Components and Mixtures

Transcription

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
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o Plant batch time is calculated
o Stream flows are displayed on a per-batch basis
o Inherently continuous processing steps can be included as unit operations
in either continuous or semi-continuous mode
•
•
Continuous
o
o
o
o
•
Scheduling information is not required
Plant batch time is not calculated
Stream flows are displayed on a per-hour basis
Inherently batch processing steps can be included if user specifies
processing time and turnaround time for these steps
Mixed Mode
•
o Allows user to have continuous and batch procedures in one design
To utilize the mixed mode option, simply choose the mode of operation that is
prominently used in the design (either batch or continuous) and denote specific
operations as continuous or batch by the scheduling options. (See Section 8.0)
When SuperPro® is opened the user is prompted to specify the mode of operation before
a new flowsheet is opened (see Section 1.1). Once a new flowsheet is opened, the mode
of operation can be changed by selecting:
Tasks>>Set Mode of Operation
Figure 2.1 depicts the necessary actions to set the mode of operation.
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Figure 2.1: Changing Mode of Operation within New Flowsheet
Once selected, the interface shown above in Figure 1.1 will appear and can be used to set
the mode of operation needed for your process.
Note: Though the program allows the user to change the mode of operation during and
after the design process, making a change late in the design will require the user to revise
earlier steps. It is suggested that the user finalize the mode of operation before adding
unit operations and procedures and as early in the design process as possible.
3.0 Set Default Physical Units
SuperPro® allows the user to define what units of measure will be used for the physical
properties needed for inputting and generating data. To edit the default physical units,
the user should click the right mouse button and select:
Preferences>>Physical Units Options
The steps taken to edit the default physical units are depicted below in Figure 3.1.
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Figure 3.1: Accessing Physical Units Options
After selecting Physical Units Options, the following interface, as shown in Figure 3.2,
will appear.
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Figure 3.2: Setting Default Physical Units
The default settings for physical units can be changed by using the button and scrolling
through the unit options. The following units are available for the above categories:
Time in: yr, mo, s, min, h, day, wk
Mass in: lbmol, mol, kmol, lb, MT, ton, oz (troy), oz (avdp), g, kg
Volume in: yd3, L, Mgal, Kgal, gal, ft3, m3
Composition in: ppb, ppm, [0…1]
Concentration in: lbmol/gal, kmol/L, micro-mol/L, mmol/L, mol/L, micro-g/L, mg/L,
g/cm3, g/L
Density in: g/cm3, g/L
Temperature in: deg R, deg K, deg F, °C
Pressure in: inH2O, inHg, cmH2O, mmHg, psi, atm, bar, Pa
Note: Though a physical property may be assigned default units, the units can be
changed within streams and operations during the process. In other words, choose
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default physical units that are most often used in your process or that you want for your
generated data, but understand that these units are not binding for all operations.
4.0 Register Components and Mixtures
Before SuperPro® will recognize the components and mixtures in a process the user must
register them in the design case. Components and mixtures can be taken from the
multiple component databases provided by the program or from user-defined
components. The following sections will discuss the SuperPro® Components and
Mixtures databases available to users as well as the steps needed to register pure
components and mixtures for a given process.
4.1 Register Pure Components
There are two options when registering Error! Reference source not found.
a) Registering pure components in database (Section 4.1.1)
b) Adding pure components not offered in database (Section 4.1.2)
The following sections will discuss the process needed to register both categories of pure
components.
4.1.1 Registering pure components in database
In order for SuperPro® to recognize the components within a process, each component
must be registered in the simulation database. The simulation program is equipped with a
database of commonly used pure components. Using the Pull-In
- allows the user to take in a material without directly knowing the amount of material
needed
Pull-Out
- allows the user to take out a material without directly knowing the amount of material
needed
Pure Components Database
, the user can register the components recognized by SuperPro® that are utilized in their
process. To access the Pure Components Database, select:
Tasks>>Register Components & Mixtures>>Pure Components
Figure 4.1 depicts the necessary actions to access the Pure Components Database.
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Figure 4.1: Accessing the Pure Components Database
Once in the Pure Components Database, shown in Figure 4.1, components can be
registered by selecting the appropriate component and instructing SuperPro® to register
the component. To register pure components available in database:
1) Select chemical needed for the simulation by either:
a. Typing name of chemical in entry box
b. Scrolling up/down in Pure Component Database and selecting a chemical
2) Click the Register button
Figure 4.2 depicts the necessary actions to register pure components available in the
database.
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Figure 4.2: Registering pure components available in database
Once Register is chosen, the registered component will appear in the Registered Pure
Components section, located on the right side of Figure 4.2.
Note: The Pure Components Database can be altered at any point in the simulation
process. It is not necessary to register all components that will appear in the flowsheet at
one time, but it is recommended that users form the habit of registering components early
in the simulation process to prevent from having to return to the Pure Components
Database multiple times.
The physical constants for the components in the Pure Components Database are
already defined within the database. Unless specified by the program, no additional
physical constants need to be added to these pure components, but can be modified for a
specific design case. Physical properties can only be edited for registered components.
4.1.2 Adding pure components not offered in database
The user has two options when introducing a new component not offered in the database:
• Introduce a new component in database temporarily for this design case
only
• Introduce a new component in the database permanently to be available in
future design cases
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If the user is uncertain of the properties of a pure component, the best option may be to
add the new component temporarily. If new accurate information is found later in the
design process, the new component can be inserted into the database permanently.
4.1.2A Introducing a new component into current design
Registering pure components not available in the database requires different actions than
described above. Once the user reaches the Pure Components Database, as depicted in
Figure 4.2, the new components need to be added. To register pure components not
available in database select:
New
Figure 4.3 visually depicts the necessary actions to register pure components not
available in the database.
Figure 4.3: Registering pure components not available in database
After selecting New, the following interface, as shown in Figure 4.4, will appear.
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Figure 4.4: New Component Registration
The new component needs to be specified in one of four ways:
1) Name: can include up to 31 characters
2) Chemical Abstract Service (CAS Number
3) ): can include up to 15 characters
4) Trade Name: can include up to 31 characters
5) Local Name: can include up to 15 characters; abbreviations of component names
recognized by your company
Note: SuperPro® will not allow more than one component to have the same local name.
Once a name is denoted for a component, this field cannot be edited without removing
the component completely and introducing it again.
SuperPro® automatically denotes the property values based on a default component.
This component can be chosen by using the drop-down menu for Source for Default
Property Values, as can be seen in Figure 4.4.
Note: SuperPro® requires that a default component be chosen to add a new component,
but these properties can be manually changed after the component is added.
Once the user is certain the component name is inserted correctly and a default
component is chosen, select OK. The new component will appear in the Registered
Pure Components list with the registered components from the Pure Components
Database. The properties of this component are set by a default component. The
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property values of the new component can be changed by the procedure described in
Section 4.2, Editing Physical Properties of Pure Components.
Note: Remember that any property not defined by the user is automatically set as the
corresponding property of the default component.
4.1.2B Introducing a new component permanently into
Pure Component Database
Within the Component Registration Interface (see Figure 4.3)
1) Click on the number associated with that component, highlighting the row
2) Select Deposit
Note: If the component already exists in the Pure Components Database, the program
will ask for confirmation that the properties of the component are to be updated. Once
confirmation is made, the new component will be added to the Pure Components
Database to be used for future design cases.
4.1.3 Editing Physical Properties of Pure Components
1) Locate pure component in registration table
3) Click on Properties
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Figure 4.5: Editing Properties of Pure Components
After selecting the Properties option, an interface presenting the ID portion of the
components properties will appear. Within the properties function are the following
categories:
• ID
• Physical (Constant)
• Physical (T-dependent)
• Aqueous
• Economics
• Pollutant Categories
These categories can be chosen by clicking on the tabs located on the top of the interface.
For example, if the Physical (Constant) tab is chosen, the following interface, as shown
in Figure 4.6, will appear on the screen.
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Figure 4.6: Properties of Pure Components
Because these pure components were registered from the Pure Components Database,
most, if not all, of their physical properties are included. These properties are set as a
default within the simulation program, but can be changed for a particular process. Pure
Components added by the user, as described in Section 4.1.2, will require the user to
manually add the physical properties of the component. A further discussion on
components properties can be found in the following section, Section 4.1.4.
4.1.4 Adding Physical Properties of Pure Components
Certain fundamental properties need to be defined in order for the simulation program to
calculate other properties. Most of the pure components available in the Pure
Component Database have defined properties provided by the simulation package,
though these can be changed by the user. Pure Components added by the user, as
described in Section 4.1.2, will require the user to manually add the physical properties of
the component.
Within the properties function, see Figure 4.6, are the following categories:
• ID
• Physical (Constant)
• Physical (T-dependent)
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•
•
•
Aqueous
Economics
Pollutant Categories
Note: All of the above mentioned categories are not necessary for all calculations.
However, it is important to recall which properties are defined and which are denoted by
the default component. It is important to provide accurate values for as many properties
as possible to prevent having to define these properties later and from generating errors in
the simulation data.
The following sections will discuss in further detail the properties included in the above
mentioned categories as well as the operations where these properties are utilized. The
user should take note which properties are necessary for particular operations, to ensure
that this property data is accurate.
ID
• Name
This is the formal name of the pure component, either supplied by the simulation
program when the database was developed or by the user when a new component
was introduced. The Name portion of the ID cannot be changed once the pure
component is introduced. The Name can consist of up to 31 characters.
• Trade Name
The Trade Name may or may not be different from the Name of the pure
component. The Trade Name is the name widely known in the market or
industry. This name was either supplied by the simulation program when the
database was developed or by the user when a new component was introduced.
Unlike the Name, however, the Trade Name can be changed later and must be
unique. The Trade Name can consist of up to 31 characters.
• Formula
This property is the formula of the pure component. It was either supplied by the
simulation program when the database was developed or by the user when a new
component was introduced. The Formula can be changed later in the process and
does not have to be unique. The Formula can consist of up to 31 characters.
• Chemical Abstract Serial Number (CAS Number
• )
The CAS Number may or may not be available for a particular component. It
was either supplied by the simulation program when the database was developed
or by the user when a new component was introduced. The CAS Number must
be unique and can consist of up to 31 characters.
•
Company ID
20
Companies may have their own number system for denoting certain components
used in their process. This tag number is reserved primarily for this purpose.
This property was defined by the user when the new component was introduced,
but can be changed later. Uniqueness is not necessary for this property. The
Company ID can consist of up to 31 characters.
•
Is Biomass
•
This property consists simply of a True/False prompt to denote whether or not the
component can be treated as a biomass. This property is used to denote biomass
components within all biological reactors.
Physical (Constant)
Main Properties
• Molecular Weight
• (g/gmol)
o Used in distillation, flash drums, condensers, absorbers,
strippers, electrostatic precipitators, and all reactors
• EIR Report: Environmental Impact Report
-presents information that describes the effects of the process output streams on the
environment
-contains a detailed tabulation of all chemicals that are regulated by the EPA or denoted
as hazardous by the user
Enthalpy of Formation
• (J/gmol)
o Used in energy balances
• Normal Boiling Point
• (°C)
o Used in distillation, flash drums, condensers, and to determine
the phase of a given component
o From this information the simulation program decides whether
to use the density correlation provided by the user or the ideal
gas law to determine density
• Normal Freezing Point
• (°C)
o Used to determine if a given component is in liquid or solid
form
Critical Properties
• Temperature (°C)
o Used in distillation, flash evaporation, and condensation
• Pressure (bar)
• Compressibility Factor
21
•
• Acentric Factor
• (omega)
o Currently not needed for this version of the simulation program
Miscellaneous
• Henry’s Constant
4
3
• * 10 (atm-m /gmol)
o Used in absorption, stripping, and VOC emission calculations
• Particle Size (microns)
o Used in filters and centrifuges
• Default Volumetric Coefficient
o Used to estimate the density of a stream that contains this
component
Physical (T-dependent)
Density (g/L)
• Used as a conversion between mass and volumetric flow rates and to
calculate the concentration of streams
• Calculated by the following equation:
D = a + bT , where T is in K
• SuperPro® allows the user to enter values for a and b for user defined
components and to edit a and b for components available in the Pure
Components Database
• For densities in the vapor phase, SuperPro® assumes the ideal gas law
and calculates the density accordingly
EPA: Environmental Protection Agency
-a national organization that attempts to lead the nation’s environmental science,
research, educational, and assessment efforts by:
• Developing and enforcing regulations for hazardous chemicals
• Offering financial assistance to state and educational institutions for
environmental research
• Performs environmental research to understand current environmental problems
• Strives to further environmental education in the public arena
Evacuate
-complete removal of unit procedure contents
Heat Capacity
(J/gmol-K)
• Liquid/Solid Cp
• Gaseous Cp
22
o Calculated by the following equation:
Cp = abT + cT 2 + dT 3 , where T is in K
o SuperPro® allows the user to enter values for a, b, c, and d for
user defined components and to edit a, b, c, and d for
components available in the Pure Components database
Saturation Vapor Pressure
: Antoine (mmHg)
• Calculated using the following equation
b
log Pi = a −
, where T is in K
c +T
• SuperPro® allows the user to enter values for a, b, and c for user
defined components and to edit a, b, and c for components available
in the Pure Components Database
Heat of Vaporization
(J/gmol)
• Currently not needed for this version of the simulation program
• Calculated using the following equations
T
Tr = , where T is in K
Tc
∆Hv = a (1 − T ) , where T is in K
Watson correlation
components and to edit a and b for components available in the Pure
Components Database
Aqueous
Used primarily for the calculation of the environmental properties of streams and for
operations dealing primarily with waste treatment and pollution prevention
operations.
•
Diffusivity Properties
6
o In Water *10 (cm2/s)
Used in VOC emissions calculations
3
o In Air *10 (cm2/s)
Used in VOC emissions calculations
•
Bio-Degradation Properties
o Intermediate Stream
23
-a stream that carries material out of a unit procedure and into a different unit procedure.
Components and flowrates for an intermediate stream are usually calculated by
SuperPro®. The exception is when the Pull-Out operation is used.
Kmaxo
(mg substrate/g biomass-h)
Used in biodegradation reaction rate calculations in
aerobic biooxidation
Denotes the maximum biodegradation rate constant
o Ks
o (mg/L)
Used in biodegradation reaction rate calculations in
aerobic biooxidation
Denotes the half-saturation constant
o
•
Oxygen Ratios
o
o Clean-in-Place (CIP)
o -used for cleaning processes using a cleaning agent
COD: Chemical Oxygen Demand
o (g O/g)
Used in calculating the COD value of material streams
Denotes the amount of oxygen required to chemically
oxidize 1g of the component
o ThOD: Theoretical Oxygen Demand
o (g O/g)
Used to calculate the ThOD in streams
Denotes the theoretical amount of oxygen needed to
oxidize 1g of the component
Often equal to the COD
o BODu/COD(g/g)
Used to calculate BODu value in stream based on the
COD value of each component
Denotes the ratio of the ultimate biochemical oxygen
demand to the COD of the component
o BOD5/BODu
o (g/g)
Used to calculate the BOD5 value in stream based on
the COD value of each component
Denotes the ratio of the five-day BOD to the ultimate
BOD value
24
•
Nitrogen Ratios
o TKN: Total Kjeldahl Nitrogen
o (g N/g)
Used to calculate the TKN value of the streams
Denotes the Kjeldahl nitrogen contribution of the
component
o NH3: Ammonia Nitrogen (g N, as NH3/g)
Used to calculate the NH3 value of the streams
o NO3-NO2 : Nitrate/Nitrite Nitrogen
o (g N, as NO3, NO2)/g)
Used to calculate the NO3-NO2 value of streams
Denotes the NO3-NO2 contribution of the component
•
Log10 (octanol/water)
o Currently not needed for this version of the simulation program
o Used to indicate the hydrophobicity of a component
o Helps determine a component’s tendency to become sludge
•
Carbon ratio
o TOC: Total Organic Carbon
o (g C/g)
Used to calculate the TOC values of streams
Denotes the organic carbon contribution of a
component
•
Phosphorus ratio
o TP: Total Phosphorus
o (g P/g)
Used to calculate the TP value of streams
Denotes the phosphorus contribution of a component
o CaCO3 (CaCO3/g)
Used to calculate the CaCO3 value of streams
Denotes the CaCO3 contribution of the component
• Solids Ratios
o Solid?
