. . . Co

1 Ge1.11.21.31.41.5

2 Tu2.1

2.2 Table of Contents i

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ntents

tting Started About This Manual .............................................................................................................. 1-2 Hardware & Software Requirements................................................................................... 1-3 Installation ........................................................................................................................... 1-3 Technical Support ................................................................................................................ 1-5 License Renewal.................................................................................................................. 1-5

torial Developing a Process Model ............................................................................................... 2-3

2.1a Summary Steps ....................................................................................................... 2-42.1b Starting a New Process File .................................................................................... 2-52.1c Specifying the Mode of Operation for the Entire Plant .......................................... 2-52.1d Setting the Default Physical Units .......................................................................... 2-62.1e Registering Components and Mixtures................................................................... 2-62.1f Saving and Opening Files........................................................................................ 2-102.1g Building the Process Flowsheet .............................................................................. 2-102.1h Initializing Unit Procedures .................................................................................... 2-182.1i Simulating the Process and Viewing the Simulation Results .................................. 2-312.1j Setting the Process Scheduling Information............................................................ 2-382.1k Viewing Scheduling, Equipment Utilization and Resource Tracking Results ....... 2-402.1l Throughput Analysis and Debottlenecking ............................................................. 2-462.1m Cost Analysis and Economic Evaluation............................................................... 2-482.1n Environmental Impact............................................................................................. 2-56

The Synthetic Pharmaceutical Process ................................................................................ 2-572.2a Process Description................................................................................................. 2-582.2b Specifying Process Sections ................................................................................... 2-632.2c Specifying Equipment Sharing ............................................................................... 2-642.2d Initialization of Reaction Operations ...................................................................... 2-662.2e Process Analysis ..................................................................................................... 2-682.2f Cost Analysis and Economic Evaluation ................................................................ 2-752.2g Environmental Impact............................................................................................. 2-76

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ii Table

2.3

2.4

2.5

3 Co3.1

3.2

3.33.4 The b-Galactosidase Process ............................................................................................... 2-762.3a Process Description................................................................................................. 2-772.3b Specifying Staggered Equipment............................................................................ 2-792.3c Initializing Data Specific to Biotech Processes ...................................................... 2-812.3d Specifying Storage Units ........................................................................................ 2-832.3e Process Analysis ..................................................................................................... 2-832.3f Cost Analysis and Economic Evaluation ................................................................ 2-872.3g Environmental Impact............................................................................................. 2-892.3h Product Formulation and Packaging....................................................................... 2-89

The Industrial Wastewater Treatment Process .................................................................... 2-902.4a Process Description................................................................................................. 2-902.4b Process Analysis ..................................................................................................... 2-972.4c Cost Analysis and Economic Evaluation ................................................................ 2-982.4d Modeling Challenges .............................................................................................. 2-101

Additional Information ........................................................................................................ 2-101

mponents and Mixtures Pure Components................................................................................................................. 3-1

3.1a Pure Component Registration ................................................................................. 3-23.1b Pure Component Registration Dialog ..................................................................... 3-53.1c Special Components................................................................................................ 3-93.1d Pre-Registered Components ................................................................................... 3-103.1e Pure Component Properties .................................................................................... 3-103.1f DIPPR Component Properties ................................................................................. 3-183.1g Synchronize Registered Component Properties with Databank ............................. 3-183.1h Component Properties in a Binary Mixture ............................................................ 3-19

Stock Mixtures..................................................................................................................... 3-203.2a Stock Mixture Registration ..................................................................................... 3-203.2b Stock Mixture Registration Dialog ......................................................................... 3-213.2c Pre-Registered Mixtures ......................................................................................... 3-253.2d Stock Mixture Properties ........................................................................................ 3-253.2e Synchronize Registered Stock Mixture Properties with Databank......................... 3-27

Pollutant Categorization Guidelines .................................................................................... 3-28 Interfaces.............................................................................................................................. 3-38

3.4a Pure Component Registration Dialog ..................................................................... 3-383.4b New Component Definition Dialog ........................................................................ 3-39 of Contents

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4 Str4.14.24.34.44.5

4.64.7

4.83.4c Pure Component Properties Dialog......................................................................... 3-403.4d Emission Limits Dialog .......................................................................................... 3-503.4e Rename Pure Component Dialog............................................................................ 3-513.4f Update Pure Component Properties From the Databank ........................................ 3-523.4g Update Pure Component Properties To the Databank ............................................ 3-543.4h T-Dependent Property Graph Dialog...................................................................... 3-563.4i T-Dependent Property Chart.................................................................................... 3-573.4j Stock Mixture Registration Dialog .......................................................................... 3-583.4k New Stock Mixture Definition Dialog.................................................................... 3-593.4l Rename Stock Mixture Dialog ................................................................................ 3-603.4m Stock Mixture Properties Dialog ........................................................................... 3-613.4n Component Composition Dialog ............................................................................ 3-653.4o Update Stock Mixture Properties From the Databank............................................ 3-663.4p Update Stock Mixture Properties To the Databank ................................................ 3-693.4q Registered Components Property Table ................................................................. 3-713.4r Registered Components Property Table: Property Selection Dialog ...................... 3-733.4s Binary Mixture Chart Dialog .................................................................................. 3-74

eams Types of Streams ................................................................................................................. 4-1 Stream Drawing ................................................................................................................... 4-3 The Streams Context (or Command) Menu ....................................................................... 4-6 Stream Elbow Editing.......................................................................................................... 4-7 Stream Tags ......................................................................................................................... 4-7

4.5a Streams Name Tag................................................................................................. 4-74.5b Streams Information Tag....................................................................................... 4-9

Stream Style......................................................................................................................... 4-9 Bulk Streams........................................................................................................................ 4-10

4.7a Viewing and Editing the Simulation Data of Bulk Streams ................................... 4-114.7b Composition & Related Properties of a Bulk Input Stream.................................... 4-114.7c Composition & Related Properties of Intermediate and Output Streams ............... 4-144.7d Physical State Options for Bulk Streams................................................................ 4-164.7e Environmental Properties of Bulk Streams............................................................. 4-17

Discrete Streams .................................................................................................................. 4-174.8a Entity & Entity Properties....................................................................................... 4-184.8b Discrete Input Streams............................................................................................ 4-184.8c Viewing and Editing the Simulation Data of Discrete Streams.............................. 4-20Table of Contents iii

