SuperPro Designer Process Simulation Overview

yeah welcome to learning sub super pro designer for students example one a superpro designer is a software package for simulating processes setting up a complete plan and so on it's a great software tool however it's of course not an educational software nevertheless we implement that in our study courses and one at the end the student should build up a company using super pro designer this is of course for one semester and real effort because the software is quite complex and as it's not educational um sometimes the learning is not so easy so therefore this example is a tailored program for students bioengineering bachelor of science biotechnology fifth semester in order to learn the software and the first example is a very simple example just setting up a very basic unit in order to get the first ideas of the program this is not a video showing you what super pro designer can do there are other videos for that this video is tailored in order to learn how to use super pro designer this is the first example and the pdf document of the example which i highly recommend if you want to do that is in the description in the it's a link in the description i would download it and use it there is also a long version of this video which is an excerpt of the complete lecture and of course there are then more insights in the program so here we go okay so i start now the super pro designer as you see on my mess on the screen so and now the first question which is asked is what would you like to do start a new process file open your last process file open another process file or we'll choose later of course in this case we start a new process file so and now the next question is what process operation mode do i want to do um most process operation modes will be batch processes but you can also go for continuous processes in this case for example a wastewater treatment plants and so on are really in a continuous mode but in general most processes will be batch operation processes so this i don't care at that point i just start now and say okay a batch process we start okay here we go so here we are so this is how it looks like if we just open the the software so our first example is a very simple example it's just neutralization of an acid with a base so this is not rocket science chemistry but this is just to show you how the software really works so you see the purpose is that we want to simply set up the simple naturalization process and what we want to do is we want to neutralize 20 um acetic acid with 15 sodium carbonate of course it's clear that the reaction product of this neutralization process is simply sodium acetate the salt and you will have production of carbon dioxide and water so therefore the first thing to do is if we start with a process we need to um collect all all substances we use in our process if we want to put in substances we need to initialize the substances in the software as described here so we go into tasks here we go pure components and then i go to register edit properties yeah here we go and now you get this this nice little windows and this is the components registration dialog and now what we do is simply we search and select each component we need to add and this is simply copy more or less copy and paste so here we go here we are so now here we have found this is the components database so these components are in the database and we will see a second what that means and we register it now i just click on register and here we have then a list of the registered pure components you have to do it then yourself you you get used to that so this is just um showing you how that works now we have the first component registered now we go uh with a second component it's sodium carbonate here we are register oh an alarm so now you see component sodium carbonate is missing the following physical properties that might be needed for a simulation eccentric factor guesses heat capacity vapor pressure heat of vaporization and what now so you see um that there might there are properties in these substances not just the substances but also physical chemical properties deposited in the database and obviously for this sodium carbonate the eccentric factor is missing at this point i don't care so i i have seen oh something is missing and if i see a procedure where i see whoa this sounds like a separation procedure where maybe the heat of vaporization comes into play then um i would go and look up this value in in a tab in the list and so on but as long as i say this is unlikely that i need it then everything is fine however you should have a list look on the list so heat capacity vapor pressure heat of vaporization you say um it's sodium carbonate and it's in solution so therefore it is unlikely that these three terms we really need now we go on we have the sodium carbonate we have the sodium acetate i get an alarm critical pressure eccentric factor vapor pressure heater vaporization so also here we have a list and also here um we say this is in solution all this is um uh not in our conditions we plan to do our neutralization that it's relevant so also here okay but have a look on this list first this is important if you realize that something is missing what you know what you need then you put it in immediately and don't wait before you get an error so and now we need carbon dioxide and then everything is fine so now we have all our substances we have acetic acid and sodium carbonate which are our reactants and our products are sodium acetate um carbon dioxide in water and you see nitrogen oxygen it always puts by default um and that's fine so therefore we have no problem there okay so we are happy and we click now okay now we come to the problem that the component sodium acetate the pressure must be above zero and you remember we have neglected it we didn't care about that and now we could of course look it up in in tables or something like that um but this takes this takes ages so let's double click on that and now you see wow we have here a vast array of of values which are put in the temperature the critical properties and so on but what i was missing was the critical pressure we have no idea how high this critical pressure should be however we know that for our process the critical pressure is of no relevance at all so i simply put in 0.01 bar which is certainly not correct and i click ok and i click again okay and now we have registered our substances however you should not save that in the default database now we we want to add a procedure now let's uh that's the big day we start with now adding a unit and of course um what we do is we go to unit procedure and we add a batch vessel procedure in a reactor so what we add is now a simple that's a procedure here we are so what we do now is we add streams so we add we go to this tool here and add streams so i add the first stream here next stream here then i add a stream here and i add a stream here okay so i've just added streams with this stream tool you see as soon as you go next to this to these ports um then this changes and then this edits it don't draw streams just like this they always have to edit somewhere so you need to start here or you need to end here yeah so now what we have to do is we have to initialize the screen so what we want to do is we want to initialize this stream 101 so we just double click on the stream the first stream is our acetic acid stream so we need to put acetic acid and we need to put of course water so this is what we put here so now our stream has a composition of 100 acetic acid this is a lot and zero percent water of course we need to um change that it's 20 acetic acid mass composition and 80 water now we have added that and now we set the mass flow to a flow rate to 1 000 kilogram per batch okay so now this is 20 80 