Superpro Manual v7 5 for Reproduction

8/10/2019 Superpro Manual v7 5 for Reproduction

1/409

SuperPro Designer

User's Guide

A Computing Environment for Modeling, Evaluation, and Analysis of

Integrated Fine Chemical, Biochemical, Pharmaceutical, Consumer

Product, Food, Biofuel, Mineral Processing, Packaging,

as well asWater Purification, Wastewater Treatment and Pollution Control Processes.

INTELLIGEN, INC. - 2326 Morse Avenue - Scotch Plains, NJ 07076 - USATel: (908) 654-0088, (262) 367-7043, (609) 410-6484, Fax: (908) 654-3866

Email: [email protected], Website: www.intelligen.com


2/409


3/409

Users Guide

for

SuperPro Designer

and

EnviroPro Designer

INTELLIGEN, INC.Copyright 2008, INTELLIGEN, INC. All rights reserved.

This manual may be reproduced without notice only by our customers who own site(academic or commercial) licenses of SuperPro and EnviroPro Designer.


4/409


5/409

Table of Contents

Chapter 1 : Getting Started

1.1 Welcome 1-1

1.2 About This Manual 1-2

1.3 Hardware and Software Requirements 1-2

1.4 Installation 1-31.5 Technical Support 1-5

1.6 Extending the License Agreement for

Another Term 1-5

1.7 Overview of the Chapters in the Manual 1-6

Chapter 2 : Tutorial

2.1 Developing a Design Case 2-1

2.2 The Synthetic Pharmaceutical Design Case 2-55

2.3 The -Galactosidase Design Case 2-74

2.4 The Industrial Wastewater Treatment Design Case 2-95

Chapter 3 : Components & Mixtures

3.0 Components and Mixtures 3-1

3.1 Registering Pure Components 3-1

3.2 Fundamental Component Properties 3-6

3.3 Pollutant Categories 3-15


6/409

3.4 User-Defined Pollutant Categories &

Emission Limits 3-17

3.5 Special Components 3-18

3.6 Registering Stock Mixtures 3-19

3.7 Mixture Properties 3-21

3.8 VLE Behavior of a Pure Component 3-22

3.9 Component and Mixture Databanks 3-24

Chapter 4 : Streams

4.0 Streams 4-1

4.1 Types of Streams 4-1

4.2 Viewing and Editing Stream Properties 4-2

4.2.1 Bulk Streams 4-2

4.2.2 Discrete Streams 4-7

4.3 Stream Drawing 4-8

4.4 Stream Elbow Editing 4-10

4.5 Stream Tags 4-11

4.6 Stream Style 4-12

4.7 Classification of Input and Output Streams 4-13

4.7.1 Raw Material and Revenue Streams 4-13

4.7.2 Main Product Rate Stream 4-14

4.7.3 Waste Streams 4-15

4.7.4 Hazardous Streams 4-15

Chapter 5 : Unit Procedures, Operations & Sections

5.1 Unit Procedures 5-1

5.1.1 What is a Unit Procedure? 5-1


7/409

5.1.1.1 Unit Procedures in a Batch Process 5-1

5.1.1.2 Unit Procedures in a Continuous Flowsheet 5-1

5.1.1.3 Common Features 5-1

5.1.2 Operating Mode 5-25.1.3 Operations in a Unit Procedure 5-3

5.1.4 Icon 5-5

5.1.5 Ports 5-5

5.1.6 Labels 5-6

5.1.7 Style 5-7

5.1.8 Unit Procedure Types 5-12

5.2 Operations 5-13

5.2.1 What is an Operation? 5-13

5.2.2 The i/o Simulation Dialog 5-14

5.2.3 The Scheduling Tab 5-16

5.2.4 The Labor, etc. Tab 5-17

5.2.5 Default Input Data Values 5-19

5.3 Equipment 5-19

5.3.1 Selection and Sizing 5-20

5.3.2 Purchase Cost 5-22

5.3.3 User-Defined Purchase Cost Models 5-23

5.3.4 Cost Adjustments 5-24

5.3.5 Equipment Consumables 5-26

5.3.6 Equipment Allocation 5-27

5.3.7 Database Site Equipment 5-28

5.3.8 Vendor Equipment 5-28

5.3.9 Equipment Vendors/Manufacturers 5-29

5.3.10 Equipment Type Databank 5-29


8/409

5.3.11 Equipment Specification Variables 5-29

5.4 Sections 5-32

5.4.1 What is a Section? 5-325.4.2 Adding a Section and Assigning Procedures 5-32

5.4.3 Editing Section Properties 5-33

5.4.4 Sites and Resources 5-34

5.4.5 Editing Section Resources 5-35

Chapter 6 : Scheduling

6.0 Process Scheduling 6-1

6.1 Definitions 6-1

6.2 Scheduling Data 6-3

6.2.1 Scheduling Information for an Operation 6-3

6.2.2 Scheduling Information for

a Unit Procedure 6-4

6.2.3 Scheduling Information for

the Entire Recipe 6-5

6.3 Scheduling Calculations 6-6

6.4 Scheduling and Equipment Sizing 6-7

6.5 The Recipe Scheduling Information Dialog 6-7

6.6 The Operations Gantt Chart 6-8

6.6.1 Accessing Scheduling and Simulation Data 6-10

6.6.2 Exporting the Chart as a Picture 6-11

6.6.3 Exporting Scheduling Data into Excel 6-12

6.6.4 Exporting Scheduling Data into MS Project 6-12

6.6.5 Exporting Scheduling Data into SchedulePro 6-12

6.6.6 Printing the Gantt Chart 6-13


9/409

6.6.7 Zooming In and Out 6-13

6.6.8 The Time Line 6-14

6.6.9 The Visual Style Dialog 6-14

6.6.10 The Bar Style Dialog 6-176.7 Equipment Gantt Chart 6-19

6.8 Equipment Occupancy Chart 6-20


6.8.2 Exporting the EOC Data into Excel 6-22

6.8.3 Printing the Chart 6-22


Chapter 7 : Resources

7.1 What is a Resource? 7-1

7.2 Ingredients 7-1

7.3 Power 7-2

7.4 Heat Transfer Agents 7-2

7.4.1 Site Utilities 7-37.4.2 Agent Properties 7-4

7.5 Labor 7-6

7.5.1 Site Labor 7-7

7.5.2 Labor Properties 7-9

7.6 Resource Demand Charts 7-9


7.6.2

Exporting Resource Data into Excel 7-11

7.6.3 Printing the Chart 7-11


7.7 Resource Inventory Tracking 7-12

7.7.1 Setting the Supply Schedule 7-12


10/409

7.7.2 Configuring the Chart 7-13

Chapter 8 : Economic Evaluation

8.0 Costing and Economic Evaluation 8-1

8.1 Definitions 8-3

8.2 Initialization 8-8

8.2.1 Stream Classification 8-8

8.2.2 Cost Data for Each Operation 8-10

8.2.3 Cost Data for Each Procedure/Equipment 8-10

8.2.4 Cost Data for Each Section 8-118.2.5 Cost Data for Entire Process 8-12

8.3 Calculations 8-12

8.3.1 Equipment Purchase Cost (PC) 8-12

8.3.2 Operating Cost (OC) 8-14

8.3.3 Profitability Analysis 8-14

8.3.4 Cash Flow Analysis 8-15

8.4 Currency 8-168.5 References 8-19

Chapter 9 : Debottlenecking

9.0 Throughput Analysis and Debottlenecking 9-1

9.1 Throughput Analysis Report 9-6

Chapter 10 : Emissions

10.0 VOC Emissions 10-1

10.1 Primary VOC Emissions 10-1


11/409

10.2 Secondary VOC Emissions 10-6

10.3 Emissions Report Structure 10-12

10.4 Emissions Limits 10-13

Chapter 11 : Reports

11.1 Generating and Viewing Reports 11-1

11.1.1 Generating Reports 11-2

11.1.2 Viewing Any Existing Reports 11-3

11.2 General (Default) Report Options 11-3

11.3 Stream & Material Balance Report 11-511.4 Costing and Economic Evaluation Reports 11-8

11.4.1 Economic Evaluation Report 11-9

11.4.2 Itemized Cost Report 11-10

11.4.3 Cash Flow Analysis Report 11-11

11.4.4 Executive Summary 11-12

11.5 Throughput Analysis Report 11-12

11.6 Environmental Impact Assessment Report 11-1311.6.1 EIR: Waste by Type Section 11-13

11.6.2 EIR: Waste by Section Section 11-13

11.6.3 EIR: Stream Section 11-13

11.6.4 EIR: Overall Balance Section 11-13

11.6.5 EIR: Component Fate Section 11-14

11.6.6 EIR: SARA 313 Chemicals Section 11-14

11.6.7 EIR: 33/50 Chemicals Section 11-14

11.6.8 EIR: Solid Waste Section 11-14

11.6.9 EIR: Aqueous Waste Section 11-15

11.6.10 EIR: Organic Waste Section 11-15

11.6.11 EIR: Emissions Section 11-15


12/409

11.6.12 EIR: Hazardous Streams Section 11-15

11.6.13 Pollution Indices 11-15

11.7 Emissions Report 11-16

11.8 Input Data Report 11-1611.9 Equipment Report 11-18

Chapter 12 : Visual Objects

12.1 What are Visual Objects? 12-1

12.2 Types of Visual Objects 12-112.3 Adding a New Visual Object 12-2

12.4 Editing Existing Visual Objects 12-4

12.5 The Visual Objects Command Menu 12-5

12.6 Editing the Style of Visual Objects 12-7

12.7 Editing the Default Style of Visual Objects 12-9

Chapter 13 : The Design Case File

13.1 Contents of a Design Case File 13-1

13.2 Design Case Description 13-2

13.3 Saving and Copying the Design Case File 13-2

13.4 Customized Default Settings 13-3

13.5 Organizing Design Case Files 13-4

Chapter 14 : Interacting with Other Window

Applications

14.0 Interacting with Other Windows Applications 14-1

14.1 Exporting Drawings (Pictures) 14-1


