Cracking the Code — Optimization in Chemical Plants
In recent years, optimization has gained a significant amount of attention as businesses are exploring various avenues to utilize resources efficiently and effectively, whilst maximizing performance and minimizing costs. During various stages in the design and operation of chemical plants different optimization modelling platforms are used to obtain the optimal operating conditions, parameters and maximize conversions, yields, recovery rates and profits, as well as minimize operating and maintenance costs.
These platforms include MATLAB and Python, or process simulators such as Aspen Plus, Hysys, ChemCAD, etc. However, optimization is not limited to chemical plant equipment and may be used to optimize plant personnel performance which will ultimately improve the overall plant performance and financials.
SAIYL executed a plant optimization project whereby process and industrial engineers analyzed the process and plant personnel structure and applied various tools and techniques to optimize the performance of the plant and improve the overall production capacity. A time and motion analysis was conducted to observe, measure, and analyze various tasks performed by plant personnel. The durations and tasks observed where then modelled into FlexSim 3D Simulation Modelling and Analysis Software. FlexSim is a state-of-the-art modelling simulation model used to simulate, analyse, and visualise and test real-time scenarios for any type of project or challenge. The software produces quick and reliable results, which can thereafter be applied practically. In this project, various scenarios were modelled into FlexSim 3D Simulation Modelling and Analysis Software and were compared against a base model to identify the bottlenecks in the process.
In essence, simulation modelling software is an extremely valuable tool in the optimization of chemical plants, to virtually explore potential changes to the system that may be physically impossible to implement due to plant downtime, damage to equipment, safety risks, time constraints and raw material wastage.
~ Melisha Singh
