Advanced modelling and simulation in other process sectors

Because of the general-purpose modelling capabilities of gPROMS, and PSE's use of first-principles modelling techniques coupled with experimental data, the models originally developed for the chemical industry can be applied with very little modification in virtually any process sector.

This means that high-accuracy modelling can be applied in many areas — such as food & beverage — that have traditionally been neglected by simulation companies, or where the complexity of processes means that modelling attempts have been largely empirical.

Some examples are:

Food and beverage

Advanced Process Modelling for food & beverages

Food and beverage companies have traditionally lacked simulation capability because the processes are chemically complex, physical properties are not readily available, or simply because traditional methods of production have been adequate.

Companies such as The Netherlands' largest dairy producer, Friesland Foods, have adopted Advanced Process Modelling for optimising process design and operation. PSE has worked with Friesland Foods to develop a properties package for dairy applications.

Other companies such as Danisco and Purac are investigating the potential for using models online as part of Model-based Predictive Control (MPC) systems.

Typical examples of application are:

off-line optimisation of process conditions for existing products
determining optimal process conditions for new processes and products
crystalliser design, scale-up and modification
operator training
determining kinetics for reaction and crystallisation processes
optimal transient control of batch processes - for example, sugar and sweetener production

Some of these are taken for granted in other industries, but are only now being applied in the food industry because of the recent availability of suitable models.

Example: Using modelling to improve particle size distribution (PSD) for lactose crystals in orde to maximise production of higher-value pharmaceutical-grade lactose.

The benefits: better and more energy-efficient designs; better understanding of processes; better controllability and lower downtime; higher margins on high-throughput, low-margin processes; greater production flexibility.

Industrial gases

A number of the world's leading industrial gas companies use gPROMS, because of its solution power, robustness and dynamic simulation capabilities, and the ease of implementing custom models.

Typical applications are in areas where other modelling and simulation tools have proven inadequate, for example:

high-purity CO2 cleanup, where PSE's Advanced Model Library for Gas-Liquid Contactors (AML:GLC) brings new levels of accuracy
cyclic separation processes, such as Pressure-Swing Adsorption (PSA) and Simulated Moving Bed (SMB) separations
membrane processes
catalytic generation of syngas for fuel cell consumption
operator training
optimising startup dynamics for complex operations.

"With gPROMS we achieved things in a few months that we could only dream of in the past"

— Dr Karl-Heinz Hoffman of Linde Engineering

Other companies use gPROMS for flowsheeting of Air Separation Unit processes, where the many recycles create difficulties for traditional simulators.

Examples: The detailed rate-based modelling of a reactor feed cleanup column for removal of CO₂ to ppb purities; the optimisation of the cyclic steady-state for a Pressure Swing Adsorption process.

The benefits: better and more energy-efficient designs; optimised startup; better controllability; quantified risk management to promote and support innovation.

Pulp & paper

Advanced Process Modelling is increasingly being applied within the pulp & paper sector, with a major supplier standardising on PSE modelling technology and services (press release).

Key modelling applications are in the areas downstream from the pulp process: optimisation of the 'additional chemistry' processes used for creating different papers and the drying and remoisturising processes, as well as the enhancing of energy integration and the optimising of water usage.

Modelling is also used to minimise the need for physical testing, and, when testing is required, to minimise the time taken to move between test steady states by optimising process trajectories .

gPROMS seen as is a key tool because of its flexibility, solution power, the custom modelling capability and the potential for re-use of models.

Minerals & mining

PSE is applying techniques and technologies developed for many applications across the chemicals industry to the minerals and mining sectors.

The main application areas are reaction, crystallisation and separation.

PSE's work with a leading South American minerals producer is resulting in significant enhancements to a variety of mineral processes, and has pioneered the application of APM techniques to the minerals industry.

Example: [Restricted]

The benefits: better and more energy-efficient designs; better controllability and lower downtime; higher margins on high-throughput, low-margin processes; greater production flexibility; leveraging the experience of modelling and simulation technology proven through many years' use in the chemical industries.

Biotreatment processes

Waste treatment is by definition at the very end of the production process, meaning that treatment systems are subject to wide variation in feed rates and composition. Wastewate treatment plant

Because of the dynamics of microbial population growth, difficulties in operation can translate into downtime in the upstream processes with potential significant losses in production.

PSE's biotreatment models use rigorous modeling of the chemistry and kinetics to address key design and operational challenges of biotreatment processes, such as the optimisation of equipment and process control schemes for optimal response to upsets.

Example: The use of PSE's advanced biotreatment modelling technology to give definitive answers to complex questions such as: "what is the optimal the number of bioreactors, their size and the oxygen injection point?" "How will the process respond to startup, shutdown and shock loads?"

The benefits: high degree of predictive accuracy from first-principles models coupled with experimental data; reduced over-design; more flexible operation; optimised operating policy. Advanced Process Modelling for metal processing

Metals production

gPROMS is increasingly being applied to the modelling of metal production, including aluminium processes.