Transcript Industrial Solutions from Nor-Par

The Nor-Par Group
The Company that Cares
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
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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
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The solutions
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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
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Special solutions
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Integration with mechanical software
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… Slides 24 – 25
… Slides 26 – 29
… Slide 30
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Reactor modelling
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Reactor modelling
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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
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Reactor models: Steady state
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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
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Reactor models: Dynamics
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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
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Advanced Process Modelling
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Advanced steady state
process models (ASSPM)
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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)
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Benefits of Advanced Steady State
Process Model
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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
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Advanced Dynamic Process & Control
Models (ADPCM)
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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 blueprint” 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)
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Benefits of Advanced Dynamic
Process & Control Model (1)
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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 be achieved and how
(continued…)
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Benefits of Advanced Dynamic
Process & Control Model (2)
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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
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Production Improvement &
Optimisation Tool
Comprehensive interface for running optimisation
and "What-If" studies
that provides clear reports for the plant management
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Production Improvement &
Optimisation Tool
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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” to Blue-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/CCDYNAMICS as Engine. The Full version of the Chemstations software can be
used as Development tool.
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Production Improvement &
Optimisation Tool: Benefits
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"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
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Training Simulator
A part of graphics interface of a Training Simulator
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Training Simulator (1)
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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
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Training Simulator (2)
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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 BluePrint 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/CCTHERM/CC-DYNAMICS as Engine. The Full version of the Chemstations
software can be used as Development tool.
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Training Simulator: Benefits
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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
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Online Process Simulation
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Online Process Simulation
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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
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Online Process Simulation: Benefits
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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
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Integration with Control
Systems and APC
Examples from Nor-Par work on Control System and APC integration
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Integration with Control Systems
and APC
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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
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Special Solutions for Ecology
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Nor-Par delivers special solutions that address the
technologies of 21st century and focus on proecological 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
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Example: Bioethanol Permeation
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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
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Bioethanol Membrane Permeation
The process as modelled by Nor-Par uses 11 times less
energy than the traditional technology
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Bioethanol Membrane Permeation
Subprogram made and owned by
Nor-Par Online A/S
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Integration with mechanical software
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Nor-Par offers mechanical software from Micro
Techno MT-MECH that consists of these modules:
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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’ CCTHERM, which is a module for thermal calculations of
heat exchangers
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