Documente Academic
Documente Profesional
Documente Cultură
Abstract
Flowsheeting program packages are now commonly used in chemical engineering for the design of
processes involving fluids. The simulation of processes which involve solids or solids and fluids is not
as advanced. In solids processing it is still common practice to design one apparatus separately from
the other. There is a lack of suitable methods to combine single apparatus models to form a process
and to treat this process as a whole. With the program package SolidSim, a simulation system
especially designed for the simulation of processes including solids has been developed. At the present
state of development, modules are available for classification, particle size reduction, crystallisation
and dissolution, liquid-solid separation, gas-solid separation, agglomeration, reaction, drying,
conveying and different general modules. The structure of the system is explained in detail and the
application to a process for the treatment of contaminated sludge is shown.
Keywords: Solids process, Flowsheet simulation
1. Introduction
Today, flowsheeting program packages are commonly used in chemical engineering for the design of
processes involving fluids (e.g. 1)). There are several
established systems for the simulation of fluid processes. Among these are, for example, Aspen plus 2),
Pro/II 3) or Chemcad 4).
The simulation of processes which involve solids
is not as advanced, but it is common practice to design and optimise each apparatus separately from the
others, neglecting its influence and dependence on
the neighbouring processes. For simulation of the
process, mathematical models for the individual units
are used and the results are transferred manually
from unit to unit. While this is feasible without sig-
*
1
146
147
148
solvers are available. This forced the decision to design SolidSim as a block-oriented system.
The program system is divided into four major parts:
the simulation environment, which provides the
basis of the whole system,
the stream objects, which transport and manage
the inserted stream information and
the model library with the unit models,
the property package, that provides the physical
data and the phase equilibrium for the materials
in the stream objects.
For the interconnection between these basic elements, the interfaces as defined by the CAPE-OPEN
standard13) are used as far as possible. The not yet
completely publicly available version 1.1 of the standard was used. A sketch of the structure is shown in
Fig. 1. The plugs and sockets denoted by ThermoSE
have been extended within the present work for
the treatment of solids (SE = Solid Extension). The
extension allows easy handling of distributed properties.
Additionally, in Fig. 1, the communication with
other simulation packages is indicated. Using the
CAPE-OPEN standard, a detailed flowsheet simulated with SolidSim may be used as one module in an
external CAPE-OPEN-compliant simulation environment, using the standard interfaces for the communication. Another possibility for use of the functionality
of other simulation packages in connection with SolidSim is to incorporate modules from other packages
as unit models into the SolidSim environment. Very
important is the possibility to use external property
packages inside SolidSim, since the development of
a detailed property package was not within the focus
of the present work, and only a very basic property
package is part of the SolidSim system. Tests with
Viig^WjiZ_
&
'
(
)
*
+
&
'
'
`
iZ
149
(1)
djiaZi
&
'
I%!%
I%!&
I%!'
I%!(
I%!)
I%!*
&
I&!%
I&!&
I&!'
I&!(
I&!)
I&!*
'
I'!%
I'!&
I'!'
I'!(
I'!)
I'!*
I(!%
I(!&
I(!'
I(!(
I(!)
I(!*
I)!%
I)!&
I)!'
I)!(
I)!)
I)!*
I*!%
I*!&
I*!'
I*!(
I*!)
I*!*
^caZi
150
unit model
geometry
data
specific model
(user
interface)
ThermoSE 1.1
socket
done
base unit
Unit 1.0
plig/socket
Werther, Hamburg
Filtration of fluids
Ripperger, Kaiserslautern
Gas filtration
E. Schmidt, Wuppertal
ThermoSE 1.1
plug
Separation processes in
centrifuges
Agglomeration, granulation
Mrl, Magdeburg
Crushing in mills
Peukert, Erlangen
Convection drying
Tsotsas, Magdeburg
Crystallisation, dissolving
Kind, Karlsruhe
Gas-solid reactions in
fluidised beds
Werther, Hamburg
Liquid spraying
Walzel, Dortmund
Wirth, Erlangen
simulation environment
Responsible partner
Separation, classification
output
stream (s)
calculate
input
stream (s)
Processing step
151
152
CVbZ
EH9
`\$h
`\$h
[ZZY
%#&(--.
%#&(--.
%#%%&.-+
b^aaT^caZi
%#(+%-.
%#(+%-.
%#%%&&-(
b^aaTdjiaZi
%#(+%-.
%#(+%-.
%#%%%,-'.
h^ZkZTXdVghZ %#'''
%#'''
%#%%&%)&
egdYjXi
%#&(--.
%#%%%*%.'
%#&(--.
&!%
F(m
%!-
Vk#XdciVb^cVi^dc/
++eeb
%!+
%!)
%!'
%!%
&*%
&%%
*%
aZVYXdciVb^cVi^dcPeebR
%!%&
%!&
&
&%
mPbbR
Fig. 11 Size-dependent contamination of dredged sludge (harbour of Hamburg) with lead. On the right side, the
cumulative mass distribution of the particle size is plotted.
153
Fig. 12 Flowsheet for the mechanical dewatering and separation of harbour sediments.
154
8dVghZ
;ZZY
B^mZg*
;ZZY&
;ZZYB:I=6
8dVghZbViZi^Va
&*
&(
8dVghZhXgZZc^c\
Ejbe'
%&
'cY=nYgdh^o^c\
&)
%*
Ejbe'
HajY\Z
%)
B^mZg(
B^mZg%
'%
He^gVah
&hi=nYgdh^o^c\
%'
I]^X`ZcZi
&'
%(
%+
%-
HajY\Z
B^mZg)
&,
&&
9ZXVciZg
B^mZg&
KVXjjb9ZlViZg^c\
Hea^iiZg&
:ajig^Vidg
B^mZg'
:mXZhhlViZg
:mXZhhlViZg
Hea^iiZg'
9ZlViZg^c\
%.
