Simulation Of BioprocessERT 315

Batch/Bioprocess Modeling,Scheduling & Optimization

Subject covered Modeling and optimization of batch and

continuous processes

Batch Process Scheduling

Resources and inventory tracking

Cost analysis & project economic evaluation

Throughput Analysis & Debottlenecking

What is “Process Simulation”?

Q: What does the word “simulate” mean?

Building a process model Predicting how a process would actually behave Performing an experiment (on computer)

Incentives: Highly cost effective Reasonably accurate Proactive approach

IDEA GENERATIONProject Screening, Strategic Planning

PROCESS DEVELOPMENTEvaluation of Alternatives

Common Language of Communication

FACILITY DESIGNEquipment & Utility Sizing and Design

MANUFACTURINGOn-Going Optimization, Debottlenecking

Production Scheduling, Capacity Analysis

Development Groups

Development GroupsProcess EngineeringCorporate EnvironmentalTech Transfer

Manufacturing

The Role of Process Simulation and Scheduling Tools inProduct Development and Commercialization

Sequential modular approachSequential modular approach Individual equipment blocks may require

iterative solution algorithms

Overall process solution is sequential & not iterative

(Turton et al., 1998)

Sequential modular approachSequential modular approach

Objectives of simulationObjectives of simulation

ProcessThroughput

BatchSize / Batch

Cycle Time

• Raw Materials• Labor• Utilities• Capital Expenses

Product(s)

Waste

Commercial process simulatorsCommercial process simulators

Oil, Gas &Petrochemicals

Oleo Chemicals

Specialty Chemicals

Aspen Plus

HYSYS

Provision

Design II

SuperPro

SS Simulation

Dynamic Simulation

Batch

Solids

Pinch

Phys Prop

Sizing & Costing

Economics

Rating

Sensitivity Analysis

Optimization

SuperPro Designer (SPD)SuperPro Designer (SPD)

Water PurificationWastewater TreatmentAir Pollution Control

BioPro Designer

SuperPro Designer

BatchPro Designer

EnviroPro Designer

BiotechnologyBio-Fuels

Fine ChemicalsPharmaceuticalsFood ProcessingMineral Processing

SchedulePro Scheduling and Debottlenecking of Multi-Product Facilities

Available toolsAvailable tools

•Intuitive user interface

•Wide variety of unit operation models

•Databases for components and mixtures

•M&E Balances of Integrated Processes

• Equipment Sizing and Costing

• Project Economic Evaluation

• Process Scheduling & Cycle Time Analysis

• Throughput Analysis & Debottlenecking

• Environmental Impact

• Detailed Reports and Charts for the Above

User Interface of SuperPro Designer

Double-Click

Detailed Modeling using Unit Procedures and OperationsDetailed Modeling using Unit Procedures and Operations

Operations Gantt ChartOperations Gantt Chart

Equipment Occupancy ChartEquipment Occupancy Chart

• How can I schedule production during the next 6-18 months?

• How can I schedule operations in an R&D facility?

• How to adjust scheduling if priorities change?

• Can I fit a new product into my facility?

Scheduling Questions Scheduling Questions

Resource Demand ChartResource Demand Chart

Labor Demand ChartLabor Demand Chart

Raw Materials

Equipment

Labor

Consumables

Lab/QC/QA

Waste Trtm/Disp

Utilities

Cost Breakdown

Raw materials$0.88/g39.6%

Facility$0.54/g24.4%

Consumables$0.65/g29.1%

• What is the required capital investment for a new plant?

• How much would it cost to make a kilo of product?

• Which process is better for making this product? A or

B?

• How can I reduce the operating cost of a process?

Cost Analysis QuestionsCost Analysis Questions

Stream Dialog – Env. Properties Tab

INTELLIGEN, INC.

Environmental Impact ReportEnvironmental Impact Report

Bottleneck identificationBottleneck identification

• How much product can I make in this plant?

• What limits the current production level?

• What is the capital investment for increasing production?

Debottlenecking QuestionsDebottlenecking Questions