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Advanced Process Systems Engineering

This lecture introduces advanced process systems engineering (APSE). The lecture aims to provide students with skills in modeling, simulation, and optimization of chemical production systems. It discusses a hierarchical approach to analyzing chemical processes, decomposing systems into five levels from production systems down to the molecular level. Examples of large chemical production sites like BASF Ludwigshafen and the TOTAL refinery in Leuna are also presented to illustrate hierarchical structures in real industrial systems.

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161 views7 pages

Advanced Process Systems Engineering

This lecture introduces advanced process systems engineering (APSE). The lecture aims to provide students with skills in modeling, simulation, and optimization of chemical production systems. It discusses a hierarchical approach to analyzing chemical processes, decomposing systems into five levels from production systems down to the molecular level. Examples of large chemical production sites like BASF Ludwigshafen and the TOTAL refinery in Leuna are also presented to illustrate hierarchical structures in real industrial systems.

Uploaded by

Asiful islam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Lecture Advanced Process Systems Engineering

(APSE)

1) Introduction
§ Target competence profile of students
§ Hierarchical approach of this lecture
§ Some examples

Literature:
[1] K. Sundmacher, Systemverfahrenstechnik, German Lecture Manuscript, April
2019.

Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 1


Target Competence Profile of
Students: M S O

a) Modeling: ability to define goals, introduce


variables, and establish the governing
equations as well as constraints.
b) Simulation: ability to solve model equations
for given parameter settings by suitable
numerical algorithms and tools.
c) Optimization: ability to optimize chemical
production systems and their parts regarding
their structure and/or operating conditions.

Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 2


Hierarchical Approach

§ Every chemical production systems can be decomposed


into 5 essential hierarchical levels.

§ On every level constituting components are assembled to


aggregates. The latter have names that are used as
labels for the respective hierarchical levels.

§ Decomposition of systems into modules and assembly


of parts to new system configurations is a typical approach
in different engineering disciplines (mechanical, electrical,
civil, chemical).

§ Modularity and hierarchical structures can be found in


living systems, too (biomolecules, cells, tissues, organs).
Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 3
Hierarchical Levels of Chemical Production
Systems … define names
of levels!

Levels Components Links Aggregates

Supply systems à Production


1. Production Processes,
for feeding, heat- system
system level storage tanks
ing, electricity, … („Verbund“)
Process elements Pumps, com-
2. Plant level (mixer, reactors, pressors, heat à Process
separators) exchangers, …
3. Level of
Phases (gas, à Process
process Interfaces
liquid, solid) element
elements

Molecular
4. Phase level Molecules à Phase
interaction forces

5. Molecular Atoms,
Chemical bonds à Molecule
level functional groups

Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 4


Example: BASF Production Sites

Ludwigshafen

Antwerp

[Link]

Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 5


Example: BASF Production Site Ludwigshafen

§ 110 production lines with 200 plants


§ Area: 10 km²
§ 39.000 employees
§ 230 km rails
§ 2.850 km pipelines
§ 106 km road network

[Link]
Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 6
Example: TOTAL Refinery Mitteldeutschland,
Leuna

[Link]
[Link]

§ Total area: 320 ha (= 500 football grounds)


§ Flare: 140 m high (= highest building in the city of Leipzig)
§ 700 km pipelines above ground (= distance Leuna à Paris)
§ 12.000 t stainless steel (= 2 x steel mass of Eiffel tower)
§ Feedstock: 12 Mio. t / a crude oil (= 180.000 tank wagons)
§ Products: 1 Mio. L/h gasoline + Diesel (= 30 tank cars/h)
§ Transport: 100.000 railway tank wagons per year)
Prof. Dr.-Ing. K. Sundmacher Lecture Advanced Process Systems Engineering 7

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