User can define if component is a dissolved or
suspended solid
o TS: Total Solids (g solids/g substance)
Used to calculate the TS value of streams
Denotes the fraction of a component that is dissolved or
present as a suspended solid
o TSS/TS: Total Suspended Solids (g TSS/g TS)
Used to calculate the total TSS value of a stream based
on the TSS values of the stream components
25

o
o
o
o
o
o
o
o
Economics
•
•
•
•
•
•
Denotes the fraction of solid component that is
suspended in solution
VSS/TSS: Volatile Suspended Solids
(g VSS/g TSS)
Used to calculate the total VSS value of a stream based
on the VSS values of the stream components
Denotes the fraction of the suspended solid component
that is biodegradable
Measured as the organic fraction that oxidizes at
550±50°C that comes off as a gas
DVSS/VSS: Degradable Volatile Suspended Solids
(g
DVSS/g VSS)
Used to calculate the total DVSS value of a stream
based on the DVSS values of the stream components
Denotes the fraction of the volatile suspended solid of
the component that is biodegradable
VDS/TDS: Volatile Dissolved Solids
(g VDS/g TDS)
Used to calculate the total VDS value of a stream based
on the VDS values of the stream components
Denotes the fraction of the dissolved solid of a
component that is volatile
DVDS/VDS: Degradable Volatile Dissolved Solids
(g
DVDS/g VDS)
Used to calculate the total DVDS value of a stream
based on the DVDS values of the stream components
Denotes the fraction of the volatile dissolved solid
amount of a component that is biodegradable
Error! Reference source not found. ($/kg)
o Used in economic calculations
Selling Price
($/kg)
Waste Treatment or Disposal Cost
($/kg)
o Used to estimate waste treatment and disposal costs
o If no cost is specified, the program will estimate the cost from
the contribution of the components
Supplier
o Name
o Comments
26
Pollutant Categories
This group of properties is related mainly to classifying components within the
classes of pollutants monitored by the Environmental Protection Agency (EPA).
Emissions Report
• VOC
o Specific
VCM
TVOS
EVOS
HAP-VOC
o Other
• Particulate
o Removal by Emission (%)
o Specific
Biological
Radionuclide
Asbestos
Cr+6
Metal
Dioxin
LOC
HAP
o Other
• Acid Gas
o HAP-Acid
o Acid (Non-HAP)
• ETG
o HAP-Gas
o Gas (Non-HAP)
• CO
• NOx
• SO2
• Base
Environmental Impact Report
• Is Hazardous?
o Selecting option (clicking mouse on empty box), denotes that
component is hazardous
o Threshold (ppm)
Specifies the concentration level that would signify an
entire stream is hazardous
27
o If the presence of a hazardous component is higher than the
threshold concentration, the entire stream is denoted as
hazardous
• Is in the SARA 313 Report?
o If selected, this component is included in the SARA-313
Chemicals section of the Environmental Impact Report (EIR)
• Is in the EIR Report: Environmental Impact Report
• ?
o If selected, this component is included in the 33/50 EPA
Program Report and is included in the 33/50 Chemicals section
of the EIR report
• Is Reported in Solid Wastes?
o If selected, the component will be included in the Solid Waste
section of the EIR report and should be tracked through the
solid waste streams in the design
• Is Reported in Liquid Wastes?
o If selected, the component will be included in the Liquid
Wastes section of the EIR report and should be tracked through
the liquid waste streams in the design
• Is Reported in Emissions?
o If selected, the component will be included in the Emissions
section of the EIR report and should be tracked through all
emissions streams in the design
A more extensive discussion of how to categorize pollutants can be found in the
following section, Section 11.0.
4.2 Defining Special Components
Once all of the simulation components are registered, special components can be defined.
These components are used by SuperPro® during the simulation process. The special
components include:
•
•
•
Primary Biomass Component: Component defined to represent the biomass
in the current simulation; associated with the portions of other components
defined as intracellular
Water Component: Component defined to represent the liquid form of water
in the simulation
Activity Reference Component: Component used to determine the total
activity of a stream
If a primary biomass is formed in a reaction and both the primary biomass and water
components have been specified, the simulation program will automatically adjust
intracellular water amount to satisfy the biomass water content specified in registration.
28
Note: The primary biomass component relates to components that have the Is option
selected.
4.3 Register Stock Mixtures
Similar to pure components, before SuperPro® will recognize the mixtures in a process
the user must register them in the design case. Mixtures can be taken from the multiple
component databases provided by the program or from user-defined components. The
following sections will discuss the SuperPro® Mixtures databases available to users as
well as the steps needed to register mixture for a given process.
There are two options when registering Stock Mixtures
c) Registering stock mixtures in database (Section 4.6.1)
d) Adding stock mixtures not offered in database
The following sections will discuss the process needed to register both categories of
stock mixtures.
4.3.1 Registering Stock Mixtures in Database
Similar to pure components, SuperPro® is equipped with a database of commonly used
stock mixtures. Using the Stock Mixture Database, the user can register the mixtures
recognized by SuperPro® that are utilized in their process. To access the Stock
Mixtures Database
, select:
Tasks>>Register Components & Mixtures>>Stock Mixtures
Note: Refer back to Figure 4.1: Accessing the Pure Components Database to see the
necessary actions to access the Stock Mixtures Database.
When a stock mixture is registered, SuperPro® will automatically register the
components needed to make that stock mixture.
Figure 4.7 depicts the Stock Mixture Database the process required to register a stock
mixture for a particular process.
29
Figure 4.7: Registering Stock Mixtures
To register a stock mixture for a particular process:
1) Select stock mixture needed for simulation by either:
• Typing name of mixture in entry box
• Scrolling up/down in Stock Mixtures Database and selecting desired
mixture
2) Click the Register button
4.3.2 Adding Stock Mixtures not offered in Database
The user has two options when introducing a new component in the database:
• Introduce a new mixture in database temporarily for this design case only
• Introduce a new mixture in the database permanently to be available in
future design cases
Note: If the user is uncertain of the properties of a stock mixture, the best option may be
to add the new mixture temporarily. If new accurate information is found later in the
design process, the new mixture can be inserted into the database permanently.
30
4.3.2A Introducing a new stock mixture into current
design
Registering stock mixtures not available in the database requires different actions than
described above. Once the user reaches the Stock Mixtures Database, as depicted in
Figure 4.7, the new mixtures need to be added. To register stock mixtures not available in
database select:
New
Figure 4.8 depicts the necessary actions to register stock mixtures not available in the
database.
Figure 4.8: Registering a Stock Mixture Not in Database
4.3.2B Introducing a new stock mixtures permanently in
Stock Mixtures Database
Within the Stock Mixture Registration Interface (see Figure 4.10)
2) Select Deposit
31
Note: If the mixture already exists in the Stock Mixture Database, the program will ask
for confirmation that the properties of the mixture are to be updated. Once confirmation
is made, the new mixture will be added to the Stock Mixture Database to be used for
future design cases
4.3.3 Editing Physical Properties of Stock Mixtures
1) Locate stock mixture in registration table
2) Click on the number associated with that mixture, highlighting the row
3) Click on Properties
After selecting the Properties option, an interface presenting the ID portion of the
components properties will appear. Within the properties function are the following
categories:
• ID
• Composition
• Economics
These categories can be chosen by clicking on the tabs located on the top of the interface.
Note: All of the above mentioned categories are not necessary for all calculations.
However, it is important to recall which properties are defined and which are denoted by
the default component. It is important to provide accurate values for as many properties
as possible to prevent having to define these properties later and from generating errors in
the simulation data.
Different processes will require different properties to be specified. The following
section will discuss which operations require certain properties.
ID
• Name
This is the formal name of the stock mixture, either supplied by the simulation
program when the database was developed or by the user when a new mixture
was introduced. The Name portion of the ID cannot be changed once the stock
mixture is introduced. The Name can consist of up to 31 characters.
• Trade Name
The Trade Name may or may not be different from the Name of the stock
mixture. The Trade Name is the name widely known in the market or industry.
This name was either supplied by the simulation program when the database was
developed or by the user when a new component was introduced. Unlike the
Name, however, the Trade Name can be changed later and must be unique. The
Trade Name can consist of up to 31 characters.
32
• Local Name
Companies may have their own number system for denoting certain mixtures used
in their process. This tag number is reserved primarily for this purpose. This
property was defined by the user when the new mixture was introduced, but can
be changed later. Uniqueness is not necessary for this property. The Local Name
can consist of up to 31 characters.
Composition
Available Ingredients
Mixtures can be made up of either:
• Pure Components
• Other Stock Mixtures
Ingredient Composition
Can be defined as either:
• Mass
• Molar
Density (g/L)
• Used as a conversion between mass and volumetric flow rates and to
calculate the concentration of streams
• Calculated by the following equation:
D = a + bT , where T is in K
components and to edit a and b for mixtures available in the Stock
Mixtures database
• For densities in the vapor phase, SuperPro® assumes the ideal gas law
and calculates the density accordingly
Economics
•
•
Purchasing Price ($/kg)
o Can be set by user or calculated from components
Supplier
o Name
o Comments
33
5.0 Add Unit Procedures
After the components in the process have been specified, it is necessary to add the Unit
Procedure in the process to the simulation. A unit procedure is a piece of equipment in
which a sequence of modeled unit operations takes place. However, before the unit
procedures are added, it is important for the user to understand which unit procedures are
capable of certain functions, or unit operations, that are needed for the particular process.
Table 5.1, below, lists the unit procedures that SuperPro® offers that are useful in
bioprocesses along with the unit operations available for each unit procedure.
Table 5.1: Unit Operations Available in Unit Procedures
Procedure
Operations Available
Vessel Procedures
In a Fermenter
Agitate
Pressurize
Charge
Pull In
Clean-in-Place (CIP)
Pull Out
Cool
Purge / Inert
Crystallize
React (Equilibrium)
Evacuate
React (Kinetic)
Extract/Phase Shift
React (Stoichiometric)
Ferment (Kinetic)
Steam-in-Place (SIP)
Ferment (Stoichiometric)
Transfer In
Gas Sweep
Transfer Out
Heat
Vaporize/Concentrate
Hold
Vent
In a Seed Fermenter
Agitate
Pressurize
Charge
Pull In
Pull Out
Cool
Purge / Inert
Crystallize
React (Equilibrium)
Evacuate
React (Kinetic)
Extract/Phase Shift
Ferment (Kinetic)
Transfer In
Gas Sweep
Transfer Out
Heat
Hold
Vent
34
In an Air-Lift Fermenter
Agitate
Charge
Cool
Crystallize
Evacuate
Extract/Phase Shift
Ferment (Kinetic)
Gas Sweep
Heat
Hold
Continuous Reaction Procedures
Stoichiometric: In a
Fermenter
Hold
Stoichiometric: In a Seed
Fermenter
Hold
Stoichiometric: In an Air-Lift Clean-in-Place (CIP)
Fermenter
Hold
Kinetic: In a Fermenter
Ferment (Kinetic)
Hold
Kinetic: In a Seed Fermenter Clean-in-Place (CIP)
Ferment (Kinetic)
Hold
Environmental: Well-Mixed
Bio-oxidize*
Aerobic BioOxidation
Hold
Environmental: Plug Flow
Bio-oxidize*
Aerobic BioOxidation
Hold
Environmental: Trickling
Bio-oxidize*
Filtration
Hold
Environmental: Anoxic
Bio-oxidize*
Reaction
Hold
Environmental:
Hold
Neutralization
Neutralize*
Environmental: Wet Air
Hold
Oxidation
Oxidize*
Environmental: Incineration
Hold
Incinerate*
Environmental: UV
Hold
Radiation
Radiate*
Pressurize
Pull In
Pull Out
Purge / Inert
React (Equilibrium)
React (Kinetic)
Transfer In
Transfer Out
Vent
35
Filtration Procedures
Microfiltration (Batch)
Microfiltration (feed and
bleed)
Ultrafiltration (Batch)
Ultrafiltration (feed and
bleed)
Reverse Osmosis (Batch)
Reverse Osmosis (feed and
bleed)
Diafiltration
Dead End
Nutsche
Plate & Frame
Charge
Concentrate (Batch)*
Hold
Charge
Concentrate (feed & bleed)*
Hold
Charge
Hold
Charge
Hold
Charge
Hold
Charge
Hold
Charge
Concentrate(Batch)
Diafilter*
Filter*
Hold
Charge
Cool
Dry Cake
Filter*
Gas Sweep
Heat
Cake Wash
Filter*
Gas Sweep
Transfer In
Transfer Out
Transfer In
Transfer Out
Transfer In
Transfer Out
Transfer In
Transfer Out
Transfer In
Transfer Out
Transfer In
Transfer Out
Hold
Transfer In
Transfer Out
Hold
Purge / Inert
Transfer In
Transfer Out
Wash Cake
Hold
Transfer Out
36
Rotary Vacuum
Air Filtration
Belt
Granular Media
Electrostatic Precipitation
Centrifugation Procedures
In a Decanter Centrifuge
Disk-Stack
Bowl
Basket
Centritech
Filter*
Hold
Filter*
Hold
Filter*
Hold
Filter*
Hold
Hold
Precipitate*
Centrifuge*
Hold
Centrifuge*
Hold
Centrifuge*
Hold
Charge
Filter*
Gas Sweep
Hold
Centrifuge*
Hold
Purge / Inert
Transfer In
Transfer Out
Wash Cake
Homogenization Procedures
High-Pressure
Hold
Homogenize*
37
Bead Milling
Hold
Homogenize*
Chromatography/Adsorption Procedures
Gel Filtration
Elute*
Equilibrate
Hold
Load*
PBA Chromatography
Elute*
Equilibrate*
Hold
Load*
EBA Chromatography
Elute*
Equilibrate*
Hold
Load*
Ion Exchange (for
Hold
Demineralization)
Load*
Regenerate*
Wash*
Drying Procedures
Freeze
Charge
Cool
Dry*
Extraction Procedures
In a Mixer-Settler
Extract*
Hold
Differential
Extract*
Hold
Centrifugal
Extract*
Hold
Phase Change Procedures
Crystallization (Continuous) Clean-in-Place (CIP)
Crystallize*
Hold
Regenerate
Wash*
Regenerate*
Wash*
Regenerate*
Wash*
Hold
Transfer In
Transfer Out
38
Storage Procedures
Batch: Blending Tank
Batch: Flat Bottom Tank
Batch: Receiver
Batch: Horizontal Tank
Batch: Vertical On Legs
Tank
Agitate
Charge
Cool
Evacuate
Extract / Phase Split
Gas Sweep
Heat
Hold
Agitate
Charge
Cool
Evacuate
Gas Sweep
Heat
Hold
Agitate
Charge
Cool
Evacuate
Gas Sweep
Heat
Hold
Agitate
Charge
Cool
Evacuate
Gas Sweep
Heat
Hold
Agitate
Charge
Cool
Evacuate
Gas Sweep
Heat
Hold
Pressurize
Pull In
Pull Out
Purge / Inert
Store*
Transfer In
Transfer Out
Vent
Pressurize
Pull In
Pull Out
Purge / Inert
Store*
Transfer In
Transfer Out
Vent
Pressurize
Pull In
Pull Out
Purge / Inert
Store*
Transfer In
Transfer Out
Vent
Pressurize
Pull In
Pull Out
Purge / Inert
Store*
Transfer In
Transfer Out
Vent
Pressurize
Pull In
Pull Out
Purge / Inert
Store*
Transfer In
Transfer Out
Vent
39
Batch: Silo
Continuous: Blending Tank
Continuous: Flat Bottom
Tank
Continuous: Receiver
Continuous: Horizontal Tank
Continuous: Vertical On
Legs Tank
Continuous: Silo
Continuous: Hopper
Heat Exchange Procedures
Heating
Electric Heating
Cooling
Heat Exchanging
Charge
Hold
Pull In
Hold
Store*
Hold
Store*
Hold
Store*
Hold
Store*
Hold
Store*
Hold
Store Solids*
Handle Solids Flow*
Hold
Pull Out
Store Solids*
Transfer In
Transfer Out
Heat*
Hold
Heat*
Hold
Cool*
Hold
Exchange Heat*
Hold
40
Heat Sterilization
Mixing Procedures
Bulk Flow
Bulk Flow: Custom
Bulk Flow: Mixture Making
Bulk Flow: Tumble
Discrete Flow
Splitting Procedures
Bulk Flow
Bulk Flow: Custom
Discrete Flow
Component Flow
Hold
Sterilize*
Hold
Mix*
Hold
Mix*
Hold
Mix*
Charge
Hold
Hold
Mix*
Mix Solids*
Transfer In
Transfer Out
Hold
Split*
Hold
Split*
Hold
Split*
Hold
Split*
41
Formulation and Packaging Procedures
Filling
Fill*
Hold
Tableting
Hold
Tablet*
Transport (near) Procedures
Liquids: Pump
Hold
Pump
Generic Boxes
Discrete: Bulk to Discrete
Convert to Discrete*
Hold
Discrete: Discrete to Bulk
Convert to Bulk*
Hold
* denotes an operation that is automatic in the unit procedure
After the necessary unit procedures have been determined, the user can add those unit
procedures to the simulation.
