SuperPro® Designer User’s Manual

[Pages:208]SuperPro? Designer User's Manual

Shawna Berg Greg Brobst Josh Edmonds Allison McGuire Robyn Menard Bryan Tracy

Table of Contents

List of Figures.......................................................................................................................3 List of Tables ........................................................................................................................5 0.0 Introduction....................................................................................................................6 1.0 Creating a Design Simulation .......................................................................................6

1.1 Opening SuperPro? Designer .....................................................................................................................6

2.0 Specify Mode of Operation ...........................................................................................7 3.0 Set Default Physical Units .............................................................................................9 4.0 Register Components and Mixtures.............................................................................11

4.1 Register Pure Components ..........................................................................................................................11 4.1.1 Registering Pure Components in Database ................................................................................11 4.1.2 Adding Pure Components not offered in Database ....................................................................13 4.1.2A Introducing a new component into current design ....................................................14 4.1.2B Introducing a new component permanently into Pure Components Database ..........16 4.1.3 Editing Physical Properties of Pure Components.......................................................................16 4.1.4 Adding Physical Properties of Pure Components.......................................................................18

4.2 Defining Special Components .....................................................................................................................25 4.3 Register Stock Mixtures ..............................................................................................................................26

4.3.1 Registering Stock Mixtures in Database ....................................................................................26 4.3.2 Adding Stock Mixtures not offered in Database ........................................................................27

4.3.2A Introducing a new stock mixtures into current design...............................................28 4.3.2B Introducing a new stock mixtures permanently in Stock Mixtures Database............28 4.3.3 Editing Physical Properties of Stock Mixtures...........................................................................29

5.0 Add Unit Procedures .....................................................................................................31

5.1 Editing the Procedure Data..........................................................................................................................42 5.2 Editing the Equipment Data ........................................................................................................................44 5.3 Set Breakpoints............................................................................................................................................48 5.4 Physical Characteristics...............................................................................................................................53

5.4.1 Changing the Color of the Unit Procedure .................................................................................55 5.4.2 Editing the Tag Properties..........................................................................................................56

5.4.2A Changing the Tag Label ............................................................................................56 5.4.2B Editing the Tag Text Style.........................................................................................56 5.4.2C Editing the Appearance of the Tag Frame.................................................................57 5.4.2D Picking Up and Applying an Icon Style....................................................................59

6.0 Adding Streams..............................................................................................................60

6.1 ? Types of Streams ......................................................................................................................................60 6.2 ? Drawing Streams ......................................................................................................................................62

6.2.1 ? Drawing Input Streams............................................................................................................62 6.2.2 ? Drawing Output Streams .........................................................................................................63 6.2.3 ? Drawing Intermediate Streams ................................................................................................64 6.3 ? Viewing and Editing Stream Properties of a Bulk Stream .......................................................................64 6.3.1 ? Specifying Stream Components of a Bulk Input Stream (Components, Etc. Tab)..................66 6.3.2 ? Editing the Composition of a Bulk Input Stream (Composition, Etc. Tab).............................67 6.3.3 ? The Composition, Etc. Tab for an Intermediate or Output Bulk Stream.................................69 6.3.4 ? Setting Units (Composition, Etc. Tab) ....................................................................................70 6.3.5 ? Setting the Density Value (Density Tab).................................................................................71 6.3.6 ? Viewing the Environmental Properties ...................................................................................73 6.3.7 ? Adding Comments...................................................................................................................74 6.4 ? Viewing and Editing Stream Properties of a Discrete Stream ..................................................................74 6.4.1 ? Setting the Description of the Entity for a Discrete Input Stream (Entity Tab) ......................76 6.4.2 ? Setting the Flow of the Entity for a Discrete Input Stream (Entity Tab).................................77 6.4.3 ? The Entity Tab for an Intermediate or Output Discrete Stream ..............................................77

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6.4.4 ? Specifying Stream Components of a Discrete Input Stream (Components, Etc. Tab) ............78 6.4.5 ? Editing the Composition of a Discrete Input Stream (Composition, Etc. Tab) .......................79 6.4.6 ? The Composition, Etc. Tab for an Intermediate or Output Discrete Stream ...........................81 6.4.7 ? Setting the Density Value (Density Tab).................................................................................82 6.5 ? Physical Characteristics............................................................................................................................84 6.5.1 ? Changing the Color, Style, and Thickness of the Stream ........................................................86 6.5.2 ? Editing the Tag Properties.......................................................................................................87

