Example - 03UnitModels Projects 1

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Navigation: User Guide -> Example Projects -> Examples - 03UnitModels Projects

This page is for SysCAD 9.3 distributed Example projects, for SysCAD 9.2 distributed Example projects, please see Example Steady State General Projects 2

Absorption Tower Example Project

Absorption Tower Example2.png

Project Location

This is a Steady State project and is stored at:
..\SysCADXXX\Examples\03 UnitModels\Absorption Tower Example.spf

Features demonstrated

  1. A simple project showing how to emulate a column using:
    • Flowsheet 01: two sections with the Tie unit operation.
    • Flowsheet 02: three sections with the Tie unit operation.
    • Flowsheet 03: Flexible number of sections with the Counter Flow Tie unit operation.
  2. Shows the use VLE.
  3. Shows the use Solubility
  4. Shows the use of Simple Heat Exchanger
  5. Shows the use of Multi-Stage Counter Flow Tie
  6. Shows the use of Makeup Source for setting the re-circulation flow.
  7. Shows the use of PID Controller
  8. Shows the use of General Controller for side calculation.

Brief Project Description

This project shows how to use simple process units to model complex systems. The Project has three flowsheets, first one showing the absorption tower modelled as two sections, the second one modelled as three sections and the last flowsheet showing the absorption tower modelled as the 3 stage Counter Flow Tie unit operation.

  • Absorption tower: Uses solubility and VLE to remove HCl from fumes.
  • Simple Heat Exchanger provides the cooling required.

Project Configuration

  • Solubility Data
    1. Define the solubility data in the species database
    2. Once this is done, user can turn on the solubility Globally or on per unit operation basis. In this example, it is turned on per unit operation.
  • Absorption Tower:
    1. Modelled using two / three simple Ties with VLE / Solubility / SplitFlow sub-models.
    2. Modelled using counter flow tie with VLE / Solubility sub-models. With this setup, user can freely change the number of stages without having to change the flowsheet.
    3. User defines the concentration leaving the tower bottom, the recycle is manipulated to achieve this concentration.
    4. Makeup water is added to maintain a predefined re-circulation rate.
    5. Cooling water is added to maintain a user defined absorption gas outlet temperature.


Included Excel Report

None

Boiler & Combustion Project

Boiler and Combustion Example 2.png

Project Location

This is a Steady State project and is stored at:
..\SysCADXXX\Examples\03 UnitModels\Boiler and Combustion Example.spf

Features demonstrated

  1. A simple project showing how to calculate the heat energy required for the Boiler.
  2. Shows the use of a Tank with reactions - Combustion reactions.
  3. Shows the use of Hot Flash Tie
  4. Shows the use of Gas/Gas heater exchanger (This has been changed to Simple Heat Exchanger in SysCAD 138)
  5. Shows the use of Set Tag Controller
  6. Shows the use of PID Controller
  7. Shows the use of PGM file for side calculation.
  8. Shows the use of EHX as a method of stabilising the solution.

Brief Project Description

This project shows how to use simple process units to model complex systems. The Project is set up as two separate sections, Boiler and Combustion.

  • Boiler: The boiler section will heat and vapourise the boiler feed water, producing steam at the defined conditions. It will also report the energy required to achieve this.
  • Combustion: Fuel is used to produce energy in the combustion chamber, the amount of energy produced is dictated by the boiler.
  • Air to the combustion chamber is preheated by heat exchange with the flue gas. Air supply is in excess, done via a PID controller.

Project Configuration

  • Boiler Section:
    1. User specifies the BFW condition (in the feeder)
    2. User defines the Final T&P, Blowdown % and boiler efficiency
    3. SysCAD calculates the heat required for boiling and superheating the steam
    4. SysCAD calculated the fuel energy requirements based on boiler efficiency. This energy is tells the combustion chamber how much heat is required.
  • Fuel Section:
    1. When Preheated Air is combined with the Fuel, any moisture present is evaporated, this is done in the Hot Flash Tie.
    2. The total combustion reaction energy should be equal to the required fuel energy calculated by the boiler.
    3. A PID controller measures this and adjusts the Fuel input to achieve the required energy. (This is coupled with a EHX sub-model on Flue out stream to stabilise the solution.)
    4. Energy is removed from the combustion outlet stream by the boiler.
    5. The hot flue gas is then used to preheat the air to the combustion chamber.

Included Excel Report

None

Calcine & Fuel Project

Calcine and Fuel Example138.png This image has been updated to SysCAD 138 version.