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iv Tabl

4.94.14.1

5 Pr5.1

5.2

5.35.45.5

5.65.75.85.95.1 Auto-Initialization of Input Streams.................................................................................... 4-200 Classification of Input and Output Streams....................................................................... 4-211 Interfaces............................................................................................................................ 4-24

4.11a Bulk Input Stream Dialog ..................................................................................... 4-244.11b Volumetric Coefficients Dialog............................................................................ 4-294.11c Vapor Phase Pure Component Composition Dialog............................................. 4-324.11d Pure Component Composition Dialog .................................................................. 4-334.11e Target Concentration Calculator Dialog ............................................................... 4-344.11f Bulk Intermediate/Output Stream Dialog.............................................................. 4-364.11g Discrete Input Stream Dialog ............................................................................... 4-384.11h Discrete Intermediate/Output Stream Dialog ....................................................... 4-404.11i Input Stream Initialization Options Dialog............................................................ 4-434.11j Stream Data Summary Dialog ............................................................................... 4-454.11k Stream Editing Tag Name Dialog......................................................................... 4-464.11l Stream Style Dialog ............................................................................................... 4-464.11m Stream Classification Dialog ............................................................................... 4-524.11n Rate Reference Flows Dialog ............................................................................... 4-53

ocedures & Operations What Is a Unit Procedure?................................................................................................... 5-1

5.1a The Unit Procedures Context (or Command) Menu.............................................. 5-15.1b A Unit Procedure in a Batch Process...................................................................... 5-25.1c A Unit Procedure in a Continuous Process ............................................................. 5-35.1d Common Features ................................................................................................... 5-3

Unit Procedure Operating Mode.......................................................................................... 5-45.2a Holdup Time ........................................................................................................... 5-45.2b Procedure Cycle and Cycle Time ........................................................................... 5-5

Operation Sequence ............................................................................................................. 5-6 Unit Procedure Icon............................................................................................................. 5-9 Unit Procedure Ports............................................................................................................ 5-10

5.5a Default Input Ports & Auto-Initialization ............................................................... 5-115.5b Default Output Port & Auto-Removal.................................................................... 5-12

Unit Procedure Labels ......................................................................................................... 5-12 Unit Procedure Icon Style.................................................................................................... 5-13 Unit Procedure Types .......................................................................................................... 5-14 What Is a Unit Operation? ................................................................................................... 5-150 Tree-View of a Process...................................................................................................... 5-16e of Contents

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5.1

5.15.1

6 Re6.1

6.21 The Input/Output (i/o) Simulation Dialog ......................................................................... 5-165.11a The Labor Etc. Group of Variables....................................................................... 5-175.11b The Description Group Variables ......................................................................... 5-185.11c The Batch Sheet Group of Variables .................................................................... 5-185.11d The Scheduling Group of Variables ..................................................................... 5-19

2 Default Data Values for Input Variables ........................................................................... 5-203 Interfaces............................................................................................................................ 5-21

5.13a The Operation Sequence Dialog ........................................................................... 5-215.13b Operation i/o Simulation Dialog........................................................................... 5-235.13c Procedure Data Dialog .......................................................................................... 5-245.13d Procedure Physical State Properties Dialog.......................................................... 5-275.13e Edit Procedure Labels Dialog ............................................................................... 5-315.13f Unit Procedure Icon Style Dialog.......................................................................... 5-315.13g The Master-Slave Relationship Dialog................................................................. 5-375.13h View Procedure Utilization Breakdown ............................................................... 5-465.13i Procedure Activity Overview Dialog .................................................................... 5-485.13j Procedure Activity Overview: Contents Selection Dialog .................................... 5-51

sources Main Equipment .................................................................................................................. 6-2

6.1a Equipment Sizing (Design vs Rating Mode) .......................................................... 6-26.1b Equipment Selection & Sharing ............................................................................. 6-36.1c Staggered Mode ...................................................................................................... 6-56.1d Contents .................................................................................................................. 6-66.1e Local Receptacle & Automatic Emptying of Contents........................................... 6-76.1f Purchase Cost .......................................................................................................... 6-76.1g Cost Adjustments .................................................................................................... 6-96.1h Consumables ........................................................................................................... 6-106.1i Equipment Allocation .............................................................................................. 6-106.1j Vendors, Vendor Equipment & Type Specification Variables ............................... 6-116.1k Equipment Type Categories.................................................................................... 6-11

Main Equipment Charts & Tables ....................................................................................... 6-116.2a Equipment Occupancy Chart .................................................................................. 6-126.2b Equipment Gantt Chart ........................................................................................... 6-146.2c Equipment Utilization Breakdown.......................................................................... 6-156.2d Equipment Occupancy Data Table ......................................................................... 6-15Table of Contents v

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vi Tabl

6.36.4

6.5

6.6

6.7

6.8

6.9

6.1

6.16.2e Equipment Occupancy Data Chart.......................................................................... 6-15 Auxiliary Equipment ........................................................................................................... 6-15 Auxiliary Equipment Charts & Tables ................................................................................ 6-18

6.4a Auxiliary Equipment Occupancy Chart .................................................................. 6-186.4b Auxiliary Equipment Gantt Chart........................................................................... 6-186.4c Auxiliary Equipment Demand ................................................................................ 6-186.4d Auxiliary Equipment Utilization Breakdown ......................................................... 6-19

Materials .............................................................................................................................. 6-196.5a Entering Material Consumption Classification....................................................... 6-206.5b Exiting Material Classification ............................................................................... 6-206.5c Material Rates and Timing...................................................................................... 6-216.5d Material Inventory .................................................................................................. 6-226.5e Material Storage Units ............................................................................................ 6-22

Material Charts & Tables..................................................................................................... 6-226.6a Material Consumption & Material Output Charts .................................................. 6-226.6b Material Consumption Inventory & Material Output Inventory Charts ................. 6-246.6c Material Consumption (Demand) Tables................................................................ 6-256.6d Material Production (Output) Table ....................................................................... 6-26

Heat Transfer Agents........................................................................................................... 6-266.7a Definitions in the System Database and in the User Database .......................... 6-266.7b Registered (in use) Heat Transfer Agents............................................................... 6-266.7c Heat Transfer Agents in Sites ................................................................................. 6-276.7d Heat Transfer Agent Properties .............................................................................. 6-27