To add a unit procedure select:
Unit Procedures >> [Type of Procedure] >> [Procedure]
For example, to add a Vessel Procedure in a Fermentor, select:
Unit Procedures >> Vessel Procedure >> in a Fermentor
Figure 5.1 below depicts the steps needed to add a vessel procedure in a fermentor.
42
Figure 5.1: Adding a Unit Procedure
After the procedure is selected, the Add Step cursor will appear:
Click on the simulation where you want the unit procedure to appear. A visual of the
procedure will then appear on the flowsheet. For the example of a vessel procedure in a
fermentor, the following image will appear to represent the procedure:
Figure 5.2: A Vessel Procedure in a Fermentor
43
Note: To move a unit procedure after it has been added to the simulation, click on the
procedure and drag it to the new location. If more than one procedure needs to be
moved, select each procedure by pressing the Shift button and left-clicking. Once all
procedures are highlighted (they will appear red), click and drag them to the new
location. Precise movements of one pixel can be made using the arrow keys on the
keyboard.
Each unit procedure has a unique appearance that correlated to how the equipment would
appear in reality.
To add more procedures, follow the same steps until all of the procedures needed in the
process are present.
It is important to pay close attention to the location and orientation of each procedure
when adding it to the simulation. SuperPro® will automatically add the procedure in the
standard left-to-right orientation. However, it is often necessary to show the procedure
flowing right-to-left. This needs to be done immediately after the procedure is added,
before any streams are connected. To change the orientation of the procedure, right click
on the procedure to open the menu, and select:
Flip (reverse flow direction)
Figure 5.3: Reversing the Flow Direction of a Unit Procedure
After Flip has been selected, the input and output ports will flow right-to-left, as shown
in Figure 5.4.
44
Figure 5.4: A Procedure Flowing Right-to-Left
After all of the necessary unit procedures are added to the simulation, the user then has
the option to edit the procedure data within each unit procedure.
5.1 Editing the Procedure Data
To open the Procedure Data Window, right click on the procedure and select:
Procedure Data
Figure 5.5: Accessing the Procedure Data Window
After selecting Procedure Data, the following window will appear:
45
Figure 5.6: The Procedure Data Window for a Batch Process
The Scheduling tab allows the user to designate the operating mode of the procedure.
There are only two fields on this tab that are editable by the user. The number of cycles
per batch can be specified, and it can be told to operate in Stagger Mode. More
information on scheduling can be found in Chapter 8. The other tabs in the Procedure
Data window include Throughput, in which the user can choose to include the procedure
in the throughput analysis, and Description, which is a blank text box that allows the user
to enter comments about the procedure.
Note: For a batch process, the Continuous option on the Scheduling tab is gray and
cannot be selected by the user. For procedures that are running constantly during a
continuous process, this option will be available.
46
5.2 Editing the Equipment Data
After the unit procedures are added to the simulation, it is necessary to set the equipment
data in order for the simulation to accurately represent the desired procedure.
To open the Equipment Data Window, right click on the procedure and select:
Equipment Data
Figure 5.7: Accessing the Equipment Data Window
After Equipment Data has been selected, the following window will appear:
47
Figure 5.8: The Equipment Data Window
The categories available in the Equipment Data Window are:
•
•
•
•
•
•
•
Equipment
Purchase Cost
Adjustments
Scheduling
Throughput
Comments
Allocation
Note: This section will be focusing on the Equipment tab. For information about Cost
Analysis, refer to Chapter 10. For information about Scheduling, refer to Chapter 8.
48
The different sections of the Equipment tab include selection, size, and description.
Selection
•
SuperPro® automatically assumes that each unit procedure takes place in
exclusive equipment. However, it is possible for more than one unit
procedure to share equipment with another unit procedure. This is specified
in the Selection section of the Equipment tab. To specify which equipment
should be used for the procedure, click on the drop-down arrow to open the
list of available equipment.
Figure 5.9: Choosing the Equipment for a Unit Operation
If there is more than one procedure in identical equipment, both of the
procedures will appear in the drop-down menu. Select the equipment to be
49
used by the procedure. To ensure that the shared equipment is being used by
the other procedure, perform the same steps to choose the equipment.
Note: The selection of the equipment takes place under the Select option in
the Selection section of the Equipment tab. The other option, Request New
is not editable by the user, due to the fact that SuperPro® automatically
determines the type of equipment used based on the unit procedure. Also note
that equipment can only be shared in batch processes. For a continuous
process, separate equipment is required. Therefore, in a continuous process,
the Select option appears gray and is not editable by the user.
Size
•
The Size Section of the Equipment tab allows the user to set the equipment
size or have SuperPro® perform the calculations. If the user chooses to size
the equipment, the simulation is in Error! Reference source not found.. If
SuperPro® is instructed to perform the calculations, the simulation is in
Error! Reference source not found..
Description
•
The Description section of the Equipment tab contains information about the
physical aspects of the equipment. The information includes:
o
o
o
o
o
o
o
o
o
o
o
Name
Type
Number of Units
Error! Reference source not found.
Height
Diameter
Design Pressure
When in Design Mode, the areas that are editable by the user are: Max.
Volume, Max. Allowable Working Volume/Vessel Volume Ratio,
Height/Diameter Ratio, Design Pressure, and whether the vessel is an ASME
Vessel. All other areas are calculated and set by SuperPro®.
When in Rating Mode, the areas that are editable by the user are: Number of
Units, Volume, Height/Diameter Ratio, Design Pressure, and whether the
vessel is an ASME Vessel. All other areas are calculated and set by
SuperPro®.
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5.3 Set Breakpoints
During the simulation process, it is sometimes necessary to have SuperPro® stop at a
certain unit procedure when performing the mass and energy balances. This can be done
by setting Error! Reference source not found..
To access the Breakpoints window, right-click on the procedure and select:
Set Breakpoints…
Figure 5.10: Accessing the Breakpoints Window
After Set Breakpoints… is selected, the following window will appear:
51
Figure 5.11: The Breakpoints Window
There are three general locations in which a breakpoint can be added:
•
•
•
Upon entering the unit procedure
Before an operation in the procedure
Upon exiting the procedure
In some special cases, there are other options available. If there is an automatic material
pull-in, an option will be present to insert a breakpoint after the automatic pull-in, as is
show in the figure below:
52
Figure 5.12: The Breakpoint Window with Automatic Material Pull-In
It is also possible to insert a breakpoint after an automatic push-out operation, as shown
in the figure below:
53
Figure 5.13: Breakpoint Window with Automatic Push-Out
There are three different settings that can be chosen when designating breakpoints:
•
•
•
Set and Active
Set and Inactive
Cleared
To set and activate a breakpoint, click once on the box next to the operation that will
follow directly after the breakpoint. When a breakpoint is set and active, it will be
designated by a black check in the square. Once a breakpoint is set and active, it can be
changed to set and inactive by clicking once more on the square. A set but inactive
breakpoint is designated by a black check in a gray square. To remove or clear the
breakpoint, click again on the box and the check will be removed. These three settings
are illustrated in Figure 5.14.
54
Figure 5.14: The Different Breakpoint Settings
After breakpoints have been set, a red circle with a white X appears on the simulation
where the breakpoint is located. If a breakpoint is set but inactive, it appears as a gray
circle with a white X. These indicators can be seen in Figure 5.15 below. The menu
changes slightly after breakpoints are added to include a sub-menu for editing
breakpoints. The new menu appearance is shown in the figure below:
55
Figure 5.15: The Breakpoints Sub-menu
The Edit option allows the user to return to the Breakpoint Window to edit the
breakpoints. The Clear All option removes all breakpoints, the Activate All option
activates all of the set breakpoints, and the Deactivate All option deactivates all set
breakpoints.
Note: If there are no deactivated breakpoints, there will not be an Activate All option on
the Breakpoints sub-menu. Likewise, if there are no activated breakpoints, there will not
be a Deactivate All option on the Breakpoints sub-menu.
5.4 Physical Characteristics
It is often important to adjust the physical appearance of a unit procedure or change the
title from the generic number notation. This section will provide instructions on how to
format the flow diagram to improve the aesthetic quality of the flowsheet.
To reach the Unit Procedure Icon Style Window, right-click on the icon and select:
Style… >> Edit…
56
Figure 5.16: Accessing the Unit Procedure Icon Style Window
After Edit… has been selected, the following window will appear:
Figure 5.17: The Unit Procedure Icon Style Window
57
5.4.1 Changing the Color of the Unit Procedure
By adding a color scheme to the simulation, the user can organize sections of the process.
Different sections of the simulation can be colored to indicate different purposes within
the overall simulation, such as production fermentation versus a purification procedure.
To change the color of the unit procedure icon, it is first necessary to open the Unit
Procedure Icon Style Window, as described above.
To change the color of the icon,
1) Click on the Icon tab at the top of the Unit Procedure Icon Style Window.
Note: The Icon tab will automatically appear on top when the Unit Procedure
Icon Style Window is opened.
2) Click on the Colors… button to open a separate colors window.
Figure 5.18: Changing the Color of a Unit Procedure Icon
3) Select the desired color and click OK to accept the changes.
Note: Changing the color of the unit procedure icon does not change the color of the tag
under the unit procedure. This option will be shown in the next section.
58
5.4.2 Editing the Tag Properties
The Tag is the description that can be seen in Figure 5.2: A Vessel Procedure in a
Fermentor underneath the unit procedure icon. It is often useful to alter the tag properties
for descriptive as well as aesthetic purposes.
5.4.2A Changing the Tag Label
SuperPro® uses a generic naming scheme for unit procedures based on the type of
procedure and the order in which it was added to the simulation. It is possible, however,
to alter the label to contain more specific information about the procedure.
To access the Edit Procedure Labels Window, right-click on the procedure and select:
Edit Labels…
After Edit Labels… has been selected, the following window will appear:
Figure 5.19: The Edit Procedure Labels Window
The Procedure Name and Equipment name can both hold up to 15 characters, while the
Procedure Description can hold up to 31 characters. The label will appear with the
Procedure Name and Equipment Name on one line, separated by a “/” delimiter, and the
Procedure Description will follow on the next line:
Procedure Name / Equipment Name
Procedure Description
5.4.2B Editing the Tag Text Style
To edit the Tag Text Style, perform the following tasks:
1) Click on the Name Tag: Text tab at the top of the Unit Procedure Icon Style
Window. For information on how to reach the Unit Procedure Icon Style
window, refer to Section 5.4.1.
59
2) To remove the tag completely, click on the box in front of Show Label to remove
the “x”.
3) To change the font of the tag, click on the Font button to open a separate font
window in which the user can select the desired font, size, and font style.
4) To change the color of the tag text, click on the Font button to open the font
window and click on the drop down menu labeled Color to choose from a list of
colors.
5) To change the color of the background of the tag, click on the Color button on the
Name Tag: Text tab to open a separate color window in which the user can select
the desired color. Note that a color can be chosen only if the text background is
specified as Opaque. If the desired background is clear, choose the Transparent
option. This will allow any lines behind the tag to show through.
Figure 5.20: The Name Tag: Text Window
In addition to editing the text of the tag, it is also possible to have a frame around the tag.
The following section with discuss this option.
5.4.2C Editing the Appearance of the Tag Frame
To access the Name Tag: Frame section of the Unit Procedures Icon Style Window:
1) Click on the Name Tag: Frame tab at the top of the Unit Procedure Icon Style
Window.
60
2) Click the circle in front of the style of choice. Choices include solid, dotted,
dashed, dash-dot, dash-dot-dot, and invisible.
3) Click the circle in front of the thickness of choice. Note that different thicknesses
are only available for solid lines. All options other than 1 pt are non-editable
when a style other than solid is selected.
4) Click on the button marked Colors… to open a separate color window in which
the user can select the desired color.
Figure 5.21: The Name Tag: Frame Window
Because there are so many options to customize the appearance of the unit procedure icon
and tag, SuperPro® has a function that allows the user to pick up a style and apply it to
another unit procedure icon and tag.
61
5.4.2D Picking Up and Applying an Icon Style
To pick up an icon style, right-click on the unit procedure icon and select:
Style… >> Pick up
Figure 5.22: Picking Up a Unit Procedure Icon Style
button on the
An alternate way to pickup a unit procedure icon style is to click the
Visual Objects Toolbar along the right side of the SuperPro® window.
After a unit procedure icon style has been picked up, it is possible to apply that style to
another unit procedure. To do this, right-click on the unit procedure icon and select:
Style… >> Apply
62
Figure 5.23: Applying a Unit Procedure Icon Style
button on the
An alternate way to apply a unit procedure icon style is to click the
Visual Objects Toolbar along the right side of the SuperPro® window.
6.0 Adding Streams
Streams are used in SuperPro® to transport materials into, between, and out of unit
procedures. The following sections describe the different types of streams used in
SuperPro®, explain how to draw streams, and describe how to edit stream properties and
physical characteristics.
6.1 Types of Streams
There are two distinct types of streams incorporated into the SuperPro® software
package: Bulk Stream
and Discrete Stream
.
