Aspen Plus Innovations (fluid/solid) Classifying ... – Based on drying kinetics ... –Aspen Plus can be used to model fluidized bed dryers
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© 2013 Aspen Technology, Inc. All rights reserved |
1 © 2013 Aspen Technology, Inc. All rights reserved
Modeling Solids Dryers and Granulators with Aspen Plus V8
Ajay Lakshmanan and Claus Reimers
Product Management, AspenTech
Solids Process Modeling Webinar
April 16, 2013 Hosted by:
Julie Levine and Ron Beck,
Product Marketing, AspenTech
© 2013 Aspen Technology, Inc. All rights reserved |
2
Ongoing Series of Technical Webinars Engineering webinars for education and best practices
RECENT WEBINARS:
Model Solids Processes Easily with Aspen Plus (Technical)
Case Study: Maximizing Energy Efficiency with Maturus Optimi
UPCOMING WEBINARS OF INTEREST:
Compressor Modeling using Aspen HYSYS Dynamics (Technical) – April 23rd
Utilizing Property Data with Aspen Properties in Aspen Plus (Technical) – May 15th
ALSO UPCOMING:
OPTIMIZE 2013 Global Conference – May 6th-8th
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Common Models & Data
aspenONE Integration
Support Manufacturing & Supply Chain
Conceptual Engineering
Basic Engineering
Detailed Engineering
aspenONE Engineering Best-in-class engineering solutions in an integrated workflow
Aspen Simulation Workbook & Aspen Online Deployment
Aspen Petroleum Downstream & HYSYS Upstream
Aspen Equipment Design & Rating
Aspen Basic Engineering Aspen Capital
Cost Estimator (ACCE)
Aspen Plus Dynamics, ACM & Flare System & Energy Analyzer
Aspen Plus
Aspen HYSYS
Aspen Process Economic Analyzer (APEA)
Detailed Engineering
Aspen Plus
Aspen HYSYS
© 2013 Aspen Technology, Inc. All rights reserved |
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Why is Solids Modeling Important?
Mineral Raw Material
Fluid Products
Extractive Industry Process Coal, Oil Sands, Cement, Phosphates, Alumina
Solids + Fluids Solids + Fluids
Grinding (solids)
Separation (solids/liquid
/gas)
Reactions (fluid/solid)
Classifying (fluid/solid)
Specialty & Agricultural Chemical Process Fertilizers, ChlorAlkali, pTA, Silicones
Solids + Fluids Fluids
Reactions (liquid/gas)
Drying (solids/gas)
Crystallization (liquid/solid)
Fluid Raw Material
Solid Product
Separation (liquid/gas)
© 2013 Aspen Technology, Inc. All rights reserved |
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Modeling Processes with Solids Traditional Approach
Manual Data Transfer
Inconsistent Properties
Aspen Plus Urea Synthesis Model
SolidSim Urea Granulation Model
Local Optimization
Two Models
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AspenTech and SolidSim Bringing Our Strengths Together
Physical Properties
Reactions & Electrolytes
Fluid Unit Operations
Integrated Workflows
Worldwide Support
University Program
Solids Process Modeling
Solids Characterization
Solids Unit Operations
Deep Expertise
Relationship with universities researching solids technology
© 2013 Aspen Technology, Inc. All rights reserved |
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Aspen Plus V8.0 Optimizing Processes with Solids – Made Easy
Sample Templates
Online Training
Visualize PSD
10 Unit Operations
Optimize Entire Process
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Why is Convective Drying Important?
Problem: High Energy Consumption
Benefit: Optimizing design and operation reduces energy use by 25-30%
© 2013 Aspen Technology, Inc. All rights reserved |
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Drying periods
Initial period
Heat the wet solids
Constant rate period 1st Drying period
– Dry moisture on surface
– Moisture content above critical moisture content
Falling rate period 2nd Drying period
– Dry moisture inside particles
– Moisture content below critical moisture content and above equilibrium moisture content
– Ends at equilibrium moisture content
Convective Drying – Drying Curves 11
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Convective Drying – Model Description
Flow patterns
– Co-current
– Counter-current
– Cross-current
Solids in plug flow in axial, ideally mixed in lateral direction, gas in plug flow
Solids ideally mixed, gas in plug flow
Drying model
– Based on drying kinetics
– Normalized drying curve describes falling rate drying
– Mass transfer coefficient between particles and gas:
Sherwood number
Mass transfer coefficient
Product of mass transfer coefficient and surface area
Number of Transfer Units
– Heat Transfer Coefficient user defined or calculated
© 2013 Aspen Technology, Inc. All rights reserved |
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Normalized drying curve describes the falling rate period
Normalized drying rate Normalized moisture content
eqcr
eq
XX
XX
Normalized Drying Curve
period drying 1 rate drying
rate dryingcurrent )(
stv
X: Current moisture content Xcr: Critical moisture content Xeq: Equilibrium moisture content
Normalization
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How is the Normalized Drying Curve Determined from Measured Data?