Heat Transfer Agent Charts & Tables ................................................................................. 6-286.8a Heat Transfer Agent Consumption Chart ............................................................... 6-286.8b Heat Transfer Agent Consumption Inventory Chart............................................... 6-296.8c Heat Transfer Agent Consumption (Demand) Table .............................................. 6-30

Power ................................................................................................................................... 6-306.9a Definitions in the System Database and in the User Database .......................... 6-316.9b Power Types Currently Consumed (or Produced) by the Process.......................... 6-316.9c Power Types in Database Sites ............................................................................... 6-316.9d Power Type Properties............................................................................................ 6-32

0 Power Charts & Tables...................................................................................................... 6-336.10a Power Demand & Power Generation Chart .......................................................... 6-336.10b Power Demand Table............................................................................................ 6-346.10c Power Production Table........................................................................................ 6-35

1 Labor.................................................................................................................................. 6-35e of Contents

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6.1

6.1

6.1

6.16.11a Definitions in System DB and User DB ............................................................... 6-356.11b Labor Types Currently Used by the Process ........................................................ 6-356.11c Labor Types in Database Sites.............................................................................. 6-356.11d Labor Type Properties .......................................................................................... 6-36

2 Labor Charts & Tables....................................................................................................... 6-376.12a Labor Requirement Chart...................................................................................... 6-376.12b Labor Requirement (Demand) Tables .................................................................. 6-37

3 Material Storage Units....................................................................................................... 6-386.13a Registered (in use) Material Storage Units ........................................................... 6-406.13b Material Storage Unit Properties .......................................................................... 6-40

4 Material Storage Units Charts ........................................................................................... 6-416.14a Material Supply & Receiving Unit Rate Charts.................................................... 6-416.14b Material Supply & Receiving Inventory Charts ................................................... 6-426.14c Material Storage Unit Tables ................................................................................ 6-43

5 Interfaces............................................................................................................................ 6-436.15a Equipment Data Dialog......................................................................................... 6-436.15b View/Edit Staggered Equipment Names Dialog .................................................. 6-576.15c User-Defined Cost Model Dialog ......................................................................... 6-586.15d User-Defined Cost Model Select Dialog .............................................................. 6-596.15e Equipment Contents Dialog .................................................................................. 6-606.15f Equipment Contents Customization Dialog .......................................................... 6-636.15g Styles for Common Physical Quantities Dialog ................................................... 6-646.15h Format Cells in a Table Dialog............................................................................. 6-656.15i Link Table to MS-Excel Dialog .......................................................................... 6-676.15j Initial Equipment Contents: Initialization Options Dialog .................................... 6-706.15k Initial Equipment Contents (View/Edit) Dialog ................................................... 6-726.15l Empty Contents Before Reuse Dialog ................................................................... 6-736.15m Equipment Occupancy Chart (Single Batch)....................................................... 6-746.15n Equipment Occupancy Chart Style Dialog ........................................................... 6-776.15o Equipment Occupancy Chart (Multiple Batches) ................................................. 6-846.15p Equipment Gantt Chart (Single Batch) ................................................................. 6-866.15q Equipment Gantt Chart (Multiple Batches) .......................................................... 6-906.15r Equipment Gantt Chart Style Dialog..................................................................... 6-906.15s Equipment Gantt Chart Bar Style Dialog.............................................................. 6-936.15t Main Equipment Utilization Breakdown............................................................... 6-966.15u Auxiliary Equipment Utilization Breakdown ....................................................... 6-986.15v Main Equipment Occupancy Data Table.............................................................. 6-99Table of Contents vii

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viii Tab6.15w Main Equipment Occupancy Data Chart ............................................................. 6-1016.15x Graph Style for Equipment Occupancy Data Chart.............................................. 6-1016.15y Consumables Currently Used by the Process Dialog ........................................... 6-1036.15z Consumable Properties Dialog.............................................................................. 6-1046.15aa Consumable Usage Breakdown Dialog............................................................... 6-1136.15ab Entering Material Consumption Chart (Single Batch)........................................ 6-1146.15ac Material Chart Style Dialog ................................................................................ 6-1166.15ad Material Selection for Consumption Chart ......................................................... 6-1216.15ae Entering Material Consumption Chart (Multiple Batches) ................................. 6-1236.15af Material Selection for Output Chart .................................................................... 6-1296.15ag List of Entering Materials (& View of Total Consumption Demand) ................ 6-1356.15ah List of Exiting Materials (& View of Total Output) ........................................... 6-1366.15ai Entering or Exiting Material Properties Dialog ................................................... 6-1366.15aj Entering Material Demand Breakdown ............................................................... 6-1426.15ak Heat Transfer Agent Demand Chart (Single Batch) ........................................... 6-1446.15al Utility Chart Style Dialog .................................................................................... 6-1456.15am Utility Selection For Consumption Chart .......................................................... 6-1506.15an Heat Transfer Agent Demand Chart (Multiple Batches) .................................... 6-1516.15ao Heat Transfer Agent Inventory Chart (Single Batch) ......................................... 6-1526.15ap Heat Transfer Agent Inventory Chart (Multiple Batches) .................................. 6-1546.15aq List of Heat Transfer Agents Currently in Use ................................................... 6-1556.15ar Heat Transfer Agent Properties Dialog ............................................................... 6-1566.15as Mass-To-Energy Estimation Dialog.................................................................... 6-1586.15at Heat Transfer Agent Demand Breakdown........................................................... 6-1646.15au Labor Demand Chart (Single Batch) .................................................................. 6-1666.15av Labor Chart Style Dialog .................................................................................... 6-1676.15aw Labor Type Selection For Demand Chart .......................................................... 6-1686.15ax Labor Demand Chart (Multiple Batches)............................................................ 6-1686.15ay List of Labor Types Currently Used by the Process ........................................... 6-1706.15az Labor Type Properties Dialog ............................................................................. 6-1716.15ba Labor Demand Breakdown ................................................................................. 6-1756.15bb Power Demand Chart (Single Batch).................................................................. 6-1776.15bc Power Chart Style Dialog ................................................................................... 6-1786.15bd Power Type Selection Dialog ............................................................................. 6-1796.15be Power Demand Chart (Multiple Batches) ........................................................... 6-1796.15bf Power Output Chart (Single Batch)..................................................................... 6-180le of Contents