13/409

14.1.1 Exporting a Process Drawing

Using the Clipboard 14-2

14.1.2 Exporting the Drawings as a

metafile (.wmf) File 14-3

14.1.3 Exporting the Drawings in

AutoCad (.dxf) Format 14-4

14.1.4 Exporting the Gantt Chart 14-4

14.2 Importing OLE Objects 14-5

14.3 Using the Pro-Designer OLE Server 14-5

Chapter 15 : Menus and Toolbars

15.1 Main Toolbar 15-1

15.2 Visual Elements Toolbar 15-2

15.3 Sections Toolbar 15-2

15.4 Solver and Status Toolbar 15-3

15.5 Status Bar 15-3

15.6 File Menu 15-4

15.7 Edit Menu 15-5

15.8 Unit Procedures Menu 15-16

15.9 Tasks Menu 15-23

15.10 View Menu 15-24

15.11 Reports Menu 15-27

15.12 Databanks Menu 15-28

15.13 Windows Menu 15-29

15.14 Help Menu 15-30

Chapter 16 : Databanks

16.0 Databanks 16-1


14/409

16.1 Databank Registration 16-1

16.2 Importing Data from Older User Databanks 16-3

16.3 Pure Component Databank 16-4

16.4 Stock Mixture Databank 16-516.5 Heat Transfer Agent Databank 16-6

16.6 Labor Databank 16-7

16.7 Consumables Databank 16-8

16.8 Equipment Materials Databank 16-9

16.9 Currencies Databank 16-10

16.10 Equipment in Sites Databank 16-11

16.11 Vendor Equipment Databank 16-16

16.12 Vendor/Manufacturer Databank 16-17

16.13 Equipment Type Databank 16-19

16.14 Specification Variable Databank 16-20

16.15 Site Databank 16-22

16.16 MS Project Databank 16-26


15/409

Chapter 1: Getting Started

1.1 Welcome 1-1

1.2 About This Manual 1-2

1.3 Hardware and Software Requirements 1-2

1.4 Installation 1-3

1.5 Technical Support 1-5

1.6 Extending the License Agreement for

Another Term 1-5

1.7 Overview of the Chapters in the Manual 1-6


16/409


17/409

Getting Started 1-1

1.1 Welcome

Congratulations on your purchase of a member of the Pro-Designer family of

software tools.

The Pro-Designer series of software tools currently includes SuperPro Designer and

EnviroPro Designer. By acquiring any member of our Pro-Designer series, you are

joining a large group of engineers and scientists from companies like Amgen, Abbott

Laboratories, ADM, Baxter, Bayer Technology Services (Europe and USA), Biogen

Idec, Bio-Rad Laboratories, Bio-Springer (France), Bristol-Myers Squibb, Cangene

(Canada), CDI, Centocor, CH2M Hill, Chugai Pharmaceuticals (Japan), CJ Corporation

(Korea), Colgate Palmolive, Crucell (Holland), CRB Engineers, Dow Chemical,

DuPont, Eli Lilly, Fluor, FMC BioPolymer, Foster Wheeler (UK), GE Healthcare,

Genencor, Genentech, Genmab (Denmark and USA), GlaxoSmithKline, Hitachi Plant

(Japan), Hoffmann-La Roche (multiple sites), Human Genome Sciences, Jacobs

Engineering, Janssen (Belgium), Laporte Consultants (Canada), Lonza (multiple sites),

Medarex, MedImmune, Merck, Merck Serono (Switzerland), Monsanto, NNEPharmaplan (Europe), Novartis, Petrobras (Brazil), Pfizer, Procter & Gamble,

Regeneron, Roquette (France), SAIC-Frederick, Sandia National Laboratories, Sanofi-

Pasteur (Europe, Canada, and USA), Talecris Biotherapeutics, U.S. DOA, DOD, DOE,

Wyeth Pharmaceuticals, etc. (just to name a few) in the U.S. and abroad who already

are employing our technology to design new processes or improve the performance of

existing ones.

The Pro-Designer set of software tools is todays best option for any chemical,

biochemical or environmental engineer and scientist in R&D, process engineering or

manufacturing. Whether you are a member of a biochemical, pharmaceutical, specialty

chemical, food company or whether you are employed by an environmental consulting

firm or a water purification/treatment plant, you can benefit from making this product

part of your every day computing options. Its use will enhance the productivity andcommunication efficacy of all members in your group as well between your group and

other parts of your organization.

All of the Pro-Designer software tools feature a unique balance between flexibility,

ease of use and computational power. They can be readily used by a computer novice

who is not very familiar with simulation and economic evaluation. You will find that all

of the Pro-Designer software tools are based on the same user-friendly interface

making it easy to migrate from one product to another as your needs may change in the

future. And in case you stumble across a question, help is one keystroke away. Hitting

F1will get you into a sophisticated hypertext-based help system, featuring the already

familiar MS-Windows Help interface. The system allows you to search for topics

related to keywords, jump from one help topic to another, and so on.

While we have made every effort to make all of our products learning curve as smooth

and short as possible, at the same time, we have equipped our software with several

features that will satisfy even the simulation veteran when it comes to preliminary

design and evaluation of process alternatives:

Material and Energy Balances of Integrated Processes


18/409

1-2 Getting Started

Equipment Sizing

Scheduling and Cycle Time Analysis of Batch Processes

Cost Analysis and Economic Evaluation

Throughput Analysis and Debottlenecking

Environmental Impact Assessment

just to name a few of many issues that can be explored. Further, including your results

into reports created by your word processor or spreadsheet is just a couple of mouse

clicks away. Using the latest OLE technology, you can simply copy all or parts of your

flowsheet or the Gantt chart and simply paste it into your favorite Windows

application.

1.2 About This Manual

Users generally dont like reading manuals. The manual you are holding in your hands

was put together with that in mind. As a minimum, however, you should read the firsttwo chapters.

Chapter 1

Introduction

You will find useful information about hardware and software

requirements for this program in order to run flawlessly on your

machine; directions about the installation procedure; and a guide

for the rest of the manual.

Chapter 2

Tutorial

In this chapter you will find a step-by-step approach to what it

takes to develop a design case using this program. This is done

using a very simple process. In addition, three more examples are

described in greater detailed. The first, which deals with the

production of -galactosidase, is recommended for users in the

biochemical and related industries. The second, which deals with asynthetic pharmaceutical process, is recommended for users in the

pharmaceutical, agrochemical, and specialty chemical industries.

The third, which analyzes an industrial wastewater treatment plant,

is recommended for users in the environmental field.

If you look at the end of this chapter you will find a listing with all the chapters

contained in the manual and a brief description of each chapter. You dont have to read

them all now. You can visit them at your own pace and as questions may arise related

with the subject they describe.

1.3 Hardware and Software Requirements

All of the Pro-Designer series software will run on any IBM PC and 100% compatible

based on the Intel Pentium II (or better) processor that runs Win98, WinNT 4.0,

Win2000, WinXP or Windows Vista. Heres a more detailed description of the

hardware requirements:

Hard Disk Depending on your choices during installation, the programs will

occupy anywhere from 350 MB (for minimum installation) to 450


19/409

Getting Started 1-3

MB (for full installation, including the on-line help and examples)

of space on your hard disk.

Processor / RAM Although any of our programs will run under the minimum

configuration requirements for Windows 98 / 2000 (Pentium II

processor and 256 MB), a Pentium 4 with 512 MB of RAM or

better is recommended.