6.5.2A ? Changing the Tag Name.........................................................................................87 6.5.2B ? Editing the Tag Text Style......................................................................................88 6.5.2C ? Editing the Appearance of the Tag Frame..............................................................89 6.5.2D ? Editing the Location of the Stream Tag .................................................................89 6.5.2E ? Picking Up and Applying a Stream Style ...............................................................90

7.0 Specify Operations .........................................................................................................92

7.1 Adding/Removing Operations.....................................................................................................................92 7.2 Renaming Operations ..................................................................................................................................96 7.3 Operation Data ............................................................................................................................................97

8.0 Schedule Process ............................................................................................................101

8.1 Specification of Setup Time ........................................................................................................................102 8.1.1 User Specified ............................................................................................................................103 8.1.2 Simulation Specified ..................................................................................................................103 8.1.3 Master-Slave Relationship .........................................................................................................103

8.2 Scheduling Relationships ............................................................................................................................107 8.2.1 Using the "Beginning of the Batch" Relationship......................................................................109 8.2.2 Using the "Previous Operation in the Same Procedure" Relationship .......................................110 8.2.3 Using the "Another Operation in the Same Procedure" Relationship ........................................110 8.2.4 Using the "Another Operation in Another Procedure" Relationship..........................................111

8.3 Process Schedule Information .....................................................................................................................113 8.4 Accessing Gantt Charts ...............................................................................................................................114

9.0 Specify Labor Requirements ........................................................................................115 10.0 Perform Economic Evaluation....................................................................................120

10.1 Specifying Component Costs ....................................................................................................................121 10.2 Stream Costs..............................................................................................................................................123

10.2.1 Product Stream Specification ...................................................................................................123 10.2.2 Output Stream Classification....................................................................................................124 10.2.3 Input Stream Classification ......................................................................................................126 10.3 Equipment Costs........................................................................................................................................127 10.4 Labor & Utility Costs ................................................................................................................................128 10.5 Economic Evaluation Reports ...................................................................................................................129

11.0 Perform Emissions and Environmental Impact Assessment ...................................133

11.1 Defining Pollutant Category for Registered Components and Mixtures ...................................................133 11.1.1 Defining Emissions Pollutant Categories.................................................................................134 11.1.1A User-Defined Emissions Pollutant Categories ........................................................145 11.1.2 Defining Environmental Pollutant Categories..........................................................................146

11.2 Generation of Emissions and Environmental Impact Reports ...................................................................148 11.2.1 Generation of Emissions Report (EMS)...................................................................................149 11.2.2 Generation of Environmental Impact Report (EIR) .................................................................149

11.3 Viewing an Emissions and Environmental Impact Report ........................................................................150 11.4 Interpreting an Emissions and Environmental Impact Report ...................................................................152

11.4.1 Interpreting an Emissions Report .............................................................................................152 11.4.2 Interpreting an Environmental Impact Report..........................................................................153 Glossary.............................................................................................................................................................156 Index..................................................................................................................................................................163

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List of Figures

Figure 1.1: Specifying Mode of Operation for Plant .............................................................7 Figure 2.1: Changing Mode of Operation within New Flowsheet.........................................8 Figure 3.1: Accessing Physical Units Options.......................................................................9 Figure 3.2: Setting Default Physical Units ..........................................................................10 Figure 4.1: Accessing the Pure Components Database .......................................................12 Figure 4.2: Registering pure components available in database..........................................13 Figure 4.3: Registering pure components not available in database....................................14 Figure 4.4: New Component Registration ...........................................................................15 Figure 4.5: Editing Properties of Pure Components ............................................................16 Figure 4.6: Properties of Pure Components.........................................................................17 Figure 4.7: Registering Stock Mixtures ...............................................................................27 Figure 4.8: Registering a Stock Mixture Not in Database ...................................................28 Figure 5.1: Adding a Unit Procedure.....................................................................................40 Figure 5.2: A Vessel Procedure in a Fermentor.....................................................................40 Figure 5.3: Reversing the Flow Direction of a Unit Procedure .............................................41 Figure 5.4: A Procedure Flowing Right-to-Left ....................................................................42 Figure 5.5: Accessing the Procedure Data Window ..............................................................42 Figure 5.6: The Procedure Data Window for a Batch Process ..............................................43 Figure 5.7: Accessing the Equipment Data Window.............................................................44 Figure 5.8: The Equipment Data Window.............................................................................45 Figure 5.9: Choosing the Equipment for a Unit Operation....................................................46 Figure 5.10: Accessing the Breakpoints Window..................................................................48 Figure 5.11: The Breakpoints Window..................................................................................49 Figure 5.12: The Breakpoint Window with Automatic Material Pull-In...............................50 Figure 5.13: Breakpoint Window with Automatic Push-Out ................................................51 Figure 5.14: The Different Breakpoint Settings ....................................................................52 Figure 5.15: The Breakpoints Sub-menu ...............................................................................53 Figure 5.16: Accessing the Unit Procedure Icon Style Window ...........................................54 Figure 5.17: The Unit Procedure Icon Style Window ...........................................................54 Figure 5.18: Changing the Color of a Unit Procedure Icon...................................................55 Figure 5.19: The Edit Procedure Labels Window .................................................................56 Figure 5.20: The Name Tag: Text Window...........................................................................57 Figure 5.21: The Name Tag: Frame Window........................................................................58 Figure 5.22: Picking Up a Unit Procedure Icon Style ...........................................................59 Figure 5.23: Applying a Unit Procedure Icon Style ..............................................................60 Figure 6.1: Appearance of Bulk and Discrete Streams.........................................................61 Figure 6.2: Different Types of Process Streams ..................................................................61 Figure 6.3: Location of the Connect Mode Button ..............................................................62 Figure 6.4: Input Ports .........................................................................................................63 Figure 6.5: Output Ports.......................................................................................................63 Figure 6.6: How to Reach the Properties Window for a Stream .........................................65 Figure 6.7: Bulk Stream Properties Window.......................................................................65 Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk

Stream ................................................................................................................67

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Figure 6.9: Steps Taken to Input Ingredient Flows..............................................................68 Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk

Input Stream....................................................................................................69 Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams..................70 Figure 6.12: How to Change Units in SuperPro? ...............................................................71 Figure 6.13: Setting a Known Mixture Density for a Bulk Stream .....................................72 Figure 6.14: Setting the Density Based on Ingredient or Component Contributions ..........73 Figure 6.15: The Environmental Properties Tab for a Bulk Stream ....................................74 Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream ...75 Figure 6.17: Properties Window for a Discrete Input Stream .............................................75 Figure 6.18: Setting the Description of a Discrete Input Stream.........................................76 Figure 6.19: How to Edit the Flow of a Discrete Input Stream ...........................................77 Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams.......................78 Figure 6.21: Adding Components to a Discrete Input Stream.............................................79 Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows 80 Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete

Input Stream....................................................................................................81 Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams....82 Figure 6.25: Setting a Known Mixture Density...................................................................83 Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a

Discrete Stream................................................................................................84 Figure 6.27: How to Reach the Stream Style Window........................................................85 Figure 6.28: The Stream Style Window ..............................................................................85 Figure 6.29: The Colors Window ........................................................................................86 Figure 6.30: How to Reach the Edit Tag Window...............................................................87 Figure 6.31: The Edit Tag Name Window...........................................................................87 Figure 6.32: The Name Tag: Text Window.........................................................................88 Figure 6.33: The Name Tag: Frame Window......................................................................89 Figure 6.34: The Name Tag: Location Window.................................................................90 Figure 6.35: How to Pickup a Stream Style.........................................................................91 Figure 6.36: How to Apply a Stream Style..........................................................................91 Figure 7.1: Unit Procedure Menu ........................................................................................92 Figure 7.2: Operation Interface............................................................................................93 Figure 7.3: >>Add>>Function.............................................................................................94 Figure 7.4: Result of>>Add>>Function ..............................................................................95 Figure 7.5: >>Insert>>Function...........................................................................................96 Figure 7.6: Renaming an Operation.....................................................................................97 Figure 7.7: Accessing Operation Data Interface..................................................................98 Figure 7.8: Operation Data Interface ...................................................................................99 Figure 7.9: Accessing Help Menu .....................................................................................100 Figure 8.1: Accessing the Properties Window of a Unit Operation ..................................101 Figure 8.2: Operation Duration Conditions .......................................................................102 Figure 8.3: Operation Duration: Master-Slave Relationship .............................................104 Figure 8.4: Master-Slave Relationship ? Master Procedure Setup ....................................105 Figure 8.5: Master-Slave Relationship ? Master Single Operation Setup .........................106 Figure 8.6: Master-Slave Relationship ? Master Sequence Operation Setup....................107

