Application examples

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.

 

 

ProSim 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.

 

 

ProSimPlus

The examples presented below are designed to illustrate the use of ProSimPlus.

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Absorption heat pumps

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This document presents the simulations of different absorption heat pump cycles. Two types of absorption heat pump are presented: an absorption heat transformer and an absorption refrigerator. A industrial example is also presented to illustrate the utilization of absorption heat pump.

Bioethanol production plant

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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.

Biofuel production plant

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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.

Claus Process

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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.

CO2 capture using an amine solution

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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.

CO2 refrigeration cycle

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This example presents the simulation of refrigeration machines with transcritical CO2. Two transcritical cycles are presented, a simple cycle and a two-stage cycle. The cycles allow to provide temperatures below 0°C.

Cogeneration plants with steam turbines

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This example presents the simulation of a cogeneration plant fueled by natural gas (NG). The objective of the process is to merge the production of usable heat and electricity into a single process that can substantially reduce carbon emissions and energy costs. Electricity is produced through a cascade of turbines while the heat is recovered by heat exchangers.

Cyclohexane production unit

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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.

Deethanizer with thermosiphon

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This example deals with the simulation of a deethanizer. The aim of this column is to recover as much as possible of ethane in the overhead product. Thus, the propane and the heavier lie in the bottoms. The particular point which is detailed is the modeling of the thermosiphon reboiler. This equipment is precisely taken into account by the representation of the downcomer and the riser. The pressure drop balance is computed in a Windows Script module.

Economic evaluation of a toluene hydrodealkylation process

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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…).

Energy analysis of an esterification process from vegetable oil

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This example illustrates the simulation of a production unit of ester and glycerin (glycerol) by esterification of vegetable oil. The "Pinch analysis" module is used to perform an energy analysis of the process.

Example of use of an external optimization algorithm

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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.

Gas deacidification with a purisol process

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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.

Heterogeneous extractive distillation

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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.

Integrated Gasification Combined Cycle (IGCC) plant

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This example presents an Integrated Gasification Combined Cycle (IGCC) based on coal gasification using ProSimPlus.

Load and export of data between ProSimPlus and Excel by scripting

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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.

LPG recovery

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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.

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

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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.

Methanol Synthesis

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This example illustrates the synthesis of methanol from a syngas. The syngas can be provided by a gasifier (e.g. “PSPS_E28_EN - IGCC Plant”). The different steps are modeled: syngas compression reaction, flash purification and then final distillation purification of the methanol produced. The synthesis reactor is modelled using Gibbs energy minimization. The particular points which are detailed in this example are the use of a Gibbs reactor, the modeling of the distillation column condenser as an outside unit operation and the use of a “Calculator Switch” to change the thermodynamic model in some part of the process.

Naphthalene separation

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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.

Natural gas deacidification with the Selexol process

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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.

Natural gas dehydration unit with TEG

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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.

Operating balance optimization of a natural gas liquids plant

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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.

Simple example

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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.

Simulation of a FCCU main fractionator

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

Simulation of a vacuum distillation unit

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

Simulation of an atmospheric distillation unit

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

Simulation of an atmospheric distillation unit with a preflash column

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

Simulation of different Rankine cycles

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This example presents the simulation of different Rankine cycles powered by geothermal energy. Three types of Rankine cycle are presented: simple cycle, flash cycle and mixed cycle.

Syngas deacidification with the Rectisol process

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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.

Three stage letdown

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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.

Thymol production

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The main interest of this example is to show how it is possible to simulate a process integrating steady-state parts and batch parts with ProSim software. (use of the BatchReactor and BatchColumn software in the ProSimPlus simulation environment).

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