Documente Academic
Documente Profesional
Documente Cultură
Shawna Berg Greg Brobst Josh Edmonds Allison McGuire Robyn Menard Bryan Tracy
Table of Contents
List of Figures.......................................................................................................................3 List of Tables ........................................................................................................................5 0.0 Introduction....................................................................................................................6 1.0 Creating a Design Simulation .......................................................................................6
1.1 Opening SuperPro Designer .....................................................................................................................6
2.0 Specify Mode of Operation ...........................................................................................7 3.0 Set Default Physical Units .............................................................................................9 4.0 Register Components and Mixtures.............................................................................11
4.1 Register Pure Components ..........................................................................................................................11 4.1.1 Registering Pure Components in Database ................................................................................11 4.1.2 Adding Pure Components not offered in Database ....................................................................13 4.1.2A Introducing a new component into current design ....................................................14 4.1.2B Introducing a new component permanently into Pure Components Database ..........16 4.1.3 Editing Physical Properties of Pure Components.......................................................................16 4.1.4 Adding Physical Properties of Pure Components.......................................................................18 4.2 Defining Special Components .....................................................................................................................25 4.3 Register Stock Mixtures ..............................................................................................................................26 4.3.1 Registering Stock Mixtures in Database ....................................................................................26 4.3.2 Adding Stock Mixtures not offered in Database ........................................................................27 4.3.2A Introducing a new stock mixtures into current design...............................................28 4.3.2B Introducing a new stock mixtures permanently in Stock Mixtures Database............28 4.3.3 Editing Physical Properties of Stock Mixtures...........................................................................29
6.4.4 Specifying Stream Components of a Discrete Input Stream (Components, Etc. Tab) ............78 6.4.5 Editing the Composition of a Discrete Input Stream (Composition, Etc. Tab) .......................79 6.4.6 The Composition, Etc. Tab for an Intermediate or Output Discrete Stream ...........................81 6.4.7 Setting the Density Value (Density Tab).................................................................................82 6.5 Physical Characteristics............................................................................................................................84 6.5.1 Changing the Color, Style, and Thickness of the Stream ........................................................86 6.5.2 Editing the Tag Properties.......................................................................................................87 6.5.2A Changing the Tag Name.........................................................................................87 6.5.2B Editing the Tag Text Style......................................................................................88 6.5.2C Editing the Appearance of the Tag Frame..............................................................89 6.5.2D Editing the Location of the Stream Tag .................................................................89 6.5.2E Picking Up and Applying a Stream Style ...............................................................90
List of Figures
Figure 1.1: Specifying Mode of Operation for Plant .............................................................7 Figure 2.1: Changing Mode of Operation within New Flowsheet.........................................8 Figure 3.1: Accessing Physical Units Options.......................................................................9 Figure 3.2: Setting Default Physical Units ..........................................................................10 Figure 4.1: Accessing the Pure Components Database .......................................................12 Figure 4.2: Registering pure components available in database..........................................13 Figure 4.3: Registering pure components not available in database....................................14 Figure 4.4: New Component Registration ...........................................................................15 Figure 4.5: Editing Properties of Pure Components ............................................................16 Figure 4.6: Properties of Pure Components.........................................................................17 Figure 4.7: Registering Stock Mixtures ...............................................................................27 Figure 4.8: Registering a Stock Mixture Not in Database ...................................................28 Figure 5.1: Adding a Unit Procedure.....................................................................................40 Figure 5.2: A Vessel Procedure in a Fermentor.....................................................................40 Figure 5.3: Reversing the Flow Direction of a Unit Procedure .............................................41 Figure 5.4: A Procedure Flowing Right-to-Left ....................................................................42 Figure 5.5: Accessing the Procedure Data Window ..............................................................42 Figure 5.6: The Procedure Data Window for a Batch Process ..............................................43 Figure 5.7: Accessing the Equipment Data Window.............................................................44 Figure 5.8: The Equipment Data Window.............................................................................45 Figure 5.9: Choosing the Equipment for a Unit Operation....................................................46 Figure 5.10: Accessing the Breakpoints Window..................................................................48 Figure 5.11: The Breakpoints Window..................................................................................49 Figure 5.12: The Breakpoint Window with Automatic Material Pull-In...............................50 Figure 5.13: Breakpoint Window with Automatic Push-Out ................................................51 Figure 5.14: The Different Breakpoint Settings ....................................................................52 Figure 5.15: The Breakpoints Sub-menu ...............................................................................53 Figure 5.16: Accessing the Unit Procedure Icon Style Window ...........................................54 Figure 5.17: The Unit Procedure Icon Style Window ...........................................................54 Figure 5.18: Changing the Color of a Unit Procedure Icon...................................................55 Figure 5.19: The Edit Procedure Labels Window .................................................................56 Figure 5.20: The Name Tag: Text Window...........................................................................57 Figure 5.21: The Name Tag: Frame Window........................................................................58 Figure 5.22: Picking Up a Unit Procedure Icon Style ...........................................................59 Figure 5.23: Applying a Unit Procedure Icon Style ..............................................................60 Figure 6.1: Appearance of Bulk and Discrete Streams.........................................................61 Figure 6.2: Different Types of Process Streams ..................................................................61 Figure 6.3: Location of the Connect Mode Button ..............................................................62 Figure 6.4: Input Ports .........................................................................................................63 Figure 6.5: Output Ports.......................................................................................................63 Figure 6.6: How to Reach the Properties Window for a Stream .........................................65 Figure 6.7: Bulk Stream Properties Window.......................................................................65 Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk Stream ................................................................................................................67
Figure 6.9: Steps Taken to Input Ingredient Flows..............................................................68 Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk Input Stream....................................................................................................69 Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams..................70 Figure 6.12: How to Change Units in SuperPro ...............................................................71 Figure 6.13: Setting a Known Mixture Density for a Bulk Stream .....................................72 Figure 6.14: Setting the Density Based on Ingredient or Component Contributions ..........73 Figure 6.15: The Environmental Properties Tab for a Bulk Stream ....................................74 Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream ...75 Figure 6.17: Properties Window for a Discrete Input Stream .............................................75 Figure 6.18: Setting the Description of a Discrete Input Stream.........................................76 Figure 6.19: How to Edit the Flow of a Discrete Input Stream ...........................................77 Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams.......................78 Figure 6.21: Adding Components to a Discrete Input Stream.............................................79 Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows 80 Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete Input Stream....................................................................................................81 Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams....82 Figure 6.25: Setting a Known Mixture Density...................................................................83 Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a Discrete Stream................................................................................................84 Figure 6.27: How to Reach the Stream Style Window........................................................85 Figure 6.28: The Stream Style Window ..............................................................................85 Figure 6.29: The Colors Window ........................................................................................86 Figure 6.30: How to Reach the Edit Tag Window...............................................................87 Figure 6.31: The Edit Tag Name Window...........................................................................87 Figure 6.32: The Name Tag: Text Window.........................................................................88 Figure 6.33: The Name Tag: Frame Window......................................................................89 Figure 6.34: The Name Tag: Location Window.................................................................90 Figure 6.35: How to Pickup a Stream Style.........................................................................91 Figure 6.36: How to Apply a Stream Style..........................................................................91 Figure 7.1: Unit Procedure Menu ........................................................................................92 Figure 7.2: Operation Interface............................................................................................93 Figure 7.3: >>Add>>Function.............................................................................................94 Figure 7.4: Result of>>Add>>Function ..............................................................................95 Figure 7.5: >>Insert>>Function...........................................................................................96 Figure 7.6: Renaming an Operation.....................................................................................97 Figure 7.7: Accessing Operation Data Interface..................................................................98 Figure 7.8: Operation Data Interface ...................................................................................99 Figure 7.9: Accessing Help Menu .....................................................................................100 Figure 8.1: Accessing the Properties Window of a Unit Operation ..................................101 Figure 8.2: Operation Duration Conditions .......................................................................102 Figure 8.3: Operation Duration: Master-Slave Relationship .............................................104 Figure 8.4: Master-Slave Relationship Master Procedure Setup ....................................105 Figure 8.5: Master-Slave Relationship Master Single Operation Setup .........................106 Figure 8.6: Master-Slave Relationship Master Sequence Operation Setup....................107
Figure 8.7: Scheduling Overview Screen ..........................................................................108 Figure 8.8: Scheduling Overview Screen Start Time Information .................................109 Figure 8.9: Start Time Relationship Relative to Another Operation in this Procedure ..111 Figure 8.10: Start Time Relationship Relative to Another Operation in Another Procedure ............................................................................................................................112 Figure 8.11: Recipe Scheduling Information Command Screen .......................................113 Figure 8.12: Recipe Scheduling Information Data ............................................................114 Figure 8.13: The Gantt Charts Menu .................................................................................115 Figure 9.1: Operation Data Command Screen...................................................................116 Figure 9.2: Operation Conditions Main Screen .................................................................117 Figure 9.3: Operation Operator Specifications ..................................................................118 Figure 9.4: Operation Labor Units Specification...............................................................119 Figure 9.5: Operation Add/Delete Labor ...........................................................................120 Figure 10.1: Component Registration Interface.................................................................121 Figure 10.2: Component Economic Properties Interface...................................................122 Figure 10.3: Stream Specifications Command Interface ...................................................123 Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface ...........124 Figure 10.5: Specifying Output Stream Classifications.....................................................125 Figure 10.6: Specifying Input Stream Classifications .......................................................126 Figure 10.7: Equipment Data Specification Command .....................................................127 Figure 10.8: Equipment Purchase Cost Information..........................................................128 Figure 10.9: Labor Tab for Operation Conditions Interface..............................................129 Figure 10.10: Performing Economic Calculations Interface .............................................130 Figure 10.11: Generating Economic Report Interface.......................................................131 Figure 10.12: Saving EER Interface ..................................................................................131 Figure 10.13: View Economic Evaluation Report Command Screen ...............................132 Figure 11.1: Selecting the component or stock mixture for registering emissions and environmental classifications........................................................................133 Figure 11.2: Pollutant Categories Window........................................................................134 Figure 11.3: Selection of VOC and Acid gas for emissions consideration .......................144 Figure 11.4: Accessing the Emission Limits Window.......................................................145 Figure 11.5: Adding User-Defined Pollutant Categories...................................................146 Figure 11.6: Selection of hazard and waste considerations ...............................................148 Figure 11.7: Selection steps for generating an emissions report .......................................149 Figure 11.8: Selection steps for generating an environmental impact report ....................150 Figure 11.9: Selection steps for viewing an emissions report ...........................................151 Figure 11.10: Illustration of a stream section from an emissions report ...........................152 Figure 11.11: Illustrates the per batch portion of the emissions report .............................153
List of Tables
Table 5.1: Unit Operations Available in Unit Procedures ....................................................31 Table 11.1: Pollutant Categories...........................................................................................135
0.0 Introduction
The following users manual is formatted for easy use by both SuperPro masters and those with no prior simulation experience. If you have no previous experience with SuperPro, read the manual chronologically to ensure that the proper functions are performed in the correct order. For users familiar with the SuperPro simulation package, this manual can be navigated through easily by the use of the table of contents and index. This particular manual targets a pharmaceutical audience and may leave out information concerning the software that does not pertain to this industry. Note: Keywords underlined in blue font are hyperlinked to the glossary to allow the user to gather additional information, if needed, about a particular term.
File>>New After selecting New and before the simulation will open a new flowsheet, the user must define whether the process is batch or continuous. After choosing to start a new flowsheet by selecting File and New, the following interface, Figure 1.1, will appear.
