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Plant Design Report Series STUDIES on COMPUTER-AIDED Plant Design Report Series Tehdassuunnittelun raporttisarja No. 90 Espoo 2006 STUDIES ON COMPUTER-AIDED CONCEPTUAL PROCESS DESIGN Timo Seuranen Plant Design Report Series Tehdassuunnittelun raporttisarja No. 90 Espoo 2006 STUDIES ON COMPUTER-AIDED CONCEPTUAL PROCESS DESIGN Timo Seuranen Dissertation for the degree of Doctor of Technology to be presented with due permission for public examination and debate in Auditorium T2 at Helsinki University of Technology (Espoo, Finland) on the 18th of August, 2006, at 12 o’clock noon. Helsinki University of Technology Department of Chemical Technology Laboratory of Chemical Engineering and Plant Design Teknillinen korkeakoulu Kemian tekniikan osasto Kemian laitetekniikan ja tehdassuunnittelun laboratorio Distribution: Helsinki University of Technology Laboratory of Chemical Engineering and Plant Design P.O. Box 6100 FIN-02015 HUT Tel. +358-9-451 2634 Fax. +358-9-451 2694 E-mail: [email protected] © Timo Seuranen ISBN 951-22-8266-6 (print) ISBN 951-22-8267-4 (pdf, available at http://lib.ttk.fi/Diss/) ISSN 0358-0776 Otamedia Oy Espoo 2006 ABSTRACT Conceptual process design phase is of prime importance to the performance and the profitability of a new or retrofit process. It is also a highly complex task with a large number of process alternatives, a large variety of requirement specifications and large differences in temporal and spatial scales. Therefore, it is essential to continuously im- prove design methods. The research should not only be focused on modelling unit op- erations or processes but also to develop a framework to support design tasks during the lifecycle of the chemical process. Main target of this thesis is to study and present methods how to intensify the concep- tual process design phase. The newly developed methods and tools are applied to proc- ess equipment selection and pre-design, separation process synthesis and process de- sign support. First, the theory of case-based reasoning (CBR) was studied with focus in applicability in process engineering. CBR was utilised for general separation process synthesis. The main phases of general CBR-based separation process synthesis algorithm consist of selection of the methods of single separations, selection of separation sequences and se- lection of combined (hybrid) separations. Selection of single separation also includes selection of azeotropic separations. The applicability of CBR in separation process se- lection and design was studied by building few prototype CBR systems. The possibilities of CBR and object database techniques in chemical process engineer- ing field have been illustrated by building applications for an inherently safer process design and for a heat exchanger selection. A web-service based approach in conceptual process design, parameterised construc- tors, which are able to construct process and initial data for control system configura- tion is also introduced in the thesis. The preliminary process design task can be first de- fined in a more general level and as the design process proceeds; more accurate models (e.g. PI and control system diagrams, simulation models) are composed and used. TIIVISTELMÄ Käsitteellisen prosessisuunnittelun vaihe on erittäin tärkeä uuden tai uudistettavan pro- sessin suorituskyvyn ja tuottavuuden kannalta. Se on myös erittäin monimutkainen teh- tävä johtuen lukuisista prosessivaihtoehtoista, vaatimusmäärittelyiden monimuotoisuu- desta sekä tila- ja aikaskaalojen eroavuuksista. Tämän vuoksi on välttämätöntä, että prosessisuunnittelumenetelmiä jatkuvasti kehitetään paremmiksi. Tutkimusta pitäisi kohdentaa yksikköoperaatioiden ja –prosessien mallituksen lisäksi myös kemiallisen prosessin koko elinkaaren aikaisia suunnittelutehtäviä tukevan palvelukehyksen kehit- tämiseen. Väitöskirjassa tutkittiin ja esitettiin menetelmiä, joiden avulla käsitteellistä prosessi- suunnittelua voidaan tehostaa. Kehitettyjä menetelmiä ja työkaluja on sovellettu pro- sessilaitteen valintaan ja esisuunnitteluun, erotusprosessisynteesiin ja prosessisuunnitte- lun tukemiseen. Työssä tutkittiin tapauspäättelyn teoriaa keskittyen sen soveltuvuuteen prosessisuunnit- telussa. Tapauspäättelyä sovellettiin erityisesti erotusprosessien synteesimenetelmän kehittämiseen. Tapauspäättelypohjaisen erotusprosessisynteesialgoritmin päävaiheet koostuvat yksittäisen erotuksen valintamenetelmistä, erotusjärjestyksen valinnasta ja yhdistettyjen (hybridi) erotusten valinnasta. Yksittäisen erotuksen valintamenetelmä si- sältää myös atseotrooppiset erotukset. Tapauspäättelyn soveltuvuutta erotusprosessin valintaan tutkittiin rakentamalla muutamia prototyyppisovelluksia. Oliokantatekniikan ja tapauspäättelyn etuja demonstroitiin rakentamalla luontaisesti turvallisemman prosessin