Simulation of Mixing Processes -...
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V V i i s s i i M M i i x x Simulation of Mixing Processes VisiMix Ltd, PO Box 45170, Jerusalem, 91450, Israel Tel: 972 - 2 - 5870123 Fax: 972 - 2 - 5870206 E-mail: [email protected]
Transcript of Simulation of Mixing Processes -...
VV iissiiMM iix x
Simulation of Mixing Processes
VisiMix Ltd, PO Box 45170, Jerusalem, 91450, Israel Tel: 972 - 2 - 5870123 Fax: 972 - 2 - 5870206 E-mail: [email protected]
VV iissiiMM iix x
Simulation of Mixing Processes
Presentation Contents:
- The Customers
- The Technology
- ROI
- VisiMix Products
- Saving Examples
About UsAbout Us
VisiMix is a unique software enabling chemical engineers, process engineers and R&D
personnel to visualize mixing processes via a simple, user friendly interface.
Our products allow significant savings in time and costs by drastically reducing the need for trial-and-error. They have been successfully
adopted by hundreds of companies.
VisiMixVisiMix is a unique software enabling chemical is a unique software enabling chemical engineers, process engineers and R&D engineers, process engineers and R&D
personnel to personnel to visualize mixing processesvisualize mixing processes via a via a simple, user friendly interface. simple, user friendly interface.
Our products allow significant savings in time Our products allow significant savings in time and costs by drastically reducing the need for and costs by drastically reducing the need for trialtrial --andand --error. They have been successfully error. They have been successfully
adopted by hundreds of companies.adopted by hundreds of companies.
Customers and MarketsCustomers and Markets
Our Customers
What Our Customers Say About Us
From the Dow Chemicals Intranet Website
“VisiMix: This is a highly accessible PC software for mixing calculations available from VisiMix Ltd., an Israeli company. It is a rating calculation tool for both non-reactive and reactive mixing involving blending, solid suspension, gas dispersion, liquid-liquid dispersion, or heat transfer processes in stirred vessels. It calculates the important process parameters for single- and two-phase systems – power consumption, circulation rates, local concentrations of solutes and suspended particles, drop size, concentrations of reactants, etc … ”
Dr. Victor Atiemo-Obeng
Dow Chemicals Co.
What Our Customers Say About Us
“I am very pleased in applying your software.”
L'Oreal, France
“We have been using VisiMix. We have found it an accurate tool ... Based on our success with the product, our Japanese colleagues at Fuji Xerox have bought a copy for their work.”
Emily Moore,Xerox Research Center of Canada
Customers and MarketsCustomers and Markets
Customer List
1. L'Oreal, France2. BASF AG, Germany 3. Dow Chemical Company, USA 4. Searle (MONSANTO), USA5. Lightnin, USA6. LG Chemicals, S. Korea 7. Xerox , Canada & USA 8. The Gillette Co., USA & UK 9. De Dietrich, France & USA 10. ENIChem, Italy 11. Eli Lilly & Company, USA 12. NIPPON, Japan 13. Novartis, USA14. Millennium, USA15. ICI, UK 16. Hercules, USA 17. Pfizer, USA&UK&Gr.18. Mitsubishi Chemicals 19. Abbott Laboratories, USA20. GlaxoWellcome,UK&Singapore
1. L'Oreal , France2. Techmix S.r.o, Czesh Republic3. BASF AG, Germany 4. BASF, Denmark 5. BP Chemicals - Wingles, France6. Sanofi Recherche, France7. Technimont, Italy 8. Nycomed Imaging, Norway9. Hoesch & Sohne, Germany10. DSM, The Netherlands11. Searle (MONSANTO), USA12. Lightnin, USA13. Chevron, USA14. Teva, Israel 15. Plantex, Israel16. Bromine Compounds, Israel17. ENSIC, France18. LG Chemicals, Taejon-city, S. Korea 19. LG Tech, Yeochon-city, S. Korea 20. Lonza, Switzerland21. Thai Plastic and Chemical Public Company, Thailand22. Xerox Research Centre of Canada, Canada 23. Xerox, USA 24. The Gillette Co., USA 25. Gillette, UK 26. Lecaros, Chile 27. SK Chemicals, S. Korea 28. Dow Chemical Company, USA 29. Monsanto, USA 30. Buchi AG, Switzerland31. Agisys, Hungary 32. Samsung, S. Korea 33. Mervers, Holland 34. American Cyanamid Company, USA35. Belinka Belles, d.o.o., Slovenia36. LG Chem. , ABS Division (S. Korea)37. BFGoodrich Advanced Technology Group, US38. PT MECO INOXPRIMA, Indonesia39. Ion Exchange, India40. IL JIN Eng. & Const. Ltd., Korea41. CSIR Ltd., South Africa42. PTI, Brazil