•
•
Bulk streams have flow rates such as kg/h or kg/batch, where the amount of
medium in the stream is apparent in the value of the flow rate.
Discrete streams have flow rates such as vials/batch or bottles/batch, where each
vial contains a particular mass or volume, making it possible to calculate the
amount of medium in the stream.
63
Note: It is not necessary to specify explicitly the nature of the stream. SuperPro® will
automatically designate the type of stream based on which Error! Reference source not
found. the stream is connected.
Discrete flow is only available for five of the unit procedures that SuperPro® offers.
These procedures include Flow Mixing, Flow Splitting, Generic Boxes, Grinding, and
Shredding. Flow mixers and flow splitters use the same type of stream as inputs and
outputs, so, for example, a discrete flow mixer will have a discrete output. Generic boxes
allow the user to change a discrete stream to a bulk stream and vice versa. Discrete
grinders and shredders have discrete inputs and bulk outputs. For more information on
these unit operations, refer back to Section 5.0.
SuperPro® distinguishes between bulk and discrete streams in three ways: the color of
the stream, the appearance of the port, and the stream properties. For a bulk stream, the
stream is drawn black and the input port is designated by an arrow. For a discrete stream,
the stream is drawn blue and the input port is designated with a small square next to the
arrow. These differences can be seen on a flow splitter shown below in Figure 6.1.
Figure 6.1: Appearance of Bulk and Discrete Streams
Note: Discrete flows are also designated as DS-101 (as opposed to S-101) and the
procedure description is automatically set as “Discrete Flow Splitting” for the flow
splitter using discrete flows. If an operation has a discrete flow in, it must also have a
discrete flow out.
In addition to the two types of streams, there are three categories of process streams:
Input Stream
, Intermediate Stream
, and Error! Reference source not found.. These streams are highlighted below in
Figure 6.2.
64
Figure 6.2: Different Types of Process Streams
6.2 Drawing Streams
There are two modes in which the user can draw streams, Connect Mode
and Temporary Connect Mode
.
Connect Mode is more convenient for drawing several streams at a time.
•
To enter Connect Mode, click the Connect Mode button on the main toolbar:
Figure 6.3: Location of the Connect Mode Button
When in Connect Mode, the cursor will change to the Connect Mode Cursor:
Note: The simulation will remain in connect mode after you draw the stream(s). To
leave connect mode and return to Select Mode
, click the Arrow button next to the Connect Mode button.
Temporary Connect Mode is convenient for drawing only one stream.
•
To enter Temporary Connect Mode, hold down the Control (Ctrl) key on the
keyboard and double-click to begin the stream. To end the stream, double-click
again.
65
6.2.1 Drawing Input Streams
► In Connect Mode:
1) Click once on an open area to begin drawing the stream.
2) To change the direction of the stream, click once on the open area. The stream
will bend at a 90 degree angle. Click once more to change direction again. These
direction changes are called Stream Elbow
3) .
4) Click once on an input port to connect the stream to the unit operation.
Figure 6.4: Input Ports
► In Temporary Connect Mode:
1) Hold the Ctrl key and double-click on an open area to begin the stream. After
beginning the stream, it is no longer necessary to hold the Ctrl key.
will bend at a 90 degree angle. Click once more to change direction again.
3) Click once on an input port to connect the stream to the unit operation.
6.2.2 Drawing Output Streams
1) Click once on an output port to begin the stream.
Figure 6.5: Output Ports
2) To change the direction of the stream, click once on an open area. The stream
3) Double-click on an open area to end the stream.
66
1) Hold the Ctrl key and double-click on an output port to begin the stream. After
3) Double-click on an open area to end the stream.
6.2.3 Drawing Intermediate Streams
1) Click once on an output port to begin the stream.
3) Click once on an input port of another unit operation to end the stream.
1) Hold the Ctrl key and double-click on an output port to begin the stream. After
3) Click once on an input port of another unit operation to end the stream.
Note:
• It is not necessary to draw stream elbows for intermediate streams. The stream
drawn by clicking an output port and ended by clicking an input port. SuperPro®
will automatically place elbows in the stream where needed. These elbows can
later be edited to place the stream in the best location.
• If an elbow is placed in an undesirable location, a right click will remove the
elbow.
• Connect Mode can be exited without finishing the current stream by pushing the
Esc key on the keyboard. The stream being drawn will be aborted.
• A stream must be in a horizontal position in order to be connected to a port.
6.3 Viewing and Editing Stream Properties of a Bulk
Stream
67
The properties window for a bulk stream has four tabs: Composition, etc., Density,
Env. Properties, and Comments. To access the properties window for a stream, rightclick on the stream and select:
Simulation Data
Figure 6.6: How to Reach the Properties Window for a Stream
After selecting Simulation Data, the following window will appear:
68
Figure 6.7: Bulk Stream Properties Window
The interface presented in the above figure can be used to specify the components and
flowrates of streams. The following sections will describe these functions in further
detail.
6.3.1 Specifying Stream Components of a Bulk Input
Stream (Components, Etc. Tab)
From the Bulk Stream Properties Window, Figure 6.7, the stream components of a bulk
input stream can be specified for a particular process.
1) Begin by clicking the Composition, Etc. tab along the top of the properties
window. (See Figure 6.8 below).
2) Choose either Components or Stock Mixtures based on the ingredient to be
added.
3) Choose the component or stock mixture to be added in the Registered
Ingredients List.
69
Note: If the component or mixture to be added does not appear on the list of
Registered Ingredients, refer to Section 4.1.1 on how to register components.
4) Click the >>> button to add the component or stock mixture to the stream.
Figure 6.8 below depicts the necessary actions to specify the stream components of a
bulk input stream.
Figure 6.8: Steps Taken to Register a Pure Component or Stock Mixture to a Bulk Stream
Once pure components and stock mixtures are registered in the Simulation Data
Interface, the user has the option to edit the composition of each component in a stream.
6.3.2 Editing the Composition of a Bulk Input Stream
(Composition, Etc. Tab)
There are two ways to determine the composition of the stream including:
• Setting the component flowrates
70
•
Setting the total flowrate and the mass composition of the stream
► To set component flowrates:
1) Select Ingredient Flows by clicking on the small circle in front of “Ingredient
Flows” in the Set area below the Composition area.
2) Click on the cell in the Flowrate column to enter edit mode.
3) Input the flowrate in kg/batch for batch processes or kg/h for continuous
processes.
Figure 6.9: Steps Taken to Input Ingredient Flows
Note: When setting ingredient flows, SuperPro® will automatically calculate the total
flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be
manually edited and the boxes appear gray.
► To set mass composition:
71
1) Select Mass Composition by clicking on the small circle in front of “Mass
Composition” in the Set area below the Composition area.
2) Click on the cell in the Mass Comp. column to enter edit mode.
3) Input the mass composition in percentage form (%).
4) Enter the total flowrate for the stream. This can be done in either mass flow or
volumetric flow. Click on the circle in front of the flow of choice, and the box
will change to edit mode.
Figure 6.10: Steps Taken to Set the Mass Composition and Total Flowrate of a Bulk Input Stream
Note: SuperPro® will automatically calculate the ingredient flows based on the mass
composition and total flowrate. Therefore the component flows cannot be manually
altered while setting mass compositions.
6.3.3 The Composition, Etc. Tab for an Intermediate or
Output Bulk Stream
72
While the Density, Env. Properties, and Comments tabs are the same for all three types
of streams, the Composition, Etc. tab is different for an input stream than for an
Intermediate or Output stream. Figure 6.11 below shows the Composition, Etc. tab for
Intermediate and Output streams.
Figure 6.11: The Composition, Etc. Tab for Intermediate and Output Streams
Note: The only difference between this section for Intermediate and Output Streams
and that for Input Streams is the lack of the Registered Ingredients section. SuperPro®
will automatically calculate the components and flows of the streams based on the inputs
and unit operations and, therefore, this section does not need to be included.
73
6.3.4 Setting Units (Composition, Etc. Tab)
1) To change the units of the mass, volume, composition, or concentration, click on
the drop-down arrow next to the unit of choice.
2) Select the desired from the drop-down menu.
Figure 6.12: How to Change Units in SuperPro®
6.3.5 Setting the Density Value (Density Tab)
1) Click on the Density tab at the top of the stream properties window.
2) If the density of the mixture in the stream is known, this value can be inputted by
clicking the circle in front of the words “Set by User”. The box will be in edit
mode after the circle is selected.
74
Figure 6.13: Setting a Known Mixture Density for a Bulk Stream
3) If the density is unknown, SuperPro® can calculate the density based on the
contribution to each ingredient in the stream.
4) Click the circle in front of the word “Calculated” to access the Volumetric
Contribution Coefficients area.
5) Click the circle in front of “Ingredient
6) ” or “Component
7) ” based on the data to be inputted. If all of the ingredients are pure components,
there will be no difference between the Ingredients and Components options.
8) Click on the cell in the Coefficient column to enter edit mode.
9) Enter the desired coefficient.
75
Figure 6.14: Setting the Density Based on Ingredient or Component Contributions
6.3.6 Viewing the Environmental Properties
The Env. Properties tab contains information on the environmental contributions of the
stream. The values are calculated based on environmental characteristics of the
individual ingredients, so all of the boxes are gray and unable to be edited by the user.
For more information about the environmental properties or to change the environmental
characteristics of the ingredients, refer to Section 4.1.4.
76
Figure 6.15: The Environmental Properties Tab for a Bulk Stream
6.3.7 Adding Comments
The Comments tab has a text box that allows the user to enter any comments they may
have about the stream that cannot be entered elsewhere in the stream properties window.
6.4 Viewing and Editing Stream Properties of a Discrete
Stream
The properties window for a discrete stream has three tabs: Entity, Composition, etc.,
and Density. To access the properties window for a stream, right-click on the stream and
select:
Simulation Data
77
Figure 6.16: How to Reach the Stream Properties Window for a Discrete Input Stream
After you have selected Simulation Data, the following window will appear:
Figure 6.17: Properties Window for a Discrete Input Stream
78
6.4.1 Setting the Description of the Entity for a Discrete
Input Stream (Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will
automatically be on top when the properties window appears.
2) Click on the text box next to Name under the Description area to enter the name
of the entity (for example, bottle or vial). If the entity is present in more than one
area of the process, both entities should be given the same name.
3) To set the Bulk Conversion Factor
4) , first choose the units and click the circle next to mass or volume depending on
preference. Then click the text box next to Bulk Amount Per Entity to enter the
number. Units are in g/entity or cm3/entity. If the entity is present in more than
one area of the process, both entities should be given the same bulk conversion
factor.
5) To set the purchasing price, click the text box next to Purchasing Price and enter
the price. Units are given in $/entity.
6) To set the selling price, click on the text box next to Selling Price and enter the
price. Units are given in $/entity.
Figure 6.18: Setting the Description of a Discrete Input Stream
79
6.4.2 Setting the Flow of the Entity in the Input Stream
(Entity Tab)
1) Click on the Entity tab to bring the window to the top. The Entity tab will
automatically be on top when the properties window appears.
2) Click on the text box in the Flow area to enter the number of entities per batch.
Figure 6.19: How to Edit the Flow of a Discrete Input Stream
6.4.3 The Entity Tab for an Intermediate or Output
Discrete Stream
The Entity tab is different for an input stream than for an Intermediate or Output stream.
Figure 6.20, below, shows the Entity tab for Intermediate and Output streams.
80
Figure 6.20: The Entity Tab for Intermediate and Output Discrete Streams
Note: The only difference here is the inability to alter the description and flowrates of
the entity. SuperPro® will automatically update the description and flow of the entity
based on the input entity.
6.4.4 Specifying Stream Components of a Discrete Input
Stream (Components, Etc. Tab)
1) Begin by clicking the Composition, Etc. tab along the top of the properties
window
2) Choose either Components or Stock Mixtures based on the ingredient to be
added.
3) Choose the component or stock mixture to be added in the Registered Ingredients
list. If the component or mixture to be added does not appear on the list of
Registered Ingredients, refer to Section 4.0 on how to register components.
4) Click the >>> button to add the component or stock mixture to the stream.
81
Figure 6.21: Adding Components to a Discrete Input Stream
6.4.5 Editing the Composition of a Discrete Input Stream
(Composition, Etc. Tab)
There are two ways to input the composition of the stream. One is to set the component
flowrates. The other is to set the total flowrate and the mass composition of the stream.
► To set component flowrates:
1) Select Ingredient Flows by clicking on the small circle in front of “Ingredient
Flows” in the Set area below the Composition area.
2) Click on the cell in the Flowrate column to enter edit mode.
3) Input the flowrate in kg/batch for batch processes or kg/h for continuous
processes.
82
Figure 6.22: Setting the Composition of a Discrete Input Stream Using Ingredient Flows
Note: When setting ingredient flows, SuperPro® will automatically calculate the total
flowrate based on the ingredient flows entered. Therefore the total flowrates cannot be
manually edited and the boxes appear gray.
► To set mass composition:
1) Select Mass Composition by clicking on the small circle in front of “Mass
Composition” in the Set area below the Composition area.
2) Click on the cell in the Mass Comp. column to enter edit mode.
3) Input the mass composition in percentage form (%).
4) Enter the total flowrate for the stream. This can be done in either mass flow or
volumetric flow. Click on the circle in front of the flow of choice, and the box
will change to edit mode.
83
Figure 6.23: Steps Taken to Set the Mass Composition and Total Flowrate of a Discrete Input
Stream
Note: SuperPro® will automatically calculate the ingredient flows based on the mass
composition and total flowrate. Therefore the component flows cannot be manually
altered while setting mass compositions.
6.4.6 The Composition, Etc. Tab for an Intermediate or
Output Discrete Stream
The Composition, Etc. tab is different for an input stream than for an intermediate or
output stream. Figure 6.24, below, shows the Composition, Etc. tab for intermediate and
output streams.
84
Figure 6.24: The Composition, Etc. Tab for Intermediate and Output Discrete Streams
Note: SuperPro® will automatically calculate the components and flows of the streams
based on the inputs and unit operations, so these fields cannot be edited by the user.
6.4.7 Setting the Density Value (Density Tab)
1) Click on the Density tab at the top of the stream properties window.
2) If the density of the mixture in the stream is known, this value can be inputted by
clicking the circle in front of the words “Set by User”. The box will be in edit
mode after the circle is selected.
85
Figure 6.25: Setting a Known Mixture Density
3) If the density is unknown, SuperPro® can calculate the density based on the
contribution to each ingredient in the stream.
4) Click the circle in front of the word “Calculated” to access the Volumetric
Contribution Coefficients area.
5) Click the circle in front of “Ingredient
6) ” or “Component
7) ” based on the data to be inputted. If all of the ingredients are pure components,
there will be no difference between the Ingredients and Components options.
8) Click on the cell in the Coefficient column to enter edit mode.
9) Enter the desired coefficient.
86
Figure 6.26: Setting the Density Based on Ingredient or Component Contributions for a Discrete
Stream
Note that intermediate and output streams from flow mixers or splitters do not include a
Density tab. This is because the density of the intermediate and output streams are the
same as the input stream.
6.5 Physical Characteristics
It is often important to adjust the physical appearance of a stream or change the title from
the generic number notation. This section will provide instructions on how to format the
flow diagram to look appealing.