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7 Sc7.17.26.15bg Power Output Chart (Multiple Batches) ............................................................. 6-1816.15bh List of Power Types Currently Consumed by the Process ................................. 6-1836.15bi List of Power Types Currently Generated by the Process ................................... 6-1846.15bj Power Type Properties Dialog............................................................................. 6-1856.15bk Supply Unit Material Demand Chart (Single Batch).......................................... 6-1916.15bl Storage Unit Selection for Material Demand Chart ............................................ 6-1926.15bm Supply Unit Material Inventory Chart (Single Batch)....................................... 6-1946.15bn Supply Unit Material Inventory Chart (Multiple Batches) ................................. 6-1966.15bo Storage Unit Supply (or Receive) Chart Style Dialog ........................................ 6-1976.15bp Receiving Unit Material Deposit Chart (Single Batch) ...................................... 6-1986.15bq Storage Unit Selection for Material Deposit Chart............................................. 6-1996.15br Receiving Unit Material Deposit Chart (Multiple Batches)................................ 6-2006.15bs Receiving Unit Material Inventory Chart (Single Batch) ................................... 6-2016.15bt Receiving Unit Material Inventory Chart (Multiple Batches) ............................. 6-2036.15bu Storage Unit Supply (or Receive) Inventory Chart Style Dialog ....................... 6-2046.15bv Material Storage Units Dialog ............................................................................ 6-2056.15bw Material Supply Storage Unit Property Dialog.................................................. 6-2076.15bx Material Receiving Storage Unit Property Dialog.............................................. 6-2096.15by Assign Storage Unit Dialog ................................................................................ 6-2126.15bz Auxiliary Equipment Properties Dialog.............................................................. 6-2126.15ca CIP Skid demand Chart (Single Batch)............................................................... 6-2156.15cb CIP Skid demand Chart (Multiple Batches) ....................................................... 6-2166.15cc CIP Skid Demand Chart Style Dialog................................................................. 6-2176.15cd SIP Panels demand Chart (Single Batch)............................................................ 6-2196.15ce SIP Panel demand Chart (Multiple Batches)....................................................... 6-2206.15cf SIP Panel Demand Char Style Dialog ................................................................. 6-2216.15cg Recipe Summary Information Popup.................................................................. 6-2226.15ch Export Resource Tracking Data to Excel Dialog................................................ 6-223

heduling Scheduling Terms & Definitions ......................................................................................... 7-1 Scheduling Data................................................................................................................... 7-4

7.2a Operation-Level Scheduling Information ............................................................... 7-57.2b Procedure-Level Scheduling Information............................................................... 7-67.2c Recipe/Process-Level Scheduling Information....................................................... 7-67.2d Output of Scheduling Calculations ......................................................................... 7-6Table of Contents ix

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x Table

7.3

7.4

7.57.67.7

8 Pr8.1

8.2

8.38.48.58.6

8.7 Scheduling Calculations ...................................................................................................... 7-77.3a Scheduling Output Calculations.............................................................................. 7-77.3b Scheduling Constraints ........................................................................................... 7-87.3c Cycle Time Bounds Calculation ............................................................................. 7-97.3d Scheduling and Equipment Sizing .......................................................................... 7-10

The Operations Gantt Chart (OGC)..................................................................................... 7-107.4a Accessing Scheduling and Simulation Data ........................................................... 7-127.4b Exporting Chart & Data to Other Applications ...................................................... 7-127.4c Zooming / Time Scale............................................................................................. 7-137.4d Appearance (Visual Style) ...................................................................................... 7-14

The Equipment Gantt Chart (EGC) ..................................................................................... 7-14 The Equipment Occupancy Chart (EOC) ............................................................................ 7-15 Interfaces.............................................................................................................................. 7-15

7.7a Recipe Scheduling Information Dialog................................................................... 7-157.7b Cycle Time Calculator Dialog ................................................................................ 7-177.7c Operations Gantt Chart (Single Batch) ................................................................... 7-207.7d Operations Gantt Chart (Multiple Batches) ............................................................ 7-227.7e Operations Gantt Chart Style Dialog ...................................................................... 7-237.7f Cycle Description Dialog ........................................................................................ 7-26

ocess Properties & Simulation Sections & Branches............................................................................................................ 8-2

8.1a Sections & Branches Toolbar ................................................................................. 8-38.1b Adding (Creating) a New Section........................................................................... 8-38.1c Adding Unit Procedures to a Section ...................................................................... 8-48.1d Section Properties ................................................................................................... 8-4

Branches .............................................................................................................................. 8-78.2a Adding (Creating) a New Branch ........................................................................... 8-78.2b Adding Sections to a Branch .................................................................................. 8-78.2c Branch Properties .................................................................................................... 8-8

Default Style for Process Elements ..................................................................................... 8-8 Units of Measure (Physical Units Options) ......................................................................... 8-10 Process Documentation (Description) ................................................................................. 8-11 Procedure & Equipment Order ............................................................................................ 8-11

8.6a Procedure Order ...................................................................................................... 8-118.6b Equipment Order..................................................................................................... 8-12

Drawing Size ....................................................................................................................... 8-12 of Contents

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8.88.98.18.18.18.18.1

8.18.18.18.1

8.1

8.2 Overview Navigator............................................................................................................. 8-13 Search and Locate Process Elements................................................................................... 8-140 Process Explorer ................................................................................................................ 8-151 The Stream Summary Table .............................................................................................. 8-172 Physical State Options ....................................................................................................... 8-203 Rigorous VLE Options ...................................................................................................... 8-244 The Process Simulation Engine ......................................................................................... 8-24

8.14a Simulation 101 ...................................................................................................... 8-248.14b Simplicity and the Art of Simulation .................................................................... 8-258.14c Simulation Philosophy .......................................................................................... 8-268.14d Process Operating Mode: Batch vs. Continuous .................................................. 8-308.14e Countdown to Simulation Execution: The Pre-Simulation Checks...................... 8-318.14f Partition & Sequencing.......................................................................................... 8-318.14g Loop Identification and Tear Stream Selection .................................................... 8-338.14h Convergence Strategy ........................................................................................... 8-358.14i Back-Propagation: Sources (Initiators) & Sinks (Terminals)................................ 8-38

