444594 Modeling of the First of a Kind Technology for the Process Design Packages

Tuesday, April 12, 2016: 9:00 AM
343B (Hilton Americas - Houston)
Minghua Ye1,2, Brian Peng2 and Sergio Mohedas3, (1)Process Technology, SABIC Americas Inc, Sugar Land, TX, (2)Process Technology, Sabic Americas Inc, Sugar Land, TX, (3)Process Technology, SABIC, Sugar Land, TX

The first of a kind technology is developed in laboratory and pilot unit. In order to scale-up an innovative technology to a commercial plant, a process design package (PDP) must be developed to provide the PFD, P&ID, specifications of all equipment and instrument, as well as heat and material balance. A reliable simulation model for the whole plant is the soul and foundation for PDP. This presentation illustrates the main steps to construct a simulation model: (1) select reliable simulation tool; (2) develop and evaluate thermodynamic package (VLE, LLE, and VLLE parameters); (3) Validate reaction kinetics, determine the key factors affecting reaction yield and selectivity, and select the suitable type of reactors; (4) Evaluate available utility sources and conditions; (5) Determine separation equipment, verify effectiveness of the separation processes using available experimental data and commercial operating data; (6) determine the over design factors for all equipment; (7) determine the range of operating conditions (normal operation, typical feedstock changes, start-up, end-of-run, and runaway conditions, and shut-down procedures); (8) Build the simulation model for the whole plant; and (9) Risk assessment and mitigation, and the model finalization.

A successful and reliable model for PDP development shall be capable of (1) matching the computation flow diagrams with the actual plant process flow diagrams; (2) generating heat and material balance, utility usage summarization, energy consumption or production, and waste emissions for environmental and HAZOP analysis; (3) predicting the detailed stream physical properties for piping, safety, and instrument design; (4) estimating the heat duty, heat curves, liquid / vapor profiles, and hydraulic data for equipment design; and (5) executing preliminary equipment sizing.

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