To reach the Stream Style Window, right-click on the stream and select:
Style >> Edit Style…
87
Figure 6.27: How to Reach the Stream Style Window
Once Edit Style… is selected, the following window will appear:
Figure 6.28: The Stream Style Window
88
6.5.1 Changing the Color, Style, and Thickness of the
Stream
Colors, styles, and thicknesses can be used to classify streams and provide an indication
of the nature of a stream. For example, if a stream contains a hazardous substance, it can
be changed to a specific color, along with all other streams containing hazardous
substances, to allow the user and other readers to recognize that the stream contains a
hazardous substance. Entire sections of a process can also be edited to be a specific
color, separating the section from the rest of the process. The following steps describe
how to change the color, style, and thickness of a stream.
1) Click on the Stream Line tab at the top of the Stream Style window.
Note: The Stream Line tab will automatically appear on top when the Stream
Style window is opened.
4) Click on the button marked Colors… to open a separate color window.
Figure 6.29: The Colors Window
5) Click on the color of choice and click OK to accept the change.
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6.5.2 Editing the Tag Properties
In addition to colors, the appearance and location of the stream tags can be edited, as well
as the actual text of the tag. The following sections explain how to change these
properties.
6.5.2A Changing the Tag Name
To edit the stream’s tag name, right-click on the stream and select:
Edit Tag Name…
Figure 6.30: How to Reach the Edit Tag Name Window
After Edit Tag Name… is selected, the following window will appear:
Figure 6.31: The Edit Tag Name Window
To change the tag name, enter the desired name in the text box and click OK to accept
the change.
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6.5.2B Editing the Tag Text Style
6) Click on the Name Tag: Text tab at the top of the Stream Style Window. For
information on how to reach the Stream Style window, refer to 6.5 Physical
Characteristics.
7) To remove the tag completely, click on the box in front of Show Label to remove
the “x”.
8) To change the font of the tag, click on the Font button to open a separate font
window in which the user can select the desired font, size, and font style.
9) To change the color of the tag text, click on the Font button to open the font
window and click on the drop down menu labeled Color to choose from a list of
colors.
10) To change the color of the background of the tag, click on the Color button on the
Name Tag: Text tab to open a separate color window in which the user can select
the desired color. Note that a color can be chosen only if the text background is
specified as Opaque. If the desired background is clear, choose the Transparent
option. This will allow any lines behind the tag to show through.
Figure 6.32: The Name Tag: Text Window
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6.5.2C Editing the Appearance of the Tag Frame
1) Click on the Name Tag: Frame tab at the top of the Stream Style Window.
4) Click on the button marked Colors… to open a separate color window in which
the user can select the desired color.
Figure 6.33: The Name Tag: Frame Window
6.5.2D Editing the Location of the Stream Tag
1) Click on the Name Tag: Location tab at the top of the Stream Style Window.
2) Select the segment of the stream in which the tag should be located by clicking
the circle in front of the desired segment. Note that if Next to Source Point is
selected, the two bottom sections become non-editable.
3) Select the necessary locations in the Rel. Location (Vert. Segment) and Rel.
Location (Horz. Segment) areas to position the tag as desired.
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Figure 6.34: The Name Tag: Location Window
6.5.2E Picking Up and Applying a Stream Style
If a particular stream style is desired for more than one stream, it is possible to apply all
of the same properties for another stream without having to change the options again. To
utilize this option, right-click on the stream and select:
Style…>> Pickup Style
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Figure 6.35: How to Pickup a Stream Style
An alternate way to pickup a stream style is to click the
Toolbar along the right side of the SuperPro® window.
button on the Visual Objects
To apply the style to another stream, right-click on the stream and select:
Style…>>Apply Style
Note: If the style of a stream has not been picked up, the Apply Style option will not be
present.
Figure 6.36: How to Apply a Stream Style
An alternate way to apply a stream style is to click the
Toolbar along the right side of the SuperPro® window.
button on the Visual Objects
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7.0 Specify Operations
Once the user has added unit procedures and input, output, and intermediate streams, it is
necessary to specify the Operation that will occur within each piece of equipment. The
design in its current state is inactive. The pieces of equipment and piping between units
are present, but nothing is actually happening. Individual pieces of equipment allow for a
wide variety of operations. It is important for the user to specify operations from simply
mixing and fermenting to transferring stream contents in and out of units. The following
sections will describe in further detail how to add, remove, and insert operations in
SuperPro®.
7.1 Adding/Removing Operations
To add or remove operations for a particular unit, click the right mouse button over the
unit procedure to access the Unit Procedure Menu. Figure 7.1 below depicts the Unit
Procedure Menu.
Figure 7.1: Unit Procedure Menu
Within the Unit Procedure Menu, select:
Add/Remove Operations
Note: This option is only available for processes in the batch or semi-continuous modes.
The following figure, the Operation Interface, will appear in the design window.
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Figure 7.2: Operation Interface
The available operations will be different for different types of unit procedures. For
example, a fermentation procedure, as in Figure 7.2, gives the user twenty-four options
for types of operations, where a mixing tank only has three options. To access a list of
the available operations, refer back to Table 5.1.
To add a particular operation, simply click on the desired operation in the left-hand
Available Operations Column and select:
>>Add>>
The selected operation will then be added to the right-hand Operation Sequence
Column. Additional operations can be added to the operation sequence, however, the
SuperPro® functions >>Add>> and >>Insert>> are sensitive to the order in which they
are utilized.
For example, if the operation sequence presented in Figure 7.3 below is the current
sequence and the user wants to incorporate a TRANSFER OUT operation after the
FERMENT operation, simply:
1) Highlight the FERMENT option (as shown in Figure 7.3)
2) Highlight the TRANSFER OUT option
3) Select >>Add>>
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1
3
2
Figure 7.3: >>Add>> Function
Once these steps are taken, TRANSFER OUT will be added as an operation following
the FERMENT operation, as shown in Figure 7.4.
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Figure 7.4: Result of >>Add>> Function
To add an operation between two current operations, the >>Insert>> function needs to be
utilized. For example, to insert a TRANSFER IN operation before the FERMENT
operation and after the CHARGE operation, simply:
1) Highlight the FERMENT option
2) Highlight the TRANSFER IN option
3) Select >>Insert>>
As shown in Figure 7.5, the TRANSFER IN operation is now inserted between
CHARGE and FERMENT.
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Figure 7.5: >>Insert>> Function
Once operations are added or inserted in the operation sequence, they can be deleted by
highlighting the particular operation and selecting the Delete button, as shown above in
Figure 7.5.
Note: It is important to develop the proper operation sequence early in the process.
Once additional specifications are made in the simulation, the operation sequence can be
changed or reordered, however changing the sequence may cause problems with
scheduling and other design parameters.
7.2 Renaming Operations
The names of operations can be changed by utilizing the Rename option. By
highlighting an operation and selecting the Rename option, the following interface,
shown in Figure 7.6, will appear.
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Figure 7.6: Renaming an Operation
The user is given the option to rename an operation to allow for easy reference, such as,
for example, saying “Charge Glucose” versus “Charge Water” or to utilize the
terminology familiar to a particular business.
7.3 Operation Data
Once operations are added to unit procedures, operation data can be monitored and edited
through the Operation Data Interface. To access this interface:
1) Click the right mouse button over the unit procedure
2) Select Operation Data
3) Select the operation of choice
Figure 7.7 below represents the steps need to access the Operation Data Interface for a
particular operation.
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Figure 7.7: Accessing Operation Data Interface
For example, if Charge-1 were selected from the above figure, the following interface, in
Figure 7.8 would appear.
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Figure 7.8: Operation Data Interface
As showing in Figure 7.8 above, the Operation Data Interface allows the user to
manually input operation characteristics for the following categories:
• Operation Conditions
• Emissions
• Labor, etc.
• Description
• Scheduling
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For more complicated operations, such as reactions and fermentations, additional tabs
such as Reactions and Volume will be present. For these types of operations, the user is
required to specify the kinetic and stoichiometric data as well as the maximum allowable
and minimum allowable volume for that procedure. For additional information on the
functions of each individual operation, refer to the Help menu of SuperPro® that is
located in the top right-hand corner of the flowsheet, as shown in Figure 7.9.
Figure 7.9: Accessing Help Menu
Users can access the Help Topics section of this menu and search for more specific
information on the many types of operations.
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8.0 Schedule Process
After the process has been specified with unit procedures, streams, and operations, it is
necessary to begin scheduling the process. To begin scheduling the first unit procedure,
right-click on the unit procedure and select:
Operation Data >> [First Operation in Procedure]
Figure 8.1: Accessing the Properties Window of a Unit Operation
This menu lists the unit operations that are present in the unit procedure in the order that
they were added to the procedure. If the operations are not in the desired sequence, refer
to Section 7.1 for information on how to change the order of the operations.
Note: Scheduling is only necessary for batch processes. Continuous processes require no
scheduling information in order for the procedure to run.
Once the order of the operations has been verified, the scheduling process can begin. The
user should choose the first operation in the unit procedure and they will arrive at a
screen similar to Figure 8.2.
1) Click on Oper. Cond’s tab. Note: The Oper. Cond’s tab will automatically
appear on top when the Unit Operation Properties window is opened.
2) Specify setup time.
3) Specify process time (three methods: user specified, simulation calculated,
master-slave relationship).
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Figure 8.2: Operation Duration Conditions
To continue directly to the next operation for the unit procedure, select:
OK>>
8.1 Specification of Setup Time
The setup time will be specified by SuperPro® for each operation based on simulation
standards. To change the setup time to be more specific for a certain process, click on the
white space around the value and enter the desired value. To change the units of time
click on the arrow next to the units box and select the desired units.
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8.1.1 User Specified
If the process time for a particular operation is known, the user may provide the time
numerically by choosing the Set by User option as seen in Figure 8.3. In the box next to
the Set by User option, the user may enter the desired time value and select the
appropriate corresponding units.
8.1.2 Simulation Calculated
The process time for any operation can be calculated by SuperPro® by choosing the
Calculated Based on function. In order to utilize this function the user must specify a
rate-determining step (example: for a transfer-in/transfer-out operation, the ratedetermining step is the mass or volumetric flow rate). In the example where the
operation is transfer-in, the user must input a mass flow rate or a volumetric flow rate.
This can be done by clicking the box next to the appropriate units and entering the
desired rate value (see Figure 8.2).
8.1.3 Master-Slave Relationship
The final option for specifying the process time for an operation is to set up a masterslave relationship. The master-slave relationship option allows the user to specify the
duration of a process based on the duration of another process or a series of processes.
To use this option, click the circle next to Set by Master-Slave Relationship. After the
option has been chosen, the conditions of the relationship can be specified by clicking the
Setup… button (see Figure 8.3).
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Figure 8.3: Operation Duration: Master-Slave Relationship
Once the user chooses the Setup… button, a screen similar to Figure 8.4 will appear.
The Slave Operation at the top of Figure 8.4 should be verified as the operation that the
user is currently scheduling. The user must then specify the Master Procedure. The
master procedure can be specified as either the same as the slave operation’s procedure,
or as another procedure in the process.
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Figure 8.4: Master-Slave Relationship – Master Procedure Setup
Once the master procedure is chosen, the Master Operation can be specified. This is
done by choosing to match a single operation or to match a sequence of operations.
Choosing to match a single operation will specify to SuperPro® that the slave operation
should take the same amount of time as the master operation, while choosing to match a
sequence of operations will specify that the slave operation should take the same amount
of time as a group of operations in sequence.
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Figure 8.5: Master-Slave Relationship – Master Single Operation Setup
When matching a sequence of operations, the user should specify which operation the
master sequence should start with and which operation it should finish with (i.e., the
beginning of the slave operation should start at the same time as the master operation that
is chosen in the Starting With box, and the slave operation should end at the same time
as the master operation that is in the Ending With box). As indicated by Figure 8.5, the
master operations are chosen by clicking on the down arrow next to the corresponding
box.
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Figure 8.6: Master-Slave Relationship – Master Sequence Operation Setup
8.2 Scheduling Relationships
After the operation duration time has been specified, the next step in the scheduling
process is to specify the scheduling relationships. As seen in Figure 8.7, the screen
needed to specify these relationships can be found by choosing the Scheduling tab on the
operation data screen. The scheduling screen has three sections including: Start Time,
Duration, and Cycle Information. The Duration process and setup time will
automatically be calculated by SuperPro® once the information has been specified on the
Operation Conditions tab. In the event that the entries for the duration time section are
erroneous, they can be corrected by selecting the corresponding value and entering the
adjustment. The duration section also has a third time that needs to be specified by the
user. The Turnaround Time for the operation will not be specified by SuperPro® and
must be keyed in by the user in the corresponding box (see Figure 8.7).
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Figure 8.7: Scheduling Overview Screen
The next task in the scheduling process is to indicate when each operation should start.
This can be done in the Start Time section of the scheduling screen (see Figure 8.8). If
the starting time of the operation is known, the user can indicate a start time shift. If the
starting time is not known, a scheduling relationship can be used to determine when the
operation will begin. The four scheduling relationships are:
•
•
•
•
Relative to the beginning of the batch
Relative to a previous operation in the procedure
Relative to another operation in the procedure
Relative to an operation in another procedure
Note: When using a scheduling relationship, remember that indicating a start time shift
will cause a shift from the beginning of the relationship time specification.
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Figure 8.8: Scheduling Overview Screen – Start Time Information
8.2.1 Using the “Beginning of the Batch” Relationship
Scheduling an operation using the beginning of the batch relationship allows the user to
indicate a start time relative to the beginning of the batch for a certain operation in the
unit procedure. This is the simplest method of scheduling, however should only be used
if the duration of each operation known so that the proper start time shift can be
specified.
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8.2.2 Using the “Previous Operation in the Same
Procedure” Relationship
The start time of an operation can also be scheduled according to the start or end time of
another operation in the same unit procedure. This is done by choosing the circle next to
Relative to Previous Operation in the Procedure, and choosing the desired operation
for comparison. Then it must be specified whether the operation should begin at the start
or the end of the previous operation.
Note: If the user is specifying the first operation in the unit procedure, this start time
scheduling option is not available, as seen in Figure 8.8.
8.2.3 Using the “Another Operation in Same Procedure”
Relationship
The next scheduling relationship allows the user to specify the start time of a certain
operation based on the starting or ending time of another operation in the same
procedure. To characterize this scheduling relationship, the user should click the down
arrow next to the corresponding box and choose the other operation (see Figure 8.9).
After the other operation has been selected, start or end should be specified to indicate
whether the start time for the current operation should be at the start of the selected
operation or at then end of it.
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Figure 8.9: Start Time Relationship – Relative to Another Operation in this Procedure
8.2.4 Using the “Another Operation in Another
Procedure” Relationship
The final relationship to program the start time of an operation is to schedule according to
the start or end time of an operation in another procedure in the process. As seen in
Figure 8.10, this is done by choosing the circle next to Relative to Another Operation
in Another Procedure. To specify this relationship, the user should indicate the other
procedure and other operation that the current operation should correspond to (see Figure
8.10). Again, it must be indicated whether the start time of the operation will begin at the
start or end of the other operation.
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Figure 8.10: Start Time Relationship – Relative to Another Operation in Another Procedure
Once the start time and the duration time have been completely specified according to the
procedures above, scheduling for the operation in the unit procedure is complete. This
process should be repeated for all of the operations in each unit procedure. When the
scheduling process is finished, the simulation should run to completion without any
scheduling errors. Scheduling errors for specific operations can be corrected by ensuring
proper scheduling according to the above procedures.
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8.3 Process Schedule Information
Once the scheduling process is complete and the simulation runs without errors, the user
can view the scheduling information for the process by selecting:
Task >> Recipe Scheduling Information
Figure 8.11: Recipe Scheduling Information Command Screen
Selecting this option will bring up a screen similar to Figure 8.12. This figure is an
overview of all the scheduling information for the process. It indicates the total time to
complete a batch, the number of batches that can be made in a year, the amount of time
the process will be running through out the year, and the longest procedure and
bottleneck of the process. The number of batches per year can be user specified by
clicking on the circle in front of Set by User, in the number of batches per year section.
If there are changes made to the scheduling process after this screen is viewed, click on
Update Sched. Outputs to update this scheduling summary.
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Figure 8.12: Recipe Scheduling Information Data
8.4 Accessing Gantt Charts
SuperPro® will generate Gantt charts to aid in the scheduling of the simulation. After all
of the operations have been scheduled and the simulation runs smoothly, it is possible to
create the Gantt charts. To open a Gantt chart, select:
Tasks >> Gantt Charts
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Figure 8.13: The Gantt Charts Menu
There are four different kinds of Gantt charts:
•
•
•
•
Operations GC
Equipment GC
Operations GC (Multiple Batches)
Equipment GC (Multiple Batches)
The Operations Gantt Chart displays the time involved in each operation, segmented
by the unit procedures in which the operations take place. The Operations Gantt Chart
for multiple batches contains the same information, but includes more than one batch run.
The Equipment Gantt Chart displays the time involved in each operation, segmented by
both the unit procedures and the equipment in which the operations take place.
9.0 Specify Labor Requirements
Specifying labor requirements allows the user to perform a more accurate economic
evaluation of the process. Labor requirements can be specified for each operation in each
unit procedure. To begin labor specifications, right-click on the unit procedure and
select:
Operation Data >> [First Operation in Procedure]
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Figure 9.1: Operation Data Command Screen
Once the first operation is selected, the user will see a screen similar to Figure 9.2 and
should click on the Labor, etc. tab at the top of the screen.
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Figure 9.2: Operation Conditions Main Screen
Once the labor window is open, the user should first choose the type of operator for the
operation. To access a list of the available types of operators, click on the word
“Operator” to make a down arrow appear and then click the down arrow next to it. The
list of available operator types is shown below in Figure 9.3. The type of operator chosen
should be decided by the type of operation. If the user prefers a more generalized labor
assessment, the general operator can be used instead of a more specific one.
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Figure 9.3: Operation Operator Specifications
Next, the user should specify the value of the operator in Labor-hrs/hr or Labor-hrs/cycle
by clicking on the corresponding box and the downward arrow associated with it (see
Figure 9.4).
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Figure 9.4: Operation Labor Units Specification
Once the operator and units are determined, the number of operators can be changed by
clicking on the Add Labor or Delete Labor buttons (see Figure 9.5).
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Figure 9.5: Operation Add/Delete Labor
10.0 Perform Economic Evaluation
The economic evaluation is arguably the most important aspect of any process. Before
an economic analysis can be performed in SuperPro®, a number of things have to be
specified:
1)
2)
3)
4)
Component Costs
Stream Costs
Equipment costs
Labor & Utility costs
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The following sections will describe how to determine each of these costs using
SuperPro® and how to use SuperPro® to perform an economic evaluation of the process.
10.1 Specifying Component Costs
Chapter 4 discusses how to register components for a process. Once the components are
registered, the cost of the components can be specified by selecting Properties on the
component registration interface. For more information about how to access the
Component Registration interface, refer to Chapter 4.
Figure 10.1: Component Registration Interface
Selecting properties will bring up the Component Properties interface, which will look
similar to Figure 10.2. To input economic information such as purchasing price, selling
price, or waste treatment cost, the Economics tab must be selected, as is done in the
following figure.
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Figure 10.2: Component Economic Properties Interface
1) If the component is a reactant, the user should specify the purchasing cost of the
component.
2) If the component is a product, the user should specify the selling price of the
component.
3) If the component is a waste product or byproduct, the user should specify the
waste treatment or disposal cost.
These costs can be specified by clicking on the box next to the corresponding cost
description, as shown above in Figure 10.2. Then the known values from suppliers or
other sources can be entered into the appropriate space. There is also space available to
specify the supplier from whom the component is purchased and any comments regarding
the component.
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10.2 Stream Costs
When determining the costs of streams, the first thing that needs to be evaluated is the
economic classification of the stream. Each stream can be designated as Revenue, Raw
Material, or Waste and then specified with revenue or cost values. Figure 10.3 is the
command interface for bringing up the revenue, raw material, and waste stream
information. To get to the information screen, select:
Tasks >> Revenue, Raw Material, and Waste Streams
Figure 10.3: Stream Specification Command Interface
The Revenue, Raw Material, and Waste Streams Specification Interface, as shown below
in Figure 10.4, allows the user to specify which streams will be a source of income, and
which screens will be a cost to the process. The streams on this interface are separated
into groups of input streams and output streams.
10.2.1 Product Stream Specification
The user can also indicate which stream is the main product stream and which component
of the stream is the desired product. When choosing the main product stream, the user
can direct SuperPro® to consider all streams in the process or just revenue streams. This
can be done by clicking on the circle next to either Show Revenue Streams Only or Show
all streams. Once that is decided, the user should click on the down arrow next to the
stream box and choose the main product stream. After the main product stream is
determined, the user can designate, by clicking on the corresponding circle that the entire
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stream is the desired product or a particular component in the stream is the desired
product. If a particular component of the product stream is the desired product, click on
the down arrow next to the corresponding box and select that component.
Figure 10.4: Revenue, Raw Material, and Waste Streams Specification Interface
10.2.2 Output Stream Classification
Before stream costs can be entered into SuperPro®, each output stream must be classified
as either Revenue or Waste. SuperPro® gives the user four choices for the classification
of output streams:
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•
•
•
•
Revenue
Solid Waste
Liquid Waste
Emissions
All of the output streams are listed on the left side of the Specifying Output Stream
Classifications interface. To specify the classification of the stream, the user should click
on the down arrow next to the corresponding box in the classification column of the table.
Then the unit cost of treatment/disposal or selling price of the stream can be specified in
the third column. Some streams may be automatically determined by SuperPro®, but
most will need to be set by the user. Finally, once the streams have been classified and
quantified, they can be marked as hazardous if applicable, using the fifth column in
Figure 10.5.
Figure 10.5: Specifying Output Stream Classifications
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10.2.3 Input Stream Classification
Specifying the input streams is done in much the same way as the output streams. In the
case of input streams there are only two possible classifications for the streams: Revenue
and Raw Material. Again, all the input streams are listed on the left hand side of the table
at the bottom of Figure 10.6, the streams are classified by clicking the down arrow in the
corresponding box in the classification column. However, for input streams, most of the
costs associated with the streams are obtained from component cost information, which
has already been entered. The values in the purchasing price/processing fee column may
be altered by clicking on the box and entering the desired value.
Figure 10.6: Specifying Input Stream Classifications
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10.3 Equipment Costs
The next area of cost specification is for the equipment in the process. To specify the
economic information for equipment, right-click on the piece of equipment and select:
Equipment Data
Figure 10.7: Equipment Data Specification Command
Choosing this command will bring up a screen similar to Figure 10.8. On this screen, the
purchase cost tab should be selected so the equipment economics can be viewed and
further specified if necessary. In most cases, SuperPro® will indicate a equipment cost
based on user specified size and capacity that was discussed in Chapter 5. The cost that
is specified is adjusted for the year 2004, but can be altered by clicking on the box and
entering the desired value.
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Figure 10.8: Equipment Purchase Cost Information
10.4 Labor & Utility Costs
Labor costs are determined from the labor information input in Chapter 9 of this manual.
However, the utility costs can be specified by selecting the Labor, etc. tab on the
operation conditions interface as shown below in Figure 10.9. In the bottom section of
the interface, each utility is given prices which are determined by SuperPro® according
to the national average cost. These prices are displayed in gray boxes and can’t be edited
by the user.
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In order for SuperPro® to accurately determine the utility costs of the process, it is
necessary to input the rate at which the utilities are being used. To do this, click the box
next to Rate, for each utility, and enter the desired value.
Figure 10.9: Labor Tab for Operation Conditions Interface
10.5 Economic Evaluation Reports
Once all the costs associated with each aspect of the process have been specified, the
economic evaluation of the process can be performed. The economic evaluation of the
process is a process calculation performed by the simulation and output from SuperPro®.
In order to perform this function, the mass and energy balances must first be run and
completed. Then the user can perform the evaluation by selecting:
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Tasks >> Perform Economic Calculations
from the menu bar, as shown in Figure 10.10.
Figure 10.10: Performing Economic Calculations Interface
Note that choosing this command does not bring up any additional interfaces. Instead,
SuperPro® does the calculations internally and the user can then generate the economic
evaluation report. To access this report, select:
Tasks >> Generate Economic Evaluation Report (EER)
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Figure 10.11: Generating Economic Evaluation Report Interface
Performing this command will bring up the screen below, which requires the user to save
the economic evaluation report as a file. This file can be opened in WordPad or Notepad.
Figure 10.12: Saving EER Interface
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After the Economic Evaluation Report has been saved, the file can be opened and
viewed. To view the Economic Evaluation report, select:
View >> Economic Evaluation Report
as shown in figure 10.13. This command will bring up all the economic information for
the process including total revenue and payback period.
Figure 10.13: View Economic Evaluation Report Command Screen
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11.0 Perform Emissions and Environmental Impact
Assessment
Prior to performing an emissions and environmental impact assessment in SuperPro®,
the environmental properties of each pure and stock component must be registered within
SuperPro® designer. Various classifications exist for both emission and environmental
impact reporting. The following sections will describe the necessary steps to define
emissions and environmental properties, generate the emissions and environmental
impact reports and understand the resulting reports.
11.1 Defining Pollutant Category for Registered
Components and Mixtures
To define pollutant categories for emissions and environmental impact wastes for Pure
Components, select:
Tasks>>Register Pure Components & Mixtures>>Pure Components
Figure 11.1: Selecting the component or stock mixture for registering emissions and environmental
classifications
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Note: To access the Component Registration window for a Stock Mixture, select:
Tasks>>Register Pure Components & Mixtures>>Stock Mixtures
After the Component Registration window is open, click on the number beside the
component of choice to highlight the component and click the Properties button to
access the Pure Components Properties window:
Figure 11.2: Pollutant Categories Window
Two tasks may be performed through the Pollutant Categories window:
a) Defining Emissions Report considerations
b) Defining Environmental Impact Report considerations
The following sections will assist the user in determining which classifications to specify.
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11.1.1 Defining Emissions Pollutant Categories
SuperPro® allows for the specification of eight major air pollutant classes in addition to
up to five other user defined categories. The following information will help the user
decide which emissions classifications to select.
Based on the New Jersey Department of Environmental Protection, raw materials and air
pollutants can be categorized into specific pollutant categories. These categories do not
include the air distillates described in the New Jersey Department of Environmental
Protection Amendment NJAC 7:27-8.1. Some materials may fit into more than one
category and should be categorized twice if there is any uncertainty. The current version
of SuperPro® will not allow the user to categorize components into more than one
category, but future versions plan to allow the user to specify as such.
Note: Additional categories are available if needed for state regulations. For information
on how to specify additional categories, refer to Section 11.1.1A.
The following table presents the major categories of emissions based on information
given by SuperPro®.
Category
Category I
Total Particulate:
materials which
could not be
detected by NJ Air
Test Method 1
(See Note 6)
Table 11.1: Pollutant Categories
Sub-Category
Material Description
A. Infectious agents which require
Biological
practices, safe equipment, and facilities
that constitute Biosafety Level 2 or higher
(See Error! Reference source not
found.)
B. Radionuclide which are contained as
Radionuclide
particulates (as listed in N.J.A.C. 7:286.5)
C. Compounds of hexavalent chromium
Cr+6
which are contained as particulates
D. Compounds of any of the following
Metal
metals which are contained as
particulates: Pb, Hg, Cd, Be, As, Ni, and
Cr
E. Particulates which contain asbestos
Asbestos
F. Dioxins (See Error! Reference
Dioxin
source not found.)
G. Materials which are liquid organic
LOC
compounds emitted as particulates
H. Hazardous Air Pollutants (See Error!
HAP-Particulate
Reference source not found.)
I. Particulates which do not fit into the
Other Particulate
above sub-categories
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VCM
TVOS
Category II
Total VOC
(Volatile Organic
Compound):
materials which
could not be
detected under NJ
Air Test Method 3
Category III
Acid Gases:
materials that are
acid gases and may
or may not be
detected as a
particulate using
NJ Air Test
Method 1 or as
VOC using
Method 3
EVOS
HAP-VOC
Other VOC
HAP-ACID
ACID
A. Vinyl Chloride Monomer
B. Materials which are toxic volatile
organic substances listed in the NJAC
7:27-17 Table 1
C. Materials which are exempt volatile
organic substances listed in the NJAC
7:27-16.1 (See Error! Reference source
not found.)
D. Hazardous Air Pollutants listed in
Note 10 except VCM (See Error!
E. Volatile Organic Compounds which
are not included in the above subcategories
A. Hazardous Air Pollutants (See Error!
B. Acid Gases which are not included in
sub-category A, including but not limited
to F2, SO3, and H2S
Category IV
HAP-GAS
Extraordinarily
Toxic Gases
(ETG)
GAS
A. Hazardous Air Pollutants (See Error!
B. Gases which are not listed in Note 5
found.)
Category V
CO
A. Carbon Monoxide
NOx
A. Nitrogen Oxides: including N2O, NO,
N2O3, N2O4, NO2, N2O5, N3O4, and NO3
found.)
A. Sulfur Dioxide
CO
Category VI
NOx
Category VII
Category VIII
SO2
Base
A. Materials which are base gases and
may not be detected as a particulate using
the NJ Air Test Method 1 or as VOC
using Method 3
139
Note 1:
For the purpose of SuperPro® simulation, the above categories will be used to
characterize all air pollutants and raw materials. Substances that cannot be fit into the
above categories and subcategories, may be listed individually or included in a userdefined category (see Section 4.1.4B).
Note 2:
The biological subcategory includes infectious substances that require practices, safety
equipment, and facilities that represent a Biosafety Level 2 or higher as denoted by the
Biosafety in Biomedical and Microbiological Laboratories Report in Section III.
Note 3:
The Dioxin subcategory includes the following isomers of chlorinated dibenzo-p-dioxin
(CDDs) and CAS Number
-a unique numeric identifier that designates one substance
Charge
- a method for adding an input to the unit
Chlorinated dibenzofuran (CDFs)
:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
2,3,7,8-TCDD
1,2,3,7,8-PeCDD
1,2,3,4,7,8-HxCDD
1,2,3,7,8,9-HxCDD
1,2,3,6,7,8-HxCDD
1,2,3,4,6,7,8-HpCDD
2,3,7,8-TCDF
1,2,3,7,8-PeCDF
2,3,4,7,8-PECDF
1,2,3,4,7,8-HxCDF
1,2,3,7,8,9-HxCDF
1,2,3,6,7,8-HxCDF
2,3,4,6,7,8-HxCDF
1,2,3,4,6,7,8-HpCDF
1,2,3,4,7,8,9-HpCDF
For more information about Dioxin compounds see Error! Reference source not
found..