5 Simulation Breakpoints ..................................................................................................... 8-426 Simulation Control Toolbar............................................................................................... 8-447 Error Output Window........................................................................................................ 8-468 Other (Misc.) Process Properties ....................................................................................... 8-48

8.18a Show Page Breaks................................................................................................. 8-488.18b Report Scheduling Violations Only After M&E Balances ................................... 8-488.18c Always Perform Section Yield Calculations ........................................................ 8-498.18d Show Simulation Breakpoints .............................................................................. 8-498.18e Show Simulation Status Indicators for Each Procedure ....................................... 8-498.18f Update Simulation Status Indicators During M&E Balances ............................... 8-498.18g Slow Down Simulation Speed .............................................................................. 8-498.18h Apply External Auto-Initializations Upon Opening of Process File .................... 8-49

9 The Process File................................................................................................................. 8-508.19a Customizing Default Settings for a Domain of Applications ............................... 8-518.19b Working on a Long Term Project ......................................................................... 8-518.19c Automatic Versioning (Archiving) of the Process File ........................................ 8-52

0 Application Settings........................................................................................................... 8-528.20a Announcements Upon Opening a Process File..................................................... 8-538.20b Automatic Background Saving of Modified Files ................................................ 8-538.20c Temporary Directory Location ............................................................................. 8-548.20d Startup Task .......................................................................................................... 8-548.20e Batch Sheet Forms Folder..................................................................................... 8-55Table of Contents xi

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8.2

9 Ec9.18.20f Workspace Appearance ......................................................................................... 8-558.20g Database Access UserID & Password .................................................................. 8-578.20h Automatic Name Generation ................................................................................ 8-57

1 Interfaces............................................................................................................................ 8-578.21a Section Properties Dialog...................................................................................... 8-578.21b Economic Data After Allocation Change Dialog ................................................. 8-618.21c Branch Properties Dialog ...................................................................................... 8-678.21d Section Resource Allocation Dialog..................................................................... 8-698.21e Drawing Size Dialog ............................................................................................. 8-778.21f Page Setup Dialog ................................................................................................. 8-788.21g Error Output Window ........................................................................................... 8-788.21h Overview Navigator Interface............................................................................... 8-798.21i Find Dialog ............................................................................................................ 8-798.21j Physical Units Options Dialog............................................................................... 8-808.21k Process Description Dialog................................................................................... 8-818.21l Process Explorer Toolbar ...................................................................................... 8-828.21m Stream Summary Table ....................................................................................... 8-838.21n Stream Summary Table: Edit Contents Dialog..................................................... 8-858.21o Component Include/Exclude Dialog..................................................................... 8-868.21p Cell Format Dialog ............................................................................................... 8-878.21q Physical Quantities Format Dialog ....................................................................... 8-888.21r Include / Exclude / Order Unit Procedures Dialog................................................ 8-898.21s Include / Exclude / Order Equipment Dialog........................................................ 8-918.21t Physical State Default Options Dialog .................................................................. 8-928.21u Rigorous VLE Options Dialog ............................................................................. 8-968.21v Error / Warning Output Filter Threshold Dialog .................................................. 8-1028.21w Application Settings Dialog ................................................................................. 8-1028.21x Startup Task Dialog .............................................................................................. 8-1068.21y Miscellaneous Process Preferences Dialog........................................................... 8-1078.21z Recycle Loop & Tear Stream Options Dialog ...................................................... 8-1098.21aa Edit Name Dialog................................................................................................ 8-1108.21ab Breakpoints Dialog ............................................................................................. 8-1118.21ac Process Operating Mode Dialog ......................................................................... 8-113

onomics Overview.............................................................................................................................. 9-1le of Contents

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9.2

9.3

9.4

9.5

9.69.79.89.9 Total Capital Investment...................................................................................................... 9-39.2a Direct Fixed Capital (DFC)..................................................................................... 9-39.2b Working Capital...................................................................................................... 9-109.2c Startup and Validation Cost .................................................................................... 9-109.2d Up-Front R&D Cost................................................................................................ 9-109.2e Up-Front Royalties.................................................................................................. 9-119.2f Capital Investment Charged to This Project............................................................ 9-11

Operating Cost ..................................................................................................................... 9-119.3a Materials Cost ......................................................................................................... 9-129.3b Consumables Cost................................................................................................... 9-139.3c Labor-Dependent Cost ............................................................................................ 9-159.3d Utilities Cost ........................................................................................................... 9-179.3e Waste Treatment/Disposal Cost.............................................................................. 9-199.3f Facility-Dependent Cost .......................................................................................... 9-199.3g Laboratory / QC / QA Cost..................................................................................... 9-219.3h Transportation Cost................................................................................................. 9-229.3i Miscellaneous Operating Costs ............................................................................... 9-239.3j Advertising and Selling Costs ................................................................................. 9-239.3k Running Royalties................................................................................................... 9-249.3l Failed Product Disposal Cost................................................................................... 9-249.3m Cost of Heat Transfer Agents ................................................................................ 9-249.3n Unit Production/Processing Cost ............................................................................ 9-259.3o Depreciation............................................................................................................ 9-269.3p Net Annual Operating Cost..................................................................................... 9-289.3q Main Product/Revenue Rate ................................................................................... 9-299.3r Unit Reference Rate (or Flow) ................................................................................ 9-29

Income ................................................................................................................................. 9-309.4a Revenues ................................................................................................................. 9-309.4b Credits ..................................................................................................................... 9-329.4c Power Generation Procedures ................................................................................. 9-33

Profits................................................................................................................................... 9-349.5a Profitability Analysis .............................................................................................. 9-349.5b Cash Flow Analysis ................................................................................................ 9-36

Reporting of Economic Figures........................................................................................... 9-42 Currency .............................................................................................................................. 9-42 References............................................................................................................................ 9-43 Interfaces.............................................................................................................................. 9-43Table of Contents xiii

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10 Em10.

10.

10.10.10.

11 De11.

11.11.9.9a Economic Evaluation Parameters for Entire Project Dialog................................... 9-439.9b Capital Investment Dialog ...................................................................................... 9-499.9c Operating Cost Adjustments Dialog ....................................................................... 9-569.9d Executive Summary Dialog .................................................................................... 9-719.9e Operating Cost Options Dialog............................................................................... 9-809.9f Currency Selection Dialog ...................................................................................... 9-81

issions1 Venting and Primary VOC Emissions............................................................................... 10-1

10.1a Displacement - Emission Model ........................................................................... 10-310.1b Evacuation - Emission Model............................................................................... 10-410.1c Gas Sweep - Emission Model ............................................................................... 10-510.1d Heating - Emission Model .................................................................................... 10-610.1e Gas Evolution - Emission Model .......................................................................... 10-810.1f Vacuum - Emission Model .................................................................................... 10-810.1g Drying - Emission Model ..................................................................................... 10-8

2 Secondary VOC Emissions................................................................................................ 10-910.2a Quiescent Tanks - Emission Model ...................................................................... 10-910.2b Agitated Tanks - Emission Model ........................................................................ 10-12

3 Emissions Report (EMS) ................................................................................................... 10-164 Emission Limits ................................................................................................................. 10-165 Interfaces............................................................................................................................ 10-16

10.5a Venting/Emissions Tabs ....................................................................................... 10-1610.5b Emission Limits Dialog ........................................................................................ 10-3210.5c Quiescent Tank Operations: Emission Model Dialog........................................... 10-3410.5d Agitated Tank Operations: Emission Model Dialog............................................. 10-35

bottlenecking1 Definitions & Theory of Throughput Analysis ................................................................. 11-1

11.1a Identifying Equipment Time (Scheduling) Bottlenecks ....................................... 11-211.1b Identifying Equipment Size and Throughput Bottlenecks.................................... 11-211.1c Potential Maximum Throughput Size ................................................................... 11-511.1d Resource Bottlenecks............................................................................................ 11-611.1e Using Multiple Equipment Sets in Staggered Mode............................................. 11-7

2 Scale-up (or down) Process Throughput ........................................................................... 11-93 Throughput Analysis Report.............................................................................................. 11-11le of Contents

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11.

12 Re12.12.12.12.

12.12.

12.12.12.12.12.12.

13 Vis13.13.

13.13.4 Interfaces............................................................................................................................ 11-1211.4a Style for Throughput Utilization Chart Dialog ..................................................... 11-1311.4b Style for Throughput Potential Chart Dialog........................................................ 11-1611.4c Process Throughput Adjustment Dialog ............................................................... 11-18

ports1 Generating and Viewing Reports....................................................................................... 12-22 General (Default) Reports Options.................................................................................... 12-43 Material & Stream Report (SR)......................................................................................... 12-64 Costing and Economic Evaluation Reports ....................................................................... 12-8

12.4a Economic Evaluation Report (EER) ..................................................................... 12-812.4b Cash Flow Analysis Report (CFR) ....................................................................... 12-1312.4c Itemized Cost Report (ICR) .................................................................................. 12-15

5 Throughput Analysis Report (THR).................................................................................. 12-206 Environmental Reports ...................................................................................................... 12-21

12.6a Environmental Impact Report (EIR)..................................................................... 12-2112.6b Emissions Report (EMS) ...................................................................................... 12-24

7 Equipment Report (EQR) .................................................................................................. 12-268 CIP Skid Report (CSR)...................................................................................................... 12-279 Input Data Report (IDR).................................................................................................... 12-2710 Custom Excel Report ....................................................................................................... 12-2911 Generate-and-Save A Report Set..................................................................................... 12-3112 Interfaces.......................................................................................................................... 12-33

12.12a Create and Save Multiple Reports Dialog........................................................... 12-3312.12b Report Options Dialog ........................................................................................ 12-3412.12c Include / Exclude Streams Dialog....................................................................... 12-4012.12d Stream Order Dialog ........................................................................................... 12-4112.12e Equipment Order in Economic Evaluation Report Dialog ................................. 12-43

ual Objects1 Types of Visual Objects..................................................................................................... 13-12 Adding a New Visual Object............................................................................................. 13-2

13.2a Text Object............................................................................................................ 13-313.2b Line ....................................................................................................................... 13-313.2c Rectangle, Round Rectangle or Ellipse................................................................. 13-413.2d Polyline or Polygon .............................................................................................. 13-4

3 Editing Existing Visual Objects......................................................................................... 13-54 Visual Objects Command Menu........................................................................................ 13-6Table of Contents xv

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13.13.

13.

14 Ex14.

14.

14.14.14.14.

15 Da15.15.15.15.

15.

15.5 Visual Objects Toolbar ...................................................................................................... 13-86 Editing the Style of Visual Objects ................................................................................... 13-10

13.6a Editing the Default Style of Visual Objects.......................................................... 13-107 Interfaces............................................................................................................................ 13-11

13.7a Text Style Dialog .................................................................................................. 13-1113.7b Line Style Dialog .................................................................................................. 13-1213.7c Shape Style Dialog................................................................................................ 13-12

changing Data with Other Apps1 Exporting Flowsheet & Chart Drawings ........................................................................... 14-2

14.1a Exporting Process Flowsheet Drawing ................................................................. 14-214.1b Exporting a Chart Drawing................................................................................... 14-6

2 Exporting Process Data...................................................................................................... 14-714.2a Export Process Scheduling Data to MS-Excel...................................................... 14-714.2b Export Resource Consumption Data to MS-Excel ............................................... 14-814.2c Exporting Scheduling & Resource Consumption Data to MS-Project ................. 14-914.2d Exporting Scheduling & Resource Consumption Data to SchedulePro ............... 14-10

3 Exporting / Linking Tables (Grids) to MS-Excel .............................................................. 14-124 Importing OLE Objects ..................................................................................................... 14-135 Using SuperPro Designers OLE Server ........................................................................... 14-156 Interfaces............................................................................................................................ 14-17

14.6a Export to MS-Project Options Dialog................................................................... 14-1714.6b Exporting Recipe to SchedulePros Recipe DB Dialog........................................ 14-1814.6c Password For DB Access Dialog .......................................................................... 14-19

tabases & Databanks1 Database Registration ........................................................................................................ 15-32 Importing Data from Another User Database ................................................................. 15-43 Accessing Data in Older User Databases........................................................................ 15-54 Pure Components Databank .............................................................................................. 15-6

15.4a Viewing the Contents of the Pure Components Databank.................................... 15-715.4b Adding and Deleting Pure Components ............................................................... 15-7

5 Databank of Stock Mixtures .............................................................................................. 15-715.5a Viewing the Contents of the Stock Mixtures Databank........................................ 15-815.5b Adding and Deleting Stock Mixtures ................................................................... 15-8

6 Binary Coefficients Databank............................................................................................ 15-815.6a Viewing the Contents of the Binary Coefficients Databank................................. 15-9le of Contents

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15.