Mouse The presence of a mouse or a similar pointing device supported by

Win98 / WinNT / Win2000 / WinXP / Vista is required.

Video Adapter /

Monitor

Any video adapter and monitor supported by Win98 / WinNT /

Win2000 / WinXP / Vista. All of our Pro-Designer software will

run under any video mode (Super VGA and higher) and any

monitor combination. The program requires a minimum of

1024x768 resolution and for best efficiency and comfort a 17 inch

(or larger) monitor is recommended.

Printer Any printer supported by Win98 / WinNT / Win2000 / WinXP /Vista. A laser postscript printer with 4MB of memory is

recommended for best quality printouts. If you try to print pages

with heavy graphics (i.e., several icons and streams), you may

experience problems (like missing sections of the printout) if the

printer does not have enough memory.

1.4 Installation

Most versions of Pro-Designer (except the academic and industrial site licenses)

require the use of a hardware security key. Simply plug the key into the parallel orUSB port of your computer (depending on the type of key you have requested). If you

have received a parallel port key and the port is occupied by the printer cable, unplug

it, plug the key into the port, and then plug the printer cable into the key.

Once you have checked that you satisfy the hardware and software requirements and

plugged the security key (if one is required), you are ready to run the Setup program to

install your program. The setup program will:

1. Copy all necessary files onto your hard disk at a directory of your choice.

2. Make the necessary updates of your computers registry.

3. Personalize your copy of the program.

4. Create a program group in the Start Button and include in it icons to run theprogram, the programs on-line Help, the ReadMe file and the examples.

Caution: The installation process will overwrite any files with the same name residing

in the specified destination directory without further warning. If you are upgrading to a

newer version of the program and have modified any of the files that came with it (e.g.,

the component databank file, or the heat transfer agent databank file, or any of the

example design case files), it is highly recommended that you make a backup before


20/409

1-4 Getting Started

installing the newer version. In addition, it is strongly recommended that you install the

newer version in a different directory.

To Run the Setup Program...

1. Make sure Windows is running on your machine.

2. Insert the CD into your CD-ROM drive to open the installation program. Follow the

on-screen instructions to finish installing the functional demo of SuperPro Designer.

If the installation program does not open automatically, locate and run the

installation script (Setup.exe) that is available on the CD.

3. During the installation, you will be asked to choose:

a. The location on your hard disk where you want the program to be installed.

b.Your name and your organizations name.

c. Which components you wish to include. The Setup program will ask you to

choose a type of installation: typical, minimum or custom installation.

Depending on your choice, different sets of files will be copied. Typical

installation is recommended for most users. Custom installation will let you pickand choose what components you need copied on your disk. Minimum

installation will only copy the files that are absolutely necessary for your

program to run. It will not copy the help files and the example files. If your hard

disk space allows, it is highly recommended that you install the help files as well

as the example files. The examples contain several design cases completed with

the program, along with all their read me files. If you decide not to include the

examples during the first installation, you can always run the setup program later

and copy them to your hard disk at that time. To avoid re-installing the entire

program, the second time, select Custom from the installation options, and pick

only the Example component.

4. At the end of installation, you will be asked to choose what to do next; you can do

one of the following:

a. Start the program, and/or

b.View the README file.

It is recommended that you review the README file at some point before you start

using your program, so you might as well do it now and get it over with. The

README file is a Windows Hypertext file that contains last minute changes and other

information that became available after the printing of the manual.


21/409

Getting Started 1-5

1.5 Technical Support

Technical Support is available for registered users only. This is why it is very important

that you complete the registration card as well as the questionnaire that was included in

your package. After you fill up the registration form, please use the pre-stampedenvelope and mail it to:

Intelligen, Inc.

2326 Morse Ave.

Scotch Plains, NJ 07076, USA

To receive technical support on any of our Pro-Designer software products, you may

contact us by:

e-mail (preferred) at: [email protected]

call our tech. supp. at: (908) 654-0088 or (262) 367-7043 or (609) 410-6484 (USA)

call our tech. supp. at: +30 2 310 498-292 (Greece)call our tech. supp. at: +31 (0) 64 302-3887 (The Netherlands)

1.6 Extending the License Agreement for Another

Term

If you are licensing this program for a limited time, you will find out that after the

license expires, the program will give you several warnings and eventually will not

start unless you renew your license. The license renewal process is very simple and, in

most cases, it can be done from your own office with a simple telephone call to us.

Before you start the license renewal procedure, you must get in touch with us to informyou about your password for that time. Once you know your password, you are ready

to start the license renewal procedure. Note that the password is only good for

extending the license agreement for one term. The next time you need to extend your

license for another term, you have to acquire another password.

To Renew your License for Another Term...

1. Make sure Windows is running on your machine.

2. From the Start button, select the Run option. In the dialog that comes up, type in:

\DESIGNER.EXE /R

Then click OK(or hit ENTER). should be a string ofcharacters like: C:\Program Files\Intelligen\SuperPro Designer\. This will start the

program in the License Renewal mode. In this mode, you cannot open an old

design case or start a new design case, since as you will notice, the only active

menu option at the main (top) menu is Help.

3. From the main menu, select the Help/Renew License...option and in the dialog

that comes up, type in your password. Please note that the password supplied to


22/409

1-6 Getting Started

you is case sensitive, so make sure you type it in exactly as is (including spaces,

dashes if it happens to have any).

4. After you have finished typing your password, click on OK. Shut down the

program (by selecting Alt+F4or double-clicking at the top left window box).

Thats it. Now you are ready to start your program the usual way

NOTES:

a. The first time you start your program after your license agreement has expired (and

you havent renewed your license yet), the program will detect the violation and

prompt you to get your license agreement renewed. From that point on, you can

only start the program again a few times before it locks itself. Once the program

locks itself, the only way to get it unlocked is to contact us, at Intelligen, Inc. and

acquire the necessary password to use in the procedure described above.

b. You can only apply the above procedure (to extend your license agreement) for

only a fixed number of times (currently it is 6 times). After that, you will have to

send your old hardware key to us and we will supply you with another key that you

can use for six more terms.

c. Although it is a rare case, it may happen that your hardware key becomes defective

and does not respond to the above renewal procedure. If that is the case, your old

key will be replaced with a new one.

1.7 Overview of the Chapters in the Manual

Chapter 1

Introduction

Describes in a few words the organization of the manual, the

hardware and software requirements for this program, the

installation procedure and how to start it, getting technical support

and an overview of all the chapters in the manual.

Chapter 2

Tutorial

Presents a systematic approach to what it takes to develop a design

case using this program. This is done using a very simple process.

In addition, three more examples are described in greater detailed.

The first, which deals with the production of -galactosidase, is

recommended for users in the biochemical and related industries.

The second process, which deals with a synthetic pharmaceutical

process, is recommended for users in the pharmaceutical,

agrochemical, and specialty chemical industries. The third, which

analyzes an industrial wastewater treatment plant, is recommended

for users in the environmental field.


23/409

Getting Started 1-7

Chapter 3

Components

and Mixtures

Defines ingredients (pure components and stock mixtures).

Explains all component properties (basic and environmental) that

are necessary to describe a species as part of your component

databank and/or mixture databank. It explains in detail how to

introduce a new pure component and/or a stock mixture in the

databank or in the current design case. Finally, it explains the

special components of water, primary biomass and activity-reference and the role they play in bio-process simulation.

Chapter 4

Streams

Describes in detail all you need to know about streams: their types

(input, output or intermediate, as well as bulk or discrete); their

classification (raw material, revenue, cleaning agent, solid waste,

aqueous waste, organic waste or emission); how to edit or view

their simulation data and their environmental properties; how to

draw them on the screen and edit their corners (elbows); how to

customize their appearance or style (color, font, tag name, etc.)

Chapter 5

Unit

Procedures

This chapter describes the common features found in all unit

procedures: operations, equipment, sections, branches, icon, ports,labels, colors, costing options, sizing and number of units,

scheduling information, batch vs. continuous mode of operation,

default data values, materials of construction, heat transfer agents,

auxiliary heating/cooling/power and rating vs. design modes of

equipment sizing.

The description of operation models is available in the Help

Facility only. The file that includes that material is also supplied to

you and copied on your hard disk as part of the standard

installation. It is in MS-Word format. You may open it and print

any section you need at any time.

Chapter 6

Scheduling

When a process, as modeled by our software, is assumed to be

operating in batch mode (that is the final product is delivered in

batches, not continuously), you must describe exactly when each

operation is started and when it ends. In other words, you must

describe the sequencing of all operations leading to the

manufacturing of the final main product. This chapter presents in

detail all the scheduling information that you need to supply for

each operation and for the whole process, how to supply the data,

and how the software manipulates the data to calculate the batch

time and other related scheduling output information. This chapter

also covers Gantt charts.

Chapter 7

Resources

Pro-Designer calculates and displays consumption charts for

various resources, such as raw materials, heating and cooling

utilities, power, cleaning agents, and labor. Resource bottlenecks

are easily identified by viewing such charts.


24/409

1-8 Getting Started

Chapter 8

Economic

Evaluation

This chapter describes the data and methodologies utilized in cost

analysis and economic evaluation. An in-depth coverage of the

terms and calculations made by the economic engine is presented.

Some information is also provided on the cost analysis and

economic evaluation reports generated by the program. More

detailed information on the reports is provided in chapter nine.

Chapter 9

Debottlenecking

Presents all the terms and the methodology used when performing

throughput analysis and debottlenecking studies.

Chapter 10

Emissions

Describes how Pro-Designer estimates primary and secondary

emissions from different operations and presents information about

the emissions report.

Chapter 11

Reports

Describes in detail the content and organization of all reports

generated by the program.

Chapter 12

Visual Objects

Presents in detail how you can enhance the appearance of your

flowsheet by highlighting certain parts and by adding visualelements (rectangle boxes/shadows, arrows, comments (text), etc.)

Chapter 13

Design Case

Describes what is contained in every design case file and provides

some tips on how to maintain the files related with a given project

or several projects

Chapter 14

Interacting with

Other Windows

Programs

Explains how to export a flowsheet (or parts of it) in DXF format

so that it can be incorporated in another application (either another

graphic package like CorelDraw, AutoCAD, etc. for further

enhancing the drawing details or a word processor as part of your

submitted reports). In addition, in this chapter we examine how

you can export the results contained in the Gantt and Resource

consumption charts. Furthermore it provides useful information on

using the Pro-Designer OLE Automation Server to interoperate

with other windows applications.

Chapter 15

Menus and

Palette Buttons

Explains in brief each menu option and toolbar button of the

programs user interface.

Chapter 16

Databanks

Provides information on the various databases for materials,

consumables, utilities, labor, equipment, sites, etc. that are utilized

by the software.


25/409

Chapter 2: Tutorial

2.1 Developing a Design Case 2-1

2.2 The Synthetic Pharmaceutical Design Case 2-55

2.3 The -Galactosidase Design Case 2-74

2.4 The Industrial Wastewater Treatment Design Case 2-95


26/409


27/409

Developing a Design Case 2-1

2.1 Developing a Design Case

In this chapter, we will guide you through the steps of creating a design case. We willfirst describe how to create a simple example process. This example will illustrate the

key initialization steps involved with the creation of any type of flowsheet. Regardless ofwhich industry you are in, you should read through this example to become familiar withthe basic steps of modeling processes using either SuperPro or EnviroPro Designer.

In addition to this simple example, three other example processes will be described in thischapter. These other examples, listed below, are more complex than the first and they arebetter representations of what a real process modeled with Pro-Designer would looklike.

Synthetic Pharmaceuticals. This example deals with a synthetic pharmaceuticalprocess. It is recommended for users in the pharmaceutical and specialtychemical industries.

Biotech Processing. This example deals with the production of -galactosidase

and it is recommended for users in the bioprocessing industries. Wastewater Treatment. The third additional example deals with an industrial

wastewater treatment plant and it is recommended for users that target waterpurification and wastewater treatment applications.

Table 2.1a provides a brief description of other examples that are included with yourcopy of SuperPro/EnviroPro Designer.

Table 2.1a: Examples shipped with SuperPro / EnviroPro Designer

(in addition to those described in this chapter)

Subdirectory Available In DescriptionAIRCONTR SuperProEnviroPro

This example analyzes a three-step process forremoving dust particles and acetone (a VOCmolecule) from an air stream. It is recommended forusers with interests in air pollution controlprocesses.

CHEESE SuperPro This example analyzes a highly integrated dairyplant that produces cheese, butter, WPC, andethanol. It is recommended for users with interestsin food processing.

GE SuperProEnviroPro

This example analyzes an effort to minimizegeneration of hazardous sludge and wastewater at a

manufacturing facility of General Electric. It isrecommended for users with interests in wasteminimization, water recycling, and pollutioncontrol.

INCINRTR SuperProEnviroPro

This example describes a simple process (a singleunit) for analyzing the combustionof sludge in anincinerator. It is recommended for users withinterests in incineration and pollution control.

INSULIN SuperPro This example analyzes the production of


28/409

2-2 Developing a Design Case

biosynthetic human insulin (a variation of Eli Lillysprocess for Humulin). It is recommended for userswith interests in bioprocessing andbiopharmaceuticals.

MAB SuperPro This example analyzes the production of atherapeutic monoclonal antibody using animal cellculture. It is recommended for users with interests inanimal cell culture and high valuebiopharmaceuticals.

MISC SuperPro A set of small examples demonstrating specialfeatures of the software. (a) "BKinFerm" focuses onmodeling of Batch Kinetic Fermentor anddemonstrates how to generate composition profilesof reactants and products. (b) "BKinRxn" explainshow to model batch kinetic reactions. (c)"EquilRxn" explains how to use an equilibriumreaction to estimate extent of precipitation andcrystallization. (d) "BtchDist" explains how tomodel a batch distillation step and generatecomposition profiles. (e) PulOp explains how touse Pull In and Pull Out operations. (f) FedBRexplains how to model a fedbatch kinetic reaction.(g) MxPrp explains how to use the MixturePreparation procedure.

MUNWATER SuperProEnviroPro

This example focuses on the modeling and retrofitdesign of a municipal wastewater treatment plant. Itaddresses issues of nutrient removal and it isrecommended for users with interests in industrialand municipal wastewater treatment.

PHTABLET SuperPro This example deals with a process for makingpharmaceutical tablets. It is recommended forpeople that deal with secondary manufacturing(dosage formulation and fill-finish) ofpharmaceuticals and related products.

UPWATER SuperPro This example deals with water purification (ultra-pure water production) and wastewater treatment ata Semiconductor Manufacturing Facility. Evaluationof recycling options for minimizing city water useand wastewater disposal is included.

BIODIESL SuperPro This example deals with the production of biodieselfrom soybean oil and it is based on a process model

developed by scientists at a research center ofUSDA. It is recommended for uses that areinterested in developing fuel producing processesthat are based on the use of renewable agriculturalmaterials as feedstock.


29/409


After installation of SuperPro/EnviroPro on your computer, you can access theseexamples in the EXAMPLES subdirectory. Each example has its own detailed Read-Mefile.

2.1.1 Getting StartedThe first example of this chapter demonstrates the key initialization and analysis steps formodeling a process with Pro-Designer. The fundamental steps and analysis features used inthis example are the same as the steps and features that would be used during the creation ofany other type of flowsheet. Therefore, regardless of which type of process you intend tomodel, reading through the following example should provide you with the knowledgerequired to model processes on your own. In addition, since this example is a batch process,it serves as a medium for discussing several scheduling issues. Note: in continuousprocesses, the initialization steps related to scheduling of operations within unit procedures(described in Section 2.1.5) do not need to be performed.

The steps listed below summarize the process of developing a design case with Pro-Designer.

These steps are explained in much greater detail in the remainder of this chapter.1. Initialize the flowsheet using the first three items of the Tasksmenu: Set Mode of

Operation, Edit Pure Components,and if the mode of operation is batch,RecipeScheduling Information.

2. Build a flowsheet by selecting the desired procedures from the Unit Procedures

menu. Switch to Connect Modeby clicking on the button of the main toolbarto draw the streams and connect the process steps. When finished, exit Connect

Modeby hitting the ESCkey or by clicking on the Select Modebutton of themain toolbar.

3. Add operations, such as Charge, Agitate, Heat, React, etc. to each unit procedure (this

applies to batch procedures only) by right clicking on the unit procedure icon to bring upits context menu and selecting Add/Remove Operations. Different unit procedures havedifferent operations available to them. After the desired operations have been added,

initialize all operations by selecting Operation Dataand streams by selectingSimulation Data from the respective context menus.

4. Complete the analysis of the flowsheet using the remaining items of the Tasksmenu:Solve M&E Balances, input Stream Classificationdata,Perform EconomicCalculations, etc. Other analyses may be optionally performed.

5. Generate and view reports using items from the Reportsmenu. Use the Viewmenu tosee the results of the analyses and charts.

Starting Pro-Designer

To begin working on a new flowsheet, open Pro-Designer either by selecting it from yourStart Menu or by double-clicking the Designer.exe application file in the Pro-Designerfolder of your hard drive. The following dialog box will appear:


30/409


Figure 2.1-a Opening Dialog

Select the option entitled Start a New Flowsheet.

2.1.2 Specifying the Mode of Operation for the Entire Plant

After you choose to start a New flowsheet, the new design case dialog (Figure 2.1-b) willappear. This dialog box allows you to set the primary mode of operation and the annualoperating time for the new flowsheet. Pro-Designer can model process plants that

operate in batch, continuous, or mixed modes. You can also use the Tasks/ Set Mode ofOperation...menu item to change the mode of operation at any time. Please note thatPro-Designer allows you to have continuous unit procedures in a batch flowsheet as wellas batch (cyclical) procedures in a continuous flowsheet. Furthermore, when theoperating mode of the entire plant is set to batch, all stream flows are displayed on a per-batch basis, as opposed to on a per-hour basis. For plants operating continuously, noscheduling information is necessary. At this point, please select Batch as the PlantOperation Mode for the example process, which you will create.


31/409


Figure 2.1-b: Specifying the operating mode for the entire flowsheet.

2.1.3 Setting the Default Physical UnitsPro-Designer provides a variety of options for units of measure for the entry and display

of data. You may use the Edit/ Flowsheet Options/Physical Units Options menu itemto view or modify the default units.

2.1.4 Registering Components and Mixtures

Databanks. Pro-Designer provides for the use of multiple component databases. Thedefault databank shipped with Pro-Designer, entitled Designer, provides data for anumber of commonly used compounds. If you use the DIPPR database you may use it

with Pro-Designer. There is also an empty databank entitled User that may be used tostore data for user-defined components. Use the Databanks/ Availability, Passwords &Locations menu item to change or add component databanks. See section 3.8 in themanual for details.

Registering Components. All the components that will be used in a design case must bespecified. Many of these components may be selected from the component library inPro- Designer. To register components (in other words, to add them to your design case),


32/409


choose the Tasks/ Edit Pure Components menu item. This will activate the dialogshown below (Figure 2.1-c).

Figure 2.1-c: The Component Registration dialog

By default, nitrogen, oxygen, and water are always registered as pure components in newprocesses. For this example process, you will need to add heptane to the list of registeredcomponents as well. To add heptane, you can either scroll down to it in the pure componentdatabase list on the left, or you can begin typing heptane in the box above the list and the

database will automatically scroll to the correct location. Next, use the Registerbutton toadd heptane to the Registered Components list for this flowsheet. Alternatively, you maydouble click on heptane in the database listing and it will be added to your list of RegisteredComponents.

If a component does not appear in the library, you should use the Newbutton ( ) from theregistered pure components toolbar located at the top right of the dialog to add it. For thisprocess, you will need to create three new components: A, B, and C. These components willrepresent the reactants and products of a simple reaction. To add component A to your

database, click the button and fill in the letter A for the Name, CAS Number, etc. Forconvenience, changes in the Name are copied automatically to all other fields that werepreviously identical to it. (Note as far as the program is concerned, you do not have to have

a correct CAS Numbers, Formulas, etc. You just need to have something written in each ofthese six fields. The Local name is the one that appears in the reports and all the input/outputdialog windows of the program.) Notice that at the bottom of this dialog box, you can chooseto either initialize the physical properties to the default physical properties of water or copythem from some other component (see Figure 2.1-d).


33/409


Figure 2.1-d: The New Component Definition dialog

For this example, simply click OK to copy the property values for component A from water.

After you have added component A to your list of registered components, follow the samesteps to add components B and C. When you have completed this, you should edit some ofthe properties of these components. To access the basic properties of component A, doubleclick its row on the table of registered pure components (e.g., row 1 for component A in

Figure 2.1-e) or select its row and then click on the Propertiestoolbar button ( ). Thisbrings up another dialog window which allows you to view and edit the physical andenvironmental properties of component A as well as its cost data and regulatory information.

For the purposes of this example, the only physical parameter we will be concerned with isthe molecular weight (MW). For component A, please change the MW to 150 g/gmol in the

Physical (Constant)tab (as shown in Figure 2.1-f). In addition, please go to the Economicstab, specify a purchase price of $10/kg, and press OK.

Next, please visit the Properties dialog for component B (by double-clicking on row 2 or by

selecting row 2 and then clicking on the button ) and enter a MW of 25 g/gmol and apurchase price of $15/kg. Finally, enter a MW of 175 g/gmol and a selling price of $300/kgfor component C. This completes your initialization of components for our simple example.


34/409


Figure 2.1-e: Selecting a component to edit its properties

Notes:1) If you need to delete a component from the Registered Components listing, click on the

corresponding row (e.g., row 1 for component A) and then click on the Deletetoolbarbutton ( ).

2) If you wish to add components which you have edited or created to the User database (sothat you can access these components in future design case files), select the User database(from the Source Databank drop-down menu), highlight the component by clicking on

the corresponding row of the table (e.g., row number 1 for A) and then click on theDepositbutton.

3) The current version of Pro-Designer does not make use of the normal freezing point ofchemicals components. As a result, the value of that field can be ignored.

4) Mixtures are used to facilitate initialization of input streams in cases where certain rawmaterials (e.g., buffers) are consumed as mixtures. Mixtures are registered by selecting

the Tasks/ Edit Stock Mixtures menu item.


35/409


Figure 2.1-f: Editing the properties of component A

At this point in time, you should probably save your file by choosing File/ Save Asandgiving your flowsheet a descriptive name. In general, it is a good idea to save your workoften in order to avoid having to redo work in the event of a program or system crash, orpower-out. If the program does crash, there is sometimes a possibility that you will not beable to reopen the file you were most recently working on. In that case, you should try

opening the backup versions of your file. Anytime you save a newer version of your file, Pro-Designer changes the previous version to a .sp~ file (as opposed to a normal .spf file.) Ifthere is already a .sp~ backup file, Pro-Designer changes this older file to a .s~~ file as asecond backup. To open a backup file, simply go to the directory where you saved youroriginal file and look for the .sp~ backup (select All Files for file types). Then double-click this file to open it. The file extensions for EnviroPro are {.epf, .ep~, .e~~}, respectively.


36/409


2.1.5 Building the Flowsheet

The first step in building a flowsheet is to add processing steps (unit procedures) to theflowsheet. A unit procedure is defined as a series of operations that take place within apiece of equipment. The types of operations available depend on which type of unitprocedure you are using. Please note that continuous unit procedures are equivalent to

unit operations.

To Add a Unit Procedure...

First select the desired unit procedure from the Unit Proceduresmenu. For our example,please select Unit Procedures / Vessel Procedure / in a Reactor. Notice that after you

select this unit procedure, the mouse cursor changes to:indicating that your next mouse click on the flowsheet will lay down the reactor unitprocedure in that location. Please click near the left side of the flowsheet to place theVessel Procedure icon.

After you have added the Vessel Procedure to the flowsheet, please add a Plate and Frame

filtration procedure by selecting Unit Procedures / Filtration / Plate and FrameFiltration, and then clicking somewhere to the right of the Vessel Procedure icon. Yourflowsheet should now look something like this:

Figure 2.1-g: The example flowsheet with the Vessel Procedure and Plate and FrameFiltration icons added

Note: If you wish to modify the default equipment prefixes, e.g. V for vessel andPFF for plate and frame filtration, use the File / Application Settings... menu item andselect the prefixes tab. To edit the default prefix of an equipment or operation select thecorresponding row from the table and click on the prefix.


37/409


If You Wish to Move a Unit Procedure...

1. Select the desired unit procedure icon by clicking on it with the mouse. If more thanone icons need to be moved at the same time, you can either group-select them bydragging an enclosing rectangle around them, or you can edit the selected icon set byadding or removing icons one by one. To add an icon to the selection set, click on it

while holding down the Ctrlkey. Note that if the icon was already in the selection set,it will be de-selected if you Ctrl+Click on it.

2. Drag the selected icon to the new location. If the selection set has more than one icon,drag any member of the selection set and all icons will move simultaneously. If youwant to move the selected set of icons one pixel at a time, you can use the arrow keys.

NOTE: When you move a unit procedure icon, which has streams, attached to it, allstreams will move with it. If the destination and source icons of a stream move, thenthe stream will keep its structure intact and move with them. If one of the streamsends remains anchored while the other end is being moved, then the stream will adjustits first and/or last elbow to accommodate the change of location. You can alsomanually edit the location of the streams elbows (see Chapter 4). Adding and moving

stream lines will also be explained later in this example.If You Wish to Delete a Unit Procedure...

1. Select the unit procedure icon you wish to delete by clicking on it with the mouse. Ifdesired, you can delete multiple procedures at once (see To Move a Unit Procedureabove to learn how to select multiple unit procedures).

2.Hit the Deletekey or select the Edit: Clearoption from the main menu. The selectedunit procedure(s) will be erased.

NOTE: When you delete a unit procedure, all streams attached to it will be deleted withit.