140
Note 4:
Includes the following substances:
•
•
•
•
•
•
•
•
Methane
Trichlorofluoromethane
Dichlorodifluoromethane
Chlorodifluoromethane
Trifluoromethane
1,1,2-Trichloro-1,2,2-Trifluoroethane
1,2,-Dichloro-1,1,2,2 Tertafluoroethane
Chloropentafluoroethane
Note 5:
Extraordinarily Toxic Gases
Name
Boron Trichloride (BCl3)
Boron Trifluoride (BF3)
Bromine Chloride (BrCl)
Chlorine Dioxide (ClO2)
Chlorine Pentafluride (ClF5)
Chlorine Trifluoride (ClF3)
Diborane (B2H6)
Dichlorosilane (H2Cl2Si)
Hydrogen Selenide (H2Se)
Nitrogen Trifluoride (NF3)
Oxygen Difluoride (OF2)
Ozone (O3)
Perchloryl Fluoride (ClFO3)
Phosphorous Trifluoride (PF3)
Selenium Hexafluoride (SeF6)
Stibine (SbH3)
Sulfur Tetrafluoride (SF4)
Sulfuryl Fluoride (SF2O2)
Tellurium Hexafluoride
(TeF6)
Tetrafluorohydrazine (N2F4)
CAS Number
10294-34-5
7637-07-2
13863-41-7
10049-04-4
13637-63-3
7790-91-2
19287-45-7
4109-96-0
7783-07-5
7783-41-7
7783-41-7
10028-15-6
7616-94-6
7783-55-3
7783-79-1
7803-52-3
7783-60-0
2699-79-8
7783-80-4
10036-47-2
141
Note 6:
CO2 is NOT a VOC
Note 7:
Nitrogen Oxides include:
• N2O (nitrous oxide)
• NO (nitric oxide)
• N2O4 (dinitrogen tetroxide or nitrogen peroxide)
• NO2 (nitrogen dioxide)
• N2O5 (dinitrogen pentoxide)
• N3O4 (trinitrogen tetroxide)
• NO3 (nitrogen trioxide)
Note 8:
Includes the following chemicals:
Name
Chlorine
Hydrogen Chloride
Hydrogen Fluoride
CAS Number
7782505
7647010
7664393
Note 9:
Name
Phosphine (PH3)
Arsine (AsH3)
CAS Number
7803-51-2
7784-42-1
Note 10:
Chemical Name
Acetaldehyde
Acetamide
Acetonitrile
Acetophenone
2-Acetylaminofluorene
Acrolein
Acrylamide
Acrylic acid
Acrylonitrile
Allyl chloride
CAS Number
75070
60355
75058
98862
53963
107028
79061
79107
107131
107051
142
4-Aminobiphenyl
Aniline
o-Anisidine
Asbestos
Benzene (including benzene from
gasoline)
Benzidine
Benzotrichloride
Benzyl chloride
Biphenyl
Bis(2-ethylhexyl)phthalate (DEHP)
Bis(chloromethyl)ether
Bromoform
1,3-Butadiene
Calcium cyanamide
Caprolactam
Captan
Carbaryl
Carbon disulfide
Carbon tetrachloride
Carbonyl sulfide
Catechol
Chloramben
Chlordane
Chlorine
Chloroacetic acid
2-Chloroacetophenone
Chlorobenzene
Chlorobenzilate
Chloroform
Chloromethyl methyl ether
Chloroprene
Cresols/Cresylic acid (isomers and
mixture)
o-Cresol
m-Cresol
p-Cresol
Cumene
2,4-D, salts and esters
DDE
Diazomethane
Dibenzofurans
1,2-Dibromo-3-chloropropane
Dibutylphthalate
1,4-Dichlorobenzene(p)
92671
62533
90040
1332214
71432
92875
98077
100447
92524
117817
542881
75252
106990
156627
105602
133062
63252
75150
56235
463581
120809
133904
57749
7782505
79118
532274
108907
510156
67663
107302
126998
1319773
95487
108394
106445
98828
94757
3547044
334883
132649
96128
84742
106467
143
3,3-Dichlorobenzidene
Dichloroethyl ether (Bis(2chloroethyl)ether)
1,3-Dichloropropene
Dichlorvos
Diethanolamine
N,N-Diethyl aniline (N,NDimethylaniline)
Diethyl sulfate
3,3-Dimethoxybenzidine
Dimethyl aminoazobenzene
3,3'-Dimethyl benzidine
Dimethyl carbamoyl chloride
Dimethyl formamide
1,1-Dimethyl hydrazine
Dimethyl phthalate
Dimethyl sulfate
4,6-Dinitro-o-cresol, and salts
2,4-Dinitrophenol
2,4-Dinitrotoluene
1,4-Dioxane (1,4-Diethyleneoxide)
1,2-Diphenylhydrazine
Epichlorohydrin (l-Chloro-2,3epoxypropane)
1,2-Epoxybutane
Ethyl acrylate
Ethyl benzene
Ethyl carbamate (Urethane)
Ethyl chloride (Chloroethane)
Ethylene dibromide
(Dibromoethane)
Ethylene dichloride (1,2Dichloroethane)
Ethylene glycol
Ethylene imine (Aziridine)
Ethylene oxide
Ethylene thiourea
Ethylidene dichloride (1,1Dichloroethane)
Formaldehyde
Heptachlor
Hexachlorobenzene
Hexachlorobutadiene
Hexachlorocyclopentadiene
Hexachloroethane
91941
111444
542756
62737
111422
121697
64675
119904
60117
119937
79447
68122
57147
131113
77781
534521
51285
121142
123911
122667
106898
106887
140885
100414
51796
75003
106934
107062
107211
151564
75218
96457
75343
50000
76448
118741
87683
77474
67721
144
Hexamethylene-1,6-diisocyanate
Hexamethylphosphoramide
Hexane
Hydrazine
Hydrochloric acid
Hydrogen fluoride (Hydrofluoric
acid)
Hydrogen sulfide
Hydroquinone
Isophorone
Lindane (all isomers)
Maleic anhydride
Methanol
Methoxychlor
Methyl bromide (Bromomethane)
Methyl chloride (Chloromethane)
Methyl chloroform (1,1,1Trichloroethane)
Methyl ethyl ketone (2-Butanone)
Methyl hydrazine
Methyl iodide (Iodomethane)
Methyl isobutyl ketone (Hexone)
Methyl isocyanate
Methyl methacrylate
Methyl tert butyl ether
4,4-Methylene bis(2-chloroaniline)
Methylene chloride
(Dichloromethane)
Methylene diphenyl diisocyanate
(MDI)
4,4¬-Methylenedianiline
Naphthalene
Nitrobenzene
4-Nitrobiphenyl
4-Nitrophenol
2-Nitropropane
N-Nitroso-N-methylurea
N-Nitrosodimethylamine
N-Nitrosomorpholine
Parathion
Pentachloronitrobenzene
(Quintobenzene)
Pentachlorophenol
Phenol
p-Phenylenediamine
822060
680319
110543
302012
7647010
7664393
7783064
123319
78591
58899
108316
67561
72435
74839
74873
71556
78933
60344
74884
108101
624839
80626
1634044
101144
75092
101688
101779
91203
98953
92933
100027
79469
684935
62759
59892
56382
82688
87865
108952
106503
145
Phosgene
Phosphine
Phosphorus
Phthalic anhydride
Polychlorinated biphenyls
(Aroclors)
1,3-Propane sultone
beta-Propiolactone
Propionaldehyde
Propoxur (Baygon)
Propylene dichloride (1,2Dichloropropane)
Propylene oxide
1,2-Propylenimine (2-Methyl
aziridine)
Quinoline
Quinone
Styrene
Styrene oxide
2,3,7,8-Tetrachlorodibenzo-pdioxin
1,1,2,2-Tetrachloroethane
Tetrachloroethylene
(Perchloroethylene)
Titanium tetrachloride
Toluene
2,4-Toluene diamine
2,4-Toluene diisocyanate
o-Toluidine
Toxaphene (chlorinated camphene)
1,2,4-Trichlorobenzene
1,1,2-Trichloroethane
Trichloroethylene
2,4,5-Trichlorophenol
2,4,6-Trichlorophenol
Triethylamine
Trifluralin
2,2,4-Trimethylpentane
Vinyl acetate
Vinyl bromide
Vinyl chloride
Vinylidene chloride (1,1Dichloroethylene)
Xylenes (isomers and mixture)
o-Xylenes
75445
7803512
7723140
85449
1336363
1120714
57578
123386
114261
78875
75569
75558
91225
106514
100425
96093
1746016
79345
127184
7550450
108883
95807
584849
95534
8001352
120821
79005
79016
95954
88062
121448
1582098
540841
108054
593602
75014
75354
1330207
95476
146
m-Xylenes
p-Xylenes
Antimony Compounds
Arsenic Compounds (inorganic
including arsine)
Beryllium Compounds
Cadmium Compounds
Chromium Compounds
Cobalt Compounds
Coke Oven Emissions
Cyanide Compounds1
Glycol ethers2
Lead Compounds
Manganese Compounds
Mercury Compounds
Fine mineral fibers3
Nickel Compounds
Polycylic Organic Matter4
Radionuclides (including radon)5
Selenium Compounds
108383
106423
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Source: Environmental Protection Agencies Air Toxics Website
An example of defining emissions categories for a specific component follows:
To specify that a component has VCM emissions, click on the box next to VOC to make
the subcategory editable. After VOC has been selected, click on the circle next to
Specific to be able to choose the type of VOC. Now click on the square next to VCM.
After the square has been clicked, an X will appear in the box. Figure 11.3 depicts the
selection of VOC>>Specific>>VCM and Acid gas>>HAP-gas for glucose. To finish
and save selections, select OK.
147
Figure 11.3: Selection of VOC and Acid gas for emissions consideration
11.1.1A User-Defined Emissions Pollutant Categories
To access these categories, right-click on a blank area of the simulation and select:
Preferences>>Emission Limits
148
Figure 11.4: Accessing the Emission Limits Window
After Emission Limits… the following interface will appear:
149
Figure 11.5: Adding User-Defined Pollutant Categories
User-defined pollutant categories can be added by selecting the square to the left of the
input box (indicated by the red arrow in Figure 11.5) and typing the name of the category
in the input box.
11.1.2 Defining Environmental Pollutant Categories
SuperPro® allows the user to report pure components and mixtures as any of the
following:
1. Solid Waste
2. Liquid Waste
3. Emission
4. Hazardous
5. SARA 313
6. 33/50 EPA Program
150
The designation of solid waste, liquid waste and emission depend on the physical state of
the exiting waste stream from a unit operation. SuperPro® typically pre-selects each
component and mixture to be a solid, liquid and emission waste source. In order to
change the environmental impact classification of a component or mixture, the user must
access the Pollutant Categories window as specified in Section 11.1. In order to select
or deselect the option of reporting a component as a solid waste, liquid waste or
emissions, the user must toggle the preceding box so that desired specifications are
marked with an X and undesired specifications contain empty boxes.
The user is responsible for designating a pure component and/or mixture as a hazardous,
SARA 313 or 33/50 source of waste with the aid of the following information:
Information on both hazardous and SARA 313 reportable chemicals are accessible at the
following URL: http://www.epa.gov/tri/chemical/RY2003ChemicalList.pdf
Listed 33/50 wastes:
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
Benzene
Carbon tetrachloride
Chloroform
Dichloromethane
Methyl ethyl ketone
Methyl isobutyl ketone
Tetrachloroethylene
Toluene
1,1,1-Trichloroethane
Trichloroethylene
Xylenes
Cadmium and cadmium compounds
Chromium and chromium compounds
Cyanide compounds
Lead and lead compounds
Mercury and mercury compounds
Nickel and nickel compounds
Once the appropriate hazardous material classifications have been determined, the user
inputs the selections in the same manner as was performed for defining emissions
categories.
Note: If the component or mixture is considered a hazardous waste, a concentration limit
in units of ppm (parts per million) must be specified.
Access Pollutant Categories window. Toggle the box for the appropriate hazard
consideration and waste consideration so that an X appears in the box. Figure 11 depicts
the selection of Is Reported in Liquid Wastes?>>Is Hazardous>>threshold value of
0.500ppm for Sodium Hydro Phosphate. To finish and save selections, select OK.
151
Figure 11.6: Selection of hazard and waste considerations.
11.2 Generation of Emissions and Environmental Impact
Reports
Once all emissions and environmental impact properties have been user defined,
SuperPro® is prepared to generate either an emissions or environmental impact report.
152
11.2.1 Generation of Emissions Report (EMS)
To generate an emissions report, proceed with the following selections, also illustrated in
Figure 11.6:
Tasks>>Generate Emissions Report (EMS)….
Figure 11.7: Selection steps for generating an emissions report
Note: SuperPro® will prompt the user to designate a name and location for saving the
generated emissions report. The file type should be left at default designation, THR File
(*.ems). In addition, SuperPro®, by default, saves the file in the same directory as the
simulation file and names the emissions report by the same file name as the simulation.
If the user desires to name the file under a different name, or desires to save the file in a
different directory, SuperPro® will not be able to access the report when prompted to
generate a viewable emissions report.
11.2.2 Generation of Environmental Impact Report (EIR)
To generate an environmental impact report, select:
Tasks>>Generate Environmental Impact Report (EIR)….
153
Figure 11.8: Selection steps for generating an environmental impact report.
Note: SuperPro® will prompt the user to designate a name and location for saving the
generated emissions report. The file type should be left at default designation, EIR File
(*.eir). In addition, SuperPro®, by default, saves the file in the same directory as the
simulation file and names the emissions report by the same file name as the simulation.
If the user desires to name the file under a different name, or desires to save the file in a
different directory, SuperPro® will not be able to access the report when prompted to
generate a viewable environmental impact report.
11.3 Viewing an Emissions and Environmental Impact
Report
After generating either an emissions or environmental impact report, the user may view
the generated information by performing the following selections, which are illustrated in
Figure 11.9:
For emissions report:
View>>Emissions Report
For environmental impact report:
View>>Environmental Impact Report
154
Figure 11.9: Selection steps for viewing an emissions report.
Note: SuperPro® automatically searches the file directory containing the simulation file
for files with the same name as the simulation file, but with the appropriate extension
(.ems and .eir for emissions and environmental impact reports, respectively). If the
appropriate file is located, SuperPro® will automatically generate a text file containing
the calculated information for emissions or environmental impact.
If the user has decided to save the generated emissions and/or environmental impact
report under a different name or file directory than defaulted by SuperPro®, the
generated report may be viewed by performing the following selections:
View>>Any Report…
SuperPro® will then prompt the user to specify the directory and file to open.
155
11.4 Interpreting an Emissions and Environmental
Impact Report
Once SuperPro® has generated a viewable text file for the desired emissions and/or
environmental impact report, the user is presented with the daunting task of making sense
of the presented data.
11.4.1 Interpreting an Emissions Report
Emissions reports contain two sections:
1. Emissions on a mass/time basis for each individual stream
2. Emissions on a mass/batch basis for total emissions for each batch
The first section specifies the stream name, source of the stream and the destination of the
stream. The emissions specifications are presented in the 8 main categories of emissions
as well as the subclassifications for each main emission category. A comparison between
the calculated values versus the allowable values is given on a kg/h basis for each
individual stream. Figure 11.10 depicts the stream portion of the emission report.
Figure 11.10: Illustration of a stream section from an emissions report.
156
The second section of the emissions report presents information on the total emissions
per batch. Again, a comparison between calculated values and allowable values is given
for further comparison. Figure 11.11 depicts the emissions report on a per batch basis.
Figure 11.11: Illustrates the per batch portion of the emissions report.