The user must choose a primary mode of operation and annual operating time for the design before the remainder of the designing process can take place. The following section will discuss the two possible selections for mode of operation in SuperPro.
o Plant batch time is calculated o Stream flows are displayed on a per-batch basis o Inherently continuous processing steps can be included as unit operations in either continuous or semi-continuous mode Continuous o o o o o Allows user to have continuous and batch procedures in one design To utilize the mixed mode option, simply choose the mode of operation that is prominently used in the design (either batch or continuous) and denote specific operations as continuous or batch by the scheduling options. (See Section 8.0) When SuperPro is opened the user is prompted to specify the mode of operation before a new flowsheet is opened (see Section 1.1). Once a new flowsheet is opened, the mode of operation can be changed by selecting: Tasks>>Set Mode of Operation Figure 2.1 depicts the necessary actions to set the mode of operation. Scheduling information is not required Plant batch time is not calculated Stream flows are displayed on a per-hour basis Inherently batch processing steps can be included if user specifies processing time and turnaround time for these steps
Mixed Mode
Once selected, the interface shown above in Figure 1.1 will appear and can be used to set the mode of operation needed for your process. Note: Though the program allows the user to change the mode of operation during and after the design process, making a change late in the design will require the user to revise earlier steps. It is suggested that the user finalize the mode of operation before adding unit operations and procedures and as early in the design process as possible.
After selecting Physical Units Options, the following interface, as shown in Figure 3.2, will appear.
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The default settings for physical units can be changed by using the button and scrolling through the unit options. The following units are available for the above categories: Time in: yr, mo, s, min, h, day, wk Mass in: lbmol, mol, kmol, lb, MT, ton, oz (troy), oz (avdp), g, kg Volume in: yd3, L, Mgal, Kgal, gal, ft3, m3 Composition in: ppb, ppm, [01] Concentration in: lbmol/gal, kmol/L, micro-mol/L, mmol/L, mol/L, micro-g/L, mg/L, g/cm3, g/L Density in: g/cm3, g/L Temperature in: deg R, deg K, deg F, C Pressure in: inH2O, inHg, cmH2O, mmHg, psi, atm, bar, Pa Note: Though a physical property may be assigned default units, the units can be changed within streams and operations during the process. In other words, choose
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default physical units that are most often used in your process or that you want for your generated data, but understand that these units are not binding for all operations.
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Once in the Pure Components Database, shown in Figure 4.1, components can be registered by selecting the appropriate component and instructing SuperPro to register the component. To register pure components available in database: 1) Select chemical needed for the simulation by either: a. Typing name of chemical in entry box b. Scrolling up/down in Pure Component Database and selecting a chemical 2) Click the Register button Figure 4.2 depicts the necessary actions to register pure components available in the database.
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Once Register is chosen, the registered component will appear in the Registered Pure Components section, located on the right side of Figure 4.2. Note: The Pure Components Database can be altered at any point in the simulation process. It is not necessary to register all components that will appear in the flowsheet at one time, but it is recommended that users form the habit of registering components early in the simulation process to prevent from having to return to the Pure Components Database multiple times. The physical constants for the components in the Pure Components Database are already defined within the database. Unless specified by the program, no additional physical constants need to be added to these pure components, but can be modified for a specific design case. Physical properties can only be edited for registered components.
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If the user is uncertain of the properties of a pure component, the best option may be to add the new component temporarily. If new accurate information is found later in the design process, the new component can be inserted into the database permanently.
After selecting New, the following interface, as shown in Figure 4.4, will appear.
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The new component needs to be specified in one of four ways: 1) Name: can include up to 31 characters 2) Chemical Abstract Service (CAS Number 3) ): can include up to 15 characters 4) Trade Name: can include up to 31 characters 5) Local Name: can include up to 15 characters; abbreviations of component names recognized by your company Note: SuperPro will not allow more than one component to have the same local name. Once a name is denoted for a component, this field cannot be edited without removing the component completely and introducing it again. SuperPro automatically denotes the property values based on a default component. This component can be chosen by using the drop-down menu for Source for Default Property Values, as can be seen in Figure 4.4. Note: SuperPro requires that a default component be chosen to add a new component, but these properties can be manually changed after the component is added. Once the user is certain the component name is inserted correctly and a default component is chosen, select OK. The new component will appear in the Registered Pure Components list with the registered components from the Pure Components Database. The properties of this component are set by a default component. The
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property values of the new component can be changed by the procedure described in Section 4.2, Editing Physical Properties of Pure Components. Note: Remember that any property not defined by the user is automatically set as the corresponding property of the default component.
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After selecting the Properties option, an interface presenting the ID portion of the components properties will appear. Within the properties function are the following categories: ID Physical (Constant) Physical (T-dependent) Aqueous Economics Pollutant Categories These categories can be chosen by clicking on the tabs located on the top of the interface. For example, if the Physical (Constant) tab is chosen, the following interface, as shown in Figure 4.6, will appear on the screen.
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Because these pure components were registered from the Pure Components Database, most, if not all, of their physical properties are included. These properties are set as a default within the simulation program, but can be changed for a particular process. Pure Components added by the user, as described in Section 4.1.2, will require the user to manually add the physical properties of the component. A further discussion on components properties can be found in the following section, Section 4.1.4.
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Note: All of the above mentioned categories are not necessary for all calculations. However, it is important to recall which properties are defined and which are denoted by the default component. It is important to provide accurate values for as many properties as possible to prevent having to define these properties later and from generating errors in the simulation data. The following sections will discuss in further detail the properties included in the above mentioned categories as well as the operations where these properties are utilized. The user should take note which properties are necessary for particular operations, to ensure that this property data is accurate. ID Name This is the formal name of the pure component, either supplied by the simulation program when the database was developed or by the user when a new component was introduced. The Name portion of the ID cannot be changed once the pure component is introduced. The Name can consist of up to 31 characters. Trade Name The Trade Name may or may not be different from the Name of the pure component. The Trade Name is the name widely known in the market or industry. This name was either supplied by the simulation program when the database was developed or by the user when a new component was introduced. Unlike the Name, however, the Trade Name can be changed later and must be unique. The Trade Name can consist of up to 31 characters.
Formula This property is the formula of the pure component. It was either supplied by the simulation program when the database was developed or by the user when a new component was introduced. The Formula can be changed later in the process and does not have to be unique. The Formula can consist of up to 31 characters. Chemical Abstract Serial Number (CAS Number ) The CAS Number may or may not be available for a particular component. It was either supplied by the simulation program when the database was developed or by the user when a new component was introduced. The CAS Number must be unique and can consist of up to 31 characters. Company ID 20
Companies may have their own number system for denoting certain components used in their process. This tag number is reserved primarily for this purpose. This property was defined by the user when the new component was introduced, but can be changed later. Uniqueness is not necessary for this property. The Company ID can consist of up to 31 characters. Is Biomass
This property consists simply of a True/False prompt to denote whether or not the component can be treated as a biomass. This property is used to denote biomass components within all biological reactors. Physical (Constant) Main Properties Molecular Weight (g/gmol) o Used in distillation, flash drums, condensers, absorbers, strippers, electrostatic precipitators, and all reactors EIR Report: Environmental Impact Report -presents information that describes the effects of the process output streams on the environment -contains a detailed tabulation of all chemicals that are regulated by the EPA or denoted as hazardous by the user Enthalpy of Formation (J/gmol) o Used in energy balances Normal Boiling Point (C) o Used in distillation, flash drums, condensers, and to determine the phase of a given component o From this information the simulation program decides whether to use the density correlation provided by the user or the ideal gas law to determine density Normal Freezing Point (C) o Used to determine if a given component is in liquid or solid form Critical Properties Temperature (C) o Used in distillation, flash evaporation, and condensation Pressure (bar) o Used in distillation, flash evaporation, and condensation Compressibility Factor 21
o Used in distillation, flash evaporation, and condensation Acentric Factor (omega) o Currently not needed for this version of the simulation program Miscellaneous Henrys Constant 4 3 * 10 (atm-m /gmol) o Used in absorption, stripping, and VOC emission calculations Particle Size (microns) o Used in filters and centrifuges Default Volumetric Coefficient o Used to estimate the density of a stream that contains this component Physical (T-dependent) Density (g/L) Used as a conversion between mass and volumetric flow rates and to calculate the concentration of streams Calculated by the following equation: D = a + bT , where T is in K SuperPro allows the user to enter values for a and b for user defined components and to edit a and b for components available in the Pure Components Database For densities in the vapor phase, SuperPro assumes the ideal gas law and calculates the density accordingly EPA: Environmental Protection Agency -a national organization that attempts to lead the nations environmental science, research, educational, and assessment efforts by: Developing and enforcing regulations for hazardous chemicals Offering financial assistance to state and educational institutions for environmental research Performs environmental research to understand current environmental problems Strives to further environmental education in the public arena Evacuate -complete removal of unit procedure contents Heat Capacity (J/gmol-K) Liquid/Solid Cp o Used in energy balances Gaseous Cp
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o Used in energy balances o Calculated by the following equation: Cp = abT + cT 2 + dT 3 , where T is in K o SuperPro allows the user to enter values for a, b, c, and d for user defined components and to edit a, b, c, and d for components available in the Pure Components database Saturation Vapor Pressure : Antoine (mmHg) Calculated using the following equation b log Pi = a , where T is in K c +T SuperPro allows the user to enter values for a, b, and c for user defined components and to edit a, b, and c for components available in the Pure Components Database
Heat of Vaporization (J/gmol) Currently not needed for this version of the simulation program Calculated using the following equations T Tr = , where T is in K Tc Hv = a (1 T ) , where T is in K Watson correlation SuperPro allows the user to enter values for a and b for user defined components and to edit a and b for components available in the Pure Components Database
Aqueous
Used primarily for the calculation of the environmental properties of streams and for operations dealing primarily with waste treatment and pollution prevention operations. Diffusivity Properties 6 o In Water *10 (cm2/s) Used in VOC emissions calculations 3 o In Air *10 (cm2/s) Used in VOC emissions calculations Bio-Degradation Properties o Intermediate Stream
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-a stream that carries material out of a unit procedure and into a different unit procedure. Components and flowrates for an intermediate stream are usually calculated by SuperPro. The exception is when the Pull-Out operation is used.