43. De Dietrich, France 44. De Dietrich, USA 45. Rhodia (Rhone Poulenc Group), Brazil46. Inymassa, Spain 47. ENIChem, Italy 48. Satake, Japan49. Chesebrough-Pond’s, USA 50. Unilever, Italy51. Schering-Plough, USA52. Ontec, Israel53. Cytec, USA54. Degussa, Germany55. IHN Groningen BV, the Netherlands 56. PEAS BV, the Netherlands57. Eli Lilly & Company , USA 58. BSL (Dow group), Germany 59. VMD PTE Ltd., Singapore 60. Tecnicas Reunidas, Spain 61. NIPPON, Japan 62. Chr. Hansen, Denmark63. Danisco, Denmark 64. Novartis, USA 65. SNECMA, France 66. Millennium, USA 67. Ucosan B.V., Holland 68. Norde Veenendaal B.V., Holland 69. Akzo Nobel, Germany 70. Astra Charnwood, UK 71. ICI , UK 72. Stork, Netherlands73. Hercules, USA 74. Luigi Menestrina, Italy 75. Siersma Leidshendam, the Netherlands76. Sara Lee, the Netherlands 77. Pfizer, USA 78. Pfizer, UK 79. Pfizer, Germany 80. Beiersdorf AG, Germany81. Sintef Applied Chemistry, Norway 82. Chemitec OY, Finland 83. Makhteshim, Israel 84. Chemagis, Israel
85. Nitto Denco, Japan 86. 3M, USA 87. Broom Chemie, the Netherlands88. Atlas-Stord, Denmark89. Canon, Japan 90. Mitsubishi Chemicals91. Imation, USA92. NIKKI, Japan 93. Fuji Xerox, Japan94. Oxy Vynils95. Scanlube, Sweden 96. GlaxoWellcome, Singapore97. GlaxoSmithKline, UK98. SmithKline Beecham, USA 99. M&F Process Simulation, The Netherlands100. Abbott Laboratories, USA 101. Air Products, USA102. Gruppo Lepetit, Italy 103. Johnson Polymer, Holland 104. Dow Corning, USA 105. Pharmacia Biotech, Sweden106. Panandiker Research & Development (P) Ltd., India107. Fujifilm , Japan108. Katholieke Hogeschool Brugge-Oostende, Belgium109. The Casali Institute, Israel110. Noordelijke Hogeschool Leeuwarden, the Netherlands111. Stettin University112. Taiwan University113. Ecole d'Electrochemie, France114. Ecole Polytechnique, Canada115. University of Western Ontario, Canada 116. University of Barcelona, Spain 117. Taejon National University, S. Korea118. Otto von Guericke Universitat, Germany119. Tsinghua University, China120. VUOS, Czesh Republic121. Universita di Roma, Italy122. Hanyang University, S. Korea123. Royal Institute of Technology, Sweden
Total : 123 customers
De Dietrich De Dietrich -- ExampleExample
http://www.ddpsinc.com/MixingSimulations.htm
De Dietrich De Dietrich -- ExampleExample
http://www.ddpsinc.com/Visimix.htm
Simple and EffectiveSimple and Effective
Technology - Simulation of Mixing Processes
The First and the only tool in the IndustryThe First and the only tool in the Industry
Reliable and accurate resultsReliable and accurate results
Based on More Than 300 Man Years of R&D andBased on More Than 300 Man Years of R&D andIndustry ExperienceIndustry Experience
Replacing Pilot Experiments Replacing Pilot Experiments
Accelerated TimeAccelerated Time--toto--Market processMarket process
User Friendly and easily accessibleUser Friendly and easily accessible
Simple and EffectiveSimple and Effective
Return On Investment (ROI)
Per Year basisPer Year basis
$15,000$15,000Savings
Per project - $20,000 Per year - $150,000(5-10 projects per year)
SavingsPer project - $20,000 Per year - $150,000(5-10 projects per year)
QualityQuality
TimeTime
Time To MarketTime To Market
Product Cost Benefits (The ICI Example)
$15,000$15,000$15,000$15,000$15,000$15,000$15,000$15,000
VisiMix Products
VisiMix software:
• Based on advanced scientific knowledge and practical expertise
• User-friendly and easy to operate
• Requires easily accessible initial data
The latest VisiMix products are: • VisiMix 2K8 Turbulent • VisiMix 2K8 Laminar • VisiMix 2K8 Different Impellers• VisiXcel- Data Base• Pipe Line• Rotor Stator Disperser – RSD
Introduction
NEW!