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Figure 8.7: Scheduling Overview Screen ..........................................................................108 Figure 8.8: Scheduling Overview Screen ? Start Time Information .................................109 Figure 8.9: Start Time Relationship ? Relative to Another Operation in this Procedure ..111 Figure 8.10: Start Time Relationship ? Relative to Another Operation in Another Procedure ............................................................................................................................112 Figure 8.11: Recipe Scheduling Information Command Screen .......................................113 Figure 8.12: Recipe Scheduling Information Data ............................................................114 Figure 8.13: The Gantt Charts Menu .................................................................................115 Figure 9.1: Operation Data Command Screen...................................................................116 Figure 9.2: Operation Conditions Main Screen .................................................................117 Figure 9.3: Operation Operator Specifications ..................................................................118 Figure 9.4: Operation Labor Units Specification...............................................................119 Figure 9.5: Operation Add/Delete Labor ...........................................................................120 Figure 10.1: Component Registration Interface.................................................................121 Figure 10.2: Component Economic Properties Interface...................................................122 Figure 10.3: Stream Specifications Command Interface ...................................................123 Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface ...........124 Figure 10.5: Specifying Output Stream Classifications.....................................................125 Figure 10.6: Specifying Input Stream Classifications .......................................................126 Figure 10.7: Equipment Data Specification Command .....................................................127 Figure 10.8: Equipment Purchase Cost Information..........................................................128 Figure 10.9: Labor Tab for Operation Conditions Interface..............................................129 Figure 10.10: Performing Economic Calculations Interface .............................................130 Figure 10.11: Generating Economic Report Interface.......................................................131 Figure 10.12: Saving EER Interface ..................................................................................131 Figure 10.13: View Economic Evaluation Report Command Screen ...............................132 Figure 11.1: Selecting the component or stock mixture for registering emissions and

environmental classifications........................................................................133 Figure 11.2: Pollutant Categories Window........................................................................134 Figure 11.3: Selection of VOC and Acid gas for emissions consideration .......................144 Figure 11.4: Accessing the Emission Limits Window.......................................................145 Figure 11.5: Adding User-Defined Pollutant Categories...................................................146 Figure 11.6: Selection of hazard and waste considerations ...............................................148 Figure 11.7: Selection steps for generating an emissions report .......................................149 Figure 11.8: Selection steps for generating an environmental impact report ....................150 Figure 11.9: Selection steps for viewing an emissions report ...........................................151 Figure 11.10: Illustration of a stream section from an emissions report ...........................152 Figure 11.11: Illustrates the per batch portion of the emissions report .............................153

List of Tables

Table 5.1: Unit Operations Available in Unit Procedures ....................................................31 Table 11.1: Pollutant Categories...........................................................................................135

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0.0 Introduction

The following user's manual is formatted for easy use by both SuperPro? masters and those with no prior simulation experience. If you have no previous experience with SuperPro?, read the manual chronologically to ensure that the proper functions are performed in the correct order. For users familiar with the SuperPro? simulation package, this manual can be navigated through easily by the use of the table of contents and index. This particular manual targets a pharmaceutical audience and may leave out information concerning the software that does not pertain to this industry.

Note: Keywords underlined in blue font are hyperlinked to the glossary to allow the user to gather additional information, if needed, about a particular term.

1.0 Creating a Design Simulation

This section of the user's manual will list the steps needed to create a basic simulation using the SuperPro? Designer package. More detailed information about the different functions of SuperPro? can be found in future sections. The following are the basic steps that need to be taken to create a new design case in SuperPro?.

Basic Steps to Creating a Design Case:

1) Specify Mode of Operation 2) Set Default Physical Units 3) Register Components and Mixtures 4) Add Unit Procedures 5) Add Input and Output Streams 6) Specify Operations 7) Schedule Process 8) Specify Labor Requirements 9) Perform Cost Analysis 10) Perform Environmental Impact Assessment

In order to perform these basic functions, the user must first be able to open the program to a blank flowsheet. Section 1.1 will discuss opening SuperPro? Designer.

1.1 Opening SuperPro? Designer

SuperPro? Designer can be opened by selecting the Shortcut Icon available on your desktop, or through the Start menu of your computer. Once the program is selected, a new flowsheet can be opened by selecting:

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File>>New After selecting New and before the simulation will open a new flowsheet, the user must define whether the process is batch or continuous. After choosing to start a new flowsheet by selecting File and New, the following interface, Figure 1.1, will appear.

Figure 1.1: Specifying Mode of Operation for Plant

The user must choose a primary mode of operation and annual operating time for the design before the remainder of the designing process can take place. The following section will discuss the two possible selections for mode of operation in SuperPro?.

2.0 Specify Mode of Operation

SuperPro? allows the user to model processes as one of the following: ? Batch ? o Scheduling information is required 7

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