focused on process simulation Page 1 of 13 CHEMCAD helps to reduce product changeover times Introduction Being able to produce different products with just one production facility has been an attractive option for plant operators not just since the focus on raw material change and the transition to alternative energies has increased. Flexible production is an important part of their implementation. While the system lifecycles of 20 to 40 years have not changed, the product lifecycles are shortening. At the same time, the type, quality, price and availability of the resources required for production in the globalized world are changing with increasing speed. It is therefore of economic advantage if production can react flexibly to such changes, if necessary even with modified or new products. Rigorous computer-assisted simulation of the production processes helps to analyze and evaluate different raw material product scenarios within a short time. In doing so, thermodynamic and technical limitations are consistently taken into account. Without the simulation, numerous costly and time-consuming tests on the production facilities would be required to verify the new scenarios. During these tests, the facilities can normally not be used for production. If the different, ideally optimized, individual operating parameters of a production facility are known for the individual scenarios, losses of production only still occur when changing over from one product raw material combination to another. This article deals with minimizing the losses of production caused by the product changeover time with the help of the CHEMCAD process simulator. Using a precise example from the oleochemical industry, we will show how optimum stationary operating points are determined, missing system parameters estimated and trajectories of the dependent state variables, such as the product concentration, calculated, analyzed and optimized with CHEMCAD. Case example oleochemistry As a processor of natural products and recycled materials, the oleochemical industry traditionally encounters fluctuating compositions of the source materials for its processes. To create largely stable feed conditions for downstream processes, a distillation system can be connected upstream in which the heavy fluctuations in the composition of the oil from renewable feedstock can be reduced to a defined measure. Such a distillation system is the object of this case study. Table 1 shows the composition of different oils from renewable feedstock. We can see that even the pure oils from renewable feedstock offer a broad spectrum of chemical compositions. When using oil mixtures and when using recycled oils, additional combination possibilities arise.
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CHEMCAD helps to reduce product changeover times · focused on process simulation Page 1 of 13 CHEMCAD helps to reduce product changeover times Introduction Being able to produce
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focused on process simulation Page 1 of 13
CHEMCAD helps to reduce product changeover times
Introduction
Being able to produce different products with just one production facility has been an attractive
option for plant operators not just since the focus on raw material change and the transition to
alternative energies has increased. Flexible production is an important part of their
implementation. While the system lifecycles of 20 to 40 years have not changed, the product
lifecycles are shortening. At the same time, the type, quality, price and availability of the resources
required for production in the globalized world are changing with increasing speed. It is therefore
of economic advantage if production can react flexibly to such changes, if necessary even with
modified or new products.
Rigorous computer-assisted simulation of the production processes helps to analyze and evaluate
different raw material product scenarios within a short time. In doing so, thermodynamic and
technical limitations are consistently taken into account. Without the simulation, numerous costly
and time-consuming tests on the production facilities would be required to verify the new
scenarios. During these tests, the facilities can normally not be used for production.
If the different, ideally optimized, individual operating parameters of a production facility are
known for the individual scenarios, losses of production only still occur when changing over from
one product raw material combination to another. This article deals with minimizing the losses of
production caused by the product changeover time with the help of the CHEMCAD process
simulator.
Using a precise example from the oleochemical industry, we will show how optimum stationary
operating points are determined, missing system parameters estimated and trajectories of the
dependent state variables, such as the product concentration, calculated, analyzed and optimized
with CHEMCAD.
Case example oleochemistry
As a processor of natural products and recycled materials, the oleochemical industry traditionally
encounters fluctuating compositions of the source materials for its processes. To create largely
stable feed conditions for downstream processes, a distillation system can be connected upstream
in which the heavy fluctuations in the composition of the oil from renewable feedstock can be
reduced to a defined measure.
Such a distillation system is the object of this case study. Table 1 shows the composition of different
oils from renewable feedstock. We can see that even the pure oils from renewable feedstock offer
a broad spectrum of chemical compositions. When using oil mixtures and when using recycled oils,
additional combination possibilities arise.
focused on process simulation Page 2 of 13
Table 1: Composition of different oils from renewable raw materials
Infraserv GmbH & Co. Knapsack KG in cooperation with Chemstations offers the corresponding
services for the described implementation. For example, the product changeover times for 12 raw
material product scenarios were minimized for a customer in the oleochemical industry, and the
raw material and energy input reduced thanks to the additionally gained production time.
Conclusion
CHEMCAD provides all tools for stationary and for dynamic simulation and optimization of
processes in one package. Scenarios can be calculated quickly and easily, and improvement
suggestions developed through complete integration of the tools for process optimization (Process
Optimizer), for apparatus dimensioning (Sizing Tool), and for dynamic simulation (CC-DYNAMICS).
System owners and operators can obtain support and advice in all phases from Infraserv GmbH &
Co. Knapsack KG, which has already helped numerous customers to significantly reduce the
operating costs in production.
Are you interested in further publications, tutorials, seminars or other solutions with CHEMCAD? Then please contact us: Mail: [email protected] Phone: +49 (0)30 20 200 600 www.chemstations.eu Authors: