(383d) An Integrated Framework for Model-Based Solids Process Engineering

Solids
processes are estimated to rarely reach more than 60% of design capacity and
require 10 times longer to start-up than those involving only liquid-gas
streams.  The business costs associated with these staggering statistics are
exacerbated by the capital and energy-intensive nature of solids processes.

This
contribution therefore focuses on the development of a model-based engineering
tool that can help address these problems through a better understanding of the
process and associated risks.

The
first part of this contribution describes a new modelling framework for solids
process aimed at providing a step change in the facilities available to engineers
responsible for the design and operation of industrial solids processes.  This
framework has the following characteristics:

The
second part of this paper covers a number of typical case studies investigated
with this new framework:

1. Model discrimination and parameter estimation using
   experimental data from a fed-batch agglomeration process.
2. Analysing the impact of uncertainty in model and
   design parameters on process performance in order to quantify risk associated
   with capital expenditure decisions.
3. Determining the optimal trade-off between on the one
   hand low capital cost and reduced start-up times of the process and on the other
   hand the robustness of the process with respect to downstream disturbances
   (e.g. blockages).
4. How does the operation of upstream units, in this case
   a crystalliser, impact the capacity of downstream solids handling?
5. How can information from lab-scale studies coupled
   with CFD simulations of plant-scale equipment be coupled to aid plant scale
   equipment design and optimisation?