AdvancedTopic 92 of 100Materials & Chemical
Process simulation
Software such as Aspen models plants.
In depth
Software (Aspen Plus, HYSYS, gPROMS, DWSIM) solves material and energy balances, thermodynamics and unit models for steady-state and dynamic simulation, optimisation and sensitivity studies. Validate with plant data; choice of property method is critical.
Key points
- Sequential modular vs equation-oriented
- Convergence of recycles
- Digital twins
ExampleA simulation tests the effect of reflux ratio on energy use before plant changes.
What is Process simulation?
Software such as Aspen models plants.
Why is it important to understand process simulation?
Process simulation models a plant on a computer, so designers can test options and optimise before building.
What does a process simulator use?
Thermodynamic models, unit operation models and the flowsheet, with mass and energy balances solved across the whole plant.
What is a risk of simulation?
Results depend on the chosen property method and model assumptions, so the inputs must be validated against plant data.
How is Process simulation used in practice?
Typical applications include comparing two separation schemes in a process simulator before choosing one, estimating the energy use of a plant to set utility sizes and checking the effect of recycling a stream on product purity.
What should I learn before Process simulation?
Study "Process safety" first (topic 91 of 100 in Materials & Chemical). It covers the groundwork this topic builds on.
What are the key points of Process simulation?
Sequential modular vs equation-oriented. Convergence of recycles. Digital twins.
Can you give an example of Process simulation?
A simulation tests the effect of reflux ratio on energy use before plant changes.
What comes after Process simulation?
The next topic is "Process economics", which builds directly on this one.
How difficult is Process simulation?
It is classed as Advanced in Materials & Chemical (topic 92 of 100). It is an advanced topic. It assumes you are comfortable with the intermediate topics in Materials & Chemical.