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  Home / RESOURCES / APPLICATION EXAMPLES

ProSim is making these application examples available to you to demonstrate how our simulation solutions are able to handle the different processes encountered in the chemical industries.

Note: these files are provided "as is" without any warranty of any nature whatsoever. ProSim does not warrant that the functions contained in the programs are error free nor that they will meet user's requirements. ProSim makes no warranties, express or implied, including but not limited to, any warranties of fitness for a particular purpose. ProSim shall have no responsibility or liability for damages arising out of or related to the delivery, use, efficiency, or suitability of these examples or the application of the results.

With ProSimPlus

The examples provided below demonstrate ProSimPlus ability to handle the different processes encountered in the industry and show how the software can be used in activities such as process conception or revamping, optimization in running phases, feasibility or safety studies. Far from being exhaustive, this list will show the processes often encountered in the chemical engineering field, or those that illustrate ProSimPlus specific strengths in terms of flexibility, efficiency and reliability.

Example of use of an external optimization algorithm

This example illustrates the use of an external optimization algorithm in the ProSimPlus simulation environment.
The communication interfaces with the external algorithm are detailed along with a short application example.

Operating balance optimization of a natural gas liquids plant

This example presents the optimization of an existing natural gas liquids plant operating balance with ProSimPlus. This example especially illustrates the combined use of the “Economic evaluation” and the “SQP Optimization” modules of ProSimPlus.

Simulation of a FCCU main fractionator

This example illustrates the simulation of a FCCU main fractionator with ProSimPlus.

Simulation of a vacuum distillation unit

This example illustrates the simulation of a vacuum distillation unit with ProSimPlus.

Simulation of an atmospheric distillation unit

This example illustrates the simulation of a crude oil atmospheric distillation unit with ProSimPlus.

Simulation of an atmospheric distillation unit with a preflash column

This example illustrates the simulation of a crude oil atmospheric distillation unit with a preflash column with ProSimPlus.

Load and export of data between ProSimPlus and Excel by scripting

This example illustrates the possibility to link ProSimPlus to Excel: ProSimPlus loads parameters from an Excel file and exports simulation results to the same Excel file.

CO2 capture using an amine solution

This example presents the simulation of a CO2 capture process by absorption using an amine solution. The flue gas is first cooled in a direct contact cooler with water before to be CO2 impoverished in an absorber (absorption column) using an amine solution. The amine is then regenerated in a desorber (distillation column) to be reused in the absorber. The desorber gas outlet composed of CO2 and water is then cooled and put in a drum to separate water from CO2.
This example especially illustrates the use of the ProSimPlus “Script” module for make-up amine and make-up water flowrates calculation.

Economic evaluation of a toluene hydrodealkylation process

This example presents the economic evaluation of a toluene hydrodealkylation process with ProSimPlus. The hydrodealkylation reactor is fed with pre-heated hydrogen and toluene. The products of the reaction (benzene, biphenyl and methane) and the residual reactants are separated by a flash and three separation units. The recycling allows to reinject a part of the residual reactants into the hydrodealkylation reactor.
This example especially illustrates the use of the ProSimPlus “Economic evaluation” module on a process including different types of unit operations (reactors, columns, pumps, heat exchangers…).

LPG recovery unit using propane refrigeration. Simulation of BPFHE with CO-ProSec unit operation

This example shows a process of LPG recovery in a natural gas with a propane refrigeration loop. This process is particularly inter-connected and includes several recycling loops.
Additionally, beside the implementation of the absorber module and of the refrigeration loop, this process uses a brazed plate-fin heat exchanger. This heat exchanger is modeled using ProSec, ProSim’s CAPE-OPEN compliant unit operation dedicated to the simulation of brazed plate-fin heat exchangers. ProSec allows taking into account the effect of the stacking and of the pressure drop on the enthalpy curves.

Natural gas deacidification with the Selexol process

This example illustrates a natural gas deacidification with the Selexol process. Selexol, mixture of polyethylene glycol dimethyl ether, is used as the solvent. The deacidification is done through a contactor and the solvent regeneration needs three successive flashes. The process objective is to highly decrease the CO2 composition of the input gas. Selexol make-up is automatically calculated with simple modules. This example is taken from [RAN76] publication which describes main features of this process.

Gas deacidification with a purisol process

This example illustrates a gas deacidification of a hydrogen stream with the Purisol process. N-Methyl-2-Pyrrolidone (NMP) is used as the solvent. The deacidification is done through a contactor and the solvent regeneration needs three successive flashes. The process objective is to highly decrease the CO2 composition of the input gas. NMP make-up is automatically calculated with simple modules. This example is taken from [KOH97] publication which describes main features of this process.