percent mass flow is set okay so now the stream is initialized um now we could also initialize the second stream the same way you remember this is then the sodium carbonate stream but we will initialize it in a different way just to show you that there are different possibilities how to initialize streams okay now we set up the vessel operations we right click on the vessel and then you see different things appearing so we have add remove operation and other things at this point we don't care about the other things we go for add remove operations and there are a couple of available operations and of course the operations depend on what unit you choose if you have a disk stack centrifuge the operations will be different to the operations you have in the vessel procedure want to know what is this unit about also here right click help it's a good idea because then you get an overview about this process you get an overview of the operations and you can click on an operation like the charge operation and then it's described for what this operation is used obviously we need to charge the acetic acid we need to charge the sodium carbonate they need to react and then we need to transfer out so we add one charge operation and we add another charge operation we need to charge two things for each stream we add a charge operation then we add a react operation we have a reaction going on in this reactor now you see we could also act at mix operations and so on but we don't care we just make it very simple now um react equilibrium react kinetic react stoichiometric we remember bioprocess engineering kinetics was so complicated so we don't touch this button we just go straight geometric so there we are happy reaction stoichiometric reaction and then at the end we need to pump everything out and this is then a transfer out operation now we want to set up the operation so we have are at point 2.7 and we first of all set the charge one over so now we go don't go to add remove operations now we have a new uh topic here which is operation data and we go to our charge one operation uh we need to tell the software what stream to you so we want to use the stream 101 for this charge one operation so we charge using stream 101. it's not port one you see on port one there is nothing you just look where we have our 101 stream that's it and then you remember we have initialized this stream so the amount we want to charge is the amount which is given in this stream so everything was written in the stream so we click here amount use amount of stream and then everything is fine with the remaining part we leave untouched so the setup time and so on we keep okay so we have initialized our first operation now you remember our charge 2 operation was a bit different because the stream of the charge 2 operation was not initialized so in the stream we have not told the software what is in this stream so for of course for charge 2 we need they take the stream 102 we take the stream but now we need to tell the software first before we proceed what is in so therefore we go to this symbol here we go to this symbol click it and you see it's view edit the streams composition and here we are a new window opens but the cool thing is that you have already seen this window because this is exactly the window which gives you the stream composition that's cool yeah it's something which is not new to you so you go there and you remember the first stream was our acetic acid stream and the second stream is our sodium carbonate stream so what you do is you simply add sodium carbonate add ingredient and of course also here water adding gradient so now we have initialized the stream and now the same is true we need to correct the percentages so sodium carbonate [Music] is 15 and water don't forget to adjust the water it's 85 so this is our stream composition um now we don't touch here these flow rates and you can cannot change them anyhow here so we just have given now the composition of the stream okay and now um we need to tell the software how much um is being charged so we cannot use the amount of the stream because the stream in this case just contains the composition uh we want to set um it here so um mass flow um we add also here 1 000 kilograms and the remaining things also will leave untouched okay so now we came to the reaction tab and this is of course now the king's discipline so so we use a statiometric reaction model you see what what's written here um so we need to if it's a statiometric model we need to tell the software about the statiometry we go now to this is the first tab but we go now to the tab reactions here so not operation operation conditions here we leave everything the same but we now go to the reaction progress and here we have a set conversion so here we can say how much percent to convert in such a reaction this neutralization reaction uh we allow one hour we have set the time to one hour and this will be 100 so we have no problem here so this is of course something um you need to know based on your vast knowledge in chemistry what you can put here it's a state the software doesn't complain if you if you put in here 100 and it's a an equilibrium reaction and this can be the software will convert to 100 if you give a time of uh one minute and it takes five hours for the reaction pro to proceed and you give it nevertheless a conversion of 100 the software will do it so it's up to you to come here with values which are uh reasonable now we have to edit the stash symmetry so this is our first reaction and we have to go to the statiometry of the selected reaction so we have to tell the software what is happening here now we have here we need to add our reactants and we need to add our products so here we go so let's add our reactants and we have acetic acid and we have sodium carbonate it's not the water the water gets in but it's not involved in the reaction it's not a reactant it's a solvent and of course what we produce is sodium acetate carbon dioxide and water you see that now the the masses are not balanced you would need to set up the statiometry correctly but this is of course easier if you use instead of mass coefficients then molar coefficients so here we go we put click on molar and you see now also the model coefficients appeared two molecules of acetic acid react with one molecule of sodium carbonate and yielding two molecules of sodium acetate one molecule carbon dioxide one molecule of water this is the reaction statiometry simple and you see then of course then the mass in this case is balanced okay so we're happy with that so we have added the reaction we have added the conversion rate often this is forgotten gotten because the default value there is zero and then of course nothing happens and um we're we're quite happy with what we have done now and so we can we say okay now you can you can always say okay um but what you can also do is making life simpler in this case if you click here it's okay next operation then you don't have to redo this right click and so on it's just then quicker you go directly to the next operation and everything which you have what you have put in is saved okay next operation and now uh we come to our transfer out and the transfer out stream this is this one here this is this 104 so we use stream 104 here we are okay and now the big moment comes because now we have set up all our streams and now we perform the mass and energy balance by the way what i did not yet do is save don't forget to save regularly okay now i perform the mass balance this is the big deal so i go to this symbol here and i do solve the mass and energy balances i click and that's it and you see down here mass and energy balances ended successfully this is cool if you have an error for example let's go to the operation transfer out [Music] maybe i use an empty port so if i now click massman's ah you see now i've used an invalid port and now you see that what you will get used to you see error messages stream so4 104 is not currently be used by any operation in p1 remember we kicked that stream or we used another port stream on output 4 in procedure p1 is used by transfer out but it's currently missing and therefore the simulation has failed and the mass and energy balance is not being done you can only proceed by solving these errors and you have to go step by step you will see if you have more procedures you will get more errors yeah so you need to read carefully what happened so you see oh there is a red star with the red errors the yellow errors but the red errors so stream on output for port 4 in procedure p1 is used by transfer out but it's currently missing this means you have to go to this procedure transfer out and check where the problem is port 4 was um was chosen so let's go operation data and this is procedure one this is vessel procedure one you will see of course later on if we have more procedure um how to allocate then the correct one so this is procedure one right click operation data transfer out we need to go to terms out here operation data transfer out and now we look so port 4 we have port 4 but no stream is associated here so and then we also understand the first message that we have drawn a stream here 104 which is not used by any operation because we have clicked the wrong port so we have to use port 6 because there we have the stream 104 being associated click ok and we redo the mass balance and now everything is fine yeah okay so the mass balance worked so what now it's a big uh big time we can look what really happened here now we can for example right click on our vessel procedure operation data you see we have all this setting and now we want to go to equipment contents and we want to see what is happening during our p1 reaction and here we are and this is what we see so you see this shows us now the contents during the execution of p1 then we have our charge operation and you see this charge operation takes 1.9 hours because we need to pump it in it's often forgotten that pumping takes time and then you see as long as you charge nothing happens then we charge the second one and then we have our reaction happening of course we are all aware that most likely if we pump in our sodium carbonate it will immediately react at the end yeah so uh but we don't care we separate this charge and react operations and it's not something which hurts us because at the end it's just important that after the this time here 4.8 hours at the end our reaction is complete this is the point whether this has started with to react a bit earlier a lot later it's a statiometric reaction it's not a kinetic reaction what we have set up here we don't care and then we have the transfer out and of course this also takes a while and we pump everything out now you see also what we want what do you plan to do is a neutralization um so we pumped in this already looks good we pumped in 20 acetic acid and 15 sodium carbonate um and you see that yet we wanted to neutralize this acetic acid but we only partially neutralized it so we have 30 kilograms of acidic acid left and we have completely consumed our sodium carbonate this is the content of r1 what i can also do is i can double click now on this stream here and then i have the stream content after the reaction happening so this transfer out automatically puts that now in this output stream of course usually i would then have a downstream operation that's clear but you see that this is done exactly the composition of my output stream i have 30 kilogram acetic acid of course i have no sodium carbonate because this is not in the stream i have sodium acetate and i have water and i have only you see in this stream i have only stuff which is liquid there is no um gas in this stream so this is kind of the basic basic basic setup and i think the most important thing at the beginning is just really try out this very simple setup and now it's your turn so pause the video and do it yourself try to do the setup of the process yourself and also the second part please try to do it yourself the refining of the process before you go on watching the video so we have now set up our process and now we want to refine a bit the process and the formatting so how do we go now first of all if we have a look again in our equipment contents during p1 we realize that the pressure what we see inside there looks quite dramatic so we see here if we look at all this we have already seen we have 30 kilograms acidic acid left which is of course something we need to take care about but you also see that here the pressure at the beginning is one bar this is what we expect but then it decreases after reaction one to 140 bars this is high so this is something you should not stand next to such a buyer at such a reactor if you have such a pressure so we need to take care about that there is something we need to obviously if you look at this it looks like simply we pump something in the pressure increases we pump more in the pressure increases and here in the reaction we have carbon dioxide being produced this vessel is simply closed so we need to open it so what we need to do first is thinking of where can we change it and uh is there a is there something at the equipment most likely it will be in the operation so that we can in the operation change something and if you go to help you see that we have here this vent valve and we have connected even already a stream to this vent valve so this means that this looks like that here at the vent something should come out so let's see whether we find a way to operate that well this is how you go it's just try it just look for it it's a complex software you will not find you will not have learned everything before you use the software you should learn to just try things and then go for it you should also learn save different versions so it's now time to save and then if something doesn't work you go back to this version and then you can save the next version and so on so now let's see in the operations where we could do the things and if we look at at this chart we see we have the operation operators conditions volumes and here we have a tab vent emissions that sounds good so therefore let's go to this and let's see what we have here okay the contents temperature we are fine with that but here we have venting and of course then if we click then renting should be enabled and as you see the event stream in this case is automatically assigned this is the stream 103 and all the remaining stuff we keep unchanged of course in the vent you could also have emissions for example of acetic acid which is relevant if this needs to be treated and so on or if you lose a relevant amount of acetic acid which is clearly you have the order of acetic acid already in your mind if we talk about that so therefore there will be in the vent and of course this can be adjusted but for this simple case we don't care about that we just want to have the air inside so we and we just use an open vessel we don't have a pressure in our vessel this could you also can also do so we just open it so that's fine now for charge one now we go to the next operation and we use this okay next operation tab and do exactly the same for the charge 2 operation venting and we want to have an open vessel to the next operation it's the reactor of the operation it looks a bit differently you see there are others there are some other things but also here we do use an open vessel and finally the transfer out operation also here venting open vessel okay and if we now do the mass balance and if we look now on the operation the equipment content you see now it looks better so we have here the pressure now is what it should be it's always one bar we have opened the vessel this is just an example where to look and how to approach it you will realize that if you use the software you will have a lot of times things you have never seen before just go and try this is very important this is the way how you deal with that okay now the next point is just mass flows so at present acetic acid is only partially neutralized so of course what you need to do is you need to calculate um how many it's clear we have put in 1 000 kilograms of 20 acetic acid and 1 000 kilograms of 15 carb um sodium carbonate this would be luck if this would have neutralized equally so what you do is you need to calculate yourself how how much you need to pump in and this is what you then do via the stratimetric equation you know that two molecules of acetic acid are neutralized with one molecule of sodium carbonate so just calculate what is the molar amount of 200 kilograms acetic acid then you know this is this corresponds to then half of it molar amount of sodium carbonate and then you calculate how many um kilograms these are of sodium carbonate and then you calculate how many kilograms these are of um sodium carbonate 15 and that's it and then you adjust that and then it should be exactly what you expect but we go to the next point this is um we want to do the we want to use mixtures instead of pure materials so what we do now is for this example i don't redraw the complete thing i delete these two streams now of course we have a problem with the process because the incoming streams are not no more there so if we now do our mass balance we have of course error messages here yeah so what we need to do now is we want to have instead of pure components we want to have stock mixtures going in we are at the point 3.3 so now we register edit a stock mixture here we go so we don't have the stock mixtures in the database we want to have here we add a new stock mixture add a new stock mixture and then we say okay new mixture is acetic acid 20 this is our new stock mixture and now i'm having a look whether maybe if we have luck there is already a mixture which comes close to that and let's see i look at this ascetic asset 0.5 molar so let's copy the default values from this is already better than nothing okay of course what we have to do now is we have to adjust the composition so we go to the composition and this composition we have here is of course the composition which comes from this 0.5 molar acetic acid now we just adjust that and we want to have here 20 20 mass percent and and this is 80 and okay so acidic acid is fine next thing we want to add is sodium carbonate 15 and here we we don't have a real mixture so therefore we initialize to zero we say okay i also double click here in case of dart you use just nacl that's already fine and then change um change the composition later on and now we go to composition let's put sodium carbonate and water and don't forget to adjust the percentages and we update this and okay okay so now we have these two stock measures and you see by default air is already there as a stock mixture okay so what we do now is we have deleted this stream so we have to redraw these streams now of course one stream and the other stream and now we go to the selection tool and we double click and now we initialize the first stream as using a stock mixture so we click on stock mixtures here and it's acidic acid 20 okay and we initialize the second stream and we use again stock mixture and we use sodium carbonate 15 okay if we now do the mass balance you will realize you still have an error because the problem is that's of course um we have not yet told um the charge operation that we have changed something you see we have deleted uh the streams and redrawn it but the charge operation then has lost the stream so we have to re-initialize also the charge operation charge one and now if the the port before was port four um now we need to go to we have connected it to port five so this is the stream which goes on and now we have not put in the stream how much to put so we need to put it here one thousand kilogram okay and we go to charge two the same as before here we have the same we use there we had luck we had connected to the same stream set by user one thousand kilogram everything is fine okay so now let's do the mass balance and you see everything is fine and it should look the same as before so if we go now to our equipment contents during p1 you see that we have basically the same values here so the same just looking at the ascetic acid you see also here we have 30 kilograms acetic acid left so everything is fine we have correctly done that now the streams and so on looking at these streams um it's hard to see what is getting in so therefore it makes very much sense to assign to the streams the names and assigned to the uh vessel procedures the names this is the point 3.4 to add labels that makes the overall process then way easier to see first of all we give names to the stream so let's put it and if i right click on the stream i have to point edit labels and then i can say okay this is acetic acid 20 percent this is just a description so if i pump in there and sodium carbonate and i name it acetic acid then of course the software will not complain so make sure that um it's the thing what you write there is also inside 15 and then we name this stream vent right click edit labels event and we name this stream for example product stream because if you want to produce sodium carbonate this would be a sodium acetate this would be our product stream and of course we can also edit the labels of the vessel and we could say okay this is neutralization okay so this is neutralization r101 and then we know what is happening there and then what is of course interesting we can also put um the style and we can say okay i wanna have i wanna have the content which is actually going in so if you have many streams it's good to see what is the actual mass flow even what is that might be the master of one component and of course you can also do that so in this case we go to stream style click here in for tech then we have here an info tech and what we want to have is let's say the total master you're fine with that you see you could have also other options and then we can choose the location so in vertical segments it's located like this and in on horizontal segments we also want to have it lock localized over um the stream and then we are fine okay now if you of course need to do that with all streams this takes a day so what you can do is you can simply now right click the stream style and then simply pick up style choose pick up style and now things are easy right click on the other stream style apply style and we do the same here style apply style and here style lifestyle and now the style is obviously applied to the others so this is how you can make it a bit more look a bit better okay so this is the first part of the example um and the second part of the example um will come then when we talk about the economics part so this i would propose this we will do in an extra video which will be quite short but this is then also nice that the videos are shorter so this is the first part of the example how to set up a very simple neutralization process i would strongly recommend that doing it yourself and then maybe looking from time to time in the description but now i would i would like you to do it start right away do it yourself in order that you learn how to use the program and then we go to the economics thank you very much for your attention and goodbye you

yeah welcome to learning sub super pro designer for students example one a superpro designer is a software package for simulating processes setting up a complete plan and so on it&#39;s a great software tool however it&#39;s of course not an educational software nevertheless we implement that in our study courses and one at the end the student should build up a company using super pro designer this is of course for one semester and real effort because the software is quite complex and as it&#39;s not educational um sometimes the learning is not so easy so therefore this example is a tailored program for students bioengineering bachelor of science biotechnology fifth semester in order to learn the software and the first example is a very simple example just setting up a very basic unit in order to get the first ideas of the program this is not a video showing you what super pro designer can do there are other videos for that this video is tailored in order to learn how to use super pro designer this is the first example and the pdf document of the example which i highly recommend if you want to do that is in the description in the it&#39;s a link in the description i would download it and use it there is also a long version of this video which is an excerpt of the complete lecture and of course there are then more insights in the program so here we go okay so i start now the super pro designer as you see on my mess on the screen so and now the first question which is asked is what would you like to do start a new process file open your last process file open another process file or we&#39;ll choose later of course in this case we start a new process file so and now the next question is what process operation mode do i want to do um most process operation modes will be batch processes but you can also go for continuous processes in this case for example a wastewater treatment plants and so on are really in a continuous mode but in general most processes will be batch operation processes so this i don&#39;t care at that point i just start now and say okay a batch process we start okay here we go so here we are so this is how it looks like if we just open the the software so our first example is a very simple example it&#39;s just neutralization of an acid with a base so this is not rocket science chemistry but this is just to show you how the software really works so you see the purpose is that we want to simply set up the simple naturalization process and what we want to do is we want to neutralize 20 um acetic acid with 15 sodium carbonate of course it&#39;s clear that the reaction product of this neutralization process is simply sodium acetate the salt and you will have production of carbon dioxide and water so therefore the first thing to do is if we start with a process we need to um collect all all substances we use in our process if we want to put in substances we need to initialize the substances in the software as described here so we go into tasks here we go pure components and then i go to register edit properties yeah here we go and now you get this this nice little windows and this is the components registration dialog and now what we do is simply we search and select each component we need to add and this is simply copy more or less copy and paste so here we go here we are so now here we have found this is the components database so these components are in the database and we will see a second what that means and we register it now i just click on register and here we have then a list of the registered pure components you have to do it then yourself you you get used to that so this is just um showing you how that works now we have the first component registered now we go uh with a second component it&#39;s sodium carbonate here we are register oh an alarm so now you see component sodium carbonate is missing the following physical properties that might be needed for a simulation eccentric factor guesses heat capacity vapor pressure heat of vaporization and what now so you see um that there might there are properties in these substances not just the substances but also physical chemical properties deposited in the database and obviously for this sodium carbonate the eccentric factor is missing at this point i don&#39;t care so i i have seen oh something is missing and if i see a procedure where i see whoa this sounds like a separation procedure where maybe the heat of vaporization comes into play then um i would go and look up this value in in a tab in the list and so on but as long as i say this is unlikely that i need it then everything is fine however you should have a list look on the list so heat capacity vapor pressure heat of vaporization you say um it&#39;s sodium carbonate and it&#39;s in solution so therefore it is unlikely that these three terms we really need now we go on we have the sodium carbonate we have the sodium acetate i get an alarm critical pressure eccentric factor vapor pressure heater vaporization so also here we have a list and also here um we say this is in solution all this is um uh not in our conditions we plan to do our neutralization that it&#39;s relevant so also here okay but have a look on this list first this is important if you realize that something is missing what you know what you need then you put it in immediately and don&#39;t wait before you get an error so and now we need carbon dioxide and then everything is fine so now we have all our substances we have acetic acid and sodium carbonate which are our reactants and our products are sodium acetate um carbon dioxide in water and you see nitrogen oxygen it always puts by default um and that&#39;s fine so therefore we have no problem there okay so we are happy and we click now okay now we come to the problem that the component sodium acetate the pressure must be above zero and you remember we have neglected it we didn&#39;t care about that and now we could of course look it up in in tables or something like that um but this takes this takes ages so let&#39;s double click on that and now you see wow we have here a vast array of of values which are put in the temperature the critical properties and so on but what i was missing was the critical pressure we have no idea how high this critical pressure should be however we know that for our process the critical pressure is of no relevance at all so i simply put in 0.01 bar which is certainly not correct and i click ok and i click again okay and now we have registered our substances however you should not save that in the default database now we we want to add a procedure now let&#39;s uh that&#39;s the big day we start with now adding a unit and of course um what we do is we go to unit procedure and we add a batch vessel procedure in a reactor so what we add is now a simple that&#39;s a procedure here we are so what we do now is we add streams so we add we go to this tool here and add streams so i add the first stream here next stream here then i add a stream here and i add a stream here okay so i&#39;ve just added streams with this stream tool you see as soon as you go next to this to these ports um then this changes and then this edits it don&#39;t draw streams just like this they always have to edit somewhere so you need to start here or you need to end here yeah so now what we have to do is we have to initialize the screen so what we want to do is we want to initialize this stream 101 so we just double click on the stream the first stream is our acetic acid stream so we need to put acetic acid and we need to put of course water so this is what we put here so now our stream has a composition of 100 acetic acid this is a lot and zero percent water of course we need to um change that it&#39;s 20 acetic acid mass composition and 80 water now we have added that and now we set the mass flow to a flow rate to 1 000 kilogram per batch okay so now this is 20 80 percent mass flow is set okay so now the stream is initialized um now we could also initialize the second stream the same way you remember this is then the sodium carbonate stream but we will initialize it in a different way just to show you that there are different possibilities how to initialize streams okay now we set up the vessel operations we right click on the vessel and then you see different things appearing so we have add remove operation and other things at this point we don&#39;t care about the other things we go for add remove operations and there are a couple of available operations and of course the operations depend on what unit you choose if you have a disk stack centrifuge the operations will be different to the operations you have in the vessel procedure want to know what is this unit about also here right click help it&#39;s a good idea because then you get an overview about this process you get an overview of the operations and you can click on an operation like the charge operation and then it&#39;s described for what this operation is used obviously we need to charge the acetic acid we need to charge the sodium carbonate they need to react and then we need to transfer out so we add one charge operation and we add another charge operation we need to charge two things for each stream we add a charge operation then we add a react operation we have a reaction going on in this reactor now you see we could also act at mix operations and so on but we don&#39;t care we just make it very simple now um react equilibrium react kinetic react stoichiometric we remember bioprocess engineering kinetics was so complicated so we don&#39;t touch this button we just go straight geometric so there we are happy reaction stoichiometric reaction and then at the end we need to pump everything out and this is then a transfer out operation now we want to set up the operation so we have are at point 2.7 and we first of all set the charge one over so now we go don&#39;t go to add remove operations now we have a new uh topic here which is operation data and we go to our charge one operation uh we need to tell the software what stream to you so we want to use the stream 101 for this charge one operation so we charge using stream 101. it&#39;s not port one you see on port one there is nothing you just look where we have our 101 stream that&#39;s it and then you remember we have initialized this stream so the amount we want to charge is the amount which is given in this stream so everything was written in the stream so we click here amount use amount of stream and then everything is fine with the remaining part we leave untouched so the setup time and so on we keep okay so we have initialized our first operation now you remember our charge 2 operation was a bit different because the stream of the charge 2 operation was not initialized so in the stream we have not told the software what is in this stream so for of course for charge 2 we need they take the stream 102 we take the stream but now we need to tell the software first before we proceed what is in so therefore we go to this symbol here we go to this symbol click it and you see it&#39;s view edit the streams composition and here we are a new window opens but the cool thing is that you have already seen this window because this is exactly the window which gives you the stream composition that&#39;s cool yeah it&#39;s something which is not new to you so you go there and you remember the first stream was our acetic acid stream and the second stream is our sodium carbonate stream so what you do is you simply add sodium carbonate add ingredient and of course also here water adding gradient so now we have initialized the stream and now the same is true we need to correct the percentages so sodium carbonate [Music] is 15 and water don&#39;t forget to adjust the water it&#39;s 85 so this is our stream composition um now we don&#39;t touch here these flow rates and you can cannot change them anyhow here so we just have given now the composition of the stream okay and now um we need to tell the software how much um is being charged so we cannot use the amount of the stream because the stream in this case just contains the composition uh we want to set um it here so um mass flow um we add also here 1 000 kilograms and the remaining things also will leave untouched okay so now we came to the reaction tab and this is of course now the king&#39;s discipline so so we use a statiometric reaction model you see what what&#39;s written here um so we need to if it&#39;s a statiometric model we need to tell the software about the statiometry we go now to this is the first tab but we go now to the tab reactions here so not operation operation conditions here we leave everything the same but we now go to the reaction progress and here we have a set conversion so here we can say how much percent to convert in such a reaction this neutralization reaction uh we allow one hour we have set the time to one hour and this will be 100 so we have no problem here so this is of course something um you need to know based on your vast knowledge in chemistry what you can put here it&#39;s a state the software doesn&#39;t complain if you if you put in here 100 and it&#39;s a an equilibrium reaction and this can be the software will convert to 100 if you give a time of uh one minute and it takes five hours for the reaction pro to proceed and you give it nevertheless a conversion of 100 the software will do it so it&#39;s up to you to come here with values which are uh reasonable now we have to edit the stash symmetry so this is our first reaction and we have to go to the statiometry of the selected reaction so we have to tell the software what is happening here now we have here we need to add our reactants and we need to add our products so here we go so let&#39;s add our reactants and we have acetic acid and we have sodium carbonate it&#39;s not the water the water gets in but it&#39;s not involved in the reaction it&#39;s not a reactant it&#39;s a solvent and of course what we produce is sodium acetate carbon dioxide and water you see that now the the masses are not balanced you would need to set up the statiometry correctly but this is of course easier if you use instead of mass coefficients then molar coefficients so here we go we put click on molar and you see now also the model coefficients appeared two molecules of acetic acid react with one molecule of sodium carbonate and yielding two molecules of sodium acetate one molecule carbon dioxide one molecule of water this is the reaction statiometry simple and you see then of course then the mass in this case is balanced okay so we&#39;re happy with that so we have added the reaction we have added the conversion rate often this is forgotten gotten because the default value there is zero and then of course nothing happens and um we&#39;re we&#39;re quite happy with what we have done now and so we can we say okay now you can you can always say okay um but what you can also do is making life simpler in this case if you click here it&#39;s okay next operation then you don&#39;t have to redo this right click and so on it&#39;s just then quicker you go directly to the next operation and everything which you have what you have put in is saved okay next operation and now uh we come to our transfer out and the transfer out stream this is this one here this is this 104 so we use stream 104 here we are okay and now the big moment comes because now we have set up all our streams and now we perform the mass and energy balance by the way what i did not yet do is save don&#39;t forget to save regularly okay now i perform the mass balance this is the big deal so i go to this symbol here and i do solve the mass and energy balances i click and that&#39;s it and you see down here mass and energy balances ended successfully this is cool if you have an error for example let&#39;s go to the operation transfer out [Music] maybe i use an empty port so if i now click massman&#39;s ah you see now i&#39;ve used an invalid