Efficient process operation and superior product quality are essential
goals in developing and maintaining a competitive edge in today's chemical
industry. ChemSim uses rigorous mathematical process models to help you
achieve these goals.
Applying process simulation leads to greater understanding of the complex
relationship between operating conditions and process performance characteristics;
plant capacity, product properties, and energy consumption. Plant models
can be used to perform debottlenecking studies, process optimization studies,
plant retrofit design testing, process troubleshooting and other process
Following are examples of some of the application areas for process modeling.
Revamp / Retrofit / Debottlenecking studies
Revamp examples are often targeted at production of commodity chemicals.
Pain - Often older plants are still in use. Customer needs to lower operating
costs while continuing to meet demand.
Solution - Produce a complete plant model including all complex interactions
of these highly integrated processes
Benefits - Sensitivity studies can often reveal potentials for increased
profitability with corresponding decreases in energy consumption. For
these large chemical complexes, decreasing energy consumption by just
1 or 2 percent can realize huge cost savings.
Polymer production is an example of a complex process where key
parameters often considered are:
- Optimal production of monomer
- Degree of polymerization
- Product quality specifications of the polymer
- By-product contents
Pain - Improve product quality
Solution - Incorporate process data and fundamentals (polymerization
kinetics, phase equilibrium, mass transfer, heat transfer, equipment configuration)
into a complete plant model.
Benefits - Obtain a thorough understanding of the relationship between
the process conditions/ configuration and product quality.
Environmental Auditing / Waste Minimization / Pollution Control.
Pain - Chemical plants need to comply with environmental regulations.
Solution - From an original flow sheet of the process, add extra unit
describe the treatment of the various waste streams
Benefits - Modeling allows prediction of emissions under various operational
conditions. Models are used to predict the removal efficiency of contaminants
from various process streams in order to show compliance with environmental
permits granted under Title V of the Clean Air Act.
Resource Management - Water Use
Pain - Industries such as the pharmaceutical and semiconductor industries
require large quantities of ultrapure water.
Solution - Produce a complete mass balances of all material flows, and
investigate process alternatives, optimizing the consumption of the specified
Benefits - Optimization and sensitivity studies can show where the greatest
savings can be made, by reducing water consumption.
Environmental Impact Assessment - Semiconductor Industry
Pain - The manufacture of computer chips consumes lots of energy and
generates harmful, toxic waste products, thus producing a high value for
the environmental impact.
Solution - Construct models for different process alternatives. The objective
is to ensure accurate material balances, and account for every component. Component
attributes may be included to provide weighting factors for the environmental
Benefits - Modeling allows alternative scenarios to be tested to determine
the best methods for reducing the environmental impact.