Transcript Overview - VisiMix – Mixing Simulation for Chemical

VisiMix
Simulation of Mixing Processes
VisiMix Ltd,
PO Box 45170,
Jerusalem, 91450,
Israel
Tel: 972 - 2 - 5870123
Fax: 972 - 2 - 5870206
E-mail: [email protected]
VisiMix
Simulation of Mixing Processes
Presentation Contents:
- The Customers
- The Technology
- ROI
- VisiMix Products
- Saving Examples
About Us
VisiMix is a unique software enabling
chemical engineers, process engineers and
R&D personnel to visualize mixing processes
via a simple, user friendly interface.
Our products allow significant savings in time
and costs by drastically reducing the need for
trial-and-error. They have been successfully
adopted by hundreds of companies.
Customers and Markets
Our Customers
What Our Customers Say About Us
From the Dow Chemicals Intranet Website
“VisiMix: This is a highly accessible PC software for mixing
calculations available from VisiMix Ltd., an Israeli
company. It is a rating calculation tool for both nonreactive and reactive mixing involving blending, solid
suspension, gas dispersion, liquid-liquid dispersion, or
heat transfer processes in stirred vessels. It calculates the
important process parameters for single- and two-phase
systems – power consumption, circulation rates, local
concentrations of solutes and suspended particles, drop
size, concentrations of reactants, etc … ”
Dr. Victor Atiemo-Obeng
Dow Chemicals Co.
What Our Customers Say About Us
“We have been using VisiMix. We have found it an accurate tool ...
Based on our success with the product, our Japanese colleagues at
Fuji Xerox have bought a copy for their work.”
Emily Moore,
Xerox Research Center of Canada
“I am very pleased in applying your software.”
L'Oreal, France
Customers and Markets
Customer List
1. L'Oreal, France
2. BASF AG, Germany
3. Dow Chemical Company, USA
4. Searle (MONSANTO), USA
5. Lightnin, USA
6. LG Chemicals, S. Korea
7. Xerox , Canada & USA
8. The Gillette Co., USA & UK
9. De Dietrich, France & USA
10. ENIChem, Italy
11. Eli Lilly & Company, USA
12. NIPPON, Japan
13. Novartis, USA
14. Millennium, USA
15. ICI, UK
16. Hercules, USA
17. Pfizer, USA&UK&Gr.
18. Mitsubishi Chemicals
19. Abbott Laboratories, USA
20. GlaxoWellcome,UK&Singapore
1. L'Oreal, France
2. Techmix S.r.o, Czesh Republic
3. BASF AG, Germany
4. BASF, Denmark
5. BP Chemicals - Wingles, France
6. Sanofi Recherche, France
7. Technimont, Italy
8. Nycomed Imaging, Norway
9. Hoesch & Sohne, Germany
10. DSM, The Netherlands
11. Searle (MONSANTO), USA
12. Lightnin, USA
13. Chevron, USA
14. Teva, Israel
15. Plantex, Israel
16. Bromine Compounds, Israel
17. ENSIC, France
18. LG Chemicals, Taejon-city, S. Korea
19. LG Tech, Yeochon-city, S. Korea
20. Lonza, Switzerland
21. Thai Plastic and Chemical Public Company, Thailand
22. Xerox Research Centre of Canada, Canada
23. Xerox, USA
24. The Gillette Co., USA
25. Gillette, UK
26. Lecaros, Chile
27. SK Chemicals, S. Korea
28. Dow Chemical Company, USA
29. Monsanto, USA
30. Buchi AG, Switzerland
31. Agisys, Hungary
32. Samsung, S. Korea
33. Mervers, Holland
34. American Cyanamid Company, USA
35. Belinka Belles, d.o.o., Slovenia
36. LG Chem. , ABS Division (S. Korea)
37. BFGoodrich Advanced Technology Group, US
38. PT MECO INOXPRIMA, Indonesia
39. Ion Exchange, India
40. IL JIN Eng. & Const. Ltd., Korea
41. CSIR Ltd., South Africa
42. PTI, Brazil
43. De Dietrich, France
44. De Dietrich, USA
45. Rhodia (Rhone Poulenc Group), Brazil
46. Inymassa, Spain
47. ENIChem, Italy
48. Satake, Japan
49. Chesebrough-Pond’s, USA
50. Unilever, Italy
51. Schering-Plough, USA
52. Ontec, Israel
53. Cytec, USA
54. Degussa, Germany
55. IHN Groningen BV, the Netherlands
56. PEAS BV, the Netherlands
57. Eli Lilly & Company, USA
58. BSL (Dow group), Germany
59. VMD PTE Ltd., Singapore
60. Tecnicas Reunidas, Spain
61. NIPPON, Japan
62. Chr. Hansen, Denmark
63. Danisco, Denmark
64. Novartis, USA
65. SNECMA, France
66. Millennium, USA
67. Ucosan B.V., Holland
68. Norde Veenendaal B.V., Holland