'(
;^cZhVcY
;^cZhVcY
HVcY
HVcY
Fig. 13 SolidSim flowsheet for the mechanical dewatering and separation of harbour sediments.
5)
6)
7)
8)
Acknowledgements
Financial support of this work by the Association
of Industrial Research Institutions (Arbeitsgemeinschaft industrieller Forschungsvereinigungen AiF)
under grant no. 94 ZBG/1-12 and by the industrial
consortium IK SolidSim is gratefully acknowledged.
9)
10)
11)
12)
13)
Bibliography
1)
2)
3)
4)
14)
15)
16)
17)
18)
2006.
USIM PAC, http://www.svedala-cisa.com/usimpac/
upac.htm, 2006.
JKSimMet, http://www.jksimmet.com/, 2006.
Grainsoft: PMP Sim, http://www.grainsoft.com/index.
htm, 2006.
Wilichowski, M., T. Pawletta, : SoProSim - A Tool for
the flowsheet-orientated Simulation of Classification
Processes, in: Pratsinis, S. E., Schulz, H., Strobel, R. &
Schreglmann, C. (Eds.), Proceedings of International
Congress for Par ticle Technology PAR TEC 2004.
Nuremberg: 2004, Proceedings on CD.
Bedrock Software: AGGflow, http://www.aggflow.
com/, 2006.
Rockware Inc.: Rockworks, http://www.rockware.
com/catalog/pages/rockworks2004.html, 2006.
metsim: MetSim, http://www.metsim.com/, 2006.
CO-LaN: CO-Lan, www.co-lan.org, 2006.
CO-LaN consortium: Thermodynamic and Physical
Properties v1.1, http://www.colan.org/Spec%2011/
CO%20Thermo%201.1%20Specification.pdf, 2005.
Moltz, S.: Reduktion populationsdynamischer Modelle, Dusseldorf: VDI-Verlag, 2004.
Aspentech: Aspen Properties, http://www.aspentech.
com/includes/product.cfm?IndustryID=0&ProductI
D=77, 2006.
Infochem: Infochem Multiflash, http://www.infochemuk.com/product/products.htm, 2006.
ProSim: Simulis Thermodynamics, http://www.prosim.net/prod_simulist.html, 2006.
Vogel, L. and W. Peukert, : Modelling of grinding in
155
&!%
HVcY
idiVa[adl/
a^fj^Ye]VhZ[adl/
hda^Ye]VhZ[adl/
Vk#XdciVb^cVi^dc/
%#(&`\$h
%#%(`\$h
%#'-`\$h
.#,eeb
F(m
%!%!+
%!)
%!'
%!%
&*%
&%%
*%
%!%&
%!&
aZVYXdciVb^cVi^dcPeebR
&
&%
mPbbR
&!%
HajY\Z
F(m
%!idiVa[adl/
a^fj^Ye]VhZ[adl/
hda^Ye]VhZ[adl/
Vk#XdciVb^cVi^dc/
%#*'`\$h
%#&%`\$h
%#)'`\$h
&(*#%eeb
%!+
%!)
%!'
%!%
&*%
&%%
*%
aZVYXdciVb^cVi^dcPeebR
%!%&
%!&
&
&%
mPbbR
Fig. 14 Simulation results: particle size distributions and distribution of contamination in the two products sand and sludge.
an air classifier mill based on a fundamental material function, KONA Powder and Particle, 21, 2003,
109-120.
19) Vogel, L. and W. Peukert, : Breakage behaviour of different materials - construction of a mastercur ve for
the breakage probability, Powder Technology, 129,
2003,
20) Rogers, R. S. C.: A Classification Function for Vibrating Screens, Powder Technology, 31, 1982, 135-137.
21) Werther, J., G. Gruhn, M. Kind, L. Morl, W. Peukert,
S. Ripperger, E. Schmidt, H. Nirschl, E. Tsotsas, P.
Walzel, and K.-E. Wirth, Fliesschema-Simulation von
156
Matthias Pogodda
Dipl.-Ing. Matthias Pogodda is currently a research fellow in the Institute of Solids
Process Engineering and Particle Technology of the Hamburg University of Technology. The main focus of his work is the development of the flow sheet simulation
system SolidSim, which is especially designed for the simulation of complex solids processes. He is also conducting research in the field of data reconciliation and
instrumentation network design of solids processes.
Claus Reimers
Claus Reimers is currently a research fellow in the Institute of Solids Process Engineering and Particle Technology at Hamburg University of Technology, working
on the development of a flow-sheeting system for complex solids processes, called
SolidSim. His research is focused on the optimization of solids processes.
Daniel Schwier
Daniel Schwier is currently a research fellow at the Institute of Solids Process Engineering and Particle Technology at the Hamburg University of Technology. His
research topic is the treatment of inaccuracies of parameters and models in the
flowsheet simulation of solids processes.
Gnter Gruhn
Professor Gnter Gruhn was (till 2003) the head of the Department of Process and
Plant Engineering at the Hamburg University of Technology. His research interests
were mainly directed towards flowsheeting and optimisation of complex process
systems, design and operation (scheduling) of multi product plants for manufacturing fine chemicals and optimal production control of petrochemical plants.
157
Joachim Werther
Professor Joachim Werther is the head of the Institute of Solids Process Engineering and Particle technology at the Hamburg University of Technology. His research
interests are mainly directed towards fluidization technology and its application for
industrial processes, towards classification of particles and towards the physical
treatment of contaminated solids. A further major field of research is the development of advanced simulation tools for the flowsheet simulation of processes involving solids.
158