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Industrial Solutions and Services from Nor-Par

Industrial Solutions and Services from Nor-Par. The concept, applications and expected benefits By Karoly Moser PhD Chem. E., Vice-president Technology, Nor-Par and Stefan Mikulski M.Sc. Chem. E. , Vice-president Development, Nor-Par. The ultimate goal: Plant at your fingertips in the PC.

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Industrial Solutions and Services from Nor-Par

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  1. Industrial Solutions and Services from Nor-Par The concept, applications and expected benefits By Karoly MoserPhD Chem. E., Vice-president Technology, Nor-Par and Stefan Mikulski M.Sc. Chem. E.,Vice-president Development, Nor-Par

  2. The ultimate goal: Plant at your fingertips in the PC Advanced dynamic plant model that renders “blue-print” of real plant’s performance right in the PC, and which is the core for Production Improvement & Optimisation Tool, Training Simulator and Online Process Simulation as well as integration with Control Systems and APC. The model uses CHEMCAD, CC-THERM and CC-Dynamics as the Engine

  3. The solutions • Reactor modelling … Slides 4 - 7 • Advanced process modelling … Slides 8 - 13 • True “blue-print” of plant’s own performance in steady state or dynamics … relevant to all Slides • Production Improvement & Optimisation Tool • Training Simulator … Slides 17 - 20 • Online Process Simulation … Slides 21 - 23 • Integration with Control Systems and APC … Slides 24 – 25 • Special solutions… Slides 26 – 29 • Integration with mechanical software… Slide 30

  4. Reactor modelling

  5. Reactor modelling • Chemical reactors are the most critical units in the plant, since they create the most of operational, control and safety problems and they cause the greatest impact on the production economics • The key point in reactor simulation is accurate modelling of the reaction kinetics. For multi-phase reactors, mass transfer between phases as well as heat transfer must be taken into account • Reactor modelling requires sound theoretical knowledge about the kinetics, field expertise of a chemical engineer, and deep understanding of modelling concepts in CHEMCAD • Nor-Par has all necessary expertise to offer building advanced reactor models

  6. Reactor models: Steady state • Steady state reactor modelling is the right way to determine appropriate reaction kinetics and mass transfer between phases • Steady state reactor model allows analysing various operating parameters on the reactor’s performance, such as conversion and selectivity thus affecting yield. This gives the engineer tools for intensification of the production with direct economical effects • The reactor model gives perfect insight into how the reactor system really works and behaves • Steady state reactor model allows continuous calculation of the catalyst activity

  7. Reactor models: Dynamics • Dynamic simulation is important for modelling of vessel reactors, and especially for batch and semi-batch processes • Possibility to analyse detailed performance of the reactor system on technical level, taking into account the size of the reactor, construction data and details, interaction with the cooling system and with the control system • Rigorous heat transfer calculation in addition to rigorous kinetics and mass transfer • Possibility to study emergency situations and the ways to handle break-downs or avoiding them

  8. Advanced Process Modelling

  9. Advanced steady state process models (ASSPM) • Contrary to ordinary “flowsheet” that is material and heat balance around a group of process units, an ASSPM is as close representation of a process plant as possible with steady state modelling. For example, pressure profile is calculated rigorously for entire plant • Large ASSPM can be used as “plant overview” models for better understanding of operation and parameter importance for entire producing plants • Parameters of ASSPM are calibrated together with the client using historical data sets or by Online Process Simulation tools using integration with SCADA systems • Nor-Par offers building ASSPM for the client based on their flowsheet and necessary production data sets. (Secrecy Agreement will be signed)

  10. Benefits of Advanced Steady State Process Model • The major benefit of building and having an ASSPM is identification of critical process parameters, which is very helpful in production troubleshooting and economical analysis • ASSPM is the necessary base for advanced dynamic process & control models (ADPCM), since it determines the initial state of the dynamic simulation • ASSPM is also verification tool for ADPCM, since the final solution of the dynamic model must be the same as converged steady state solution for the final state • ASSPM can be used as simulation model for many applications of Online Process Simulation • The ASSPM can also be used by “turn-key” engineering companies based on good know-how of the technology, especially during re-vamping or reconstruction tasks for great accuracy of the re-design work

