Accelerated, effective R&D through modelling
Model-Based Innovation (MBI) involves combining high-fidelity models of processes or products with modern R&D methodologies to provide high-quality information for innovation decision support.
This helps companies to manage risk in innovation, design and operational enhancement based on accurate quantitative information.
The result is faster innovation, improved designs of processes and products, enhancement of existing operations and more effective R&D programmes.
PSE's ModelCare® Model-Based Innovation service covers all process industry sectors, and can be applied from laboratory R&D, through process and detailed design, to online operation.
In fact, MBI is a key mechanism for integrating R&D, design and operational activities, to achieve mutually beneficial objectives.
The benefits of Model-Based Innovation
The application of MBI can result in significant competitive advantage through modelling. Some specific benefits are:
- effective risk management. Modelling provides quantitative data on which to base R&D and design decisions, allowing you to manage risk with confidence.
- fast screening of alternatives. Modelling quickly shows you which alternatives to discard and which to pursue.
- streamlining of experimental programmes. Model-based experiment design can reduce time and cost of experimentation significantly.
- direction of Research & Development spending. The information generated by MBI techniques can be used to rank R&D investment alternatives by value.
- understanding the relationship between experimental uncertainty and design margin.
- availability of accurate validated models for design, leading to effective and accurate process or product design right from the research stage.
PSE's ModelCare service is designed to help companies innovate rapidly with relatively low investment and fast payback.
A key aim of ModelCare is to transfer MBI know-how to customers to help them build their own internal Model-Based Innovation capability.
Model-Based Innovation methodology: the fundamentals
PSE's Model-Based Innovation methodology is underpinned by major advances in modelling technology and thinking:
1. Modelling technology has come of age
Advanced Process Modelling tools and methodologies now allow modelling of many types of complex process, products or equipment - from detailed reactor systems to tablets delivering drugs in the human body - to a degree of predictive accuracy which is capable of supporting real innovation in design and operation.
Hybrid "APM-CFD" methodologies make it possible to investigate the detailed effects of equipment geometry on the behaviour of complex processes, enabling accurate scale up.
Beyond simple trial-and-error simulations, models can now be used directly for rigorous optimization of design and operating conditions involving both continuous and discrete decisions (e.g. the structure of the plant flowsheet).
2: Modelling and experimentation can be closely coupled
As shown below for the simultaneous design of a new catalyst and reactor, model-supported micro-experimentation can use small catalyst samples together with models of the experimental apparatus to generate accurate values of model parameters.
Model-based experiment design minimises the number and cost of such experiments by ensuring that each one generates the maximum amount of information.
Once the parameters are known, then they can be used in models of full-scale equipment coupled with rigorous optimization techniques to determine the optimal reactor design and operation that are achievable using this particular catalyst.
This provides a screening mechanism, reserving pilot plant testing only for catalysts which appear to be promising.
3: Modelling can establish a quantitative link between uncertainty and risk
Even formally validated models are still subject to uncertainty in their parameter values.
It is important to be able to map this uncertainty to uncertainty in Key Performance Indicators (KPIs) of the process, to allow a trade-off between research and risk.
All parameters are uncertain, but not all of them are critical.
Some parameters may have a small effect on KPIs; uncertainty in other parameters may be counteracted by control actions.
Models can help establish the quantitative relationship between fundamental R&D uncertainty in process development and technological risk during process operation.
By establishing which parameters affect KPIs most, research investment can be directed towards the most critical parameters.
In this section
See also Model-based Engineering
MBI provides answers to questions such as …
How can we reliably evaluate and compare a number of new catalysts?
How does the uncertainty in our reaction data affect the flare stack design margins?
Can we avoid constructing a costly pilot facility?
How do we guarantee that the scaled-up process will work?
MBI is a key mechanism for integrating R&D, design and operational activities, to achieve mutually beneficial objectives
Parameters are the empirical values found in any design calculation, such as heat transfer coefficients and reaction kinetic constants.
Their values are usually derived from laboratory, pilot plant or operational measurements.
The value of a parameter can have a critical effect on a design.
The more accurate the parameters, the more accurate the design, and the lower the risk and capital and operating costs.
The experimentation process is aimed at establishing accurate parameter values.
Once this is achieved, models can be used to effectively search large design or operational decision spaces, leading to significant benefits.