Solids Webinar Final

Model Solids Processes Easily with Aspen Plus Ajay Lakshmanan Senior Manager, Product Development

Hosted by: Julie Levine and Ron Beck, Product Marketing, AspenTech

Solids Process Modeling Webinar January 23, 2013

© 2013 © 2013 Aspen Aspen Technology, Technology, Inc.Inc. All All rights rights reserved reserved |

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Ongoing Series of Technical Webinars

Engineering webinars for education and best practices UPCOMING WEBINARS OF INTEREST:  Mejorar la Estimación de Costos usando Aspen Economic Evaluation – Jueves 31st  The New Aspen HYSYS Applied to Hydraulics and Flow Assurance (Technical) – February 5th

 aspenONE Engineering V8 Release Webinar for Enterprises of All Sizes (Technical) – February 6th  Optimize Carbon Capture with Rate-Based Distillation Modeling (Technical) – February 20th

 APAC Webinar: Optimize Utility Costs with Aspen Utilities Planner (Technical) – March 7th ALSO UPCOMING:  OPTIMIZE 2013 Global Conference – May 6th-8th © 2013 Aspen Technology, Inc. All rights reserved

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aspenONE Engineering

Best-in-class engineering solutions in an integrated workflow Common Models & Data Support Manufacturing & Supply Chain

Aspen Simulation Workbook & Aspen Online Deployment

Conceptual Engineering

Aspen Plus Dynamics, ACM & Flare System & Energy Analyzer

Basic Engineering

Aspen Equipment Design & Rating

Detailed Engineering

Aspen Petroleum Downstream & HYSYS Upstream

Aspen Process Economic Analyzer (APEA)

Aspen Plus Aspen Plus Aspen HYSYS

Aspen Basic Engineering

Aspen Capital Cost Estimator (ACCE)

Detailed Engineering

aspenONE Integration © 2013 Aspen Technology, Inc. All rights reserved

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Agenda  Introduction  Demonstration  Applications  Customer Comments  Questions & Discussion

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Why is Solids Modeling Important? Specialty & Agricultural Chemical Process Fertilizers, ChlorAlkali, pTA, Silicones Fluid Raw Material

Reactions (liquid/gas)

Separation (liquid/gas)

Drying

Crystallization (liquid/solid)

(solids/gas)

Solid Product

Solids + Fluids

Fluids

Extractive Industry Process

Coal, Oil Sands, Cement, Phosphates, Alumina Mineral Raw Material

Grinding (solids)

Classifying (fluid/solid)

Solids + Fluids

Separation

Reactions

(solids/liquid /gas)

(fluid/solid)

Solids + Fluids

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Fluid Products

Modeling Processes with Solids Traditional Approach Aspen Plus Urea Synthesis Model

SolidSim Urea Granulation Model

Two Models Manual Data Transfer Inconsistent Properties

Local Optimization © 2013 Aspen Technology, Inc. All rights reserved

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Challenge: Optimize the Entire Process

Fluid Process Model

Solids Process Model

Optimize Entire Process © 2013 Aspen Technology, Inc. All rights reserved

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February 29, 2012: AspenTech Announced Acquisition of SolidSim Inc. What is SolidSim? Simulator designed for optimization of solids processes • • •

Extensive solids model library Excellent solids process and model documentation MS Windows graphical user interface

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AspenTech and SolidSim Bringing Our Strengths Together

 Physical Properties

 Solids Process Modeling

 Reactions & Electrolytes

 Solids Characterization

 Fluid Unit Operations

 Solids Unit Operations

 Integrated Workflows

 Deep Expertise

 Worldwide Support

 Relationship with universities researching solids technology

 University Program

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Aspen Plus V8.0

Optimizing Processes with Solids – Made Easy Sample Templates

Online Training

Visualize PSD

Optimize Entire Process

10 Unit Operations © 2013 Aspen Technology, Inc. All rights reserved

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Agenda  Introduction  Demonstration  Applications  Customer Comments  Questions & Discussion

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Demonstration

Profit Opportunity Major Chemicals Manufacturer

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Demonstration  Opportunity – Increase profit – Unexpected demand for potassium chloride from a key client

 Challenge – Can we expand production capacity?  Plant already at max capacity  CAPEX projects will take time and money

– Keep key customer happy

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Demonstration

Demonstration

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Demonstration Review  Met unexpected demand from client  Capacity expanded without additional CAPEX  Key customer is happy  And, lower energy costs

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Solids Characterization is Easy and Flexible Solid Components Solid compounds are treated as unique species

Dissolved KCl

Solid (crystalline) KCl

Solid/Liquid equilibrium defined through CHEMISTRY reactions: KCL KCL-S © 2013 Aspen Technology, Inc. All rights reserved

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Solids Characterization is Easy and Flexible Solids Sub-streams

New Solids Form

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Solids Characterization is Easy and Flexible Solids Characterization Form

Select stream class. Support for multiple conventional and non conventional solids Sub stream types: MIXED – contains the fluids CISOLID – tracks a solid phase NCSOLID – non-conventionals

Select Moisture Components

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Solids Characterization is Easy and Flexible Solids Characterization Form New: You can define and use multiple PSD “meshes” within a model Example use: A different mesh for each feed stream based on lab analysis and a separate mesh for the simulation results.

