Topic 1.1.5: Process Modeling

  • Process Modeling
    • A batch processing plant is made up of units and connections. Units process and/or hold materials while connections transfer materials between units.
    • Units – any vessel that can hold/and or process materials. Some units have no processing capabilities (bulk storage vessels, manual add stations, and hold tanks). Other units have significant processing capabilities (most reactors, blenders, mixers, dryers, retorts, and washers). Examples of processing capabilities: agitating, mixing, heating, cooling, blending, and packaging.
    • Connections – the equipment necessary for transferring a product from one unit to another (pumps, valves, separators, condensers and flow meters). Many plants have units that are connected to more than one unit and some plants have multiple connections between the same two units.
    • All units that have the same processing capabilities or perform the same function are grouped into one process class.
    • All connections between the same two process classes are grouped into one transfer class.
    • Process Classes and Transfer Classes define a family of units and connections.
    • The ability to group units and connections into classes is the essence of a true flexible batch system.
    • Processing and transferring capabilities are defined by Phases. Each phase is an independent action that may contain a unique set of Parameters.
    • Parameters configure the phase based on a recipe's requirements. Phases can be executed either automatically by the control system or manually by an operator.
    • The execution of automatic phases is performed by the control system using Phase Logic.
    • Units, Process Classes, Connections, Transfer Classes, and Processing Capabilities are the five main components of the Process Model.
    • Defining a plant's processing capabilities is called Process Modeling and involves the following steps:
      1. Identify each unit and its attribute.
      2. Group units into process classes.
      3. Identify all connections between units.
      4. Define all equipment segments and assign to connections.
      5. Group connections into transfer classes.
      6. Define the processing capabilities of each process class (phases and parameters).
      7. Define the processing capabilities of each transfer class (phases and parameters).
      8. Define equipment statuses.
      9. Define trains.
      10. Develop phase logic.
Last modified: Tuesday, 28 April 2020, 11:48 AM