  11. Advanced Dynamic Process & Control Models (ADPCM) • Since the real world is dynamic, the ADPCM gives the closest representation of the operation of a producing plant available with state-of-art simulation tools. It is very detailed way of modelling, taking into account the size of the equipment • of ADPCM are calibrated together with the client using historical data sets or by Online Process Simulation tools using integration with SCADA systems • Once calibrated, the ADPCM becomes the Blue-Print model of plant's own performance or the “true blue-print” digital model of plant’s own performance – right in your PC • Nor-Par offers building ADPCM for the client based on previously created ASSPM and necessary production data sets. (Secrecy Agreement will be signed)

  12. Benefits of Advanced Dynamic Process & Control Model (1) • The same Blue-Print model of plant's own performance ADPCM is the base for Production Improvement & Optimisation Tool, Training Simulator, and Online Process Simulation • Dynamic transients from ADPCM give far more information to the operating personnel that the steady state model • Possibility to analyse detailed performance of the plant on technical level This detail of information is necessary base for real optimisation of the process to improve the process economics. • Steady state analysis tells you what could be changed to improve the process economics. The dynamic analysis tells you what can really beachieved and how(continued…)

  13. Benefits of Advanced Dynamic Process & Control Model (2) • Possibility to study emergency situations and the ways to handle break-downs or avoiding them • Guidelines to improve the performance of the control loops (valve capacity, controllable area, sensitivity, interaction) • Analysis of transients (trajectories) between two stationary states and calculation of the time needed for it • Analysis of performance of the cooling systems, for example in situation of fouling of heat exchangers

  14. Production Improvement & Optimisation Tool Comprehensive interface for running optimisation and "What-If" studiesthat provides clear reports for the plant management

  15. Production Improvement & Optimisation Tool • Production Improvement & Optimisation Tool (PIT) is new custom software and solution from Nor-Par Online that is provided to the users of the Advanced Dynamic Process & Control Model • Production Improvement & Optimisation Tool can be treated as“human interface” toBlue-Print model of plant's own performance, so the engineer can control or operate the Blue-Print model of plant's own performance via comprehensive user interface • The Blue-Print model of plant's own performance communicates with the user of PIT by “measured” signals and it accepts “control” signals as well as any other desired adjustable model parameters • PIT works in Predictive Process Simulation mode, with means working in acceleration 2-20x compared to real time, so the answers are gathered quickly • PIT is delivered with Runtime version of CHEMCAD/CC-THERM/CC-DYNAMICS as Engine. The Full version of the Chemstations software can be used as Development tool.

  16. Production Improvement & Optimisation Tool: Benefits • "What-if" studies can be run to analyse the effect of multiple process parameters on the plant performance • The user will identify the equipment that needs modifications by studying the plant performance under varying set of process conditions • Studies of interaction and performance of control loops • Studies of performance of critical equipment (reactor or distillation system, for example) • All adjustable parameters (process & control) are visible at a glance in the User Interface and can be modified by the user • All calculated process parameters are visible in the User Interface • Time saving and understandable reports for management

  17. Training Simulator A part of graphics interface of a Training Simulator

  18. Training Simulator (1) • Training Simulator is custom software and solution from Nor-Par Online that is provided to the users of the Advanced Dynamic Process & Control Model • Training Simulator is an Operator Training System based on Blue-Print model of plant's own performance that represent the plant’s own performance at top accuracy and replaces the real plant during the training process • Training Simulator is running the Blue-Print model of plant's own performance in the background, so the trainee does not have access to it • The Blue-Print model of plant's own performance communicates with the trainee solely via emulation Operator Interface that looks identically to the DCS console or SCADA screen normally used by the client in the Control Room • Training Simulator can work in Real Time mode or Predictive Process Simulation mode. The PPS accelerated mode allows effective training for slow technologies, so training in process taking 24 real hours can be effectively done in, e.g., 2.5 hours(continued…)

  19. Training Simulator (2) • The trainee is taught in Operator Interface that works on client-server basis. Several trainees can participate in the training over one Blue-Print model of plant's own performance from their workstations (one copy of Training Simulator can only handle one Blue-Print model of plant's own performance at a time, but there is no limit on number of trainees operating a single Blue-Print model of plant's own performance at given moment) • The tutor works from his/her own Instructor Station, from which he can assign training tasks and assess the performance of trainees • Unplanned and planned events as defined by the client are stored in the Malfunction Database. The client can modify the contents of the Malfunction database as needed • Convenient tools for taking snapshots, re-starting tasks and running the “Blue-Print model of plant's own performance” stepwise have been provided • Training Simulator is delivered with Runtime version of CHEMCAD/CC-THERM/CC-DYNAMICS as Engine. The Full version of the Chemstations software can be used as Development tool.

