3 replies to this topic

[faz]

Hi All!

I know that optimization is mostly on the design stage of chemical plant, but i am interested on optimizing the present plant condition.

Is there anywhere where i can learn more of it such as work examples, etc?

regards,

[trilok_sontakke]

Hi Faz

Optimisation of a chemical plant should be done in four ways.

1. yield optimisation/consumption qty optimisation/recoveries optimisation/cost optimisation

2. batch size/production rate optimisation so that maximum capacity of all the process equipments is utilised.

3. time cycle optimization by way of process development/automation.

4. utility optimisation

you will not find specific material on optimisation. it will depend on your plant and you have to develop/optimise on your own.observe each step in the plant and be physically present at each unit operation and get the feel of the plant then you will automatically come to know what are the problems in the plant and go on solving one by on .

Hi Faz,

My work largely involves 'optimisation' of both new and existing plants - largely through dynamic process simulations. I agree with the last reply and have a few things to add.

To optimise any complex process it is important to have a very good OVERALL understanding of the movement of materials, energy, labor and hence $. A well constructed, purpose built DYNAMIC simulation covering the full mass and energy balance is an excellent way to begin an optimisation program as it gives a good picture of exactly where your energy and materials are going. It will also demonstrate the most obvious and high return improvement opportunites that can otherwise go unnoticed. Another good practice can be to add cost calculations to your simulation... often this will point out new areas for potential optimisation - sometimes in areas no one had previously considered. A simulation can be used to test the effect of various process improvement options, often in a way that would be completely unfeasible by other means considering the extensive calculation required and dynamics of many processes.

Whether you have a simulation or not there are some valuable techniques you can use, whether for a new plant or and existing one. Some of the most powerful techniques are "Thermal Pinch Analysis" and "Water Pinch" analysis. There is lots of good information on these on the internet. Minimisation and re-use of energy, water and other materials is a good place to start. An improvement in one of these areas often brings an improvement in the others - and these can often result in reduced effluent treatment and pollution abatement requirements antd other savings- leading to further operational, financial and environmental gains. All these things effectively require a good overall mass and energy balance /audit to find areas on which to focus and predict potential benefits.

Dont think of optimisation as mostly a design phase thing. Processes, companies, products, laws and economies all change with time. There are so many interacting factors in most industrial processes, not always 'technical' that there is always room for improvement.

Good luck with your optimisation program.

Nat.

[faz]

hi guys!

any websites/articles where I can refer to?

Thanks!