Kmaxo
(mg substrate/g biomass-h) Used in biodegradation reaction rate calculations in aerobic biooxidation Denotes the maximum biodegradation rate constant o Ks o (mg/L) Used in biodegradation reaction rate calculations in aerobic biooxidation Denotes the half-saturation constant
o
Oxygen Ratios o o Clean-in-Place (CIP) o -used for cleaning processes using a cleaning agent
COD: Chemical Oxygen Demand o (g O/g) Used in calculating the COD value of material streams Denotes the amount of oxygen required to chemically oxidize 1g of the component o ThOD: Theoretical Oxygen Demand o (g O/g) Used to calculate the ThOD in streams Denotes the theoretical amount of oxygen needed to oxidize 1g of the component Often equal to the COD o BODu/COD(g/g) Used to calculate BODu value in stream based on the COD value of each component Denotes the ratio of the ultimate biochemical oxygen demand to the COD of the component o BOD5/BODu o (g/g) Used to calculate the BOD5 value in stream based on the COD value of each component Denotes the ratio of the five-day BOD to the ultimate BOD value
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Nitrogen Ratios o TKN: Total Kjeldahl Nitrogen o (g N/g) Used to calculate the TKN value of the streams Denotes the Kjeldahl nitrogen contribution of the component o NH3: Ammonia Nitrogen (g N, as NH3/g) Used to calculate the NH3 value of the streams o NO3-NO2 : Nitrate/Nitrite Nitrogen o (g N, as NO3, NO2)/g) Used to calculate the NO3-NO2 value of streams Denotes the NO3-NO2 contribution of the component Log10 (octanol/water) o Currently not needed for this version of the simulation program o Used to indicate the hydrophobicity of a component o Helps determine a components tendency to become sludge Carbon ratio o TOC: Total Organic Carbon o (g C/g) Used to calculate the TOC values of streams Denotes the organic carbon contribution of a component Phosphorus ratio o TP: Total Phosphorus o (g P/g) Used to calculate the TP value of streams Denotes the phosphorus contribution of a component
o CaCO3 (CaCO3/g) Used to calculate the CaCO3 value of streams Denotes the CaCO3 contribution of the component Solids Ratios o Solid? User can define if component is a dissolved or suspended solid o TS: Total Solids (g solids/g substance) Used to calculate the TS value of streams Denotes the fraction of a component that is dissolved or present as a suspended solid o TSS/TS: Total Suspended Solids (g TSS/g TS) Used to calculate the total TSS value of a stream based on the TSS values of the stream components
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o o
o o
o o
o o
Denotes the fraction of solid component that is suspended in solution VSS/TSS: Volatile Suspended Solids (g VSS/g TSS) Used to calculate the total VSS value of a stream based on the VSS values of the stream components Denotes the fraction of the suspended solid component that is biodegradable Measured as the organic fraction that oxidizes at 55050C that comes off as a gas DVSS/VSS: Degradable Volatile Suspended Solids (g DVSS/g VSS) Used to calculate the total DVSS value of a stream based on the DVSS values of the stream components Denotes the fraction of the volatile suspended solid of the component that is biodegradable VDS/TDS: Volatile Dissolved Solids (g VDS/g TDS) Used to calculate the total VDS value of a stream based on the VDS values of the stream components Denotes the fraction of the dissolved solid of a component that is volatile DVDS/VDS: Degradable Volatile Dissolved Solids (g DVDS/g VDS) Used to calculate the total DVDS value of a stream based on the DVDS values of the stream components Denotes the fraction of the volatile dissolved solid amount of a component that is biodegradable
Error! Reference source not found. ($/kg) o Used in economic calculations Selling Price ($/kg) o Used in economic calculations Waste Treatment or Disposal Cost ($/kg) o Used to estimate waste treatment and disposal costs o If no cost is specified, the program will estimate the cost from the contribution of the components
Economics
Pollutant Categories
This group of properties is related mainly to classifying components within the classes of pollutants monitored by the Environmental Protection Agency (EPA). Emissions Report VOC o Specific VCM TVOS EVOS HAP-VOC o Other Particulate o Removal by Emission (%) o Specific Biological Radionuclide Asbestos Cr+6 Metal Dioxin LOC HAP o Other Acid Gas o HAP-Acid o Acid (Non-HAP) ETG o HAP-Gas o Gas (Non-HAP) CO NOx SO2 Base Environmental Impact Report Is Hazardous? o Selecting option (clicking mouse on empty box), denotes that component is hazardous o Threshold (ppm) Specifies the concentration level that would signify an entire stream is hazardous
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o If the presence of a hazardous component is higher than the threshold concentration, the entire stream is denoted as hazardous Is in the SARA 313 Report? o If selected, this component is included in the SARA-313 Chemicals section of the Environmental Impact Report (EIR) Is in the EIR Report: Environmental Impact Report ? o If selected, this component is included in the 33/50 EPA Program Report and is included in the 33/50 Chemicals section of the EIR report Is Reported in Solid Wastes? o If selected, the component will be included in the Solid Waste section of the EIR report and should be tracked through the solid waste streams in the design Is Reported in Liquid Wastes? o If selected, the component will be included in the Liquid Wastes section of the EIR report and should be tracked through the liquid waste streams in the design Is Reported in Emissions? o If selected, the component will be included in the Emissions section of the EIR report and should be tracked through all emissions streams in the design A more extensive discussion of how to categorize pollutants can be found in the following section, Section 11.0.
If a primary biomass is formed in a reaction and both the primary biomass and water components have been specified, the simulation program will automatically adjust intracellular water amount to satisfy the biomass water content specified in registration.
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Note: The primary biomass component relates to components that have the Is option selected.
When a stock mixture is registered, SuperPro will automatically register the components needed to make that stock mixture. Figure 4.7 depicts the Stock Mixture Database the process required to register a stock mixture for a particular process.
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To register a stock mixture for a particular process: 1) Select stock mixture needed for simulation by either: Typing name of mixture in entry box Scrolling up/down in Stock Mixtures Database and selecting desired mixture 2) Click the Register button
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Figure 4.8 depicts the necessary actions to register stock mixtures not available in the database.
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Note: If the mixture already exists in the Stock Mixture Database, the program will ask for confirmation that the properties of the mixture are to be updated. Once confirmation is made, the new mixture will be added to the Stock Mixture Database to be used for future design cases
Different processes will require different properties to be specified. The following section will discuss which operations require certain properties.
ID
Name This is the formal name of the stock mixture, either supplied by the simulation program when the database was developed or by the user when a new mixture was introduced. The Name portion of the ID cannot be changed once the stock mixture is introduced. The Name can consist of up to 31 characters. Trade Name The Trade Name may or may not be different from the Name of the stock mixture. The Trade Name is the name widely known in the market or industry. This name was either supplied by the simulation program when the database was developed or by the user when a new component was introduced. Unlike the Name, however, the Trade Name can be changed later and must be unique. The Trade Name can consist of up to 31 characters. 32
Local Name Companies may have their own number system for denoting certain mixtures used in their process. This tag number is reserved primarily for this purpose. This property was defined by the user when the new mixture was introduced, but can be changed later. Uniqueness is not necessary for this property. The Local Name can consist of up to 31 characters.
Composition
Available Ingredients Mixtures can be made up of either: Pure Components Other Stock Mixtures Ingredient Composition Can be defined as either: Mass Molar Density (g/L) Used as a conversion between mass and volumetric flow rates and to calculate the concentration of streams Calculated by the following equation: D = a + bT , where T is in K SuperPro allows the user to enter values for a and b for user defined components and to edit a and b for mixtures available in the Stock Mixtures database For densities in the vapor phase, SuperPro assumes the ideal gas law and calculates the density accordingly
Economics
Purchasing Price ($/kg) o Used in economic calculations o Can be set by user or calculated from components Supplier o Name o Comments
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Table 5.1: Unit Operations Available in Unit Procedures Procedure Operations Available Vessel Procedures In a Fermenter Agitate Pressurize Charge Pull In Clean-in-Place (CIP) Pull Out Cool Purge / Inert Crystallize React (Equilibrium) Evacuate React (Kinetic) Extract/Phase Shift React (Stoichiometric) Ferment (Kinetic) Steam-in-Place (SIP) Ferment (Stoichiometric) Transfer In Gas Sweep Transfer Out Heat Vaporize/Concentrate Hold Vent In a Seed Fermenter Agitate Pressurize Charge Pull In Clean-in-Place (CIP) Pull Out Cool Purge / Inert Crystallize React (Equilibrium) Evacuate React (Kinetic) Extract/Phase Shift React (Stoichiometric) Ferment (Kinetic) Steam-in-Place (SIP) Ferment (Stoichiometric) Transfer In Gas Sweep Transfer Out Heat Vaporize/Concentrate Hold Vent
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In an Air-Lift Fermenter
Agitate Charge Clean-in-Place (CIP) Cool Crystallize Evacuate Extract/Phase Shift Ferment (Kinetic) Ferment (Stoichiometric) Gas Sweep Heat Hold Continuous Reaction Procedures Stoichiometric: In a Clean-in-Place (CIP) Fermenter Ferment (Stoichiometric) Hold Stoichiometric: In a Seed Clean-in-Place (CIP) Fermenter Ferment (Stoichiometric) Hold Stoichiometric: In an Air-Lift Clean-in-Place (CIP) Fermenter Ferment (Stoichiometric) Hold Kinetic: In a Fermenter Clean-in-Place (CIP) Ferment (Kinetic) Hold Kinetic: In a Seed Fermenter Clean-in-Place (CIP) Ferment (Kinetic) Hold Environmental: Well-Mixed Bio-oxidize* Aerobic BioOxidation Hold Environmental: Plug Flow Bio-oxidize* Aerobic BioOxidation Hold Environmental: Trickling Bio-oxidize* Filtration Hold Environmental: Anoxic Bio-oxidize* Reaction Hold Environmental: Hold Neutralization Neutralize* Environmental: Wet Air Hold Oxidation Oxidize* Environmental: Incineration Hold Incinerate* Environmental: UV Hold Radiation Radiate*
Pressurize Pull In Pull Out Purge / Inert React (Equilibrium) React (Kinetic) React (Stoichiometric) Steam-in-Place (SIP) Transfer In Transfer Out Vaporize/Concentrate Vent
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Dead End
Nutsche
Charge Clean-in-Place (CIP) Concentrate (Batch)* Hold Charge Clean-in-Place (CIP) Concentrate (feed & bleed)* Hold Charge Clean-in-Place (CIP) Concentrate (Batch)* Hold Charge Clean-in-Place (CIP) Concentrate (feed & bleed)* Hold Charge Clean-in-Place (CIP) Concentrate (Batch)* Hold Charge Clean-in-Place (CIP) Concentrate (feed & bleed)* Hold Charge Clean-in-Place (CIP) Concentrate(Batch) Diafilter* Clean-in-Place (CIP) Filter* Hold Steam-in-Place (SIP) Charge Clean-in-Place (CIP) Cool Dry Cake Filter* Gas Sweep Heat Cake Wash Clean-in-Place (CIP) Filter* Gas Sweep
Steam-in-Place (SIP) Transfer In Transfer Out Steam-in-Place (SIP) Transfer In Transfer Out Steam-in-Place (SIP) Transfer In Transfer Out Steam-in-Place (SIP) Transfer In Transfer Out Steam-in-Place (SIP) Transfer In Transfer Out Steam-in-Place (SIP) Transfer In Transfer Out Hold Steam-in-Place (SIP) Transfer In Transfer Out
Hold Purge / Inert React (Stoichiometric) Steam-in-Place (SIP) Transfer In Transfer Out Wash Cake Hold Steam-in-Place (SIP) Transfer Out
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Rotary Vacuum
Clean-in-Place (CIP) Filter* Hold Steam-in-Place (SIP) Filter* Hold Steam-in-Place (SIP) Filter* Hold Filter* Hold Hold Precipitate*
Disk-Stack
Bowl
Basket
Centritech
Centrifuge* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Centrifuge* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Centrifuge* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Charge Clean-in-Place (CIP) Filter* Gas Sweep Hold Centrifuge* Clean-in-Place (CIP) Hold Steam-in-Place (SIP)
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Bead Milling
Clean-in-Place (CIP) Hold Homogenize* Steam-in-Place (SIP) Chromatography/Adsorption Procedures Gel Filtration Elute* Equilibrate Hold Load* PBA Chromatography Elute* Equilibrate* Hold Load* EBA Chromatography Elute* Equilibrate* Hold Load* Ion Exchange (for Hold Demineralization) Load* Regenerate* Wash* Drying Procedures Freeze Charge Clean-in-Place (CIP) Cool Dry* Extraction Procedures In a Mixer-Settler Clean-in-Place (CIP) Extract* Hold Differential Clean-in-Place (CIP) Extract* Hold Centrifugal Clean-in-Place (CIP) Extract* Hold Steam-in-Place (SIP) Phase Change Procedures Crystallization (Continuous) Clean-in-Place (CIP) Crystallize* Hold
Regenerate Steam-in-Place (SIP) Wash* Regenerate* Steam-in-Place (SIP) Wash* Regenerate* Steam-in-Place (SIP) Wash*
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Batch: Receiver
Agitate Charge Clean-in-Place (CIP) Cool Evacuate Extract / Phase Split Gas Sweep Heat Hold Agitate Charge Clean-in-Place (CIP) Cool Evacuate Extract / Phase Split Gas Sweep Heat Hold Agitate Charge Clean-in-Place (CIP) Cool Evacuate Extract / Phase Split Gas Sweep Heat Hold Agitate Charge Clean-in-Place (CIP) Cool Evacuate Extract / Phase Split Gas Sweep Heat Hold Agitate Charge Clean-in-Place (CIP) Cool Evacuate Extract / Phase Split Gas Sweep Heat Hold
Pressurize Pull In Pull Out Purge / Inert Steam-in-Place (SIP) Store* Transfer In Transfer Out Vent Pressurize Pull In Pull Out Purge / Inert Steam-in-Place (SIP) Store* Transfer In Transfer Out Vent Pressurize Pull In Pull Out Purge / Inert Steam-in-Place (SIP) Store* Transfer In Transfer Out Vent Pressurize Pull In Pull Out Purge / Inert Steam-in-Place (SIP) Store* Transfer In Transfer Out Vent Pressurize Pull In Pull Out Purge / Inert Steam-in-Place (SIP) Store* Transfer In Transfer Out Vent 39
Batch: Silo
Charge Clean-in-Place (CIP) Hold Pull In Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Store* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Store* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Store* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Store* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Store* Clean-in-Place (CIP) Hold Store Solids* Clean-in-Place (CIP) Handle Solids Flow* Hold Clean-in-Place (CIP) Heat* Hold Clean-in-Place (CIP) Heat* Hold Clean-in-Place (CIP) Cool* Hold Steam-in-Place (SIP) Clean-in-Place (CIP) Exchange Heat* Hold Steam-in-Place (SIP)
Heat Exchanging
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Heat Sterilization
Mixing Procedures Bulk Flow
Clean-in-Place (CIP) Hold Sterilize* Clean-in-Place (CIP) Hold Mix* Steam-in-Place (SIP) Clean-in-Place (CIP) Hold Mix* Steam-in-Place (SIP) Clean-in-Place (CIP) Hold Mix* Steam-in-Place (SIP) Charge Clean-in-Place (CIP) Hold Clean-in-Place (CIP) Hold Mix* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Split*
Discrete Flow
Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Split* Clean-in-Place (CIP) Hold Split* Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Split*
Component Flow
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Formulation and Packaging Procedures Filling Clean-in-Place (CIP) Fill* Hold Steam-in-Place (SIP) Tableting Clean-in-Place (CIP) Hold Steam-in-Place (SIP) Tablet* Transport (near) Procedures Liquids: Pump Clean-in-Place (CIP) Hold Pump Steam-in-Place (SIP) Generic Boxes Discrete: Bulk to Discrete Clean-in-Place (CIP) Convert to Discrete* Hold Discrete: Discrete to Bulk Clean-in-Place (CIP) Convert to Bulk* Hold
After the necessary unit procedures have been determined, the user can add those unit procedures to the simulation. To add a unit procedure select:
Unit Procedures >> [Type of Procedure] >> [Procedure]
Figure 5.1 below depicts the steps needed to add a vessel procedure in a fermentor.
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After the procedure is selected, the Add Step cursor will appear: Click on the simulation where you want the unit procedure to appear. A visual of the procedure will then appear on the flowsheet. For the example of a vessel procedure in a fermentor, the following image will appear to represent the procedure:
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Note: To move a unit procedure after it has been added to the simulation, click on the procedure and drag it to the new location. If more than one procedure needs to be moved, select each procedure by pressing the Shift button and left-clicking. Once all procedures are highlighted (they will appear red), click and drag them to the new location. Precise movements of one pixel can be made using the arrow keys on the keyboard.
Each unit procedure has a unique appearance that correlated to how the equipment would appear in reality. To add more procedures, follow the same steps until all of the procedures needed in the process are present. It is important to pay close attention to the location and orientation of each procedure when adding it to the simulation. SuperPro will automatically add the procedure in the standard left-to-right orientation. However, it is often necessary to show the procedure flowing right-to-left. This needs to be done immediately after the procedure is added, before any streams are connected. To change the orientation of the procedure, right click on the procedure to open the menu, and select:
Flip (reverse flow direction)
After Flip has been selected, the input and output ports will flow right-to-left, as shown in Figure 5.4.
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After all of the necessary unit procedures are added to the simulation, the user then has the option to edit the procedure data within each unit procedure.
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The Scheduling tab allows the user to designate the operating mode of the procedure. There are only two fields on this tab that are editable by the user. The number of cycles per batch can be specified, and it can be told to operate in Stagger Mode. More information on scheduling can be found in Chapter 8. The other tabs in the Procedure Data window include Throughput, in which the user can choose to include the procedure in the throughput analysis, and Description, which is a blank text box that allows the user to enter comments about the procedure.
Note: For a batch process, the Continuous option on the Scheduling tab is gray and cannot be selected by the user. For procedures that are running constantly during a continuous process, this option will be available.
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After Equipment Data has been selected, the following window will appear:
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The categories available in the Equipment Data Window are: Equipment Purchase Cost Adjustments Scheduling Throughput Comments Allocation
Note: This section will be focusing on the Equipment tab. For information about Cost Analysis, refer to Chapter 10. For information about Scheduling, refer to Chapter 8.
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The different sections of the Equipment tab include selection, size, and description.
Selection
SuperPro automatically assumes that each unit procedure takes place in exclusive equipment. However, it is possible for more than one unit procedure to share equipment with another unit procedure. This is specified in the Selection section of the Equipment tab. To specify which equipment should be used for the procedure, click on the drop-down arrow to open the list of available equipment.
If there is more than one procedure in identical equipment, both of the procedures will appear in the drop-down menu. Select the equipment to be 49
used by the procedure. To ensure that the shared equipment is being used by the other procedure, perform the same steps to choose the equipment.
Note: The selection of the equipment takes place under the Select option in the Selection section of the Equipment tab. The other option, Request New is not editable by the user, due to the fact that SuperPro automatically determines the type of equipment used based on the unit procedure. Also note that equipment can only be shared in batch processes. For a continuous process, separate equipment is required. Therefore, in a continuous process, the Select option appears gray and is not editable by the user. Size
The Size Section of the Equipment tab allows the user to set the equipment size or have SuperPro perform the calculations. If the user chooses to size the equipment, the simulation is in Error! Reference source not found.. If SuperPro is instructed to perform the calculations, the simulation is in Error! Reference source not found..
Description
The Description section of the Equipment tab contains information about the physical aspects of the equipment. The information includes:
o o o o o o o o o o o
Name Type Number of Units Error! Reference source not found. Error! Reference source not found. Error! Reference source not found. Error! Reference source not found. Height Diameter Design Pressure Error! Reference source not found.
When in Design Mode, the areas that are editable by the user are: Max. Volume, Max. Allowable Working Volume/Vessel Volume Ratio, Height/Diameter Ratio, Design Pressure, and whether the vessel is an ASME Vessel. All other areas are calculated and set by SuperPro. When in Rating Mode, the areas that are editable by the user are: Number of Units, Volume, Height/Diameter Ratio, Design Pressure, and whether the vessel is an ASME Vessel. All other areas are calculated and set by SuperPro.
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There are three general locations in which a breakpoint can be added: Upon entering the unit procedure Before an operation in the procedure Upon exiting the procedure
In some special cases, there are other options available. If there is an automatic material pull-in, an option will be present to insert a breakpoint after the automatic pull-in, as is show in the figure below:
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It is also possible to insert a breakpoint after an automatic push-out operation, as shown in the figure below:
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There are three different settings that can be chosen when designating breakpoints: Set and Active Set and Inactive Cleared
To set and activate a breakpoint, click once on the box next to the operation that will follow directly after the breakpoint. When a breakpoint is set and active, it will be designated by a black check in the square. Once a breakpoint is set and active, it can be changed to set and inactive by clicking once more on the square. A set but inactive breakpoint is designated by a black check in a gray square. To remove or clear the breakpoint, click again on the box and the check will be removed. These three settings are illustrated in Figure 5.14.
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After breakpoints have been set, a red circle with a white X appears on the simulation where the breakpoint is located. If a breakpoint is set but inactive, it appears as a gray circle with a white X. These indicators can be seen in Figure 5.15 below. The menu changes slightly after breakpoints are added to include a sub-menu for editing breakpoints. The new menu appearance is shown in the figure below:
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The Edit option allows the user to return to the Breakpoint Window to edit the breakpoints. The Clear All option removes all breakpoints, the Activate All option activates all of the set breakpoints, and the Deactivate All option deactivates all set breakpoints.
Note: If there are no deactivated breakpoints, there will not be an Activate All option on the Breakpoints sub-menu. Likewise, if there are no activated breakpoints, there will not be a Deactivate All option on the Breakpoints sub-menu.
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After Edit has been selected, the following window will appear:
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After Edit Labels has been selected, the following window will appear:
The Procedure Name and Equipment name can both hold up to 15 characters, while the Procedure Description can hold up to 31 characters. The label will appear with the Procedure Name and Equipment Name on one line, separated by a / delimiter, and the Procedure Description will follow on the next line: Procedure Name / Equipment Name Procedure Description
2) To remove the tag completely, click on the box in front of Show Label to remove the x. 3) To change the font of the tag, click on the Font button to open a separate font window in which the user can select the desired font, size, and font style. 4) To change the color of the tag text, click on the Font button to open the font window and click on the drop down menu labeled Color to choose from a list of colors. 5) To change the color of the background of the tag, click on the Color button on the Name Tag: Text tab to open a separate color window in which the user can select the desired color. Note that a color can be chosen only if the text background is specified as Opaque. If the desired background is clear, choose the Transparent option. This will allow any lines behind the tag to show through.
In addition to editing the text of the tag, it is also possible to have a frame around the tag. The following section with discuss this option.
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2) Click the circle in front of the style of choice. Choices include solid, dotted, dashed, dash-dot, dash-dot-dot, and invisible. 3) Click the circle in front of the thickness of choice. Note that different thicknesses are only available for solid lines. All options other than 1 pt are non-editable when a style other than solid is selected. 4) Click on the button marked Colors to open a separate color window in which the user can select the desired color.
Because there are so many options to customize the appearance of the unit procedure icon and tag, SuperPro has a function that allows the user to pick up a style and apply it to another unit procedure icon and tag.
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button on the An alternate way to pickup a unit procedure icon style is to click the Visual Objects Toolbar along the right side of the SuperPro window. After a unit procedure icon style has been picked up, it is possible to apply that style to another unit procedure. To do this, right-click on the unit procedure icon and select:
Style >> Apply
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button on the An alternate way to apply a unit procedure icon style is to click the Visual Objects Toolbar along the right side of the SuperPro window.
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Note: It is not necessary to specify explicitly the nature of the stream. SuperPro will automatically designate the type of stream based on which Error! Reference source not found. the stream is connected.
Discrete flow is only available for five of the unit procedures that SuperPro offers. These procedures include Flow Mixing, Flow Splitting, Generic Boxes, Grinding, and Shredding. Flow mixers and flow splitters use the same type of stream as inputs and outputs, so, for example, a discrete flow mixer will have a discrete output. Generic boxes allow the user to change a discrete stream to a bulk stream and vice versa. Discrete grinders and shredders have discrete inputs and bulk outputs. For more information on these unit operations, refer back to Section 5.0. SuperPro distinguishes between bulk and discrete streams in three ways: the color of the stream, the appearance of the port, and the stream properties. For a bulk stream, the stream is drawn black and the input port is designated by an arrow. For a discrete stream, the stream is drawn blue and the input port is designated with a small square next to the arrow. These differences can be seen on a flow splitter shown below in Figure 6.1.
Note: Discrete flows are also designated as DS-101 (as opposed to S-101) and the procedure description is automatically set as Discrete Flow Splitting for the flow splitter using discrete flows. If an operation has a discrete flow in, it must also have a discrete flow out.
In addition to the two types of streams, there are three categories of process streams: Input Stream , Intermediate Stream , and Error! Reference source not found.. These streams are highlighted below in Figure 6.2.
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To enter Connect Mode, click the Connect Mode button on the main toolbar:
When in Connect Mode, the cursor will change to the Connect Mode Cursor:
Note: The simulation will remain in connect mode after you draw the stream(s). To leave connect mode and return to Select Mode , click the Arrow button next to the Connect Mode button. Temporary Connect Mode is convenient for drawing only one stream.
To enter Temporary Connect Mode, hold down the Control (Ctrl) key on the keyboard and double-click to begin the stream. To end the stream, double-click again.