69. Akzo Nobel, Germany
70. Astra Charnwood, UK
71. ICI, UK
72. Stork, Netherlands
73. Hercules, USA
74. Luigi Menestrina, Italy
75. Siersma Leidshendam, the Netherlands
76. Sara Lee, the Netherlands
77. Pfizer, USA
78. Pfizer, UK
79. Pfizer, Germany
80. Beiersdorf AG, Germany
81. Sintef Applied Chemistry, Norway
82. Chemitec OY, Finland
83. Makhteshim, Israel
84. Chemagis, Israel
85. Nitto Denco, Japan
86. 3M, USA
87. Broom Chemie, the Netherlands
88. Atlas-Stord, Denmark
89. Canon, Japan
90. Mitsubishi Chemicals
91. Imation, USA
92. NIKKI, Japan
93. Fuji Xerox, Japan
94. Oxy Vynils
95. Scanlube, Sweden
96. GlaxoWellcome, Singapore
97. GlaxoSmithKline, UK
98. SmithKline Beecham, USA
99. M&F Process Simulation, The Netherlands
100. Abbott Laboratories, USA
101. Air Products, USA
102. Gruppo Lepetit, Italy
103. Johnson Polymer, Holland
104. Dow Corning, USA
105. Pharmacia Biotech, Sweden
106. Panandiker Research & Development (P) Ltd., India
107. Fujifilm, Japan
108. Katholieke Hogeschool Brugge-Oostende, Belgium
109. The Casali Institute, Israel
110. Noordelijke Hogeschool Leeuwarden, the Netherlands
111. Stettin University
112. Taiwan University
113. Ecole d'Electrochemie, France
114. Ecole Polytechnique, Canada
115. University of Western Ontario, Canada
116. University of Barcelona, Spain
117. Taejon National University, S. Korea
118. Otto von Guericke Universitat, Germany
119. Tsinghua University, China
120. VUOS, Czesh Republic
121. Universita di Roma, Italy
122. Hanyang University, S. Korea
123. Royal Institute of Technology, Sweden
Total : 123 customers
De Dietrich - Example
http://www.ddpsinc.com/MixingSimulations.htm
De Dietrich - Example
http://www.ddpsinc.com/Visimix.htm
Simple and Effective
Technology - Simulation of Mixing Processes
The First and the only tool in the Industry
Reliable and accurate results
Based on More Than 300 Man Years of R&D and
Industry Experience
Replacing Pilot Experiments
Accelerated Time-to-Market process
User Friendly and easily accessible
Simple and Effective
Return On Investment (ROI)
Per Year basis
Benefits (The ICI Example)
Product Cost
$15,000
Savings
Per project - $20,000
Per year
- $150,000
(5-10 projects per year)
Quality
Time
Time To Market
VisiMix Products
Introduction
VisiMix software:
•
Based on advanced scientific knowledge and practical
expertise
•
User-friendly and easy to operate
•
Requires easily accessible initial data
The latest VisiMix products are:
•
VisiMix 2K8 Turbulent
•
VisiMix 2K8 Laminar
•
VisiMix 2K8 Different Impellers
•
VisiXcel- Data Base
•
Pipe Line
VisiMix Products
VisiMix Software Products
•
VisiMix 2K8 Turbulent – for low-viscosity liquids and
multiphase systems.
The program provides process parameters necessary for
analysis, scaling-up and optimization of mixing tanks and
reactors with all types of impellers
Calculations of:
 Blending
 Suspension
 Dissolution
 Emulsification
 Gas dispersion
 Heat transfer
 Chemical reactions
 Mechanical stability of shafts
VisiMix Products
VisiMix Software Products
•
VisiMix 2K8 Laminar - for highly viscous media
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Newtonian and non-Newtonian
Macro-scale blending
Micromixing in high-shear areas
Heat transfer
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pastes
creams
shampoos
liquid soaps
gels
ointments
paints:
coatings
slurries
polymer solutions
VisiMix Products
VisiMix Software Products
•
VisiMix 2K8 Different Impellers – for combined mixing
devices
The program handles mixing devices consisting of any 2 – 5
impellers.
Different distances between impellers
Used in combination with VisiMix Turbulent.
Provides parameters of hydrodynamics, turbulence and heat
transfer.
VisiMix Products
VisiMix Software Products
•VisiMix VisiXcel – Data Base (DB) – automatic conversion tool:
Visimix Output to Excel Spreadsheet
•Integrates VisiMix report parameters in standard Excel worksheets
•Analysis VisiMix results in Excel
•Builds a Database of mixing tanks and reactors.