port and now you see that what you will get used to you see error messages stream so4 104 is not currently be used by any operation in p1 remember we kicked that stream or we used another port stream on output 4 in procedure p1 is used by transfer out but it&#39;s currently missing and therefore the simulation has failed and the mass and energy balance is not being done you can only proceed by solving these errors and you have to go step by step you will see if you have more procedures you will get more errors yeah so you need to read carefully what happened so you see oh there is a red star with the red errors the yellow errors but the red errors so stream on output for port 4 in procedure p1 is used by transfer out but it&#39;s currently missing this means you have to go to this procedure transfer out and check where the problem is port 4 was um was chosen so let&#39;s go operation data and this is procedure one this is vessel procedure one you will see of course later on if we have more procedure um how to allocate then the correct one so this is procedure one right click operation data transfer out we need to go to terms out here operation data transfer out and now we look so port 4 we have port 4 but no stream is associated here so and then we also understand the first message that we have drawn a stream here 104 which is not used by any operation because we have clicked the wrong port so we have to use port 6 because there we have the stream 104 being associated click ok and we redo the mass balance and now everything is fine yeah okay so the mass balance worked so what now it&#39;s a big uh big time we can look what really happened here now we can for example right click on our vessel procedure operation data you see we have all this setting and now we want to go to equipment contents and we want to see what is happening during our p1 reaction and here we are and this is what we see so you see this shows us now the contents during the execution of p1 then we have our charge operation and you see this charge operation takes 1.9 hours because we need to pump it in it&#39;s often forgotten that pumping takes time and then you see as long as you charge nothing happens then we charge the second one and then we have our reaction happening of course we are all aware that most likely if we pump in our sodium carbonate it will immediately react at the end yeah so uh but we don&#39;t care we separate this charge and react operations and it&#39;s not something which hurts us because at the end it&#39;s just important that after the this time here 4.8 hours at the end our reaction is complete this is the point whether this has started with to react a bit earlier a lot later it&#39;s a statiometric reaction it&#39;s not a kinetic reaction what we have set up here we don&#39;t care and then we have the transfer out and of course this also takes a while and we pump everything out now you see also what we want what do you plan to do is a neutralization um so we pumped in this already looks good we pumped in 20 acetic acid and 15 sodium carbonate um and you see that yet we wanted to neutralize this acetic acid but we only partially neutralized it so we have 30 kilograms of acidic acid left and we have completely consumed our sodium carbonate this is the content of r1 what i can also do is i can double click now on this stream here and then i have the stream content after the reaction happening so this transfer out automatically puts that now in this output stream of course usually i would then have a downstream operation that&#39;s clear but you see that this is done exactly the composition of my output stream i have 30 kilogram acetic acid of course i have no sodium carbonate because this is not in the stream i have sodium acetate and i have water and i have only you see in this stream i have only stuff which is liquid there is no um gas in this stream so this is kind of the basic basic basic setup and i think the most important thing at the beginning is just really try out this very simple setup and now it&#39;s your turn so pause the video and do it yourself try to do the setup of the process yourself and also the second part please try to do it yourself the refining of the process before you go on watching the video so we have now set up our process and now we want to refine a bit the process and the formatting so how do we go now first of all if we have a look again in our equipment contents during p1 we realize that the pressure what we see inside there looks quite dramatic so we see here if we look at all this we have already seen we have 30 kilograms acidic acid left which is of course something we need to take care about but you also see that here the pressure at the beginning is one bar this is what we expect but then it decreases after reaction one to 140 bars this is high so this is something you should not stand next to such a buyer at such a reactor if you have such a pressure so we need to take care about that there is something we need to obviously if you look at this it looks like simply we pump something in the pressure increases we pump more in the pressure increases and here in the reaction we have carbon dioxide being produced this vessel is simply closed so we need to open it so what we need to do first is thinking of where can we change it and uh is there a is there something at the equipment most likely it will be in the operation so that we can in the operation change something and if you go to help you see that we have here this vent valve and we have connected even already a stream to this vent valve so this means that this looks like that here at the vent something should come out so let&#39;s see whether we find a way to operate that well this is how you go it&#39;s just try it just look for it it&#39;s a complex software you will not find you will not have learned everything before you use the software you should learn to just try things and then go for it you should also learn save different versions so it&#39;s now time to save and then if something doesn&#39;t work you go back to this version and then you can save the next version and so on so now let&#39;s see in the operations where we could do the things and if we look at at this chart we see we have the operation operators conditions volumes and here we have a tab vent emissions that sounds good so therefore let&#39;s go to this and let&#39;s see what we have here okay the contents temperature we are fine with that but here we have venting and of course then if we click then renting should be enabled and as you see the event stream in this case is automatically assigned this is the stream 103 and all the remaining stuff we keep unchanged of course in the vent you could also have emissions for example of acetic acid which is relevant if this needs to be treated and so on or if you lose a relevant amount of acetic acid which is clearly you have the order of acetic acid already in your mind if we talk about that so therefore there will be in the vent and of course this can be adjusted but for this simple case we don&#39;t care about that we just want to have the air inside so we and we just use an open vessel we don&#39;t have a pressure in our vessel this could you also can also do so we just open it so that&#39;s fine now for charge one now we go to the next operation and we use this okay next operation tab and do exactly the same for the charge 2 operation venting and we want to have an open vessel to the next operation it&#39;s the reactor of the operation it looks a bit differently you see there are others there are some other things but also here we do use an open vessel and finally the transfer out operation also here venting open vessel okay and if we now do the mass balance and if we look now on the operation the equipment content you see now it looks better so we have