If You Wish to Cut/Copy and Paste a Unit Procedure...

Pro-Designer allows you to place a selection of unit procedures and streams into theclipboard by cutting or copying them and later pasting them into another area of the sameflowsheet. In addition, you can use the Cut/Copy and Paste features of the program tocopy whole sections from one flowsheet to another. To do this, select the desired unit

procedure icon(s), and then select Edit / Cut(or Ctrl+X) to cut the icons or Edit / Copy(or Ctrl+C) to copy the icons from the main menu. Next, paste the unit procedures ontoanother area of the flowsheet, or onto different flowsheet by selecting Edit / Paste (orCtrl+V) from the main menu.


38/409


Notes:

a.If you want to paste the copied icons into another application (e.g., a word processingapplication), please consult Chapter 14.

b. You cannot copy and paste streams alone. Streams are placed onto the clipboard onlyif their source and destination unit procedures (when they exist) are also placed on the

clipboard.

c. When pasting unit procedures from the clipboard into a flowsheet, you should beaware that certain features of the original unit procedures are not transferredinto thenewly created copy:

1.Stream connections to any unit procedures are not included in the pasted set.

2.If the start time of the first operation of the pasted unit procedure was defined ona relative basis (e.g., with respect to the start or end of another operation insome other procedure), then the scheduling of the pasted procedure is reset toremove the coupling.

3.If the original unit procedure was sharing equipment with another procedure, the

pasted procedure is reset to be executed in its own equipment.d. Pasting streams and certain processing steps with component-related specifications

from one flowsheet to another is not possible unless all components of the sourceflowsheet exist in the destination flowsheet as well. If that is not the case, theprogram will automatically expand the set of registered components in the destinationflowsheet to include the missing ones.

Adding Streams to the Flowsheet:

After you have placed unit procedures on your flowsheet, you may add stream connectionsto the icons. There are three types of streams: feed (input) streams, intermediate streams,and product (output) streams. Feed streams do not have a source unit procedure and inbatch processing they are mainly utilized by charge operations. Intermediate streamsconnect two unit procedures, and they are used to transfer material from the source to thedestination unit procedure. Product streams do not have a destination unit procedure. Allstreams are automatically identified with a stream tag.

In order to add streams to the flowsheet, you must first enter Connect Modeby clicking on the

Connect Modebutton of the main toolbar. When you do this, the cursor icon changes to

the following: to indicate that you are in Connect Mode. Then add the feed,intermediate, and product streams as follows:

1. Adding a Feed Stream: Click any unoccupied area on the open screen to initiate drawing of

the stream and then click on the appropriate inlet port of the destination unit procedure toterminate the stream. Notice that as the cursor moves over the inlet and outlet ports, it changes

to a Port Cursor:

You must make sure the cursor looks like this before you click to attach the stream to aport. Otherwise the computer will simply add a stream elbow at this point and will not actuallyterminate the stream. If you accidentally miss the stream port, you can simply hit ESCto


39/409


cancel the stream-drawing process. Then you can restart the stream-drawing process by

clicking the Connect Modebutton again.

Between initiation and termination of the feed stream, the mouse may (optionally) be clicked atintermediate points to create right angle bends; this permits customization of the stream routeand flexibility in flowsheet design. Pro-Designer automatically draws the feed stream symbol

and labels the stream.2. Adding an Intermediate Stream: Click on the appropriate outlet port of the source unitprocedure and then on the appropriate inlet port of the destination unit procedure to terminate

the stream. Be sure to wait until the Port Cursoricon (explained above) is displayed beforeattempting to begin or terminate a stream on a port. As before, you can create specific routingby clicking the mouse wherever a right angle bend is desired.

3. Adding a Product Stream: Click on the appropriate outlet port of the source unit procedureand then double-clicksomewhere to terminate the stream line. When you double-click, thecursor should be close to the last drawn horizontal or vertical line segment. Note that Pro-Designer automatically draws the product stream symbol.

At this point, please add feed, intermediate, and product streams to your example process. Your

flowsheet should now look something like this:

Figure 2.1-h: The example flowsheet with streams added


40/409


Notes:

1) Hitting ESCwhile drawing a stream terminates the stream drawing process. To get backinto stream mode after hitting ESC, simply hit the Connect Modebutton again.

2) In many unit procedures, there are dedicated ports, such as feed, vent, cake removal orfiltrate removal. To see which ports are dedicated to each function, you can look up the

desired unit procedure in the Helpmenu. As a shortcut to the Helpfor any procedure, youcan click the Help icon (the one with a question mark and an arrow on it) and then click onthe unit procedure icon you are interested in. Alternatively, you can click on the unitprocedure icon to highlight it, and then hit the F1 key. A portion of the Help for the Plateand Frame Filtration unit procedure appears below. Notice that the dedicated ports arelabeled next to the filter icon. The Help facility also contains a general description of eachprocedure, links to its operation models, and much more.

Figure 2.1-i: A Portion of the Help file for Plate and Frame Filtration

When you are finished drawing streams, you should exit Connect Modeand return to Select

Mode. This is done by hitting ESCor clicking on the toolbar button that looks like:


41/409


Figure 2.1-j: The streamcontext menu

When Pro-Designer is in Select Modeand the mouse is over astream line, the arrow will change to indicate the availability ofa stream context menu (see Figure 2.1-j), which may beactivated by clicking the right mouse button. Through this menu

you can view and edit (for input streams only) the composition,flowrate, and other stream properties and you may selectdifferent initialization options for the stream. You may alsochange the Tag Name (label), adjust the Elbows, and edit theStyle (e.g., label and line color, line thickness, etc.) of anystream. Note that double-clicking on a stream line with the left

mouse button is equivalent to selecting the Simulation Data...menu item of the stream context menu.

At this point, please right-click on the Vessel Procedure input stream S-101 and choose EditTag Name. Change the name of this stream to Heptane and click OK. Then right-click the

Heptane stream line, select Style/ Edit Style,andClick on the Name Labeltab (see below).

Figure 2.1-k: The Stream Style dialog


42/409


Now click the Fontsbutton to change the style, size and color of this stream tag name. Afterclicking OK, your flowsheet should look something like this:

Figure 2.1-l: The example flowsheet after the name and style for one of the input streams havebeen changed.

Please see Chapter 4 or the on-line Help facility for more information on stream-drawing.

2.1.6 Initializing Unit Procedures

Adding Operations to Unit Procedures:The first step toward initialization of unit procedures is to add relevant operations to eachunit procedure. This can be done by either 1) double-clicking a unit procedure icon or 2)

right clicking on the unit procedure icon and selecting Add: Remove Operations. Eitheraction will bring up the following dialog window of Figure 2.1-m.

At this point, please add a charge operation to the Operation Sequence in your VesselProcedure by double-clicking the word Charge in the list on the left. Alternatively, you

can add the operation by highlighting the word Charge and clicking the Add or Insertbuttons. The Addbutton (the bottom button in the middle) will add the new operation at theend of the list, while the Insertbutton (the top button in the middle) will add the newoperation beforethe currently selected operation.


43/409


Figure 2.1-m: Adding Operations to the Vessel Procedure in the example process

Now add two more Charge operations, a React (Stoichiometric) operation, and a Transfer

Out operation (so that your dialog box looks like Figure 2.1-m above). Then click OK toreturn to the flowsheet.

Note: If you make a mistake while adding operations, you can delete the operation by

selecting it in the Operation Sequence list and hitting the Deletebutton ( ). If you add anoperation in the wrong order, you can move it to a different position in the OperationSequence list using the Move Up/Down buttons. To change the name of an operation, select

the operation form the right pane and click on the Renamebutton ( ).

After you have added operations to the Vessel Procedure, double-click the Plate and Framefilter icon to add operations to it. Notice that by default, this unit procedure has an

operation (Filter-1) assigned to it. Use the same method as before to add a Cake Washoperation and a Transfer Out operation to this unit procedure (in addition to the Filtrationoperation which is already present).

Note: Double clicking on a continuous procedure (e.g., a Centrifugal Pump) that is presentin a continuous flowsheet brings up the dialog window of its essential operation instead ofthe dialog of Figure 2.1-m. Essentially, a unit procedure in a continuous flowsheet behaveslike a unit operation.


44/409


Initializing the Operations:

the operations that have been added to the unitprocedures. To do this, please right-click the mouse over a unit procedure icon to bring up

its context menu (see Figure 2.1n).

