Modern process simulator software can fed this information by actual sensor data, either prerecorded or even streamed live. One major advantage that comes with industrial digitalization and plant digitalization is that by wiring a facility with networked sensors, a valuable supply of data is created. This trove of historical data can be accessed again and again, to be used in future simulations or to help create a digital twin or model.
The software will then perform the mathematical operations that correspond to different parts of the process. As the computer works its way through the various equations that represent the components of the process simulation, new conditions will arise.
For example, the ambient temperature of the facility may start at one value, but once the process simulator software begins calculating the effects of turning on a boiler, that ambient temperature value will be increased.
The new values are processed again, and the resulting values processed again, over and over. This builds up a frame by frame picture of the simulated process. The results of the process simulation should be compared to the real world results of similar conditions. This allows for adjustments to increase the fidelity of the simulation for future simulator runs.
There are numerous reasons why an enterprise would want to spend time and effort on a process simulation. In terms of planning, being able to create a digital model of the proposed asset before you break ground means that any surprises will happen in the safety of a software environment. For existing processes, a process simulation can help a company optimize production by providing an inexpensive way to explore different production configurations and parameters.
Instead of spending money trying out a new, expensive piece of equipment—even an upgrade that may promise increased efficiency—a process simulation can visualize and spell out what kind of an effect the new piece of equipment will have on the operations of the firm as a whole. How is a process simulation different from a digital twin?
Digital twin technology seeks to replicate every aspect, from the smallest physical details of a process all the way to the resulting phenomena. For example, the Baytown Refinery in Texas, the tenth largest oil refinery in the world, covers 3, acres. There is no practical way to view the entire operation of this facility in person, and a digital abstraction can help provide an intuitive sense of the process. Increased collaboration is another benefit of the process simulation software because this digital representation can be easily shared across an organization.
Sending a file, or even collaborating in real-time with a cloud-synced process simulation, means personnel can perform useful work remotely. Because the functioning of the asset can be analyzed without making physical changes to the asset, process simulation software is invaluable for refinery optimization , value chain optimization and production optimization.
Companies looking to maximize their margins, reduce asset failure, or increase environmental compliance can test process adjustments directly in the process simulation software, exploring a variety of options until they find the parameters that best fit their goals. A company or organization that uses process simulation software can link this simulation into a live data stream from sensors on the assets being simulated. This simplifies the process of keeping the simulation up to date, as information about the actual functioning of the process is supplied in real-time.
Beyond merely enabling a demonstration of the process as it exists, process simulation software can help companies make process improvements or find entirely new paths of production by making it easier and more affordable to test process variables. How is process simulation software different from process simulator software? These terms are synonymous.
Technically, a simulation runs within a simulator, but since all process simulation software packages include the ability to both create a process simulation and to run a process simulation, the distinction is irrelevant. What kind of processes can be simulated in process simulation software?
Many different kinds of processes can be modeled. Add the assay data: By: Eng. The status message at the bottom of the Assay view will display Assay Was Calculated. Once the Assay is calculated, the working curves are displayed on the Plots and Working C u r v e s tabs. The working curves are regressed and extrapolated from the Assay input. These working curves are used in determining the properties of the hypo components generated in the Blend step. The Blend tab of the Oil Characterization view provides two functions, cutting the Oil into Hypo components and Blending two or more Assays into one set of hypo components.
In the Stream Name column, enter the name Raw Crude to which the oil composition will be transferred. Now you can return to the Simulation environment to see the stream Raw Crude with a full composition: By: Eng. Typically located after the Desalter and the Crude Furnace, the Atmospheric Tower serves to distil the crude oil into several different cuts.
These include naphtha, kerosene, light diesel, heavy diesel and AGO. In this module, you will construct, run, analyze and manipulate an Atmospheric Crude Column simulation. You will begin by building a simple column and continue by adding side operations to the column.
Pre-Heat Train By: Eng. The pressure drops for the Tube and Shell sides, will be 35 kPa and 5 kPa, respectively. The tube outlet from the HX is then sent to a desalter which is simply modeled as Three Phase Separator where desalted water, oil and gas is separated.
This is the minimum temperature difference between the hot and the cold stream. Calculate: - The vapor fraction of the product stream before entering the Atmospheric column. Atmospheric Distillation By: Eng. A water draw stream is required to remove the condensed steam from the overhead condenser. What is the flow rate of? We will install one reboiled side stripper and two steam stripped. They operate by drawing a liquid stream from one stage cooling it, and pumping it into a higher stage.
In effect, this process adds to the reflux between these two stages. Profit Min. Cost Productivity 7 By: Eng. The object of the exercise is to select the product specifications such that profit is maximized. HYSYS includes additional modelling and decision support tools that can be used to enhance the usability of your models.
Calculate: The reflux ratio and the distillate rate under the specified conditions. Save Your Case! The following figure shows the physical configuration of this system superimposed on a topographic map.
The system consists of four wells distributed over an area of approximately 2. All pipes are uninsulated Consider inner and outer HTC and the pipe wall in heat transfer estimation. Each pipe section and fitting is labeled as a segment. To fully define the pipe sections segments, you must also specify pipe schedule, diameters, pipe material and a number of increments. Specify the following information for the segment.
The Pipe Segment is not yet able to solve because we have not specified any information about the heat transfer properties of the pipe.
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