen Plus V8.0

Crystallizer
SolidSim

Crusher

Screen

Dryer

Granulator

Aspen Plus

Aspen Plus

Design Philosophy: one unit operation model can represent many different types of equipment at various levels of fidelity from conceptualdetailed

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New & Improved Solids Handling Operations in Aspen Plus V8.0

Cyclone
SolidSim

Scrubber

Centrifuge

ESP

Classifier

Aspen Plus

Aspen Plus

The updated models use state-of-the-art correlations and methods to ensure accurate sizing and design.

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Agenda
Introduction Demonstration Applications Customer Comments Questions & Discussion

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Example Applications

Model and optimize entire production processes and process areas

Processes

Process Areas

Urea

Convective Drying
Belt Fluidized Bed

Granulation Agglomeration
Fluidized Bed Spray High Shear

Potassium Chloride

Crushing Milling
Ball (Wet) Impact (Dry) Jaw, Cone (Dry)

Classification Separation

|

Cyclone Scrubber, ESP Centrifuge Screen

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Process Area Example Convective Drying

Problem: High Energy Consumption

Benefit: Optimizing design and operation reduces energy use by 25-30% Get Started: Belt Dryer example model available

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Process Area Example Granulation & Agglomeration

Problem: Product quality and process stability variability Benefit: Improve coating and product purity Increase throughput Get Started: Fluidized bed spray granulation example model available

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Process Area Example Crushing & Milling

Problem: Incorrect equipment design and operation increases recycles, energy consumption & reduces throughput Benefit: - Reduced size/capital cost - Recycle stream sizing, increase throughput, - Reduce energy consumption

Get Started: Example models that highlight high fidelity models that enable modeling of numerous equipment types
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Process Area Example Classification & Separation

Problem: Incorrect product specifications, solvent recovery and gas cleaning Benefit: Reduce equipment size / cost Reduce emissions and improve product quality & yield Get Started: Example models highlight a multiphase classification process

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Learn More
Aspen Plus solids web page
http://www.aspentech.com/products/solids-aspen-plus.aspx

Aspen Plus Solids Modeling Computer Based Training Jump start Guides for
Particle Scientists Experienced Aspen Plus Users Model Convective Dryers

On-Demand Short Presentations:

Intro to Solids Modeling Overview of Aspen Plus Dryer Overview of Aspen Plus Granulator Overview of Aspen Plus Crusher Overview of Aspen Plus Classifier Creating a Granulator Model Creating a Crusher Sieve Model Creating a Classifier Model
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Agenda
Introduction Demonstration Applications Customer Comments Questions & Discussion

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Aspen Plus V8 Solids Modeling

It is quite impressive how much progress has been made in such a short time. The new Aspen Plus looks good and works well. We look forward to using the new Aspen Plus to model our processes with solids
-Halvor Oien Department Head, Process Modeling and Control, Yara Technology

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Aspen Plus V8 Solids Modeling

We have been using Aspen Plus and SolidSim to model the fluids and solids sections of our processes. The integration of SolidSim into Aspen Plus enables us to design and optimize the entire process with one simulator and consistent physical properties.
-Ingrid Lunt-Rieg Head of Process Simulation & CFD

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Agenda
Introduction Demonstration Applications Customer Comments Questions & Discussion

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OPTIMIZE 2013 Global Conference

Join us in Boston for the industrys must-attend event!

OPTIMIZE 2013

6 8 May 2013 The Westin Waterfront Hotel Boston, MA USA EARLY BIRD RATE EXPIRES Jan 31 PAPER ABSTRACT DEADLINE Jan 31

For more information, visit www.aspentech.com/agc

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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 esales@aspentech.com Presentations, videos, and getting started resources available at: www.aspentech.com/products/solids-aspen-plus.aspx Videos also available at: www.youtube.com/user/aspentechnologyinc

Contact info for todays presenter and hosts

Ajay Lakshmanan ajay.lakshmanan@aspentech.com Ron Beck ron.beck@aspentech.com Julie Levine julie.levine@aspentech.com

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