(570t) Dynamic Simulation Model Based Analysis for Process Development Window of Operability and Control

The ability to use dynamic simulation models for the process life cycle development by effectively determining the process window of operability and select the appropriate control strategy is described in this paper. The process development life cycle, encompassing various stages, such as research stage, process development stage and technology deployment stage, depends heavily on the validated process models to enable researchers to reduce excessive and unnecessary research spending by efficiently optimizing the process schemes and process parameters. Researchers at Saudi Aramco invented a distinctive one-step process to convert mixture of Butenes into mixed Butanols liquid without the need for separation of the isomers. Preliminary simulation models developed during the research stage revealed significant issues associated with the Azeotropic nature of the mixed Butanol product, which aided researchers during the scale-up process to incorporate necessary process changes to the pilot plant. Validated simulation models based on pilot plant data were key in developing a comprehensive large scale integrated pilot plant.

The objective of this study is to understand the scaled up commercial unit operation during its startup, analyze appropriate control strategy and optimize process basis design parameters. The process constitutes of multiple reactions of isomers of Butenes to isomers of Butanols with various reaction rates. The mixed Butanols product has different ternary separation regions with different Azeotropic points. In addition, the impact of varying isomer conversion, overall mixed Butenes conversion requiring substantial recycle rates, water specification in the mixed Butanols product substantially impact the overall process design mandates a thorough understanding of the process through dynamic modelling of the Butenes to Butanols process to provide insight into the process window of operability during startup and normal operations. Through this study the process constraints were investigated and optimal control layer configurations was established. The work is part of a comprehensive feasibility study that enables the modelers and researchers to conduct rigorous process economics for potential technology deployment and licensing.