valintajärjestelmä sekä lämmönsiirtimen esisuunnittelusovel- lus. Olemassa olevia esimerkkitapauksia voi käyttää hyväksi uusien samankaltaisten ongelmien ratkaisuissa. Väitöskirjassa käsitellään myös prosessisuunnittelun lisäarvopalveluita, parametrisoitu- ja muodostimia, jotka pystyvät eri tilanteissa muodostamaan prosessi- ja automaa- tiokonfiguraatio lähtien suunnittelijan antamista korkeamman tason vaatimuksista. Suunnittelutehtävä määritellään ensin yleisemmällä tasolla. Suunnitteluprosessin ede- tessä prosessisuunnittelun lisäarvopalveluiden avulla muodostetaan ja käytetään tar- kempia malleja (esim. PI- ja säätökaavioita, simulointimalleja). Päätarkoituksena on ru- tiinisuunnittelun tehostaminen, automaatiotoimintojen (tyyppipiirikuvauksien), ajota- padokumenttien sekä automaatiosuunnittelun lähtötietojen generointi. Tavoitteena on suunnittelukulttuurin muutos ja osoittaa, miten uutta suunnittelukulttuuria voidaan to- teuttaa prosessi- ja automaatiosuunnittelun kannalta. 2 PREFACE The research described in this thesis was done in the Laboratory of Chemical Engineer- ing and Plant Design in Helsinki University of Technology during 1999-2005. I am very grateful to my supervisor Prof. Markku Hurme for his guidance and support in this work and for his help in preparing the final thesis. I also thank my co-authors for co-operation and advices. Espoo, July 2006 Timo Seuranen 3 LIST OF PUBLICATIONS This thesis is based on the following publications (Appendices I-VII), which are re- ferred to in the text by their roman numerals: I. Pajula, E., Koiranen, T., Seuranen, T., Hurme, M., Computer aided process equipment design from equipment parts, Comput. Chem. Eng. 23 (1999), Suppl. S683-S686. II. Pajula, E., Seuranen, T., Hurme, M., Selection of separation sequences by case- based reasoning, Computer-Aided Chemical Engineering, Vol 9, 469-474, 2001. III. Pajula, E., Seuranen, T., Koiranen, T., Hurme, M. Synthesis of separation proc- esses by using case-based reasoning, Comput. Chem. Eng. 25 (2001) 775-782. IV. Seuranen, T., Pajula, E., Hurme, M., Applying CBR and object database tech- niques in chemical process design, Lecture Notes in Artificial Intelligence, Vol 2080, 731-743, 2001. V. Seuranen, T., Pajula, E., Hurme, M., Synthesis of azeotropic separation systems by case -based reasoning, Computer-Aided Chemical Engineering, Vol 10, 343- 348, 2002. VI. Seuranen T., Hurme M., Pajula E., Synthesis of separation processes by case- based reasoning, Comput. Chem. Eng, 29 (2005) 1473-1482. VII. Seuranen T., Karhela T., Hurme M., Automated process design using web-service based parameterised constructors, Computer-Aided Chemical Engineering, Vol 20, 1639-1645, 2005. 4 Timo Seuranen’s contribution to the appended publications I. The author participated in the definition of research plan and writing of the manuscript together with the co-authors. II. The author participated in the methodology development and writing of the paper together with the co-authors. III. The author participated in the CBR application development, the definition of research plan and wrote the manuscript together with the co-authors. IV. The author has full responsibility in writing the manuscript and publication. The author has programmed both applications presented in the paper. Elina Pajula and Prof. Markku Hurme have commented on the paper. V. The author was responsible for definition of the research plan, wrote the manu- script together with the co-authors, and prepared the final paper. VI. The author participated in the definition of research plan and wrote the manu- script together with the co-authors. VII. The author has full responsibility in writing the manuscript and publication. Dr. Tommi Karhela and Prof. Markku Hurme have commented on the paper. 5 STUDIES ON COMPUTER-AIDED CONCEPTUAL PROCESS DESIGN ABSTRACT TIIVISTELMÄ PREFACE LIST OF PUBLICATIONS NOTATION ......................................................................................................................8 1. INTRODUCTION.........................................................................................................9 2. CONCEPTUAL PROCESS DESIGN.........................................................................10 2.1 Introduction ...........................................................................................................10 2.2 Stages of conceptual process design......................................................................11 2.3 Criteria for process design.....................................................................................11 2.4 Project/engineering steps.......................................................................................12 2.5 Process design methodologies...............................................................................13
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