VisiMix Products
• VisiMix 2K8 Turbulent – for low-viscosity liquids and multiphase systems.
The program provides process parameters necessary for analysis, scaling-up and optimization of mixing tanks and reactors with all types of impellers
VisiMix Software Products
Calculations of:� Blending� Suspension� Dissolution� Emulsification� Gas dispersion� Heat transfer� Chemical reactions� Mechanical stability of shafts
VisiMix Products
• VisiMix 2K8 Laminar - for highly viscous media
VisiMix Software Products
• pastes• creams• shampoos• liquid soaps• gels• ointments• paints:• coatings• slurries• polymer solutions
� Newtonian and non-Newtonian � Macro-scale blending� Micromixing in high-shear areas � Heat transfer
VisiMix Products
• VisiMix 2K8 Different Impellers – for combined mixing devices
VisiMix Software Products
The program handles mixing devices consisting of any 2 – 5 impellers. Different distances between impellersUsed in combination with VisiMix Turbulent. Provides parameters of hydrodynamics, turbulence and heat transfer.
VisiMix Products
•VisiMix VisiXcel – Data Base (DB) – automatic conversion tool: Visimix Output to Excel Spreadsheet
•Integrates VisiMix report parameters in standard Excel worksheets•Analysis VisiMix results in Excel•Builds a Database of mixing tanks and reactors.•Builds a Database of projects - for processes•Makes correlation between plant equipment nomenclature to VisiMix database of mixing tanks and reactors in VisiMix Project Database. •Easy access to design data of the mixing tanks, to process parameters and to corresponding results of VisiMix modelling.•Results of VisiMix mathematical modelling in the VisiMix VisiXcel-DBand arrange the data according to the reactor nomenclature.• Easy access to recalculation of the VisiMix modelling from the Database of the reactors & the projects
VisiMix Software Products
•VisiMix Pipe-Line
• Calculates hydraulic resistance of simple pipelines for liquidviscosity and non-Newtonian products.• Chemical engineers benefit from a quick and user friendly method for charging timesand the bottle-necksin the line. • Includes : - Pipes - Riffled hoses – Elbows – Valves - And more• Also comes with a database containing rheological constantsfor the typical commercial non-Newtonian products - pastes, creams, shampoos, paints, etc. (see Help Section for details)• The first and only tool calculating flow resistance for liquids that correspond to Carreau rheological model. (See Help Section for details)
VisiMix Software Products
VisiMix Products
VisiMix ProductsVisiMix Products
VisiMix Software Products
• VisiMix RSD (Rotor Stator Disperser)
The revolutionary new VisiMix RSD - Rotor Stator Disperser software is the first product of its kind that provides support for mixing devices for media subjected to high sheer stress:
Based on 3 yearsdedicated research in a lab with dedicated equipment Works with all types of media - both high and low viscosity liquids, Newtonian and Non-Newtonian.
Input geometrical data and process parameters and obtain fast and reliable results with one click
VisiMix RSD enables you to quickly calculate
· Shear rates and stresses in internal spaces· Pumping capacities· Power consumption and torque
NEW!
VisiMix Orientation
The VisiMix Demonstration Tools:
VisiMix Demonstration Tools
� VisiMix Turbulent – Examples & User Guide
� VisiMix Laminar - Examples & User Guide
� VisiMix Different Impellers – Examples & User Guide
� VisiMix Turbulent SV – Trial & Education
� VisiMix Review of Mathematical Models
� Selected Verification ExamplesThe Comparison between Published Experimental Data and VisiMix Calculations
Saving ExamplesSaving Examples
Finance Saving Examples (ROI)
1. Cooling A Paste
2. Paints
3. Suspension in a Batch Reactor
4. Scale up Methodology
Finance Saving Examples (ROI)Finance Saving Examples (ROI)
Example Case Classic Solution Visimix Solution
Saving
Cooling of a Paste
Batch Production Time
Replacement of the whole mechanical
system
Input the existing mixing systems parameters to
VisiMix software, implement small
changes
$125,000 per year
Paste and Coating
Mixing several components to
obtain high quality paint during scale-
up process
Increase the impeller speed and improve the
heat removal in the tank. No successful results
obtained
Change agitator dimension for
uniform mixing without
overheating
$40,000 per year
Suspensions in a batch reactor
Plugging of the bottom valve of the
reactor
Replacement of the agitator
Lower the impeller position
$12,000 saved on the cost of a new impeller and for all associated
operational costs
Scale up Methodology
Implementation during the Scale
studies
Calculation after finishing the
development stage
Calculation during the
development stage
Decrease in the quantity of out of
spec material in the launching and
production steps.