  20. Training Simulator: Benefits • The Operator Interface looks identical to the plant’s real DCS or SCADA console screen • Operator’s understanding of the process enhanced • Operators can study the effect of control settings • Operators can study parameter interaction • Downtime due to operator’s error reduced • Learning start-up and shutdown procedures • Consequences of operator’s action to environment can be demonstrated • Operational plant safety improved • Learning without consequences of risk/damage

  21. Online Process Simulation

  22. Online Process Simulation • Custom software (PLANT2CC/PLANT2CCD) and solutions are only delivered by Nor-Par to users of Production Improvement & Optimisation Tool or Training Simulator • The Online Process Simulation runs either calibrated ASSPM or ADPCM as a in parallel with the operation of the real plant • Online Process Simulation uses the measurements from the plant’s DCS or SCADA or Historian system for input to the model. The model returns calculated the missing parameters back to SCADA or Historian System, or gives suggestions to the operator of the DCS console • Online Process Simulation is implemented by Nor-Par together with PIDAB AB

  23. Online Process Simulation: Benefits • Surveillance (monitoring) of performance of critical and expensive process equipment (e.g., reactors, pyrolysis furnaces, large compressors, distillation towers) and better/more accurate control • Online steady state or dynamic process optimization: better control of purity and higher yield; better control of emissions and waste from the plant (reduced environmental penalties) • Estimation of unmeasured process conditions • Fault diagnosis and data reconciliation • Capital cost savings (reduced installed instrumentation by use of software sensors) • Production cost savings: smarter operation, economic calculations based on the model, significant reducing the amount of expensive laboratory tests, integration with SAP

  24. Integration with Control Systems and APC Examples from Nor-Par work on Control System and APC integration

  25. Integration with Control Systems and APC • The only way to create the Blue-Print model of true plant performance leads through integrating the operation of the process and control subsystems • Nor-Par has all necessary experience and skill to integrate process and control models and has done such integrations • To truly model the unique Control System of the client, Nor-Par writes specialty code based on the unique equations from the client • Nor-Par does the same to model Advanced Process Control (APC) based on unique equations received from the client

  26. Special Solutions for Ecology • Nor-Par delivers special solutions that address the technologies of 21st century and focus on pro-ecological trends of the modern era • Nor-Par has already developed over 100 of special solutions, such as models for Fuel Cell, most modern technologies to reduce the emmission of CO2, VOC emmision reduction, conversion of Natural Gas into liquid fuels, alternative sources of energy, cheap bioethanol production and many more • Some of the models developed by Nor-Par are based on the capabilities of CHEMCAD. Other models are developed as subprograms owned by Nor-Par Online and work as if they were a part of CHEMCAD

  27. Example: Bioethanol Permeation • Nowadays, goverments and international organizations promote bioethanol as renewable energy source • The obstacle to produce commercial bioethanol has been the high energy consumption to obtain the dry product via distillation route • Fuel-grade bioethanol can be produced cheaply by permeation using membranes • Nor-Par has built advanced membrane permeation model. We can serve you with our knowledge, too

  28. Bioethanol Membrane Permeation The process as modelled by Nor-Par uses 11 times less energy than the traditional technology

  29. Bioethanol Membrane Permeation Subprogram made and owned by Nor-Par Online A/S

  30. Integration with mechanical software • Nor-Par offers mechanical software from Micro Techno MT-MECH that consists of these modules: • MT-EXCH: mechanical design software for heat exchangers • MT-LAYOUT: mechanical design software for tubesheet • MT-VESS: mechanical design software for vessels • MT-COMP: design software for mechanical components of chemical equipment • MT-MECH is integrated with Chemstations’ CC-THERM, which is a module for thermal calculations of heat exchangers

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