•Builds a Database of projects - for processes
•Makes correlation between plant equipment nomenclature to VisiMix
database of mixing tanks and reactors in VisiMix Project Database.
•Easy access to design data of the mixing tanks, to process
parameters and to corresponding results of VisiMix modelling.
•Results of VisiMix mathematical modelling in the VisiMix VisiXcel-DB
and arrange the data according to the reactor nomenclature.
• Easy access to recalculation of the VisiMix modelling from the
Database of the reactors & the projects
VisiMix Products
VisiMix Software Products
•VisiMix Pipe-Line
• Calculates hydraulic resistance of simple pipelines for liquid
viscosity and non-Newtonian products.
• Chemical engineers benefit from a quick and user friendly method
for charging times and the bottle-necks in the line.
• Includes : - Pipes - Riffled hoses – Elbows – Valves - And more
• Also comes with a database containing rheological constants for
the typical commercial non-Newtonian products - pastes, creams,
shampoos, paints, etc. (see Help Section for details)
• The first and only tool calculating flow resistance for liquids that
correspond to Carreau rheological model. (See Help Section for
details)
VisiMix Orientation
VisiMix Demonstration Tools
The VisiMix Demonstration Tools:
 VisiMix Turbulent – Examples & User Guide
 VisiMix Laminar - Examples & User Guide
 VisiMix Different Impellers – Examples & User Guide
 VisiMix Turbulent SV – Trial & Education
 VisiMix Review of Mathematical Models
 Selected Verification Examples
The Comparison between Published Experimental Data and
VisiMix Calculations
Saving Examples
Finance Saving Examples (ROI)
1. Cooling A Paste
2. Paints
3. Suspension in a Batch Reactor
4. Scale up Methodology
Finance Saving Examples (ROI)
Example
Case
Classic Solution
Visimix
Solution
Saving
Cooling of a
Paste
Batch Production
Time
Replacement of the
whole mechanical
system
Input the existing
mixing systems
parameters to
VisiMix software,
implement small
changes
$125,000 per year
Paste and
Coating
Mixing several
components to
obtain high quality
paint during scaleup process
Increase the impeller
speed and improve the
heat removal in the tank.
No successful results
obtained
Change agitator
dimension for
uniform mixing
without
overheating
$40,000 per year
Suspensions in
a batch
reactor
Plugging of the
bottom valve of the
reactor
Replacement of
the agitator
Lower the
impeller position
$12,000 saved on the
cost of a new impeller
and for all associated
operational costs
Scale up
Methodology
Implementation
during the Scale
studies
Calculation after
finishing the
development stage
Calculation
during the
development
stage
Decrease in the
quantity of out of
spec material in the
launching and
production steps.
Cooling a Paste
Cooling a Paste
Cooling a Paste
Cooling a Paste
Cooling a Paste
PAINTS
PAINTS
PAINTS
PAINTS
PAINTS
PAINTS
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Non ideal stirring – non homogeneity
• VisiMix software is used in order to find the required stirring characteristics.
For example: The product XXXX is produced at a solid liquid reaction.
The main reaction at this process is:
BBCM + TA + POCA →XXXX
POCA reagent properties:
• Solid
• High particle size: mean=735mm
• High density: 2300 kg/m3
VisiMix was used for suspension calculation.
Scale up optimization using simulation experiments.
Scale Up Methodology
(J.M. Berty. CEP, 1979)
Scale up optimization using simulation experiments.
Scale Up Methodology
(J.M. Berty. CEP, 1979)
Scale Up optimization using simulation experiments.
In the three years since the commencement of this process, their engineers
achieved a high level of proficiency in the use of the simulation models in
order to analyze the results as a function of the process operational
parameters.
After three years of working with this integrated plan – they have summarized
their knowledge and experiences up to this point, as follows:
1. VisiMix products, when integrated in the validation process (up until they
achieved a stable process and confirmed the production) – helped to
reduce the number of lost production batches (each batch valued in
millions of dollars) - from 100 to just under 10 batches – (review slide 25)
2. VisiMix program used in conjunction with another simulation tool - as
reported in this presentation - contributed to the improvement of the
teamwork style and professionalism. Net results were observed throughout
the implementation of the new solution in better project development: EOR
(end of reaction) time reductions, projects development time and cost
reduction, and in addition - increasing the expertise and qualification level of
the professional staff.
The presentation can be review on the Visimix Website in the References Users Publications page. (Scale up optimization using simulation experiments-Chemagis
presentation)
Scale Up optimization using simulation experiments.
Financial aspects
# produced lots needed until till a stable process is achieved
Summary
• Save per project
• Save during development
Thank You
Positive reaction from customers from all over
the world confirms:
- VisiMix is of tremendous help wherever
mixing is involved.
Thank you
From the VisiMix Team
Thank you for your attention