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In Temporary Connect Mode: 1) Hold the Ctrl key and double-click on an open area to begin the stream. After beginning the stream, it is no longer necessary to hold the Ctrl key. 2) To change the direction of the stream, click once on the open area. The stream will bend at a 90 degree angle. Click once more to change direction again. 3) Click once on an input port to connect the stream to the unit operation.
2) To change the direction of the stream, click once on an open area. The stream will bend at a 90 degree angle. Click once more to change direction again. 3) Double-click on an open area to end the stream.
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In Temporary Connect Mode: 1) Hold the Ctrl key and double-click on an output port to begin the stream. After beginning the stream, it is no longer necessary to hold the Ctrl key. 2) To change the direction of the stream, click once on the open area. The stream will bend at a 90 degree angle. Click once more to change direction again. 3) Double-click on an open area to end the stream.
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The properties window for a bulk stream has four tabs: Composition, etc., Density, Env. Properties, and Comments. To access the properties window for a stream, rightclick on the stream and select: Simulation Data
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The interface presented in the above figure can be used to specify the components and flowrates of streams. The following sections will describe these functions in further detail.
6.3.1 Specifying Stream Components of a Bulk Input Stream (Components, Etc. Tab)
From the Bulk Stream Properties Window, Figure 6.7, the stream components of a bulk input stream can be specified for a particular process. 1) Begin by clicking the Composition, Etc. tab along the top of the properties window. (See Figure 6.8 below). 2) Choose either Components or Stock Mixtures based on the ingredient to be added. 3) Choose the component or stock mixture to be added in the Registered Ingredients List.
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Note: If the component or mixture to be added does not appear on the list of Registered Ingredients, refer to Section 4.1.1 on how to register components.
4) Click the >>> button to add the component or stock mixture to the stream. Figure 6.8 below depicts the necessary actions to specify the stream components of a bulk input stream.
Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk Stream
Once pure components and stock mixtures are registered in the Simulation Data Interface, the user has the option to edit the composition of each component in a stream.
6.3.2 Editing the Composition of a Bulk Input Stream (Composition, Etc. Tab)
There are two ways to determine the composition of the stream including: Setting the component flowrates 70
Setting the total flowrate and the mass composition of the stream
To set component flowrates: 1) Select Ingredient Flows by clicking on the small circle in front of Ingredient Flows in the Set area below the Composition area. 2) Click on the cell in the Flowrate column to enter edit mode. 3) Input the flowrate in kg/batch for batch processes or kg/h for continuous processes.
Note: When setting ingredient flows, SuperPro will automatically calculate the total flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be manually edited and the boxes appear gray.
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1) Select Mass Composition by clicking on the small circle in front of Mass Composition in the Set area below the Composition area. 2) Click on the cell in the Mass Comp. column to enter edit mode. 3) Input the mass composition in percentage form (%). 4) Enter the total flowrate for the stream. This can be done in either mass flow or volumetric flow. Click on the circle in front of the flow of choice, and the box will change to edit mode.
Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk Input Stream
Note: SuperPro will automatically calculate the ingredient flows based on the mass composition and total flowrate. Therefore the component flows cannot be manually altered while setting mass compositions.
6.3.3 The Composition, Etc. Tab for an Intermediate or Output Bulk Stream
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While the Density, Env. Properties, and Comments tabs are the same for all three types of streams, the Composition, Etc. tab is different for an input stream than for an Intermediate or Output stream. Figure 6.11 below shows the Composition, Etc. tab for Intermediate and Output streams.
Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams
Note: The only difference between this section for Intermediate and Output Streams and that for Input Streams is the lack of the Registered Ingredients section. SuperPro will automatically calculate the components and flows of the streams based on the inputs and unit operations and, therefore, this section does not need to be included.
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3) If the density is unknown, SuperPro can calculate the density based on the contribution to each ingredient in the stream. 4) Click the circle in front of the word Calculated to access the Volumetric Contribution Coefficients area. 5) Click the circle in front of Ingredient 6) or Component 7) based on the data to be inputted. If all of the ingredients are pure components, there will be no difference between the Ingredients and Components options. 8) Click on the cell in the Coefficient column to enter edit mode. 9) Enter the desired coefficient.
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Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream
After you have selected Simulation Data, the following window will appear:
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6.4.1 Setting the Description of the Entity for a Discrete Input Stream (Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will automatically be on top when the properties window appears. 2) Click on the text box next to Name under the Description area to enter the name of the entity (for example, bottle or vial). If the entity is present in more than one area of the process, both entities should be given the same name. 3) To set the Bulk Conversion Factor 4) , first choose the units and click the circle next to mass or volume depending on preference. Then click the text box next to Bulk Amount Per Entity to enter the number. Units are in g/entity or cm3/entity. If the entity is present in more than one area of the process, both entities should be given the same bulk conversion factor. 5) To set the purchasing price, click the text box next to Purchasing Price and enter the price. Units are given in $/entity. 6) To set the selling price, click on the text box next to Selling Price and enter the price. Units are given in $/entity.
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6.4.2 Setting the Flow of the Entity in the Input Stream (Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will automatically be on top when the properties window appears. 2) Click on the text box in the Flow area to enter the number of entities per batch.
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Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams
Note: The only difference here is the inability to alter the description and flowrates of the entity. SuperPro will automatically update the description and flow of the entity based on the input entity.
6.4.4 Specifying Stream Components of a Discrete Input Stream (Components, Etc. Tab)
1) Begin by clicking the Composition, Etc. tab along the top of the properties window 2) Choose either Components or Stock Mixtures based on the ingredient to be added. 3) Choose the component or stock mixture to be added in the Registered Ingredients list. If the component or mixture to be added does not appear on the list of Registered Ingredients, refer to Section 4.0 on how to register components. 4) Click the >>> button to add the component or stock mixture to the stream.
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6.4.5 Editing the Composition of a Discrete Input Stream (Composition, Etc. Tab)
There are two ways to input the composition of the stream. One is to set the component flowrates. The other is to set the total flowrate and the mass composition of the stream. To set component flowrates: 1) Select Ingredient Flows by clicking on the small circle in front of Ingredient Flows in the Set area below the Composition area. 2) Click on the cell in the Flowrate column to enter edit mode. 3) Input the flowrate in kg/batch for batch processes or kg/h for continuous processes.
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Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows
Note: When setting ingredient flows, SuperPro will automatically calculate the total flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be manually edited and the boxes appear gray.
To set mass composition: 1) Select Mass Composition by clicking on the small circle in front of Mass Composition in the Set area below the Composition area. 2) Click on the cell in the Mass Comp. column to enter edit mode. 3) Input the mass composition in percentage form (%). 4) Enter the total flowrate for the stream. This can be done in either mass flow or volumetric flow. Click on the circle in front of the flow of choice, and the box will change to edit mode.
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Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete Input Stream
Note: SuperPro will automatically calculate the ingredient flows based on the mass composition and total flowrate. Therefore the component flows cannot be manually altered while setting mass compositions.
6.4.6 The Composition, Etc. Tab for an Intermediate or Output Discrete Stream
The Composition, Etc. tab is different for an input stream than for an intermediate or output stream. Figure 6.24, below, shows the Composition, Etc. tab for intermediate and output streams.
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Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams
Note: SuperPro will automatically calculate the components and flows of the streams based on the inputs and unit operations, so these fields cannot be edited by the user.
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3) If the density is unknown, SuperPro can calculate the density based on the contribution to each ingredient in the stream. 4) Click the circle in front of the word Calculated to access the Volumetric Contribution Coefficients area. 5) Click the circle in front of Ingredient 6) or Component 7) based on the data to be inputted. If all of the ingredients are pure components, there will be no difference between the Ingredients and Components options. 8) Click on the cell in the Coefficient column to enter edit mode. 9) Enter the desired coefficient.
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Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a Discrete Stream
Note that intermediate and output streams from flow mixers or splitters do not include a Density tab. This is because the density of the intermediate and output streams are the same as the input stream.
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After Edit Tag Name is selected, the following window will appear:
To change the tag name, enter the desired name in the text box and click OK to accept the change.
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An alternate way to pickup a stream style is to click the Toolbar along the right side of the SuperPro window.
To apply the style to another stream, right-click on the stream and select:
Style>>Apply Style Note: If the style of a stream has not been picked up, the Apply Style option will not be present.
An alternate way to apply a stream style is to click the Toolbar along the right side of the SuperPro window.
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The available operations will be different for different types of unit procedures. For example, a fermentation procedure, as in Figure 7.2, gives the user twenty-four options for types of operations, where a mixing tank only has three options. To access a list of the available operations, refer back to Table 5.1. To add a particular operation, simply click on the desired operation in the left-hand Available Operations Column and select:
>>Add>>
The selected operation will then be added to the right-hand Operation Sequence Column. Additional operations can be added to the operation sequence, however, the SuperPro functions >>Add>> and >>Insert>> are sensitive to the order in which they are utilized. For example, if the operation sequence presented in Figure 7.3 below is the current sequence and the user wants to incorporate a TRANSFER OUT operation after the FERMENT operation, simply: 1) Highlight the FERMENT option (as shown in Figure 7.3) 2) Highlight the TRANSFER OUT option 3) Select >>Add>>
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Once these steps are taken, TRANSFER OUT will be added as an operation following the FERMENT operation, as shown in Figure 7.4.
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To add an operation between two current operations, the >>Insert>> function needs to be utilized. For example, to insert a TRANSFER IN operation before the FERMENT operation and after the CHARGE operation, simply: 1) Highlight the FERMENT option 2) Highlight the TRANSFER IN option 3) Select >>Insert>> As shown in Figure 7.5, the TRANSFER IN operation is now inserted between CHARGE and FERMENT.
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Once operations are added or inserted in the operation sequence, they can be deleted by highlighting the particular operation and selecting the Delete button, as shown above in Figure 7.5.
Note: It is important to develop the proper operation sequence early in the process. Once additional specifications are made in the simulation, the operation sequence can be changed or reordered, however changing the sequence may cause problems with scheduling and other design parameters.
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The user is given the option to rename an operation to allow for easy reference, such as, for example, saying Charge Glucose versus Charge Water or to utilize the terminology familiar to a particular business.
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For example, if Charge-1 were selected from the above figure, the following interface, in Figure 7.8 would appear.
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As showing in Figure 7.8 above, the Operation Data Interface allows the user to manually input operation characteristics for the following categories: Operation Conditions Emissions Labor, etc. Description Scheduling
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For more complicated operations, such as reactions and fermentations, additional tabs such as Reactions and Volume will be present. For these types of operations, the user is required to specify the kinetic and stoichiometric data as well as the maximum allowable and minimum allowable volume for that procedure. For additional information on the functions of each individual operation, refer to the Help menu of SuperPro that is located in the top right-hand corner of the flowsheet, as shown in Figure 7.9.
Users can access the Help Topics section of this menu and search for more specific information on the many types of operations.
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This menu lists the unit operations that are present in the unit procedure in the order that they were added to the procedure. If the operations are not in the desired sequence, refer to Section 7.1 for information on how to change the order of the operations.
Note: Scheduling is only necessary for batch processes. Continuous processes require no scheduling information in order for the procedure to run.
Once the order of the operations has been verified, the scheduling process can begin. The user should choose the first operation in the unit procedure and they will arrive at a screen similar to Figure 8.2. 1) Click on Oper. Conds tab. Note: The Oper. Conds tab will automatically appear on top when the Unit Operation Properties window is opened. 2) Specify setup time. 3) Specify process time (three methods: user specified, simulation calculated, master-slave relationship).
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To continue directly to the next operation for the unit procedure, select:
OK>>
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Once the user chooses the Setup button, a screen similar to Figure 8.4 will appear. The Slave Operation at the top of Figure 8.4 should be verified as the operation that the user is currently scheduling. The user must then specify the Master Procedure. The master procedure can be specified as either the same as the slave operations procedure, or as another procedure in the process.