Syngas deacidification with the Rectisol process

This example illustrates a syngas deacidification with the Rectisol process. Methanol is used as the solvent. The deacidification is done through a contactor and the solvent regeneration needs several columns and flashes. The process objective is to refine a syngas of CO2 and H2S in order to have a satisfactory purity in CO2 allowing its storage and a stream of H2S able to be treated in a Claus unit. Methanol make-up is automatically calculated with simple modules. This example is taken from [KOH97] publication which describes main features of this process.

Claus Process

This example corresponds to the simulation of the well-known Claus process. This process allows the recovery of elemental sulfur from acid gas containing H2S and water, and possibly hydrocarbons and carbon dioxide.

Natural gas dehydration unit with TEG

This example illustrates a process to remove water from natural gas using Triethylene Glycol (TEG) as dehydration solvent. The interesting points of this example lie in the use of the “absorption” module for the contactor model and in the representation of two columns connected in series (the TEG regenerator and the TEG stripper) by a single ProSimPlus “stripper” module.

Biofuel production plant

This example illustrates the production of biofuel from pure vegetable oil with an alkaline catalyst.
The process involves a transesterification reaction that requires using an alcohol (usually methanol) and allows producing biofuel and glycerol from oil.

Bioethanol production plant

In this example, a bioethanol production unit is presented. Ethanol is produced from biomass by hydrolysis and sugar fermentation. First, the biomass is pre-treated with acid and enzyme to produce sugar. The sugar is then fermented into ethanol. The ethanol produced still contains a significant amount of water, which is removed by using fractional distillation.

Gas gathering system with ProSimPlus

This example mainly illustrates the use of the pipe segment module included in the standard version of ProSimPlus through the modeling of a small gas condensate gathering system consisting of three wells connected to a gas plant via a network of pipelines.

LPG recovery

This example shows a process of LPG recovery in a gas with a propane refrigeration loop. This process is particularly inter-connected and includes several recycle loops.

Heterogeneous extractive distillation

This example illustrates a high purity separation process of an azeotropic mixture (ethanol-water) through heterogeneous azeotropic distillation. This process includes distillation columns. Additionally these rigorous multi-stage separation modules are part of a recycling stream, demonstrating the efficiency of ProSimPlus convergence methods.

Naphthalene separation

This example illustrates a process to purify naphthalene from a mixture containing 14 components in a three columns distillation train. This example mainly focuses on two-phase (vapor-liquid) distillation columns. For each of the three distillation columns, several specifications are set on the output streams, illustrating the way to set "non-standard" specifications in the multi-stage separation modules of ProSimPlus.

Three stage letdown

The objective of this example is to simulate a crude oil separation process. This separation process is based on the differences of pressure between the different 3-phase (liquid-liquid-vapor) and 2-phase (liquid-vapor) flashes used.
This example makes use of petroleum cuts properties generation which are considered as pseudo-components as well as a specific thermodynamic model for water-hydrocarbon systems.

Cyclohexane production unit

In this example, a cyclohexane production unit is represented. It is a typical chemical industrial process that includes a reaction section where the product is synthesized followed by a separation section where products and by-products are separated.
Particular points detailed in this example are:
• The use of a constraint management module in order to reach a specification.
• The use of an information stream to split a heat exchanger between a temperature set point and a simple exchanger, in order to avoid a stream recycle.

Simple example

The main interest of this simple example is that it allows a progressive approach to process simulation and its main concepts: components involved, thermodynamic models, unit operations and their corresponding operating parameters, recycle loops, etc.
The particular points detailed in this example are the concept of recycling loop and the principles of the simultaneous modular approach used in ProSimPlus.


With Simulis Thermodynamics

The examples presented below are designed to illustrate the use of Simulis Thermodynamics for different types of calculation, under MS Excel. Far from being complete this list demonstrates the capabilities of the software in terms of flexibility and reliability.
To run these examples, you need to have a valid version of Simulis Thermodynamics installed on your computer. Once the example is open, you need to "force calculation" to view the results.

Double pipe (single phase) heat exchanger

Calculates the length of a double pipe heat exchanger at given input and output temperature of the process fluid.

McCabe-Thiele

Calculate the necessary number of plates in a distillation column to separate two given substances, for given separation specification, reflux ratio and pressure      

Pressure relief valves

Determine the maximum mass flux for a valve according to the range of pressure defined by the user and compute the relief valve nozzle (orifice) size.

Steam electric boiler

Determine the necessary water input flowrate to obtain a specified vapor flowrate using a steam electric boiler      

Water pump

Calculate the power of a pump and the output temperature from given input temperature, input and output pressure.      

Steam expander

Calculate the power generated by an expander and the output temperature from given input temperature, pressure and fixed output pressure.


With ProSimPlus HNO3

The examples provided below demonstrate ProSimPlus HNO3 ability to handle different type of nitric acid production processes. This list shows the typical processes encountered in the industry and illustrate ProSimPlus HNO3 specific strengths in terms of flexibility, efficiency and reliability.