15.

15.

15.

15.

15.

15.

15.

15.15.6b Adding and Deleting Binary Coefficients ............................................................ 15-97 Heat Transfer Agents Databank......................................................................................... 15-9

15.7a Viewing the Contents of the Heat Transfer Agents Databanks ............................ 15-1015.7b Adding or Deleting a Heat Transfer Agent........................................................... 15-10

8 Power Types Databank ...................................................................................................... 15-1015.8a Viewing the Contents of the Power Types Databank ........................................... 15-1115.8b Adding or Deleting a Power Type ........................................................................ 15-11

9 Labor Types Databank....................................................................................................... 15-1115.9a Viewing the Contents of the Labor Types Databank ............................................ 15-1215.9b Adding or Deleting a Labor Type......................................................................... 15-12

10 Consumables Databank ................................................................................................... 15-1315.10a Viewing the Contents of the Consumables Databank......................................... 15-1315.10b Adding and Deleting a Consumable Type (Category)........................................ 15-1415.10c Adding and Deleting a New Consumable........................................................... 15-14

11 Equipment Materials Databank ....................................................................................... 15-1415.11a Viewing the Contents of the Equipment Materials Databank............................. 15-1415.11b Adding and Deleting Equipment Materials ........................................................ 15-15

12 Currencies Databank........................................................................................................ 15-1515.12a Viewing the Contents of the Currencies Databank............................................. 15-1615.12b Adding and Deleting Currencies......................................................................... 15-16

13 Sites & Resources Databank............................................................................................ 15-1615.13a Database Site (aka Database Facility)................................................................. 15-1715.13b Viewing the Contents of the Sites Databank ...................................................... 15-1815.13c Adding or Deleting a Site.................................................................................... 15-1915.13d Adding, Deleting or Editing Database Resources .............................................. 15-19

14 Equipment Databanks...................................................................................................... 15-2015.14a Site-Equipment Databank ................................................................................... 15-2015.14b Vendor-Equipment Databank ............................................................................. 15-2115.14c Databanks of Equipment Vendors/Manufacturers .............................................. 15-2215.14d Equipment Types & Specifications .................................................................... 15-2315.14e Specification Variables Databank ....................................................................... 15-2415.14f User Defined Cost Models Databank .................................................................. 15-24

15 Processes Databank ......................................................................................................... 15-2515.15a Adding a Process Record in the Processes Databank ......................................... 15-2515.15b .Viewing the Process Records in the Processes Databank.................................. 15-2615.15c Searching in the Processes Databank.................................................................. 15-26

16 The MS-Project Database ................................................................................................ 15-26Table of Contents xvii

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15.17 Interfaces.......................................................................................................................... 15-2815.17a Databases: Availability, Password & Locations Dialog ..................................... 15-2815.17b Update Database Password Dialog ..................................................................... 15-3115.17c Import Database Data Dialog.............................................................................. 15-3215.17d Convert Old-Version User DB Dialog................................................................ 15-3415.17e Pure Components Databank Dialog .................................................................... 15-3515.17f Stock Mixtures Databank Dialog ........................................................................ 15-3815.17g Binary Coefficients Databank Dialog................................................................. 15-4015.17h Heat Transfer Agents Databank Dialog.............................................................. 15-4315.17i Power Types Databank Dialog ............................................................................ 15-4515.17j Labor Types Databank Dialog............................................................................. 15-4715.17k Consumables Databank Dialog........................................................................... 15-4915.17l Consumable Category Dialog.............................................................................. 15-5215.17m Equipment Materials Databank Dialog ............................................................. 15-5315.17n Currencies Databank Dialog ............................................................................... 15-5515.17o Sites & Resources Databank Dialog ................................................................... 15-5615.17p Add Labor Type Dialog ...................................................................................... 15-5915.17q Add Power Type Dialog ..................................................................................... 15-6115.17r Add Heat Transfer Agent Dialog ........................................................................ 15-6315.17s Site Properties Dialog.......................................................................................... 15-6515.17t Site-Equipment Databank Dialog ........................................................................ 15-6915.17u Equipment Search Dialog ................................................................................... 15-7015.17v New Site-Equipment Dialog ............................................................................... 15-7115.17w Site Equipment Properties Dialog...................................................................... 15-7215.17x Vendor-Equipment Databank Dialog ................................................................. 15-7715.17y New Vendor Equipment Dialog ......................................................................... 15-7915.17z Vendor Equipment Properties Dialog ................................................................. 15-8015.17aa Equipment Vendor/Manufacturer Databank Dialog ......................................... 15-8415.17ab Equipment Vendor/Manufacturer Data Dialog................................................. 15-8615.17ac Add Equipment for Vendor/Manufacturer Dialog ............................................ 15-9015.17ad Equipment Types & Specifications Dialog....................................................... 15-9215.17ae Add Specification Dialog .................................................................................. 15-9415.17af Specification Variables Databank Dialog.......................................................... 15-9615.17ag Specification Properties Dialog ........................................................................ 15-9815.17ah Equipment User Defined Cost Models Databank Dialog ................................. 15-9915.17ai Process DB: View Contents Dialog ................................................................... 15-101ble of Contents

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APPEA.1

A.215.17aj Process DB: Search Dialog ................................................................................ 15-10215.17ak Export to the Process Databank Dialog ............................................................ 15-10315.17al Reconcile with Site DB Dialog.......................................................................... 15-104

NDIX A: Unit Operations Vessel Operations ............................................................................................................... A-1