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Solids Characterization is Easy and Flexible Built-in plots Tab for solid phase

Automatic Mesh Generation Distinct Feed Mesh

Populate PSD from distribution functions

PSD Analysis © 2013 Aspen Technology, Inc. All rights reserved

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Solids PSD Analysis to Interpret Results

Definition of Dx Properties D50

D90

D10

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Solids PSD Analysis to Interpret Results

PSD Characterization Steepness index (quartile ratio) – larger number implies narrow PSD 𝑛 3 Sauter Mean 1 𝐷𝑖 𝑤𝑖 𝐷 3,2 = 𝑛 2 Diameter 1 𝐷𝑖 𝑤𝑖 (SMD) Volume specific surface area (surface area/unit volume)

Volume Mean Diameter © 2013 Aspen Technology, Inc. All rights reserved

𝐷 4,3 = |

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𝑛 4 1 𝐷𝑖 𝑤𝑖 𝑛 3 1 𝐷𝑖 𝑤𝑖

New & Improved Solids Handling Operations in Aspen Plus V8.0 Crystallizer

Crusher

Dryer

Screen

Granulator

SolidSim

Aspen Plus

Aspen Plus

Design Philosophy: one unit operation model can represent many different types of equipment at various levels of fidelity from conceptualdetailed

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New & Improved Solids Handling Operations in Aspen Plus V8.0 Cyclone

Scrubber

Centrifuge

ESP

Classifier

SolidSim

Aspen Plus

Aspen Plus

The updated models use state-of-the-art correlations and methods to ensure accurate sizing and design.

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Agenda  Introduction  Demonstration  Applications  Customer Comments  Questions & Discussion

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Example Applications

Model and optimize entire production processes and process areas

Process Areas

Processes

Urea

Potassium Chloride

Convective Drying

Granulation Agglomeration

• Belt • Fluidized Bed

• Fluidized Bed Spray • High Shear

Crushing Milling

Classification Separation

• Ball (Wet) • Impact (Dry) • Jaw, Cone (Dry)

• • • •

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Cyclone Scrubber, ESP Centrifuge Screen

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Process Area Example Convective Drying  Problem: High Energy Consumption

 Benefit: Optimizing design and operation reduces energy use by 25-30%  Get Started: Belt Dryer example model available

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Process Area Example Granulation & Agglomeration  Problem: Product quality and process stability variability  Benefit: – Improve coating and product purity – Increase throughput  Get Started: Fluidized bed spray granulation example model available

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Process Area Example Crushing & Milling  Problem: Incorrect equipment design and operation increases recycles, energy consumption & reduces throughput  Benefit: - Reduced size/capital cost - Recycle stream sizing, increase throughput, - Reduce energy consumption

 Get Started: Example models that highlight high fidelity models that enable modeling of numerous equipment types © 2013 Aspen Technology, Inc. All rights reserved

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Process Area Example Classification & Separation  Problem: Incorrect product specifications, solvent recovery and gas cleaning  Benefit: – Reduce equipment size / cost – Reduce emissions and improve product quality & yield  Get Started: Example models highlight a multiphase classification process

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Learn More  Aspen Plus solids web page

http://www.aspentech.com/products/solids-aspen-plus.aspx

 Aspen Plus Solids Modeling Computer Based Training  “Jump start” Guides for – Particle Scientists – Experienced Aspen Plus Users – Model Convective Dryers

 On-Demand Short Presentations: – – – – – – – –

Intro to Solids Modeling Overview of Aspen Plus Dryer Overview of Aspen Plus Granulator Overview of Aspen Plus Crusher Overview of Aspen Plus Classifier Creating a Granulator Model Creating a Crusher Sieve Model Creating a Classifier Model © 2013 Aspen Technology, Inc. All rights reserved

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Agenda  Introduction  Demonstration  Applications  Customer Comments  Questions & Discussion

© 2013 Aspen Technology, Inc. All rights reserved

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Aspen Plus V8 – Solids Modeling

“It is quite impressive how much progress has been made in such a short time. The new Aspen Plus looks good and works well. We look forward to using the new Aspen Plus to model our processes with solids“ -Halvor Oien Department Head, Process Modeling and Control, Yara Technology

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Aspen Plus V8 – Solids Modeling

“We have been using Aspen Plus and SolidSim to model the fluids and solids sections of our processes. The integration of SolidSim into Aspen Plus enables us to design and optimize the entire process with one simulator and consistent physical properties.“ -Ingrid Lunt-Rieg Head of Process Simulation & CFD

© 2013 Aspen Technology, Inc. All rights reserved

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Agenda  Introduction  Demonstration  Applications  Customer Comments  Questions & Discussion

© 2013 Aspen Technology, Inc. All rights reserved

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OPTIMIZE™ 2013 Global Conference Join us in Boston for the industry’s must-attend event!

OPTIMIZE 2013

6 – 8 May 2013 The Westin Waterfront Hotel Boston, MA USA EARLY BIRD RATE EXPIRES Jan 31 PAPER ABSTRACT DEADLINE Jan 31

For more information, visit www.aspentech.com/agc

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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 [email protected] – 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 [email protected] – Ron Beck [email protected] – Julie Levine [email protected]

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