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Once the master procedure is chosen, the Master Operation can be specified. This is done by choosing to match a single operation or to match a sequence of operations. Choosing to match a single operation will specify to SuperPro that the slave operation should take the same amount of time as the master operation, while choosing to match a sequence of operations will specify that the slave operation should take the same amount of time as a group of operations in sequence.
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When matching a sequence of operations, the user should specify which operation the master sequence should start with and which operation it should finish with (i.e., the beginning of the slave operation should start at the same time as the master operation that is chosen in the Starting With box, and the slave operation should end at the same time as the master operation that is in the Ending With box). As indicated by Figure 8.5, the master operations are chosen by clicking on the down arrow next to the corresponding box.
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The next task in the scheduling process is to indicate when each operation should start. This can be done in the Start Time section of the scheduling screen (see Figure 8.8). If the starting time of the operation is known, the user can indicate a start time shift. If the starting time is not known, a scheduling relationship can be used to determine when the operation will begin. The four scheduling relationships are: Relative to the beginning of the batch Relative to a previous operation in the procedure Relative to another operation in the procedure Relative to an operation in another procedure
Note: When using a scheduling relationship, remember that indicating a start time shift will cause a shift from the beginning of the relationship time specification.
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Figure 8.9: Start Time Relationship Relative to Another Operation in this Procedure
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Figure 8.10: Start Time Relationship Relative to Another Operation in Another Procedure
Once the start time and the duration time have been completely specified according to the procedures above, scheduling for the operation in the unit procedure is complete. This process should be repeated for all of the operations in each unit procedure. When the scheduling process is finished, the simulation should run to completion without any scheduling errors. Scheduling errors for specific operations can be corrected by ensuring proper scheduling according to the above procedures.
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Selecting this option will bring up a screen similar to Figure 8.12. This figure is an overview of all the scheduling information for the process. It indicates the total time to complete a batch, the number of batches that can be made in a year, the amount of time the process will be running through out the year, and the longest procedure and bottleneck of the process. The number of batches per year can be user specified by clicking on the circle in front of Set by User, in the number of batches per year section. If there are changes made to the scheduling process after this screen is viewed, click on Update Sched. Outputs to update this scheduling summary.
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There are four different kinds of Gantt charts: Operations GC Equipment GC Operations GC (Multiple Batches) Equipment GC (Multiple Batches)
The Operations Gantt Chart displays the time involved in each operation, segmented by the unit procedures in which the operations take place. The Operations Gantt Chart for multiple batches contains the same information, but includes more than one batch run. The Equipment Gantt Chart displays the time involved in each operation, segmented by both the unit procedures and the equipment in which the operations take place.
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Once the first operation is selected, the user will see a screen similar to Figure 9.2 and should click on the Labor, etc. tab at the top of the screen.
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Once the labor window is open, the user should first choose the type of operator for the operation. To access a list of the available types of operators, click on the word Operator to make a down arrow appear and then click the down arrow next to it. The list of available operator types is shown below in Figure 9.3. The type of operator chosen should be decided by the type of operation. If the user prefers a more generalized labor assessment, the general operator can be used instead of a more specific one.
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Next, the user should specify the value of the operator in Labor-hrs/hr or Labor-hrs/cycle by clicking on the corresponding box and the downward arrow associated with it (see Figure 9.4).
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Once the operator and units are determined, the number of operators can be changed by clicking on the Add Labor or Delete Labor buttons (see Figure 9.5).
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The following sections will describe how to determine each of these costs using SuperPro and how to use SuperPro to perform an economic evaluation of the process.
Selecting properties will bring up the Component Properties interface, which will look similar to Figure 10.2. To input economic information such as purchasing price, selling price, or waste treatment cost, the Economics tab must be selected, as is done in the following figure.
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1) If the component is a reactant, the user should specify the purchasing cost of the component. 2) If the component is a product, the user should specify the selling price of the component. 3) If the component is a waste product or byproduct, the user should specify the waste treatment or disposal cost. These costs can be specified by clicking on the box next to the corresponding cost description, as shown above in Figure 10.2. Then the known values from suppliers or other sources can be entered into the appropriate space. There is also space available to specify the supplier from whom the component is purchased and any comments regarding the component.
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The Revenue, Raw Material, and Waste Streams Specification Interface, as shown below in Figure 10.4, allows the user to specify which streams will be a source of income, and which screens will be a cost to the process. The streams on this interface are separated into groups of input streams and output streams.
stream is the desired product or a particular component in the stream is the desired product. If a particular component of the product stream is the desired product, click on the down arrow next to the corresponding box and select that component.
Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface
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All of the output streams are listed on the left side of the Specifying Output Stream Classifications interface. To specify the classification of the stream, the user should click on the down arrow next to the corresponding box in the classification column of the table. Then the unit cost of treatment/disposal or selling price of the stream can be specified in the third column. Some streams may be automatically determined by SuperPro, but most will need to be set by the user. Finally, once the streams have been classified and quantified, they can be marked as hazardous if applicable, using the fifth column in Figure 10.5.
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Choosing this command will bring up a screen similar to Figure 10.8. On this screen, the purchase cost tab should be selected so the equipment economics can be viewed and further specified if necessary. In most cases, SuperPro will indicate a equipment cost based on user specified size and capacity that was discussed in Chapter 5. The cost that is specified is adjusted for the year 2004, but can be altered by clicking on the box and entering the desired value.
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In order for SuperPro to accurately determine the utility costs of the process, it is necessary to input the rate at which the utilities are being used. To do this, click the box next to Rate, for each utility, and enter the desired value.
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Note that choosing this command does not bring up any additional interfaces. Instead, SuperPro does the calculations internally and the user can then generate the economic evaluation report. To access this report, select:
Tasks >> Generate Economic Evaluation Report (EER)
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Performing this command will bring up the screen below, which requires the user to save the economic evaluation report as a file. This file can be opened in WordPad or Notepad.
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After the Economic Evaluation Report has been saved, the file can be opened and viewed. To view the Economic Evaluation report, select:
View >> Economic Evaluation Report
as shown in figure 10.13. This command will bring up all the economic information for the process including total revenue and payback period.
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Figure 11.1: Selecting the component or stock mixture for registering emissions and environmental classifications
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Note: To access the Component Registration window for a Stock Mixture, select: Tasks>>Register Pure Components & Mixtures>>Stock Mixtures
After the Component Registration window is open, click on the number beside the component of choice to highlight the component and click the Properties button to access the Pure Components Properties window:
Two tasks may be performed through the Pollutant Categories window: a) Defining Emissions Report considerations b) Defining Environmental Impact Report considerations The following sections will assist the user in determining which classifications to specify.
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The following table presents the major categories of emissions based on information given by SuperPro.
Category Table 11.1: Pollutant Categories Sub-Category Material Description A. Infectious agents which require Biological practices, safe equipment, and facilities that constitute Biosafety Level 2 or higher (See Error! Reference source not found.) B. Radionuclide which are contained as Radionuclide particulates (as listed in N.J.A.C. 7:286.5) C. Compounds of hexavalent chromium Cr+6 which are contained as particulates D. Compounds of any of the following Metal metals which are contained as particulates: Pb, Hg, Cd, Be, As, Ni, and Cr E. Particulates which contain asbestos Asbestos F. Dioxins (See Error! Reference Dioxin source not found.) G. Materials which are liquid organic LOC compounds emitted as particulates H. Hazardous Air Pollutants (See Error! HAP-Particulate Reference source not found.) I. Particulates which do not fit into the Other Particulate above sub-categories
Category I Total Particulate: materials which could not be detected by NJ Air Test Method 1 (See Note 6)
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VCM TVOS Category II Total VOC (Volatile Organic Compound): materials which could not be detected under NJ Air Test Method 3 EVOS
Category III Acid Gases: materials that are acid gases and may or may not be detected as a particulate using NJ Air Test Method 1 or as VOC using Method 3 Category IV Extraordinarily Toxic Gases (ETG) Category V CO Category VI NOx Category VII
A. Vinyl Chloride Monomer B. Materials which are toxic volatile organic substances listed in the NJAC 7:27-17 Table 1 C. Materials which are exempt volatile organic substances listed in the NJAC 7:27-16.1 (See Error! Reference source not found.) D. Hazardous Air Pollutants listed in Note 10 except VCM (See Error! Reference source not found.) E. Volatile Organic Compounds which are not included in the above subcategories A. Hazardous Air Pollutants (See Error! Reference source not found.)
ACID
B. Acid Gases which are not included in sub-category A, including but not limited to F2, SO3, and H2S
HAP-GAS GAS
A. Hazardous Air Pollutants (See Error! Reference source not found.) B. Gases which are not listed in Note 5 (See Error! Reference source not found.) A. Carbon Monoxide
CO NOx
SO2 Base
A. Nitrogen Oxides: including N2O, NO, N2O3, N2O4, NO2, N2O5, N3O4, and NO3 (See Error! Reference source not found.) A. Sulfur Dioxide A. Materials which are base gases and may not be detected as a particulate using the NJ Air Test Method 1 or as VOC using Method 3
Category VIII
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Note 1: For the purpose of SuperPro simulation, the above categories will be used to characterize all air pollutants and raw materials. Substances that cannot be fit into the above categories and subcategories, may be listed individually or included in a userdefined category (see Section 4.1.4B). Note 2: The biological subcategory includes infectious substances that require practices, safety equipment, and facilities that represent a Biosafety Level 2 or higher as denoted by the Biosafety in Biomedical and Microbiological Laboratories Report in Section III. Note 3: The Dioxin subcategory includes the following isomers of chlorinated dibenzo-p-dioxin (CDDs) and CAS Number -a unique numeric identifier that designates one substance Charge - a method for adding an input to the unit Chlorinated dibenzofuran (CDFs) :
2,3,7,8-TCDD 1,2,3,7,8-PeCDD 1,2,3,4,7,8-HxCDD 1,2,3,7,8,9-HxCDD 1,2,3,6,7,8-HxCDD 1,2,3,4,6,7,8-HpCDD 2,3,7,8-TCDF 1,2,3,7,8-PeCDF 2,3,4,7,8-PECDF 1,2,3,4,7,8-HxCDF 1,2,3,7,8,9-HxCDF 1,2,3,6,7,8-HxCDF 2,3,4,6,7,8-HxCDF 1,2,3,4,6,7,8-HpCDF 1,2,3,4,7,8,9-HpCDF
For more information about Dioxin compounds see Error! Reference source not found..