Reactor Vessel

The next step is to initialize each of

Figure 2.1-n: The context menu for the vessel procedure in this example process

The m n

ill appear

ure, delete existing ones, rename them, and rearrange their order.

unit

alysis data. You may change the mode of operation

tiesmenu item allows the user to view and editthe physical state and properties of the material as it is transformed by eachoperation within a procedure.

ea ing of each portion of the context menu in Figure 2.1-n is explained below:

The Operation Data menu allows the user to access and modify the simulationparameters for each operation in this unit procedure. (Note the Operation Datamenu will not appear until at least one operation has been added. Furthermore, ifonly one operation is present in the unit procedure, no drop-down list wto the right of the context menu. In this case, simply click on the Operation Dataline of the context menu to bring up the parameters for the operation).

The Add / Remove Operations menu allows the user to add new operationsto the procedThis is the same dialog that is brought up when you double-click on a batch

procedure.

The Procedure Data menu item allows the user to view and set somescheduling and throughput anfor the entire procedure from batch to continuous and vice versa (if the procedurecan operate in both modes).

The Procedure State Proper


45/409


Through Procedure Activity Overview the user can view a summary ofinformation for each operation, including start/end time, material transferred in/out with each operation, and batch contents after each operation.

Through Equipment Data the user can select the equipment sizing mode(Design or Rating), specify equipment sharing information, and parameters

related to size and purchase cost. Information related to staggered pieces ofequipment and consumables are also specified through this dialog.

Through Equipment Contents the user can view the contents (and theirstate) of the equipment after each operation.

The Set Break Points allows the user to place a stop in the sequentialsolution of material and energy balances. This is normally used fortroubleshooting in large or complicated flowsheets.

Through Edit Labels the user can change the name of the procedure (e.g., P-1 in the above procedure), the name of the equipment (V-101 in the above case),and the description of the procedure (Vessel Procedure in the above case).

The Disconnect menu item deletes all the streams connected to the unitprocedure.

The Flip (reverse flow direction)option from the context menu changes theflow direction, which is left-to-right by default, to right-to-left. Note that the Flipicon option is only available when the unit procedure is not connected to othersteps via material streams. You can also flip the icon by selecting it and clickingon the Flip Horizontal button of the Visual Object Toolbar (see chapter 12).

The Order option of the context menu allows you to force the unitprocedure icon to appear behind or in front of other icons, text, etc.

The Style option allows you to edit such things as the icon color, the nametag color and font, etc.

The Help (F1) item will allow the user to get information about the specificUnit Procedure.

At this point, please select Operation Data: Charge Solvent from the vessel procedurecontext menu. This will bring up the following dialog:


46/409


Figure 2.1-o: The Operating Conditions dialog for the first Charge operation in the VesselProcedure.

The Operating Conditions dialog allows you to specify the operating conditions, emissionsdata, labor, scheduling, etc. for each operation. Different tabs of input fields are available

for different operations. To initialize the Operating Conditions tab for the first chargeoperation in this example, you begin by specifying the amount of material that is going tobe charged (800 kg). To specify its composition, use the drop-down menu at the top of theOperation Data dialog box to select the stream which you renamed Heptane earlier in this

chapter. Click on the button to access the stream data for this stream (see Figure 2.1-p). To add heptane to the stream, double-click its name in the Registered Ingredients list onthe left side of the dialog box.


47/409


Figure 2.1-p: The Heptane stream dialog.

Notes:

1) You can charge multiple components in the same stream if you wish. To do this,simply add additional component names from the Registered Ingredients (Pure

Components or Stock Mixtures) list and specify their amounts. The computer willautomatically calculate the mass (%) and concentration (g/L or mole/L) of eachingredient, the streams density (if it is not set by the user), the volumetric flowrateand the activity of the stream. Alternatively, you can click on Mass Compositionand specify the total mass or volume flow and the mass (%) of each component. Youmay also select units for entry and display.

2) As an alternative to going through the Operation Data dialogs to edit streamproperties, you can initialize and edit input streams directly from the flowsheet itself.To do this, open the stream context menu by clicking the right mouse button over a

stream line and selecting Simulation Data. This will bring up the same dialog box asthe one shown in Figure 2.1-p. You could also double-click the left mouse button on a

stream line to generate this dialog box. Note that only the feed(input) streams to the

flowsheet need to be specified. The flowrates and compositions of intermediate andoutput streams are calculated by the program. However, the user can specify thedensity and volumetric contribution coefficients of such streams (see Chapter 4 formore detailed information on streams and their properties).

3) In addition to pure components, mixtures can be fed (or charged) into a processstep using an input stream.


48/409


4) For biotech processes, the extracellular percentage (Extra-Cell %) of an ingredientrepresents its fraction that is in the bulk solution (as opposed to inside the cell). For

more information on this topic, please refer to the Galactosidase example inSection 2.3.

5) If the operating mode of a flowsheet is batch, all flowrates are reported on a per batch

basis (or per cycle of source or destination process step). If the process is set tocontinuous mode, then all flowrates are reported on a per hour basis. The choice formass units can be made from each streams dialog. This choice overwrites the default

choice made by the specification at the Edit / Flowsheet Options / Physical UnitsOptions...dialog.

6) The Env. Propertiestab of a stream dialog displays the concentrations and dailythroughputs of the environmental and aqueous properties of the stream (TOC,CaCO3, TP, TKN, COD, ThOD, BOD5, BODu, etc.) All values are for display onlyand cannot be edited by the user through this dialog box. However, theenvironmental properties of the pure components (that contribute to the above stream

properties) can be edited through the Tasks/ Edit Pure Components in the PureComponent Properties Dialog of the selected pure component.

For more information on stream properties, please refer to Chapter 4.

After you have specified the charge amount of Heptane, click OKto return to theOperation Data dialog for Charge Solvent (Figure 2.1-o). Notice that there are severalways that the duration of this operation can be specified. For this example, change thesetup time of your charge to 5 minutes and set the Volumetric Flowrate to 100 L/min.

Please also visit the Volumes,Emissions, Labor etc, and Schedulingtabs to see whatthey contain. A brief description of each of these tabs follows:

Volumes tab:here the user can specify the maximum and minimum allowable working /vessel volume for this operation (i.e., by the end of the Charge operation the vesselshould not be more than 90 % full). In Design mode this is taken into account for sizingthe equipment. In Rating mode, the program makes sure that a vessel is not overfilled or

the level does not drop below the agitator level.

Vent/Emissions tab: here the user can specify which volatile organic compounds(VOCs) will be emitted, whether a sweep gas will be used (for emissions associated withreaction and crystallization operations), and what temperature the vent condenser shouldbe set at. Pro-Designer is equipped with VOC emission models that are accepted by EPA.Please see Chapter 10 or consult the on-line Help Facility for more info on emissioncalculation models. For the heptane charge in your example process, please click the

Ventingbox and then the Emissionsbox. By default the output port that has beenselected is the venting port S-104. Then click in the Emitted box next to the Heptanecomponent. After the simulation, please remember to visit the dialog of stream S-104 andcheck the amount of emitted Heptane. For particulate and other components for which

emission models are not available, the user can specify the Emission % (Figure 2.1-q).


49/409


Figure 2.1-q: The Emissions tab for the heptane charge.

Labor tab:here the user can specify labor requirements and auxiliary utilities.

Scheduling tab:The right-most tab of a batch unit procedure is always the Scheduling

tab. Through this tab, the user specifies the start time of an operation relative to the startor end of other operations in the same or different procedures. For unit procedures incontinuous mode, no scheduling information is required.

Note: Depending on the complexity of an operation, additional tabs may be employed todisplay other pertinent variables.

For this operation, leave all the default values for the Labor etcand Schedulingtabs.


50/409


Next, click the OKbutton on the Operation Data dialog to move to the second chargeoperation in this unit procedure. For this operation, use stream S-102 to add 50 kg ofmaterial A to the reactor. Also specify a 5 minute setup time and a 20 kg/min charge rate.Leave the default values for the other tabs.

Then click the OKbutton to move to the final charge operation. Initialize this similarly, but

use stream S-103 to add 40 kg of material B. Also change the setup time to 5 minutes and thecharge rate to 20 kg/min.

Once again, click the OKbutton to move to the next operation (the Batch StoichiometricReaction). Notice that the Operating Conditions tab is different for this operation than it wasfor the Charges, and that several other tabs are present.

Starting with the Operating Conditions tab, change the Final Temp to 50 oC, the Heat TransferAgent to Steam, and the Process Time to 6 hours. Leave all the other default values on thistab as they are.

Next, referring to the Volumes tab, notice that you can specify a maximum and minimumworking to vessel volume ratio. Change the Max Allowable working/vessel volume to 80%.Then move to the Reactions tab (see Figure 2.1-r).

Figure 2.1-r: The Reactions tab.