A.1a Agitation................................................................................................................. A-3A.1b In-Place-Cleaning (CIP)......................................................................................... A-9A.1c Batch Cooling......................................................................................................... A-14A.1d Batch Crystallization.............................................................................................. A-20A.1e Batch Distillation ................................................................................................... A-27A.1f Evacuation .............................................................................................................. A-38A.1g Batch Extraction / Phase Split................................................................................ A-40A.1h Gas Sweep.............................................................................................................. A-48A.1i Batch Heating ......................................................................................................... A-51A.1j Holding ................................................................................................................... A-57A.1k Pressurization ......................................................................................................... A-58A.1l Purging / Inerting .................................................................................................... A-62A.1m Sampling ............................................................................................................... A-66A.1n In-Place-Steaming (SIP) ........................................................................................ A-69A.1o Batch Component Splitting.................................................................................... A-73A.1p Batch Vaporization ................................................................................................ A-76A.1q Venting................................................................................................................... A-84

Transfer Operations ............................................................................................................ A-87A.2a Charge .................................................................................................................... A-87A.2b Pull In..................................................................................................................... A-96A.2c Pull Out .................................................................................................................. A-106A.2d Transfer In.............................................................................................................. A-111A.2e Transfer Out ........................................................................................................... A-116A.2f Charge (Solids) ....................................................................................................... A-121A.2g Pull In (Solids) ....................................................................................................... A-123A.2h Pull Out (Solids) .................................................................................................... A-124A.2i Transfer In (Solids) ................................................................................................. A-125A.2j Transfer Out (Solids) .............................................................................................. A-125A.2k Discrete Charge (by Volume) ................................................................................ A-126A.2l Discrete Transfer In (by Volume)........................................................................... A-130Table of Contents xix

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A.3

A.4A.2m Discrete Transfer Out (by Volume) ...................................................................... A-132A.2n Discrete Pull Out (by Volume) .............................................................................. A-133A.2o Discrete Charge (by Area) ..................................................................................... A-134A.2p Discrete Transfer In (by Area) ............................................................................... A-135A.2q Discrete Transfer Out (by Area) ............................................................................ A-137A.2r Discrete Pull Out (by Area) .................................................................................... A-138

Reaction Operations............................................................................................................ A-139A.3a Batch Stoichiometric Reaction............................................................................... A-140A.3b Batch Stoichiometric Reaction (in a Nutsche Filter) ............................................. A-153A.3c Batch Kinetic Reaction .......................................................................................... A-154A.3d Batch Equilibrium Reaction................................................................................... A-167A.3e Batch Stoichiometric Fermentation........................................................................ A-174A.3f Batch Kinetic Fermentation.................................................................................... A-183A.3g Perfusion Stoichiometric Fermentation ................................................................. A-189A.3h Continuous Stoichiometric Reaction ..................................................................... A-192A.3i Continuous Kinetic Reaction .................................................................................. A-200A.3j Continuous Equilibrium Reaction .......................................................................... A-203A.3k Plug Flow (PF) Stoichiometric Reaction ............................................................... A-203A.3l Plug Flow (PF) Kinetic Reaction............................................................................ A-208A.3m Continuous Stoichiometric Fermentation ............................................................. A-212A.3n Continuous Kinetic Fermentation .......................................................................... A-216A.3o Well-Mixed (WM) Stoichiometric Aerobic Bio-Oxidation .................................. A-219A.3p Well-Mixed (WM) Kinetic Aerobic Bio-Oxidation .............................................. A-224A.3q Plug-Flow (PF) Stoichiometric Aerobic Bio-Oxidation ........................................ A-232A.3r Plug-Flow (PF) Kinetic Aerobic Bio-Oxidation .................................................... A-233A.3s Stoichiometric Anaerobic Digestion ...................................................................... A-235A.3t Kinetic Anaerobic Digestion .................................................................................. A-236A.3u Trickling Filtration................................................................................................. A-239A.3v Stoichiometric Anoxic Reaction ............................................................................ A-245A.3w Kinetic Anoxic Reaction ....................................................................................... A-249A.3x Neutralization......................................................................................................... A-250A.3y Wet Air Oxidation.................................................................................................. A-254A.3z Incineration ............................................................................................................ A-259A.3aa UV Radiation........................................................................................................ A-267

Filtration Operations ........................................................................................................... A-270A.4a Batch Membrane Filtration (Batch Concentration)................................................ A-271e of Contents

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A.5

A.6

A.7A.4b Flush....................................................................................................................... A-279A.4c Continuous (Feed & Bleed) Membrane Filtration ................................................. A-281A.4d Diafiltration............................................................................................................ A-285A.4e Dead End Filtration ................................................................................................ A-291A.4f Cloth Filtration ....................................................................................................... A-294A.4g Cake Wash ............................................................................................................. A-299A.4h Cake Drying (in a Nutsche Filter).......................................................................... A-305A.4i Rotary Vacuum Filtration ....................................................................................... A-309A.4j Air Filtration ........................................................................................................... A-312A.4k Belt Filtration ......................................................................................................... A-315A.4l Granular Media Filtration ....................................................................................... A-318A.4m Baghouse Filtration............................................................................................... A-331A.4n Electrostatic Precipitation ...................................................................................... A-338

Centrifugation Operations................................................................................................... A-348A.5a Centrifugation ........................................................................................................ A-348A.5b Centritech Centrifugation....................................................................................... A-355A.5c Cycloning ............................................................................................................... A-359A.5d Hydrocycloning...................................................................................................... A-365

Homogenization / Milling Operations ................................................................................ A-371A.6a High Pressure Homogenization.............................................................................. A-371A.6b Bead Milling .......................................................................................................... A-378A.6c Nano-Milling.......................................................................................................... A-385

Chromatography / Adsorption Operations.......................................................................... A-389A.7a Gel Filtration (GFL) Column Loading................................................................... A-390A.7b Column Elution ...................................................................................................... A-394A.7c Column Wash......................................................................................................... A-400A.7d Column Equilibration............................................................................................. A-404A.7e Column Regeneration............................................................................................. A-405A.7f Packed Bed Adsorption (PBA) Column Loading................................................... A-406A.7g Expanded Bed Adsorption (EBA) Column Loading ............................................. A-411A.7h Membrane Adsorber (MA) Loading ...................................................................... A-417A.7i Membrane Adsorber (MA) Elution ........................................................................ A-423A.7j Membrane Adsorber (MA) Wash .......................................