11.4.2 Interpreting an Environmental Impact Report
Environmental Impact Reports contain the following sections:
1. Stream section
2. Overall balance
3. Component fate
4. SARA 313 chemicals
5. 33/50 chemicals
6. Solid waste
7. Liquid waste
8. Emissions
157
9. Hazardous streams
10. Pollution indices
Stream section: Each stream is described by its name, source and destination procedure
(or INPUT/OUT). A list of each stream’s environmental and aqueous properties is
included (TOC, COD, ThOD, etc.) as concentrations (in mg/l) and daily demands (kg
carbon/day or kg oxygen/day). SuperPro® denotes the beginning of the stream section
with the following title:
**** LUMPED ENVIRONMENTAL STREAM PROPERTIES SECTION ****
Overall balance section: Presents the total environmental load (increase or decrease) as
reflected by the values of TOC, COD, etc. of all streams entering and leaving the process.
Two tables are generated: 1) one presents the values either on a per hour basis (only
choice for continuous processes) or on a per batch basis (batch processes); 2) the second
table has the same numbers on a yearly basis. SuperPro® denotes the beginning of the
overall balance with the following title:
**** OVERALL BALANCE Section ****
Component fate section: Presents the allocation of each chemical that either enters or is
produced by the plant facility to all waste gateways. The first column presents the
cumulative amounts of each chemical entering in any of the input streams of the plant,
and the next three columns present the amounts leaving the plant in all waste streams
(solid, liquid or gaseous). SuperPro® denotes the beginning of the component fate
section with the following title:
**** COMPONENT FATE Section ****
SARA 313 chemicals section: Presents an accurate account of all SARA 313 chemicals
entering and leaving the plant as well as their difference. SuperPro® denotes the
beginning of the SARA 313 chemical section with the following title:
**** SARA 313 CHEMICALS Section ****
33/50 chemical section: Presents an accurate account of all 33/50 chemicals entering and
leaving the plant as well as their difference. SuperPro® denotes the beginning of the
33/50 chemical section with the following title:
**** 33/50 CHEMICALS Section ****
Solid waste section: Consists of two parts. Part 1 enumerates all streams that are
characterized as solid waste by listing their composition (weight %), flowrate (in kg/h)
and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as solid waste is
distributed in each stream. SuperPro® denotes the beginning of the solid waste section
158
**** SOLID WASTE Section ****
Liquid waste section: Consists of two parts. Part 1 enumerates all streams that are
characterized as liquid waste by listing their composition (weight %), flowrate (in kg/h)
and annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as liquid waste
is distributed in each stream. SuperPro® denotes the beginning of the liquid waste
section with the following title:
**** LIQUID WASTE Section ****
Emissions section: Consists of two parts. Part 1 enumerates all streams that are
characterized as emissions by listing their composition (weight %), flowrate (in kg/h) and
annual flowrate (kg/year). Part 2 presents a detailed accounting from the component
point of view; it shows how the total amount of each component leaving as emissions is
distributed in each stream. SuperPro® denotes the beginning of the emissions section
**** EMISSIONS Section ****
Hazardous streams section: Reports the hazardous streams. The format of this section is
similar to those of waste streams. SuperPro® denotes the beginning of the hazardous
streams section with the following title:
**** HAZARDOUS STREAMS Section ****
Pollution indices stream: Presents certain ratios that are indicative of the environmental
kindness (or lack thereof) of a design case. The first index presented applies to processes
that have a main revenue stream (e.g. manufacturing facilities with a main product
stream). It reports the ratio of total amount of waste (solid, liquid and emissions)
produced per kg of main revenue stream processed. The next three indices are similar but
report each of the three separate categories of wastes instead. The next four indices apply
to processing plants that employ raw materials. It reports the ratio of total, solid, liquid
and gaseous waste produced per kg of raw material utilized. SuperPro® denotes the
beginning of the emissions section with the following title:
**** POLLUTION INDICES Section ****
159
Glossary
33/50 EPA Program
-targeted 17 priority chemicals and set as its goal a 33% reduction in releases and
transfers of these chemicals by 1992 and a 50% reduction by 1995, measured against
a 1988 baseline
-sought to foster a pollution prevention ethic, encouraging companies to focus on
reducing releases of chemicals rather than treating and disposing of wastes
Acentric Factor
-developed by Pitzer in 1955 as a way of accounting for the ``non-central'' or
``acentric'' (size-shape) interactions empirically. The acentric factor, is defined as:
ω = − log 10 P r sat ( T r = 0 . 7 ) − 1 . 0
Agitate
- used to disturb the system as a method of mixing
Batch
-(cyclical) mode where there is a dead time (or ‘off time’)
Biomass
-any plant derived organic matter available on a renewable basis
BOD5
-amount of dissolved oxygen consumed in five days by biological processes breaking
down organic matter
BOD5/BODu
-ratio of the five-day BOD to the ultimate BOD value
BODu/COD
-ratio of the ultimate biochemical oxygen demand to the COD of the component
Bulk Conversion Factor
-amount of material present in a discrete entity. Given in units of g/entity or
cm3/entity.
Bulk Stream
-bulk streams have flow rates such as kg/h or kg/batch, where the amount of medium
in the stream is apparent in the value of the flow rate.
CaCO3
-calcium carbonate; can be used as a dehydrohalogenating agent
160
CAS Number
-a unique numeric identifier that designates one substance
Charge
- a method for adding an input to the unit
Chlorinated dibenzofuran (CDFs)
-a family of chemicals that contain one to eight chlorine atoms attached to the carbon
atoms of the parent chemical, dibenzofuran
-used for cleaning processes using a cleaning agent
COD: Chemical Oxygen Demand
-amount of oxygen required to chemically oxidize 1g of the component
Component
-can be a pure constituent in a stream or a stock mixture. Some components can be
broken down into Ingredient
. For example, air is a component that can be broken down into nitrogen and oxygen.
Compressibility Factor
- Z; corrects the gas density for deviations from the ideal gas law
Connect Mode
-mode entered after clicking the Connect Mode button. Allows user to draw several
streams in a row.
Continuous
-procedures carried out continuously (i.e. they are ‘on’ all the time
Discrete Stream
-discrete streams have flow rates such as vials/batch or bottles/batch, where each vial
contains a particular mass or volume, making it possible to calculate the amount of
medium in the stream.
DVDS/VDS: Degradable Volatile Dissolved Solids
-fraction of the volatile dissolved solid amount of a component that is biodegradable
DVSS/VSS: Degradable Volatile Suspended Solids
-fraction of the volatile suspended solid of the component that is biodegradable
161
EIR Report: Environmental Impact Report
-presents information that describes the effects of the process output streams on the
environment
-contains a detailed tabulation of all chemicals that are regulated by the EPA or
denoted as hazardous by the user
Enthalpy of Formation
-the enthalpy change associated with the formation of a compound from its
constituent elements
EPA: Environmental Protection Agency
-a national organization that attempts to lead the nation’s environmental science,
research, educational, and assessment efforts by:
• Developing and enforcing regulations for hazardous chemicals
• Offering financial assistance to state and educational institutions for
environmental research
• Performs environmental research to understand current environmental
problems
• Strives to further environmental education in the public arena
Evacuate
-complete removal of unit procedure contents
Heat Capacity
-the amount of heat required to change its temperature by one degree, and has units of
energy per degree
Heat of Vaporization
-the energy required to change a gram of a liquid into the gaseous state at the boiling
point is called the "heat of vaporization"
Henry’s Constant
-the ratio of the aqueous-phase concentration
of a chemical to its equilibrium partial pressure in the gas phase
Ingredient
-a pure constituent in a stream
Input Stream
-a stream that carries material into a unit procedure. Components and flowrates for
an input stream are usually set by the user. The exception is when the Pull-In
operation is used.
162
163
Intermediate Stream
-a stream that carries material out of a unit procedure and into a different unit
procedure. Components and flowrates for an intermediate stream are usually
calculated by SuperPro®. The exception is when the Pull-Out operation is used.
Kmaxo
-maximum biodegradation rate constant
Ks
-half-saturation constant
Log10 (octanol/water)
-used to indicate the hydrophobicity of a component
-helps determine a component’s tendency to become sludge
Master-Slave Relationship
- relationship formed between two operation to determine the duration time of the
slave piece of equipment based on the duration time of the master operation
Mixed Mode
-a combination of both a (cyclical) mode where there is a dead time (or ‘off time’)
and procedures carried out continuously
Molecular Weight
-the sum of the weights of the atoms of which it is made
NO3-NO2 : Nitrate/Nitrite Nitrogen
-NO3-NO2 contribution of the component
Normal Boiling Point
-the temperature at which a liquid's vapor pressure equals one atm
Normal Freezing Point
-the temperature at a substance melts (or freezes) at one atmosphere
Operation
-represents the simplest physico-chemical transformation step that can be modeled
from simply charging data to a reaction
-individual operations can be strung together to allow for more than one operation to
occur in one unit procedure
Process Time
- time it takes for a piece of equipment to run all the way through its part of the
process
164
Pull-In
- allows the user to take in a material without directly knowing the amount of material
needed
Pull-Out
- allows the user to take out a material without directly knowing the amount of
material needed
Pure Components Database
-from this dialog you can:
•
•
•
•
Inspect the contents of the pure component databank
View and edit the properties of any component in the databank
Add new components in the pure component databank
Delete components from the pure component databank
SARA 313
-the Superfund Amendments and Reauthorization Act (SARA)
http://www.epa.gov/superfund/action/law/sara.htm
Saturation Vapor Pressure
-the vapor pressure associated with a saturated vapor (one which cannot contain more
liquid molecules)
Select Mode
-typical mode while in SuperPro® in which streams and operations can be clicked on
and selected.
Selling Price
-cost associated with the activities of the marketing and sales department. Their
values are zero by default, assumes this cost is zero.
Setup Time
-time it takes for the equipment to be initialized and setup
-used to clean processes using steam
Stock Mixtures Database
-system pool of mixtures with pre-specified property values (including composition)
ready to be used (registered) in your design case
165
Stream Elbow
-a right angle bend in a stream, changing the stream from horizontal to vertical and
vice versa.
Temporary Connect Mode
-allows the user to draw a single stream and automatically returns to Select Mode
after the stream is drawn.
ThOD: Theoretical Oxygen Demand
-theoretical amount of oxygen needed to oxidize 1g of the component
-often equal to the COD
TKN: Total Kjeldahl Nitrogen
-Kjeldahl nitrogen contribution of the component
TOC: Total Organic Carbon
-organic carbon contribution of a component
TP: Total Phosphorus
-denotes the phosphorus contribution of a component
Transfer In
-allows the user to take in a material, but unlike Pull In, requires user to specify
amount of material needed
Transfer Out
-allows the user to take out a material, but unlike Pull Out, requires user to specify
amount of material needed
TS: Total Solids
-fraction of a component that is dissolved or present as a suspended solid
TSS/TS: Total Suspended Solids
-fraction of solid component that is suspended in solution
Turnaround Time
-time that it takes to return a piece of equipment back to its original condition (i.e., to
prepare it for the next process, cleaning, resetting, etc.)
Unit Operation
-represents the simplest physiochemical transformation step that can be modeled in
the simulation
166
Unit Procedure
- a piece of equipment in which a sequence of modeled unit operations takes place
VDS/TDS: Volatile Dissolved Solids
-fraction of the dissolved solid of a component that is volatile
VSS/TSS: Volatile Suspended Solids
-fraction of the suspended solid component that is biodegradable
Waste Treatment or Disposal Cost
-the cost of treating and/or disposing of certain process outputs, such as undesirable
by-products, solvents, etc
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Index
#
G
33/50 EPA Program................................. 25, 146, 156
A
Acentric Factor ................................................ 20, 156
Agitate ............................................................. 31, 156
B
Batch.......................................................... 7, 109, 156
Biomass ..................................................... 19, 25, 156
BOD5 ............................................................... 22, 156
Breakpoint ............................................................... 48
Bulk Conversion Factor................................... 76, 156
Bulk Stream..................................................... 60, 156
C
CaCO3 ............................................................. 22, 156
CAS Number ..................................... 15, 19, 138, 157
Charge ....................................................... 31, 95, 157
Chlorinated dibenzofuran (CDFs) ................ 137, 157
Clean-in-Place ................................................. 31, 157
COD: Chemical Oxygen Demand ........... 21, 154, 157
Color (see style)
Component ........................................ 11, 66, 120, 157
Component Registration.......................................... 11
Compressibility Factor .................................... 20, 157
Connect Mode ................................................. 62, 157
Continuous ......................................... 8, 101, 154,157
Cost
Component ....................................................... 121
Stream............................................................... 123
Equipment ........................................................ 127
Labor & Utility ................................................. 128
D
Default Physical Units............................................... 9
Density .................................................................... 82
Discrete Stream ............................................... 60, 157
DVDS/VDS ..................................................... 23, 157
DVSS/VSS ...................................................... 23, 157
E
EIR: Environmental Impact Report......... 25, 148, 158
Emissions .............................................................. 133
Enthalpy of Formation..................................... 19, 158
EPA: Environmental Protection Agency ........ 24, 158
Equipment Data............................................... 44, 127
Evacuate .......................................................... 31, 158
F
H
Heat Capacity ..................................................20, 158
Heat of Vaporization .......................................21, 158
Henry’s Constant .............................................20, 158
I
Ingredient............................................. 30, 66, 72, 158
Input Stream .................................... 61, 126, 154, 158
Intermediate Stream................................... 61, 92, 159
J
K
Kmaxo .............................................................21, 159
Ks.....................................................................21, 159
L
Labor Requirements ..............................................115
Log10...............................................................22, 159
M
Master-Slave Relationship.............................103, 159
Mixed Mode ......................................................8, 159
Mixture Registration................................................11
Mode of Operation.....................................................7
Molecular Weight ............................................19, 159
N
NO3-NO2..........................................................22, 159
Normal Boiling Point.......................................19, 159
Normal Freezing Point.....................................19, 159
O
Operations........................................ 7, 31, 49, 92, 159
Operation Data.......................................................101
P
Procedure Data ........................................................42
Process Time .................................................101, 159
Pull-in ....................................................................160
Pull-Out .................................................................160
Pure Components Database ....................... 11, 20, 160
Q
168
R
Register
Components........................................................ 11
Mixtures.............................................................. 11
S
SARA 313 ....................................... 25, 146, 153, 160
Saturation Vapor Pressure ............................... 20, 160
Scheduling ............................................................. 101
Select Mode..................................................... 62, 160
Selling Price ............................................ 76, 121, 160
Setup Time .................................................... 102, 160
Special Components ................................................ 25
Steam-in-Place................................................. 31, 160
Stock Mixtures Database................................. 26, 160
New stock mixtures ............................................ 28
Stream Elbow .................................................. 62, 161
Style
stream ................................................................. 84
unit procedure icon ............................................. 53
T
Tag
Unit procedure.................................................... 56
Stream................................................................. 87
Temporary Connect Mode............................... 62, 161
ThOD: Theoretical Oxygen Demand.............. 21, 161
TKN: Total Kjeldahl Nitrogen........................22, 161
TOC: Total Organic Carbon ................... 22, 154, 161
TP: Total Phosphorus .....................................22, 161
Transfer In ................................................. 31, 95, 161
Transfer Out............................................... 31, 93, 161
TS: Total Solids ..............................................23, 161
TSS/TS: Total Suspended Solids....................23, 161
Turnaround Time....................................... 8, 107, 161
U
Unit Operation ............................. 8, 31, 101, 147, 161
Unit Procedure.........................................................31
V
VDS/TDS: Volatile Dissolved Solids.............23, 162
VSS/TSS: Volatile Suspended Solids.............23, 162
W
Waste Treatment or Disposal Cost .......... 23, 122, 162
X
Y
Z
169