here the pressure now is what it should be it&#39;s always one bar we have opened the vessel this is just an example where to look and how to approach it you will realize that if you use the software you will have a lot of times things you have never seen before just go and try this is very important this is the way how you deal with that okay now the next point is just mass flows so at present acetic acid is only partially neutralized so of course what you need to do is you need to calculate um how many it&#39;s clear we have put in 1 000 kilograms of 20 acetic acid and 1 000 kilograms of 15 carb um sodium carbonate this would be luck if this would have neutralized equally so what you do is you need to calculate yourself how how much you need to pump in and this is what you then do via the stratimetric equation you know that two molecules of acetic acid are neutralized with one molecule of sodium carbonate so just calculate what is the molar amount of 200 kilograms acetic acid then you know this is this corresponds to then half of it molar amount of sodium carbonate and then you calculate how many um kilograms these are of sodium carbonate and then you calculate how many kilograms these are of um sodium carbonate 15 and that&#39;s it and then you adjust that and then it should be exactly what you expect but we go to the next point this is um we want to do the we want to use mixtures instead of pure materials so what we do now is for this example i don&#39;t redraw the complete thing i delete these two streams now of course we have a problem with the process because the incoming streams are not no more there so if we now do our mass balance we have of course error messages here yeah so what we need to do now is we want to have instead of pure components we want to have stock mixtures going in we are at the point 3.3 so now we register edit a stock mixture here we go so we don&#39;t have the stock mixtures in the database we want to have here we add a new stock mixture add a new stock mixture and then we say okay new mixture is acetic acid 20 this is our new stock mixture and now i&#39;m having a look whether maybe if we have luck there is already a mixture which comes close to that and let&#39;s see i look at this ascetic asset 0.5 molar so let&#39;s copy the default values from this is already better than nothing okay of course what we have to do now is we have to adjust the composition so we go to the composition and this composition we have here is of course the composition which comes from this 0.5 molar acetic acid now we just adjust that and we want to have here 20 20 mass percent and and this is 80 and okay so acidic acid is fine next thing we want to add is sodium carbonate 15 and here we we don&#39;t have a real mixture so therefore we initialize to zero we say okay i also double click here in case of dart you use just nacl that&#39;s already fine and then change um change the composition later on and now we go to composition let&#39;s put sodium carbonate and water and don&#39;t forget to adjust the percentages and we update this and okay okay so now we have these two stock measures and you see by default air is already there as a stock mixture okay so what we do now is we have deleted this stream so we have to redraw these streams now of course one stream and the other stream and now we go to the selection tool and we double click and now we initialize the first stream as using a stock mixture so we click on stock mixtures here and it&#39;s acidic acid 20 okay and we initialize the second stream and we use again stock mixture and we use sodium carbonate 15 okay if we now do the mass balance you will realize you still have an error because the problem is that&#39;s of course um we have not yet told um the charge operation that we have changed something you see we have deleted uh the streams and redrawn it but the charge operation then has lost the stream so we have to re-initialize also the charge operation charge one and now if the the port before was port four um now we need to go to we have connected it to port five so this is the stream which goes on and now we have not put in the stream how much to put so we need to put it here one thousand kilogram okay and we go to charge two the same as before here we have the same we use there we had luck we had connected to the same stream set by user one thousand kilogram everything is fine okay so now let&#39;s do the mass balance and you see everything is fine and it should look the same as before so if we go now to our equipment contents during p1 you see that we have basically the same values here so the same just looking at the ascetic acid you see also here we have 30 kilograms acetic acid left so everything is fine we have correctly done that now the streams and so on looking at these streams um it&#39;s hard to see what is getting in so therefore it makes very much sense to assign to the streams the names and assigned to the uh vessel procedures the names this is the point 3.4 to add labels that makes the overall process then way easier to see first of all we give names to the stream so let&#39;s put it and if i right click on the stream i have to point edit labels and then i can say okay this is acetic acid 20 percent this is just a description so if i pump in there and sodium carbonate and i name it acetic acid then of course the software will not complain so make sure that um it&#39;s the thing what you write there is also inside 15 and then we name this stream vent right click edit labels event and we name this stream for example product stream because if you want to produce sodium carbonate this would be a sodium acetate this would be our product stream and of course we can also edit the labels of the vessel and we could say okay this is neutralization okay so this is neutralization r101 and then we know what is happening there and then what is of course interesting we can also put um the style and we can say okay i wanna have i wanna have the content which is actually going in so if you have many streams it&#39;s good to see what is the actual mass flow even what is that might be the master of one component and of course you can also do that so in this case we go to stream style click here in for tech then we have here an info tech and what we want to have is let&#39;s say the total master you&#39;re fine with that you see you could have also other options and then we can choose the location so in vertical segments it&#39;s located like this and in on horizontal segments we also want to have it lock localized over um the stream and then we are fine okay now if you of course need to do that with all streams this takes a day so what you can do is you can simply now right click the stream style and then simply pick up style choose pick up style and now things are easy right click on the other stream style apply style and we do the same here style apply style and here style lifestyle and now the style is obviously applied to the others so this is how you can make it a bit more look a bit better okay so this is the first part of the example um and the second part of the example um will come then when we talk about the economics part so this i would propose this we will do in an extra video which will be quite short but this is then also nice that the videos are shorter so this is the first part of the example how to set up a very simple neutralization process i would strongly recommend that doing it yourself and then maybe looking from time to time in the description but now i would i would like you to do it start right away do it yourself in order that you learn how to use the program and then we go to the economics thank you very much for your attention and goodbye you

Transcript for:SuperPro Designer Process Simulation Overview

Transcript for:
SuperPro Designer Process Simulation Overview