Request
a free consultation
Model-Based Engineering for the Chemicals sector
Key technologies for process development and optimization
"What we have achieved [in high-purity CO2 removal] in only a few months goes far beyond our greatest expectations"
— Linde Engineering
The key technology areas in which PSE has expertise or helps customers implement their expertise are:
PSE is a world-leading supplier of tools, models and expertise in a number of these areas.
Reaction systems design
Reactor modelling – all types of reactor
Catalyst screening in "real reactor" conditions
PSE is a world leader in the high-accuracy modelling of reaction systems for decision support and risk management, from conceptual and detailed design to operations.
Our Advanced Model Libraries contain highly detailed models that cover the complexity of diffusion and reaction from a molecular level to the entire reaction system unit. These multi-scale models solve rapidly and robustly within the gPROMS solution engine.
PSE's Model-Based Innovation techniques combine first-principles models with laboratory or pilot plant data to shorten R&D cycles and accelerate innovation. We also work with customer R&D specialists to guide experimental programmes for maximum effectiveness.
Our Model-Based Engineering techniques apply these models within a state-of the art framework of methodologies to being high-accuracy quantitative data to key design and operating decisions.
Where it is necessary to take account of non-ideal mixing, we incorporate CFD calculations into our modelling using hybrid modelling techniques pioneered by PSE.
The result is high-accuracy, beyond design-level models of virtually any kind of reactor, that can be used for optimisation of design and operation.
The benefits: better, safer designs; faster innovation; reduced risks through better quantification; increased quality and throughput; improved operability — all leading to lower capital and operating cost and higher profitability — with little or no capital expenditure.
Catalyst assessment
Closely aligned with our reactor modelling capability is the ability to assess and screen catalysts.
Model-Based Innovation techniques can be used rapidly to determine which catalysts should go to pilot or actual plant testing, based on their modelled performance within rigorous models of pilot plant or laboratory equipment.
The benefits: more rapid catalyst development or deployment; reduced testing costs; easy optimisation of new operating conditions; accurate identification and quantification of operating risks.
Advanced separation modelling
Many chemical processes involve complex separations, or reaction and separation combined, that cannot be adequately represented using the traditional equiilibrium assumptions.
Advanced mass-transfer modelling of many different types and configuration of separation system
Many types of crystalliser
We provide high-accuracy modelling of the following types of crystalliser:
- batch, semi-batch or continuous
- single and multiple stage configu rations
- various crystalliser types
- chemical, petrochemical, food, pharmaceutical and minerals
See our chemicals example
PSE has developed world-leading capabilities for modelling of non-equilibrium separation systems on an industrial scale. These use rate-based techniques based on the Maxwell-Stefan approach to multicomponent diffusion.
Our Advanced Model Library for Gas-Liquid Contactors (AML:GLC) of high-fidelity, non-equilibrium (rate-based) component models for gas-liquid separation is designed to cover a wide range of separation operations. Custom reaction models - including very fast and ionic reactions - can be included within the AML:GLC models.
These include conventional packed columns for distillation, absorption and evaporation, and more complex units such as heat-integrated devices, dephlegmators and falling-film columns.
In addition we have novel modelling and optimisation techniques for separation process synthesis, including determination of optimal feed and draw tray location and separation stage number for stagewise equipment, and for pressure-swing adsorption (PSA) operations.
We have also developed a detailed hydraulic tray-by-tray distillation library, first applied in the Texas City Refinery accident investigation.
Example: high-accuracy modelling of Heat-Integrated Distillation columns such as the one (schematic, right) currently under trial at a chemical plant in Japan showed that such systems can save up to 60% of the energy required by conventional distillation equipment.
The benefits: more accurate designs leading to lower capital cost and reduced energy use; tighter operating envelope leading to better controllability and higher on-spec operation; accelerated innovation of novel solutions, with quantified risk management.
Crystallisation process design, scale-up and troubleshooting
PSE is also a world leader in crystallisation process modelling, having worked for many years with leading academics in the field and undertaken significant development of our own.
This has resulted in our Advanced Model Library for Solution Crystallisation (AML:GLC), a collection of high-accuracy crystallisation models, hybrid gPROMS-CFD modelling tools, and a set of industry-proven impementation methodologies.
We are leaders in the use of multiple population balances to track crystal properties accurately throughout the process, bringing exceptional accuracy to modelling.
We have also been key players in pioneering the implementation of Model-based Predictive Control (MPC) applications for crystallisation processes.
Example: One troubleshooting application for a Japanese chemical company resulted in upward of $10m per year in additional throughput.
The benefits: high-accuracy design of industrial crystallisation processes; accurate scale-up from laboratory to industrial equipment; reduced design and operating risk; simplified troubleshooting.
Polymerisation process design, scale-up and troubleshooting
PSE has developed some of the most advanced methods available for accurate modelling of polymerisation processes.
PSE's advanced polymer models go far beyond the industry-standard moments-based approach to allow modelling of millions of species and reactions. This is particularly advantageous for co-polymerisation reactions.
The results from high-fidelity polymerisation models provide unprecedented accuracy in representing the product molecular weight distribution (MWD).
This allows polymer manufacturers to design processes capable of achieving polymers with the correct molecular formulation for the desired end-user properties.
Interested in finding out more?
Request
a free consultation
Privacy policy | Accessibility | Company registration
Copyright © 1997-2010 Process System Enterprise Limited
rights reserved