Project Location

This is a Steady State project and is stored at:
..\SysCADXXX\Examples\03 UnitModels\Calcine and Fuel Example.spf

Features demonstrated

  1. A simple project showing how to calculate the heat energy required for the Calciner.
  2. Shows the use of Tanks with reactions - Calcination and Combustion reactions.
  3. Shows the use of Simple Heater
  4. Shows the use of FEM Reactor (Added in SysCAD 138)
  5. Shows the use of PID controller
  6. Shows the use of PGM file for side calculation.
  7. Shows the use of EHX to set various heat sinks.

Brief Project Description

  • The Project is set up as two separate sections, Calciner and Combustion. The temperature of the calcined alumina is interlocked with the fuel addition.
  • Combustion: The energy from the actual combustion reactions emulates the energy required by the Calciner to heat up the mixture.


Project Configuration

  • Calciner
    1. Reactions are used to dry the mixture
    2. Reaction block Heat Exchange Final Temperature option is used to bring the Product temperature to the required amount.
    3. SplitFlow is used to separate the gas and solids
  • Combustion Section
    1. Combustion reactions are used to produce the amount of heat required by the calciner.
    2. Excess Air is used, Air addition controlled via PID.
    3. The usage of two air inlets can be done in such a way that the first air inlet will provide the stoichiometric amount of oxygen to the combustion chamber, while the second inlet is adjust to give the required % of excess air. (This is not demonstrated in the example project)

Included Excel Report

None

HP Autoclave Leach Project

High Pressure Leach Example2.png

Project Location
..\SysCADXXX\Examples\03 UnitModels\High Pressure Autoclave Leach Example.spf

Features demonstrated

  1. Sulphuric acid heat of dilution and phase change are demonstrated in the acid mixer via the reaction block.
  2. Typical Base metal leach reactions are in place in the High Pressure Autoclave.
  3. Shows the use of Reaction Source & Recycle
  4. Ratio control is used when adding flocculant to the thickener. This is done via the General Control (PGM file).
  5. Acid and Steam additions are controlled via the PID controllers.
  6. Example reporting file can also be found in the project - Report.xls.

Brief Description

  • This is a simple project demonstrating a very simplified High Pressure Leach Circuit, where the slurry is leached with acid at High Temperature.
  • The leached slurry is then cooled in multistage flashing
  • The flash vapour is re-used to preheat the autoclave feed.

Project Configuration

  • Acid Mixer - Heat of dilution occurs in this vessel, compare the QFeed Temperature with QProd Temperature.
  • Autoclave
    1. User must specify a pressure for this unit. The pressure should be high enough to cover temperature changes and allow for non-condensibles.
    2. VLEquilibrium is switched on to condense the steam added to the autoclave.
    3. Reactions block is used to specify various base metal leach reactions.

Specifying the Reactions:

  • All reactions are in sequential order (this is important).
  • Looking at the reaction file, H2SO4 is consumed by a number of reactions with lower sequence numbers and then generated by some reactions with higher sequence numbers. When reactions are evaluated in sequence, normally products produced by later reactions would not be used by earlier reactions, this will lead to incorrect acid usage values.
  • To overcome this problem, we have added a H2SO4 reaction Source (in addition to the actual Conc Acid feed stream.) This H2SO4 reaction source will tell SysCAD to use up the acid generated by later reactions (shown as recycle amount).
  • For more information, please see Reaction Source & Recycle.

Included Excel Report

Report.XLS - this excel report show some basic report formats for the project, these include Input Criteria, reaction and Stream data report.

IX Column Uranium Example

IX Column Example2.png

Project Location ..\SysCADXXX\Examples\03 UnitModels\IX Column Uranium Example.spf

Features demonstrated

How to simulate the Ion Exchange Column using SysCAD.

Brief Project Description

  • The Ion Exchange column is simulated in six sections, each section is simulated using the IonExchange model.
  • The resin will travel through all the sections as it is regenerated and recycled.
  • Resin bleed is done via the resin lost stream.
  • The resin recirculation flow is topped up via Makeup source.

Project Configuration

  • All sections will have the same resin flow setting
  • Reactions blocks are used where needed to emulate the loading and regeneration of resin.
  • Resin bleed stream is import to avoid continuous build up of impurities in the resin stream.

Included Excel Report

IX Column Uranium Example.XLS - this excel report show some basic report formats for the project, these include Input Criteria, reaction and Stream data report.