Packed column for NOX absorption

This example uses a column with two packing beds to absorb the NOx of a gas stream with a weak solution of nitric acid. The flow rate of this solution is determined to respect the NOx content of the gas stream leaving the column.

Dual pressure nitric acid manufacturing process

This example corresponds to the simulation of a manufacturing unit of nitric acid by a dual-pressure process. It is a rather traditional process of industrial production of nitric acid.
The main modules specific to the simulator ProSimPlus HNO3 are implemented here: absorption column of nitrous vapors, nitrous vapors condensers, oxidation reactors, heat exchangers with oxidation volumes, nitrous vapor compressors, etc.

Mono pressure nitric acid manufacturing process

This example illustrates the simulation of a manufacturing unit of nitric acid by a monopressure process. It is also a rather traditional process of nitric acid industrial production.
The main modules specific to the simulator ProSimPlus HNO3 are implemented here: absorption column of nitrous vapors, nitrous vapors condensers, oxidation reactors, heat exchangers with oxidation volumes, nitrous vapor compressors, etc.


With BatchReactor

The example presented below is designed to illustrate the use of BatchReactor

Scale-up of a chlorination reactor

The main interest of this example is the scale-up a chlorination reactor. The chlorination of o-chlorotoluene is performed in a vapor-liquid reactor. The heating/cooling device of the reactor and the condenser geometry are specified. During the reaction step, the temperature level in the reactor is controlled with a PID.

Simulation of batch gluconic acid production with user defined kinetics

The main interest of this simple example is to show how user can very simply describe his own kinetics models using the advanced mode available in Simulis Reactions, the chemical reactions server used in BatchReactor software.
This white biotechnology example deals with the fermentation of glucose to gluconic acid, which involves the oxidation of the aldehyde group of the sugar to a carboxyl group.

Simulation of batch starch enzymatic hydrolysis with user defined kinetics

The main interest of this example is to show how user can very simply describe his own kinetics models using the advanced mode available in Simulis Reactions, the chemical reactions server used in BatchReactor software.
This food processing example deals with the enzymatic hydrolysis of starch to form fermentable carbohydrates (glucose, maltose and maltotriose) in beer production.

Simulation of batch tomato sauce oxydation

The main interest of this example is to show how user can very simply describe his own kinetics models using the advanced mode available in Simulis Reactions, the chemical reactions server used in BatchReactor software.
This food processing example deals with reactions that some components of the tomato sauce, such as ascorbic acid, chlorogenic acid and β-carotene, suffer during the production of this product.

Simulation of batch poly-B-hydroxybutyric acid (PHB) production with user defined kinetics

The main interest of this example is to show how user  can describe  his own kinetics models using the advanced mode available in Simulis Reactions, the chemical reactions server used in BatchReactor software.


With ProSim DAC

The example presented below is designed to illustrate the use of ProSim DAC.

VTSA Process - Dichloromethane adsorption on an activated carbon

This example deals with a VTSA process (Vacuum Thermal Swing Adsorption) in which dichloromethane is adsorbed on an activated carbon. The regeneration of the activated carbon is done in two steps:
1. Thermally by a hot nitrogen stream,
2. In vacuum by a low pressure nitrogen stream
 

TSA Process - Dichloromethane adsorption on an activated carbon

This example deals with a TSA process (Thermal Swing Adsorption) in which dichloromethane is adsorbed on an activated carbon. The thermal regeneration of the activated carbon is done by a hot nitrogen stream.

Propane adsorption on an activated carbon

This example deals with a TSA process (Thermal Swing Adsorption) in which propane is adsorbed on an activated carbon. The thermal regeneration of the activated carbon is done by a hot nitrogen stream.


With ProSec

The example presented below is designed to illustrate the use of ProSec.

LPG recovery unit

This example shows a brazed plate-fin heat exchanger used in a process of LPG recovery from a natural gas. This heat exchanger is modeled using ProSec, ProSim’s CAPE-OPEN compliant unit operation dedicated to the simulation of brazed plate-fin heat exchangers.
ProSec allows taking into account the effect of the stacking and of the pressure drop on the enthalpy curves.

Simulation of a brazed plate-fin heat exchanger with ProSec CAPE-OPEN unit operation

This example shows brazed plate-fin heat exchanger with two fluids. There is a side stream on the hot stream and an external recirculation on the cold stream. This heat exchanger is modeled using ProSec, ProSim’s CAPE-OPEN compliant unit operation dedicated to the simulation of brazed plate-fin heat exchangers. ProSec can take into account the effect of the stacking and of the pressure drop on the enthalpy curves.
In this example, the ProSec unit operation runs inside the ProSimPlus environment, i.e., within the ProSimPlus simulation software where the thermodynamic and physico-chemical data needed are automatically calculated using Simulis Thermodynamics, the thermodynamic calculation server of  ProSimPlus.