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Note 5: Extraordinarily Toxic Gases Name Boron Trichloride (BCl3) Boron Trifluoride (BF3) Bromine Chloride (BrCl) Chlorine Dioxide (ClO2) Chlorine Pentafluride (ClF5) Chlorine Trifluoride (ClF3) Diborane (B2H6) Dichlorosilane (H2Cl2Si) Hydrogen Selenide (H2Se) Nitrogen Trifluoride (NF3) Oxygen Difluoride (OF2) Ozone (O3) Perchloryl Fluoride (ClFO3) Phosphorous Trifluoride (PF3) Selenium Hexafluoride (SeF6) Stibine (SbH3) Sulfur Tetrafluoride (SF4) Sulfuryl Fluoride (SF2O2) Tellurium Hexafluoride (TeF6) Tetrafluorohydrazine (N2F4) CAS Number 10294-34-5 7637-07-2 13863-41-7 10049-04-4 13637-63-3 7790-91-2 19287-45-7 4109-96-0 7783-07-5 7783-41-7 7783-41-7 10028-15-6 7616-94-6 7783-55-3 7783-79-1 7803-52-3 7783-60-0 2699-79-8 7783-80-4
10036-47-2
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Note 6:
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4-Aminobiphenyl Aniline o-Anisidine Asbestos Benzene (including benzene from gasoline) Benzidine Benzotrichloride Benzyl chloride Biphenyl Bis(2-ethylhexyl)phthalate (DEHP) Bis(chloromethyl)ether Bromoform 1,3-Butadiene Calcium cyanamide Caprolactam Captan Carbaryl Carbon disulfide Carbon tetrachloride Carbonyl sulfide Catechol Chloramben Chlordane Chlorine Chloroacetic acid 2-Chloroacetophenone Chlorobenzene Chlorobenzilate Chloroform Chloromethyl methyl ether Chloroprene Cresols/Cresylic acid (isomers and mixture) o-Cresol m-Cresol p-Cresol Cumene 2,4-D, salts and esters DDE Diazomethane Dibenzofurans 1,2-Dibromo-3-chloropropane Dibutylphthalate 1,4-Dichlorobenzene(p)
92671 62533 90040 1332214 71432 92875 98077 100447 92524 117817 542881 75252 106990 156627 105602 133062 63252 75150 56235 463581 120809 133904 57749 7782505 79118 532274 108907 510156 67663 107302 126998 1319773 95487 108394 106445 98828 94757 3547044 334883 132649 96128 84742 106467 143
3,3-Dichlorobenzidene Dichloroethyl ether (Bis(2chloroethyl)ether) 1,3-Dichloropropene Dichlorvos Diethanolamine N,N-Diethyl aniline (N,NDimethylaniline) Diethyl sulfate 3,3-Dimethoxybenzidine Dimethyl aminoazobenzene 3,3'-Dimethyl benzidine Dimethyl carbamoyl chloride Dimethyl formamide 1,1-Dimethyl hydrazine Dimethyl phthalate Dimethyl sulfate 4,6-Dinitro-o-cresol, and salts 2,4-Dinitrophenol 2,4-Dinitrotoluene 1,4-Dioxane (1,4-Diethyleneoxide) 1,2-Diphenylhydrazine Epichlorohydrin (l-Chloro-2,3epoxypropane) 1,2-Epoxybutane Ethyl acrylate Ethyl benzene Ethyl carbamate (Urethane) Ethyl chloride (Chloroethane) Ethylene dibromide (Dibromoethane) Ethylene dichloride (1,2Dichloroethane) Ethylene glycol Ethylene imine (Aziridine) Ethylene oxide Ethylene thiourea Ethylidene dichloride (1,1Dichloroethane) Formaldehyde Heptachlor Hexachlorobenzene Hexachlorobutadiene Hexachlorocyclopentadiene Hexachloroethane
91941 111444 542756 62737 111422 121697 64675 119904 60117 119937 79447 68122 57147 131113 77781 534521 51285 121142 123911 122667 106898 106887 140885 100414 51796 75003 106934 107062 107211 151564 75218 96457 75343 50000 76448 118741 87683 77474 67721
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Hexamethylene-1,6-diisocyanate Hexamethylphosphoramide Hexane Hydrazine Hydrochloric acid Hydrogen fluoride (Hydrofluoric acid) Hydrogen sulfide Hydroquinone Isophorone Lindane (all isomers) Maleic anhydride Methanol Methoxychlor Methyl bromide (Bromomethane) Methyl chloride (Chloromethane) Methyl chloroform (1,1,1Trichloroethane) Methyl ethyl ketone (2-Butanone) Methyl hydrazine Methyl iodide (Iodomethane) Methyl isobutyl ketone (Hexone) Methyl isocyanate Methyl methacrylate Methyl tert butyl ether 4,4-Methylene bis(2-chloroaniline) Methylene chloride (Dichloromethane) Methylene diphenyl diisocyanate (MDI) 4,4-Methylenedianiline Naphthalene Nitrobenzene 4-Nitrobiphenyl 4-Nitrophenol 2-Nitropropane N-Nitroso-N-methylurea N-Nitrosodimethylamine N-Nitrosomorpholine Parathion Pentachloronitrobenzene (Quintobenzene) Pentachlorophenol Phenol p-Phenylenediamine
822060 680319 110543 302012 7647010 7664393 7783064 123319 78591 58899 108316 67561 72435 74839 74873 71556 78933 60344 74884 108101 624839 80626 1634044 101144 75092 101688 101779 91203 98953 92933 100027 79469 684935 62759 59892 56382 82688 87865 108952 106503 145
Phosgene Phosphine Phosphorus Phthalic anhydride Polychlorinated biphenyls (Aroclors) 1,3-Propane sultone beta-Propiolactone Propionaldehyde Propoxur (Baygon) Propylene dichloride (1,2Dichloropropane) Propylene oxide 1,2-Propylenimine (2-Methyl aziridine) Quinoline Quinone Styrene Styrene oxide 2,3,7,8-Tetrachlorodibenzo-pdioxin 1,1,2,2-Tetrachloroethane Tetrachloroethylene (Perchloroethylene) Titanium tetrachloride Toluene 2,4-Toluene diamine 2,4-Toluene diisocyanate o-Toluidine Toxaphene (chlorinated camphene) 1,2,4-Trichlorobenzene 1,1,2-Trichloroethane Trichloroethylene 2,4,5-Trichlorophenol 2,4,6-Trichlorophenol Triethylamine Trifluralin 2,2,4-Trimethylpentane Vinyl acetate Vinyl bromide Vinyl chloride Vinylidene chloride (1,1Dichloroethylene) Xylenes (isomers and mixture) o-Xylenes
75445 7803512 7723140 85449 1336363 1120714 57578 123386 114261 78875 75569 75558 91225 106514 100425 96093 1746016 79345 127184 7550450 108883 95807 584849 95534 8001352 120821 79005 79016 95954 88062 121448 1582098 540841 108054 593602 75014 75354 1330207 95476
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m-Xylenes p-Xylenes Antimony Compounds Arsenic Compounds (inorganic including arsine) Beryllium Compounds Cadmium Compounds Chromium Compounds Cobalt Compounds Coke Oven Emissions Cyanide Compounds1 Glycol ethers2 Lead Compounds Manganese Compounds Mercury Compounds Fine mineral fibers3 Nickel Compounds Polycylic Organic Matter4 Radionuclides (including radon)5 Selenium Compounds
Source: Environmental Protection Agencies Air Toxics Website
108383 106423 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
An example of defining emissions categories for a specific component follows: To specify that a component has VCM emissions, click on the box next to VOC to make the subcategory editable. After VOC has been selected, click on the circle next to Specific to be able to choose the type of VOC. Now click on the square next to VCM. After the square has been clicked, an X will appear in the box. Figure 11.3 depicts the selection of VOC>>Specific>>VCM and Acid gas>>HAP-gas for glucose. To finish and save selections, select OK.
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Figure 11.3: Selection of VOC and Acid gas for emissions consideration
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User-defined pollutant categories can be added by selecting the square to the left of the input box (indicated by the red arrow in Figure 11.5) and typing the name of the category in the input box.
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The designation of solid waste, liquid waste and emission depend on the physical state of the exiting waste stream from a unit operation. SuperPro typically pre-selects each component and mixture to be a solid, liquid and emission waste source. In order to change the environmental impact classification of a component or mixture, the user must access the Pollutant Categories window as specified in Section 11.1. In order to select or deselect the option of reporting a component as a solid waste, liquid waste or emissions, the user must toggle the preceding box so that desired specifications are marked with an X and undesired specifications contain empty boxes. The user is responsible for designating a pure component and/or mixture as a hazardous, SARA 313 or 33/50 source of waste with the aid of the following information: Information on both hazardous and SARA 313 reportable chemicals are accessible at the following URL: http://www.epa.gov/tri/chemical/RY2003ChemicalList.pdf Listed 33/50 wastes:
o o o o o o o o o o o o o o o o o
Benzene Carbon tetrachloride Chloroform Dichloromethane Methyl ethyl ketone Methyl isobutyl ketone Tetrachloroethylene Toluene 1,1,1-Trichloroethane Trichloroethylene Xylenes Cadmium and cadmium compounds Chromium and chromium compounds Cyanide compounds Lead and lead compounds Mercury and mercury compounds Nickel and nickel compounds
Once the appropriate hazardous material classifications have been determined, the user inputs the selections in the same manner as was performed for defining emissions categories.
Note: If the component or mixture is considered a hazardous waste, a concentration limit in units of ppm (parts per million) must be specified.
Access Pollutant Categories window. Toggle the box for the appropriate hazard consideration and waste consideration so that an X appears in the box. Figure 11 depicts the selection of Is Reported in Liquid Wastes?>>Is Hazardous>>threshold value of 0.500ppm for Sodium Hydro Phosphate. To finish and save selections, select OK.
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Note: SuperPro will prompt the user to designate a name and location for saving the generated emissions report. The file type should be left at default designation, THR File (*.ems). In addition, SuperPro, by default, saves the file in the same directory as the simulation file and names the emissions report by the same file name as the simulation. If the user desires to name the file under a different name, or desires to save the file in a different directory, SuperPro will not be able to access the report when prompted to generate a viewable emissions report.
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Note: SuperPro will prompt the user to designate a name and location for saving the generated emissions report. The file type should be left at default designation, EIR File (*.eir). In addition, SuperPro, by default, saves the file in the same directory as the simulation file and names the emissions report by the same file name as the simulation. If the user desires to name the file under a different name, or desires to save the file in a different directory, SuperPro will not be able to access the report when prompted to generate a viewable environmental impact report.
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Note: SuperPro automatically searches the file directory containing the simulation file for files with the same name as the simulation file, but with the appropriate extension (.ems and .eir for emissions and environmental impact reports, respectively). If the appropriate file is located, SuperPro will automatically generate a text file containing the calculated information for emissions or environmental impact.
If the user has decided to save the generated emissions and/or environmental impact report under a different name or file directory than defaulted by SuperPro, the generated report may be viewed by performing the following selections:
View>>Any Report
SuperPro will then prompt the user to specify the directory and file to open.
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The second section of the emissions report presents information on the total emissions per batch. Again, a comparison between calculated values and allowable values is given for further comparison. Figure 11.11 depicts the emissions report on a per batch basis.
Figure 11.11: Illustrates the per batch portion of the emissions report.
