Author: Nicholas W. Plentovich, Engineer II
In today’s complex industrial landscape, process simulations play a crucial role in guiding informed decision-making. Many facilities have recognized the value of implementing process simulations for their sites; however, it is disheartening when these valuable tools fall victim to neglect and inevitably become obsolete. Nonetheless, a properly updated and calibrated simulation can significantly enhance decision-making when considering process and/or operational modifications. Successfully using simulations will provide better insights into the downstream effects of any changes and will effectively troubleshoot process upsets.
Getting Started: Overcoming Challenges
While the concept of utilizing process simulations may seem simple, the first step can often be the most challenging. It is not uncommon to encounter difficulties when attempting to open an old process simulation on newer software versions, or it may not be practical to update older simulations due to their outdated structure. In these situations, it is crucial to leverage the expertise of consultants or seek assistance directly from the software providers. These subject matter experts (SMEs) will collaborate with you to develop and calibrate a new model that accurately represents the specific conditions of your facility. Once a new simulation is in place, it is essential to keep it updated to reflect changes made in real time.
The Power of Accurate Simulations in Decision-Making
In today’s data-driven world, access to accurate process simulations is critical for effective decision-making. Once you have an updated simulation, it is important to implement a plan to maintain accuracy and relevance. This can be achieved through work by process engineers in-house or by engaging a third-party service, such as E2G’s Process Technology team. If your facility has neglected the maintenance of simulations, the changes can be overwhelming and result in inefficient and outdated models.
The objective of updating and maintaining these simulations is to drive informed decision-making processes. By leveraging simulations, you can evaluate different options for higher throughputs and observe their downstream effects. For instance, you can determine how the removal of a heat exchanger can result in lower efficiencies in downstream distillation towers or how modifications to a chemical process can impact product quality.
These simulations serve as the backbone of the decision-making process, enabling you to perform what-if analyses that improve efficiency and contribute to the safety of your facilities. The Management of Change (MOC) process can benefit significantly from the insights gained through these simulations. By better understanding the complex interactions that occur within your units, you can anticipate and mitigate the downstream consequences of small upstream changes, ensuring a smooth transition and minimizing risks.
Case Study: Effects of Vapor Return on an LNG Facility
To illustrate the impact of accurate process simulations, let’s examine a recent case study conducted by E2G’s Process Technology team. The study focused on a liquefied natural gas (LNG) facility and aimed to investigate the effects of vapor return on the temperatures in a storage tank. In this particular facility, LNG is loaded into ships, the LNG boils off during this initial loading process, and vapor is returned from the ships back to the facility. The vapor is flared (wasted) until reaching a sufficiently low temperature before being returned to the tanks.
Our team used process simulation to model the mixing of warm vapor into the cold tank and assess whether returning warmer vapor would cause cyclic damage to the tank or trip the associated compressors. The simulation determined that returning warmer vapor back to the tanks would reduce the amount of vapor vented to the flare. The simulation was meticulously calibrated using process data and demonstrated remarkable accuracy, predicting the process outcomes with less than 1% deviation. Armed with this knowledge, the client made an informed decision to return the vapor to the tank at a warmer temperature. This strategic choice resulted in reduced emissions, increased profits, and improved process efficiency.
This case study exemplifies how accurate process simulations lead to smarter decision-making. By basing decisions on reliable data, facilities can enhance operational efficiency, reduce environmental impact, and optimize their overall performance.
Leveraging process simulations for informed decision-making is a critical aspect of modern industrial operations. When simulations are regularly updated, calibrated, and maintained, facilities can make real-time, data-driven decisions; gain deeper insights into process changes; and optimize efficiency while reducing risks. Embrace the power of simulations to create safer, more sustainable, and economically viable operations.
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