51/409


In this tab, you will need to specify the parameters describing a reaction in which 1molecule of reagent (A) combines with 1 molecule of reagent (B) to form a molecule ofproduct (C):

A + BC

To enter this, bring up the Edit Stoichiometry dialog (see Figure 2.1-s) by clicking on

the button. Introduce the reactants {A and B} and the product {C} using the AddReactant and Add Product buttons (located above the reactant and product tables).Select Molar for stoichiometric coefficients option and enter 1 for everything. Formore information on specifying reaction coefficients, please see Chapter 2.2. Now close theEdit Stoichiometry dialog. In addition to specifying the stoichiometric coefficients, youwill need to specify the extent of reaction. For this example set the Extent to 95%, as was

done in Figure 2.1-r. Next, click the OKbutton to move to the Transfer Out operation(leave all the default values for the Emissions, Labor etc, and Schedulingtabs.)

Figure 2.1-s: The Stoichiometry Balance tab.

In the Transfer Out dialog (Figure 2.1-t), use the drop-down menu at the top of the screento specify which stream line will be used for the transfer operation. In addition, in order toaccurately capture the time required for this operation, set the duration to be the same as the

filtration duration in P-2 (see below). To do that, select the Set By Master SlaveRelationshipduration option and then click the SetupButton. Through the dialog thatcomes up, select P2 (in PFF-101) as the Master Procedure (through the AnotherProcedure drop down menu), and FILTER-1 (Cloth Filtration) as the Master Operation(through the Match a Single Operation drop down menu).

This will ensure that the reactor will be considered utilized during filtration, since thereactor will not be completely emptied until the filtration is complete. You can leave the

default values for the other tabs in this dialog.


52/409


53/409


Figure 2.1-u: The Filtration operation dialog.

Next, please visit the Scheduling tab of the filtration operation. This tab is common to alloperations. By default, the first operation in any batch unit procedure is scheduled to startrelative to the beginning of the batch. In order to accurately schedule your filtration, youwill need to change the Start Time to be relative to the start of the Transfer Out operation inprocedure P-1 (see Figure 2.1-v).


54/409


Figure 2.1-v: The Scheduling tab of the filtration operation.

Next, click OK to move to the Cake Wash operation (Figure 2.1-w). Here you will need tospecify which stream will provide the wash solvent and which one will remove the waste(S-109 and S-108 respectively in this case). In addition, you will need to specify what

solvent is used for the wash. To do this, press the Compositionbutton and select Heptane.Then click OK to return to the Cake Wash dialog. Notice that from this dialog you canspecify the volume of wash to use based on the cake volume or a set value. Please keep thewash amount as 1 L/L of cake, use a wash time of 30 minutes, and change the wash type to

slurry from displacement. A slurry wash will essentially dilute the soluble componentstrapped in the cake and remove most of them in the wash stream, whereas a displacementwash will remove the soluble components from the cake in a plug-flow fashion.


55/409


Figure 2.1-w: The Cake Wash dialog.

Finally, click the OKbutton to initialize the Transfer Out operation in this unit procedure(Figure 2.1-x). In this operation, you will need to specify that you are going to transfer outthe cake using a specific stream (the Cake stream is the only one available in this case)

and the transfer will be done at a certain rate (10 kg/min in this case). Then Press OK.


56/409


57/409


58/409


59/409


Figure 2.1-z: Dialog of the Filtration Operation (when the Equipment is in Rating Mode).

Important note about building and initializing large flowsheets when you designcomplex flowsheets, keep in mind that you dont have to add all the unit procedures atonce. You can always add or remove procedures as desired at a later stage of the design.For complex flowsheets, it is highly recommended that you begin your design with just afew unit procedures (two is a good number) and add more of them only after you havesimulated the first unit procedures and determined that the streams and operations have

been initialized correctly and your mass balances make sense.


60/409


Using Break Points

When simulating large flowsheets it is sometimes useful to solve only part of the process.Setting breakpoints tells the simulator to halt calculations at a certain point. A briefdescription of this facility is given below.

You can place a breakpoint, and force the M&E balance execution sequence to pauseeither right before, or right after the solution of a unit procedure. You may even place abreakpoint inside the unit procedures solution sequence of unit operations. Use thefollowing steps to place a breakpoint on a unit procedure:

Right click on a unit procedure to bring up the command menu:

After selecting the "Set Breakpoint" option, a dialog will appear asking where tobreak the simulation. Check the place(s) where you wish the simulation to pause

and exit this dialog, notice a red sign, , is shown above the procedures icon toindicate that one or more breakpoints are set on this procedure. The position ofthe sign indicates whether the break is on the entry, operations or exit of theprocedure.

Once a breakpoint is set, next time the "Solve M&E Balances" command isissued, the simulation calculation sequence will pause at that location. When thesimulation sequence is paused, some of the Solve Toolbars buttons becomeactive. Also notice that while the simulation has been paused, all unit proceduredisplay another icon underneath that has indicates the simulation state of eachprocedure at that time (as the simulation is paused):

has not been visited yet

has been successfully simulated already

is being solved recursively (as part of loop convergence)

solution ended unsuccessfully (as part of an un-converged loop)

solution ended unsuccessfully (an error was encountered)

The following sequences of images, indicate the state of the unit procedure that isCURRENTLY BEING SOLVED (i.e. when the breakpoint was encountered):

Break on entry

Break in an operation

Break on exit

Break on entry

Break on material pull in/push out(applies to operations with auto adjustmaterial streams)

Break in an operation

Break on material pull in/push out(applies to operations with auto adjustmaterial streams)

Break on exit


61/409


62/409


To specify the number of cycles per batch of a procedure (the same number applies to alloperations of the procedure), simply right-click on the unit procedures icon and choose

Procedure Data. By default, all procedures start with one cycle.

To specify scheduling information for an entire process, select Tasks/ RecipeScheduling Information... (see Figure 2.1-aa below).

Figure 2.1-aa: Specifying the scheduling information for a batch process

For your example process, please change the Number of Batches per Year to 20. Thisimplies that your example process will be run in a pilot plant 20 times this year (it isassumed that the equipment used by this process is used by other processes the rest of theyear.) In addition, please change the annual operating time for this process to 240 hours toreflect the completion of one batch during every 12-hour shift.

Based on the scheduling information and the annual operating time specified for the plant,the system will do the following:

1. Make sure there is no conflict created by the specified start time and end time ofprocessing steps. Conflicts can be created if the cycle times of procedures that shareequipment overlap.

2. Make sure there is no conflict between the specification of annual operating time, the

number of batches, and the plant cycle time (as calculated from all the procedures).3. Calculate the plants batch time, the plants cycle time, the plants minimum cycle time

(with maximum batch overlapping), the maximum number of batches possible, thelongest procedure (i.e., the procedure with the longest total cycle time) and thescheduling bottlenecking equipment (the equipment with the longest occupancy time).


63/409


2.1.9 Viewing Scheduling, Equipment Utilization and ResourceTracking Results

A variety of scheduling, equipment utilization and resource tracking tools are included inPro-Designer. These include Operations and Equipment Gantt Charts, Main andAuxiliary (CIP skids & SIP panels) Equipment Occupancy Charts, and Resource Demand

and Inventory Charts.

Gantt Charts

Please generate the Operations Gantt Chart for your example process by selecting Tasks /Gantt Charts / Operations GC from the main menu. It should look similar to Figure2.1-bb below. The left view (spreadsheet view) displays in each line: the name, duration,start and end time for each activity whose bar line is shown straight across on the chart(all information is presented for viewing purposes only). You use the left view to expandand/or collapse activity summaries by clicking on the + or rectangle showing at the leftof the name of the activity. The right view (chart view) displays a bar for each activityparticipating in the overall scheduling and execution of the recipe.

Figure 2.1-bb: The Operations Gantt Chart.

Note:If you wish to modify the appearance of the chart, including the bar width andtime-scale use the Preferences / Styles / Gantt Chartmenu item on the charts menu bar.

From the Gantt Chart interfaces you can modify the scheduling parameters of eachprocedure and operation as well as the scheduling parameters for the entire process (i.e.,annual operating time, number of batches per year, etc.). In fact, anything you canaccomplish with the scheduling interfaces described in Section 2.1.7, you can also

accomplish from the Gantt chart interface. In order to edit scheduling parameters fromthis interface, right-click on the bar of the desired procedure or operation. This will bring

up the Procedure Datadialog (in the case of procedures) or the Operation Datadialog(in the case of operations.) To view and edit the scheduling information for the entirebatch, right-click on the bar which corresponds to the Complete Recipe (at the top of the

chart) and choose Recipe Scheduling Info. After you have edited a schedulingparameter, you must click the Update Chart button on the Gantt chart main menu. As youcan see, these Gantt Charts present you with a graphical way to set the schedulingparameters of each processing step and immediately visualize the effects on the entire


64/409


65/409

8/10/2019 Superpro Manual v7

Documents

Superpro Manual v7 5 for Reproduction