Minimize Energy in A BPA Process Webinar - V2 - FINAL

2013 Aspen Technology, Inc.
All rights reserved |

1
2013 Aspen Technology, Inc. All rights reserved

Minimize Energy Costs of a BPA Process
with Solids Modeling in Aspen Plus
David Tremblay
Product Management, AspenTech
Solids Process Modeling Webinar
November 7, 2013
Hosted by:
Jennifer Dyment and Ron Beck,
Product Marketing, AspenTech
2013 Aspen Technology, Inc. All rights reserved |

2
Agenda
Introduction
BPA Process Overview
Demonstration
Key Take-Away Points
Questions & Discussion

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Ongoing Series of Technical Webinars
Engineering webinars for education and best practices
RECENT WEBINARS:
Modeling Fluidized Beds and Pneumatic Conveying (Technical)-
September 2013
Modeling Solids Dryers and Granulators with Aspen Plus V8
(Technical)- April 2013
Model Solids Processes Easily with Aspen Plus (Technical)-
January 2013
UPCOMING WEBINARS OF INTEREST:
Webinar with Bilington Process Technology: Integrate Pipeline
Design and Gas Production System Models with Aspen HYSYS-
November 12, 2013
Solids Webinar: Topic TBD- February 22, 2014


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Basic
Engineering
Safety
Analysis
Aspen HYSYS
&
Aspen Plus
aspenONE Engineering
Best-in-class engineering solutions in an integrated workflow
Operations
and Planning
Support
Process
Development
Conceptual
Engineering
Equipment
Design

Economic
Evaluation

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Agenda
Introduction
Demonstration

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The Challenge
Designing a new BPA Process
Is it energy efficient?
What operating costs can I expect?
How can I reduce drying energy cost?

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Aspen Plus model of the BPA Process
Basis: SRI Process Economics Program Report #224,
Strategic Business Units for Polycarbonate and Epoxy Resins
Demo Focus

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BPA(s)
Centrifuge
S502
Product
Crystallizer
S501
Melting Vessel
V502
BPA
Dryer
S503
E504
E503
N2
N2
Toluene
Phenol
Recycle
H2O
Toluene
Toluene
Phenol
from
C303
C302
BPA from
C202
BPA is crystallized again in
toluene to remove residual
phenol. The BPA crystals
are dried with N2 to
remove toluene. The final
product is melted and sent
to a heated storage tank
BPA Purification

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Agenda
Introduction
Demonstration

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Demonstration: What You Will See
Solids
Process
Modeling
Activated
Economic
Analysis
Activated
Energy
Analysis

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Activated Economic Analysis
This is the new Activated Analysis panel in Aspen
Plus v8.2. It enables quick relative cost analysis
and energy analysis.
Under the hood, Aspen Plus uses AspenTechs
proven cost modeling technology to rigorously
evaluate capital and operating costs.
The cost estimates can be handed over
electronically to an estimator to do a more detailed
analysis using Aspen Capital Cost Estimator.

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Operating Cost Estimates
The Process Utility feature in Aspen Plus lets you specify the cost of each type of
utility (steam, hot oil, etc.). You assign the utilities to the operations that require
heating and cooling. Aspen Plus calculates the new utility cost and the carbon
equivalents (greenhouse gas).

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Activated Costing - Stream Prices
You can enter the product selling price and raw material costs for each
feed and product stream.

We can enter a negative price to address waste water processing costs.

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Activated Costing
Equipment Specifications
You can enter equipment details, such as
materials of construction, to get a more
accurate cost estimate.

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BPA(s)
Centrifuge
S502

Crystallizer
S501
Melting Vessel
V502
BPA
Dryer
S503
E504
E503
N2
N2
Toluene
Phenol
Recycle
H2O
Toluene
Toluene
Phenol
from
C303
C302
BPA
Increase
rotation
rate here
Less
residual
moisture
Lower
flow rate
Less
Steam
Less
Cooling
Optimizing Drying


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Results Changes in Rotation Rate

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Dryer Optimization Results
Centrifuge Rotation
Residual Moisture
Gas to Dryer
Blower Power
Gas Heater Duty
Condenser Duty
Operating Cost
Dryer Size
Blower Size
Gas Heater Size
Condenser Size
Capital Cost

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Economics Before & After Centrifuge Change
Payout Period reduced from 16.3 to 15.9 years
Capital Cost Reduced by $ 510,400 (1%)
Utility Costs Reduced by $ 452,000 (4%)

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The Solids Models Report Particle Sizes
You can switch between mass fraction
plot and cumulative mass fraction plots

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Activated Energy Analysis
uses pinch theory find the
energy efficiency limits.

The energy efficiency of your
process is rated against
these limits.

You can run an optimization
to find alternatives. In this
example

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The system identifies five options to place the new exchanger.
Note the first four options all involve the C303 condenser.
The first option, involving C302 reboiler, offers the best advantage

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Activated Energy Analysis Utilities
Click Saving Potentials on the ribbon to see the utility analysis
These results suggest several options to consider:
(1) Replace tower cooling water (TCW) with less expensive air cooling
(2) Opportunity to reduce refrigeration and steam costs

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Energy Analysis Recommendation
C303
C302
Energy analyzer suggests adding an exchanger upstream of C303
condenser and upstream of C302 reboiler.
This could make the process hard to control, however.
Instead, we can use C303 condenser to generate steam which can be
used in the C302 reboiler

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Switch C303 Condenser Utility from Cooling
Water to Low Pressure Steam Generation
Payout Period about equal
Capital Cost Increased by $ 1.6 million (3%)
Utility Costs Reduced by $ 322,000/year (20%)

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Agenda
Introduction
Demonstration

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Demonstration: Key Take-Away Points
New
Aspen Plus
Enables
Modeling of
Processes with
Solids
Activated
Economic
Analysis Leads
to Better
Decisions
Based on
Rigorous Cost
Estimates
Activated
Energy
Analysis Rates
Process
Energy
Efficiency and
Identifies
Improvements

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Aspen Plus V8 - Optimizing Processes with
Solids and Fluids Made Easy

Sample
Templates
Online
Training
Visualize PSD
Comprehensive Solids
Model Library
Optimize Entire Process
Visualize
Separation Curves
Economics
for Solids

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Comprehensive Solids Model Library
Design Philosophy:
One unit operation model can represent many different types of equipment
at various levels of fidelity from conceptualdetailed
17 blocks
represent
over 70
types of
equipment

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Aspen Plus Solids Modeling
- Description of Disperse Solids
Aspen Plus allows for detailed description of disperse solids

Different particle types (sub streams)

Each particle type is described by
Distributed Properties
Composition

Particle size

Scalar values per particle type (sub stream)

Moisture content(s)


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Agenda
Introduction
Demonstration

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What Next?
Get more information now
Call your AspenTech account manager or
Call Aspen Telesales Direct:
USA: +1-855-882-7736
EUROPE & MIDDLE EAST: +44-1189-226400
ASIA/PACIFIC and INDIA: +65-6395-3900
Or email us at esales@aspentech.com
Contact info for todays presenter and hosts
David Tremblay David.Tremblay@aspentech.com
Claus Reimers claus.reimers@aspentech.com
Ron Beck ron.beck@aspentech.com
Jen Dyment jennifer.dyment@aspentech.com


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Get Started with Solids Modeling in Aspen Plus
Learning Resources are Available
Presentations, videos, and getting started resources
available at: www.aspentech.com/products/solids-
aspen-plus.aspx
Computer Based Training: Getting Started with Solid
Modeling in Aspen Plus V8
Videos also available at:
www.youtube.com/user/aspentechnologyinc
Demos available in aspenONE Exchange and the Support
Center (support.aspentech.com)


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Self Guided Examples
Get up to speed easily by using 14 New Self Guided Examples
Consist of example files and detailed step-by-step slides
Included in the Support Center (http://support.aspentech.com)
and accessible via aspenONE Exchange

Search Solids,
Granulation, Dryers etc.
sort by date

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Want more help?
http://training.aspentech.com
Consider a training class from AspenTech

35
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