The normalized drying curve is typically derived from experiment data
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How is the Normalized Drying Curve Determined from Measured Data?
Step 1: Determine critical moisture content, equilibrium moisture content
– Current case Critical moisture content: Xcrit = 0.1 kg/kg
Equilibrium moisture content: Xequi = 0.005 kg/kg
© 2013 Aspen Technology, Inc. All rights reserved |
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How is the Normalized Drying Curve Determined from Measured Data?
Step 2: Calculate the drying rate and determine the drying rate at the 1st drying period
– Current case Constant drying rate: MI = 1.65 g/(kg*s)
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How is the Normalized Drying Curve Determined from Measured Data?
Step 3: Calculate normalized drying rate and normalized moisture content
Critical moisture content: Xcrit = 0.1 kg/kg
Equilibrium moisture content: Xequi = 0.005 kg/kg
period drying 1 rate drying
rate dryingcurrent )(
stv
eqcr
eq
XX
XX
© 2013 Aspen Technology, Inc. All rights reserved |
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Convective Dryer Forms 18
Drying Curve Tab
Normalized moisture content
Normalized drying rate
Define critical and equilibrium moisture content
Define normalized drying curve via tabular data or use of a function
© 2013 Aspen Technology, Inc. All rights reserved |
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Convective Drying – Fluidized Bed Dryer
The following example will demonstrate how a multi-chamber fluidized bed dryer could be modeled with Aspen Plus
Live Demo
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Convective Drying – Fluidized Bed Dryer – Summary
– Aspen Plus can be used to model fluidized bed dryers with multiple drying chambers
– Beside the drying of the material also entrainment and gas-solid separation can be considered in an Aspen Plus model
– Model shows the behavior of the overall drying process
Temperatures
Moistures
Flow rates
Particle size distributions
– Model gives information's about the internal streams in the dryer that normally could not be measured
© 2013 Aspen Technology, Inc. All rights reserved |
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Convective Drying – Belt Dryer
The following example will demonstrate how a Belt Dryer could be modeled and optimized with Aspen Plus
– Modeling of a complex apparatus
Several drying zones with profiles of air recirculation and temperature along the dryer
Cooling zone with heat recovery
Humid exhaust air
zone 1 zone 2
ambient air
cooling zonezonezone zone
preheated make-up air
© 2013 Aspen Technology, Inc. All rights reserved |
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Convective Drying – Belt Dryer
Drying of Solids – Solids are dried from ~261 g/kgdry to less than 11 g/kgdry by use of a 4
chamber belt dryer with internal air recirculation
In the current setup the dryer has an energy consumption of 561 KW-Hr/ton product
approx. 93% of that heating energy is provided by the primary heater
Objective: – Reduce the energy demand of the dryer by at least 10%
Constraints: – Throughput should be unchanged (~ 2 t/h)
– Solids Temperature profile along the dryer should be mostly unchanged
– Product moisture should be less than 11 g/kgdry
© 2013 Aspen Technology, Inc. All rights reserved |
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Belt Dryer Demonstration
Live Demo
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Convective Drying – Belt Dryer – Summary
– Aspen Plus can be used to model Belt Dryers with multiple drying and cooling chambers
– Temperature and moisture profiles along the dryer can be calculated
– Model can be used to optimize the energy demand of an industrial Belt Dryer by
Investigate the impact of cooling stages
Determining optimal flow rates and temperature
© 2013 Aspen Technology, Inc. All rights reserved |
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Why is Granulation Important?