9. Hazardous streams 10. Pollution indices Stream section: Each stream is described by its name, source and destination procedure (or INPUT/OUT). A list of each streams environmental and aqueous properties is included (TOC, COD, ThOD, etc.) as concentrations (in mg/l) and daily demands (kg carbon/day or kg oxygen/day). SuperPro denotes the beginning of the stream section with the following title:
**** LUMPED ENVIRONMENTAL STREAM PROPERTIES SECTION ****
Overall balance section: Presents the total environmental load (increase or decrease) as reflected by the values of TOC, COD, etc. of all streams entering and leaving the process. Two tables are generated: 1) one presents the values either on a per hour basis (only choice for continuous processes) or on a per batch basis (batch processes); 2) the second table has the same numbers on a yearly basis. SuperPro denotes the beginning of the overall balance with the following title:
**** OVERALL BALANCE Section ****
Component fate section: Presents the allocation of each chemical that either enters or is produced by the plant facility to all waste gateways. The first column presents the cumulative amounts of each chemical entering in any of the input streams of the plant, and the next three columns present the amounts leaving the plant in all waste streams (solid, liquid or gaseous). SuperPro denotes the beginning of the component fate section with the following title:
**** COMPONENT FATE Section ****
SARA 313 chemicals section: Presents an accurate account of all SARA 313 chemicals entering and leaving the plant as well as their difference. SuperPro denotes the beginning of the SARA 313 chemical section with the following title:
**** SARA 313 CHEMICALS Section ****
33/50 chemical section: Presents an accurate account of all 33/50 chemicals entering and leaving the plant as well as their difference. SuperPro denotes the beginning of the 33/50 chemical section with the following title:
**** 33/50 CHEMICALS Section ****
Solid waste section: Consists of two parts. Part 1 enumerates all streams that are characterized as solid waste by listing their composition (weight %), flowrate (in kg/h) and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component point of view; it shows how the total amount of each component leaving as solid waste is distributed in each stream. SuperPro denotes the beginning of the solid waste section with the following title:
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Liquid waste section: Consists of two parts. Part 1 enumerates all streams that are characterized as liquid waste by listing their composition (weight %), flowrate (in kg/h) and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component point of view; it shows how the total amount of each component leaving as liquid waste is distributed in each stream. SuperPro denotes the beginning of the liquid waste section with the following title:
**** LIQUID WASTE Section ****
Emissions section: Consists of two parts. Part 1 enumerates all streams that are characterized as emissions by listing their composition (weight %), flowrate (in kg/h) and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component point of view; it shows how the total amount of each component leaving as emissions is distributed in each stream. SuperPro denotes the beginning of the emissions section with the following title:
**** EMISSIONS Section ****
Hazardous streams section: Reports the hazardous streams. The format of this section is similar to those of waste streams. SuperPro denotes the beginning of the hazardous streams section with the following title:
**** HAZARDOUS STREAMS Section ****
Pollution indices stream: Presents certain ratios that are indicative of the environmental kindness (or lack thereof) of a design case. The first index presented applies to processes that have a main revenue stream (e.g. manufacturing facilities with a main product stream). It reports the ratio of total amount of waste (solid, liquid and emissions) produced per kg of main revenue stream processed. The next three indices are similar but report each of the three separate categories of wastes instead. The next four indices apply to processing plants that employ raw materials. It reports the ratio of total, solid, liquid and gaseous waste produced per kg of raw material utilized. SuperPro denotes the beginning of the emissions section with the following title:
**** POLLUTION INDICES Section ****
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Glossary
33/50 EPA Program -targeted 17 priority chemicals and set as its goal a 33% reduction in releases and transfers of these chemicals by 1992 and a 50% reduction by 1995, measured against a 1988 baseline -sought to foster a pollution prevention ethic, encouraging companies to focus on reducing releases of chemicals rather than treating and disposing of wastes Acentric Factor
-developed by Pitzer in 1955 as a way of accounting for the ``non-central'' or ``acentric'' (size-shape) interactions empirically. The acentric factor, is defined as: = log 10 P r sat ( T r = 0 . 7 ) 1 . 0
Agitate - used to disturb the system as a method of mixing Batch -(cyclical) mode where there is a dead time (or off time) Biomass -any plant derived organic matter available on a renewable basis BOD5 -amount of dissolved oxygen consumed in five days by biological processes breaking down organic matter BOD5/BODu -ratio of the five-day BOD to the ultimate BOD value BODu/COD -ratio of the ultimate biochemical oxygen demand to the COD of the component Bulk Conversion Factor -amount of material present in a discrete entity. Given in units of g/entity or cm3/entity. Bulk Stream -bulk streams have flow rates such as kg/h or kg/batch, where the amount of medium in the stream is apparent in the value of the flow rate. CaCO3 -calcium carbonate; can be used as a dehydrohalogenating agent
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CAS Number
-a family of chemicals that contain one to eight chlorine atoms attached to the carbon atoms of the parent chemical, dibenzofuran
Clean-in-Place (CIP) -used for cleaning processes using a cleaning agent COD: Chemical Oxygen Demand -amount of oxygen required to chemically oxidize 1g of the component Component -can be a pure constituent in a stream or a stock mixture. Some components can be broken down into Ingredient . For example, air is a component that can be broken down into nitrogen and oxygen. Compressibility Factor - Z; corrects the gas density for deviations from the ideal gas law Connect Mode -mode entered after clicking the Connect Mode button. Allows user to draw several streams in a row. Continuous -procedures carried out continuously (i.e. they are on all the time Discrete Stream -discrete streams have flow rates such as vials/batch or bottles/batch, where each vial contains a particular mass or volume, making it possible to calculate the amount of medium in the stream. DVDS/VDS: Degradable Volatile Dissolved Solids -fraction of the volatile dissolved solid amount of a component that is biodegradable DVSS/VSS: Degradable Volatile Suspended Solids -fraction of the volatile suspended solid of the component that is biodegradable
161
EIR Report: Environmental Impact Report -presents information that describes the effects of the process output streams on the environment -contains a detailed tabulation of all chemicals that are regulated by the EPA or denoted as hazardous by the user Enthalpy of Formation
-the enthalpy change associated with the formation of a compound from its constituent elements
EPA: Environmental Protection Agency -a national organization that attempts to lead the nations environmental science, research, educational, and assessment efforts by: Developing and enforcing regulations for hazardous chemicals Offering financial assistance to state and educational institutions for environmental research Performs environmental research to understand current environmental problems Strives to further environmental education in the public arena Evacuate -complete removal of unit procedure contents Heat Capacity -the amount of heat required to change its temperature by one degree, and has units of energy per degree Heat of Vaporization -the energy required to change a gram of a liquid into the gaseous state at the boiling point is called the "heat of vaporization" Henrys Constant -the ratio of the aqueous-phase concentration of a chemical to its equilibrium partial pressure in the gas phase Ingredient
162
163
Intermediate Stream -a stream that carries material out of a unit procedure and into a different unit procedure. Components and flowrates for an intermediate stream are usually calculated by SuperPro. The exception is when the Pull-Out operation is used. Kmaxo -maximum biodegradation rate constant Ks -half-saturation constant Log10 (octanol/water) -used to indicate the hydrophobicity of a component -helps determine a components tendency to become sludge Master-Slave Relationship - relationship formed between two operation to determine the duration time of the slave piece of equipment based on the duration time of the master operation Mixed Mode -a combination of both a (cyclical) mode where there is a dead time (or off time) and procedures carried out continuously Molecular Weight -the sum of the weights of the atoms of which it is made NO3-NO2 : Nitrate/Nitrite Nitrogen
164
Pull-In - allows the user to take in a material without directly knowing the amount of material needed Pull-Out - allows the user to take out a material without directly knowing the amount of material needed Pure Components Database -from this dialog you can:
Inspect the contents of the pure component databank View and edit the properties of any component in the databank Add new components in the pure component databank Delete components from the pure component databank
SARA 313
-the vapor pressure associated with a saturated vapor (one which cannot contain more liquid molecules)
Select Mode -typical mode while in SuperPro in which streams and operations can be clicked on and selected. Selling Price -cost associated with the activities of the marketing and sales department. Their values are zero by default, assumes this cost is zero. Setup Time -time it takes for the equipment to be initialized and setup Steam-in-Place (SIP) -used to clean processes using steam Stock Mixtures Database -system pool of mixtures with pre-specified property values (including composition) ready to be used (registered) in your design case
165
Stream Elbow -a right angle bend in a stream, changing the stream from horizontal to vertical and vice versa. Temporary Connect Mode -allows the user to draw a single stream and automatically returns to Select Mode after the stream is drawn. ThOD: Theoretical Oxygen Demand -theoretical amount of oxygen needed to oxidize 1g of the component -often equal to the COD TKN: Total Kjeldahl Nitrogen -Kjeldahl nitrogen contribution of the component TOC: Total Organic Carbon -organic carbon contribution of a component TP: Total Phosphorus -denotes the phosphorus contribution of a component Transfer In -allows the user to take in a material, but unlike Pull In, requires user to specify amount of material needed Transfer Out -allows the user to take out a material, but unlike Pull Out, requires user to specify amount of material needed TS: Total Solids -fraction of a component that is dissolved or present as a suspended solid TSS/TS: Total Suspended Solids -fraction of solid component that is suspended in solution Turnaround Time -time that it takes to return a piece of equipment back to its original condition (i.e., to prepare it for the next process, cleaning, resetting, etc.) Unit Operation -represents the simplest physiochemical transformation step that can be modeled in the simulation
166
Unit Procedure - a piece of equipment in which a sequence of modeled unit operations takes place VDS/TDS: Volatile Dissolved Solids -fraction of the dissolved solid of a component that is volatile VSS/TSS: Volatile Suspended Solids -fraction of the suspended solid component that is biodegradable Waste Treatment or Disposal Cost -the cost of treating and/or disposing of certain process outputs, such as undesirable by-products, solvents, etc
167
Index #
33/50 EPA Program................................. 25, 146, 156
G H
Heat Capacity ..................................................20, 158 Heat of Vaporization .......................................21, 158 Henrys Constant .............................................20, 158
A
Acentric Factor ................................................ 20, 156 Agitate ............................................................. 31, 156
B
Batch.......................................................... 7, 109, 156 Biomass ..................................................... 19, 25, 156 BOD5 ............................................................... 22, 156 Breakpoint ............................................................... 48 Bulk Conversion Factor................................... 76, 156 Bulk Stream..................................................... 60, 156
I
Ingredient............................................. 30, 66, 72, 158 Input Stream .................................... 61, 126, 154, 158 Intermediate Stream................................... 61, 92, 159
J K
Kmaxo .............................................................21, 159 Ks.....................................................................21, 159
C
CaCO3 ............................................................. 22, 156 CAS Number ..................................... 15, 19, 138, 157 Charge ....................................................... 31, 95, 157 Chlorinated dibenzofuran (CDFs) ................ 137, 157 Clean-in-Place ................................................. 31, 157 COD: Chemical Oxygen Demand ........... 21, 154, 157 Color (see style) Component ........................................ 11, 66, 120, 157 Component Registration.......................................... 11 Compressibility Factor .................................... 20, 157 Connect Mode ................................................. 62, 157 Continuous ......................................... 8, 101, 154,157 Cost Component ....................................................... 121 Stream............................................................... 123 Equipment ........................................................ 127 Labor & Utility ................................................. 128
L
Labor Requirements ..............................................115 Log10...............................................................22, 159
M
Master-Slave Relationship.............................103, 159 Mixed Mode ......................................................8, 159 Mixture Registration................................................11 Mode of Operation.....................................................7 Molecular Weight ............................................19, 159
N
NO3-NO2..........................................................22, 159 Normal Boiling Point.......................................19, 159 Normal Freezing Point.....................................19, 159
D
Default Physical Units............................................... 9 Density .................................................................... 82 Discrete Stream ............................................... 60, 157 DVDS/VDS ..................................................... 23, 157 DVSS/VSS ...................................................... 23, 157
O
Operations........................................ 7, 31, 49, 92, 159 Operation Data.......................................................101
E
EIR: Environmental Impact Report......... 25, 148, 158 Emissions .............................................................. 133 Enthalpy of Formation..................................... 19, 158 EPA: Environmental Protection Agency ........ 24, 158 Equipment Data............................................... 44, 127 Evacuate .......................................................... 31, 158
P
Procedure Data ........................................................42 Process Time .................................................101, 159 Pull-in ....................................................................160 Pull-Out .................................................................160 Pure Components Database ....................... 11, 20, 160
Q
168
R
Register Components........................................................ 11 Mixtures.............................................................. 11
S
SARA 313 ....................................... 25, 146, 153, 160 Saturation Vapor Pressure ............................... 20, 160 Scheduling ............................................................. 101 Select Mode..................................................... 62, 160 Selling Price ............................................ 76, 121, 160 Setup Time .................................................... 102, 160 Special Components ................................................ 25 Steam-in-Place................................................. 31, 160 Stock Mixtures Database................................. 26, 160 New stock mixtures ............................................ 28 Stream Elbow .................................................. 62, 161 Style stream ................................................................. 84 unit procedure icon ............................................. 53
TKN: Total Kjeldahl Nitrogen........................22, 161 TOC: Total Organic Carbon ................... 22, 154, 161 TP: Total Phosphorus .....................................22, 161 Transfer In ................................................. 31, 95, 161 Transfer Out............................................... 31, 93, 161 TS: Total Solids ..............................................23, 161 TSS/TS: Total Suspended Solids....................23, 161 Turnaround Time....................................... 8, 107, 161
U
Unit Operation ............................. 8, 31, 101, 147, 161 Unit Procedure.........................................................31
V
VDS/TDS: Volatile Dissolved Solids.............23, 162 VSS/TSS: Volatile Suspended Solids.............23, 162
W
Waste Treatment or Disposal Cost .......... 23, 122, 162
T
Tag Unit procedure.................................................... 56 Stream................................................................. 87 Temporary Connect Mode............................... 62, 161 ThOD: Theoretical Oxygen Demand.............. 21, 161
X Y Z
169