Cooling a Paste
Cooling a Paste
Cooling a Paste
Cooling a Paste
Cooling a Paste
PAINTS
PAINTS
PAINTS
PAINTS
PAINTS
PAINTS
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Suspension in a batch reactor
Non ideal stirring Non ideal stirring –– non homogeneitynon homogeneity
•• VisiMix VisiMix software is used in order to find the required stirring characteristics.
For example: The product XXXX is produced at a solid liquid reaction.
The main reaction at this process is:
BBCM + TA + POCA →XXXX
POCA reagent properties:
• Solid
• High particle size: mean=735µm
• High density: 2300 kg/m3
VisiMix was used for suspension calculation.
Scale Up MethodologyScale Up Methodology(J.M. Berty. CEP, 1979)(J.M. Berty. CEP, 1979)
Scale up optimization using simulation experiments.Scale up optimization using simulation experiments.C1
Slide 39
C1 scale up of chemical processes is a unique chalange facing the chemical and pharmaceutical industry. We face this chalange by applying modernstatistical methodology to simulation experiments using the Dynochem software.Using the simulation platform , a statistically designed simulation experiment is designed using Minitab statistical package and optimization is carried using the TITOSIM software. The main outcome is determining the conditions of full scale production.Because scale up is very complex enterprise it needs to be faced by an interdisciplinary team work were technical' chemical process, chemistry, mathe3matical statistics' comoutation and others knowladge are represented together.Chemagis, 21/05/2006
Scale Up MethodologyScale Up Methodology(J.M. Berty. CEP, 1979)(J.M. Berty. CEP, 1979)
Scale up optimization using simulation experiments.Scale up optimization using simulation experiments.C2
Slide 40
C2 scale up of chemical processes is a unique chalange facing the chemical and pharmaceutical industry. We face this chalange by applying modernstatistical methodology to simulation experiments using the Dynochem software.Using the simulation platform , a statistically designed simulation experiment is designed using Minitab statistical package and optimization is carried using the TITOSIM software. The main outcome is determining the conditions of full scale production.Because scale up is very complex enterprise it needs to be faced by an interdisciplinary team work were technical' chemical process, chemistry, mathe3matical statistics' comoutation and others knowladge are represented together.Chemagis, 21/05/2006
Scale Up optimization using simulation experiments.Scale Up optimization using simulation experiments.
In the three years since the commencement of this process, their engineers achieved a high level of proficiency in the use of the simulation models in order to analyze the results as a function of the process operational parameters. After three years of working with this integrated plan – they have summarizedtheir knowledge and experiences up to this point, as follows: 1. VisiMix products, when integrated in the validation process (up until they
achieved a stable process and confirmed the production) – helped to reduce the number of lost production batches (each batch valued in millions of dollars) - from 100 to just under 10 batches – (review slide 25)
2. VisiMix program used in conjunction with another simulation tool - as
reported in this presentation - contributed to the improvement of the teamwork style and professionalism. Net results were observed throughout the implementation of the new solution in better project development: EOR (end of reaction) time reductions, projects development time and cost reduction, and in addition - increasing the expertise and qualification level of the professional staff.
The presentation can be review on the Visimix Website in the References - Users Publications page. (Scale up optimization using simulation experiments-Chemagis
presentation)
Financial aspectsFinancial aspects# produced lots needed until till a stable process is achieved
Scale Up optimization using simulation experiments.Scale Up optimization using simulation experiments.
SummarySummary
• Save per project
• Save during development
Thank You
Positive reaction from customers from all over the world confirms:
- VisiMix is of tremendous help wherever mixing is involved .
Thank you
From the VisiMix Team
Thank you for your attentionThank you for your attention