Problem: Product quality and process stability variability
Benefit:
– Improve coating and product purity
– Increase throughput
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Granulation
Growth of particles due to deposition of solid material on primary particles (seeds)
– Granulation: Seed and deposited solids are the same material
– Coating: Seed and deposited solids are different materials
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Agglomeration
Agglomeration: Aggregation of two or more primary particles
– Agglomeration by use of a binder
Binder could be water, a suspension, solution or melt
Particles are ‘glued together’
– Agglomeration by use of mechanical forces
No binder is added
Particles are ‘pressed together’
© 2013 Aspen Technology, Inc. All rights reserved |
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Modeling Agglomeration and Granulation
The Aspen Plus Granulator can be used for: – Granulation and Coating
– Agglomeration using binder
using mechanical forces
Drum Fluidized Bed Plate
Drum Fluidized bed Plate
Compacting Press Roller Agglomerator
© 2013 Aspen Technology, Inc. All rights reserved |
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Granulation – Model
Particle Growth – Population balance
– Mixed Ideal mixing in radial and axial direction
Growth rate proportional to
– Surface, Volume or Diameter
– Plug flow Ideal mixing in radial direction
No mixing in axial direction
Drying of particles Define solids moisture content at the outlet
Entrainment in Fluidized Beds Upstream gas velocity
Terminal velocity of the particles
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Agglomeration – Model
Particle Growth
– Population balance
– Growth rate described by kernels
– Time-dependent part b0(t)
– Parameterize using experimental data
– Flux number approach used for fluidized bed
– Size-dependent part b(u,v)
– Several models implemented
– Ideal mixing for radial and axial direction
– Pure binary agglomeration is assumed
Drying of particles Define solids moisture content at outlet
Entrainment in Fluidized Beds Upstream gas velocity
Terminal velocity of the particles
© 2013 Aspen Technology, Inc. All rights reserved |
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Agglomeration Example
The following example will demonstrate how a fluidized bed agglomerator could be modeled with Aspen Plus
– Flux number approach is used to obtain the time part of the agglomeration kernel
Live Demo
© 2013 Aspen Technology, Inc. All rights reserved |
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Agglomeration Summary
Aspen Plus can be used to model fluidized bed agglomerators
The use of the Flux number approach allows calculating the time-dependent part of the agglomeration kernel based on operating conditions
– Binder flow rate and superficial gas velocity have a direct influence on the product particle size distribution
© 2013 Aspen Technology, Inc. All rights reserved |
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Granulation Example
The following example will demonstrate how a industrial granulation process can be simulated and optimized with Aspen Plus
– Simulation of a granulation process with external classification/grinding circuit and product cooling
– Optimization study to increase throughput
Live Demo
© 2013 Aspen Technology, Inc. All rights reserved |
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Granulation Summary
Aspen Plus can be used to model industrial granulation processes with external classification and grinding circuit
Multi-chamber granulators can be described by use of a hierarchy block
– Information about internal streams can be obtained
Model can be used to optimize the process with regard to
– Throughput
– Product quality
– …
© 2013 Aspen Technology, Inc. All rights reserved |
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Agenda
Introduction
Convective Drying
Demonstration 1
Belt and Fluidized Bed Drying
Granulation
Demonstration 2
Granulation and Agglomeration
Questions & Discussion
© 2013 Aspen Technology, Inc. All rights reserved |
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Registration Discount for Webinar Attendees!
$1,700 – a savings of 15% off the standard conference fee! For more information, visit www.optimize2013.com and use the promotional code APWEB2013 to receive the discount. Offer Expires April 22!
OPTIMIZE 2013 6 – 8 May 2013 The Westin Waterfront Hotel Boston, MA USA
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Optimize 2013 Global Conference
Hitachi Zosen Ethanol distillation membrane separation model with Aspen Custom Modeler and Aspen Plus
Evonik Industries Dynamic simulation for safety analysis of columns
Renmatix
Scale-up of biochemical cellulosic conversion processes
May 6-8, 2013
See these and over 50 additional presentations and training sessions
Cansolv (Shell) Modeling of CO2 Capture with unique amine solvents
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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 today’s presenter and hosts – Ajay Lakshmanan ajay.lakshmanan@aspentech.com
– Claus Reimers claus.reimers@aspentech.com
– Ron Beck ron.beck@aspentech.com
– Julie Levine julie.levine@aspentech.com
© 2013 Aspen Technology, Inc. All rights reserved |
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Questions
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