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UniSim® Design Next Generation ModelsUNISIM DESIGN
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved. Core to the Honeywell Connected Plant
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UniSim Design EO
Next Generation Reactor Models
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Motivation for EO Development
• An Equation Oriented (EO) modeling capability is a great
compliment to a Sequential Modular (SM) capability
- The strengths of EO are the weaknesses of SM and vise-versa
- Combining the approaches broadens the potential for model based
applications of the future
• EO Strengths/SM Weaknesses
- Specification flexibility, supports lifecycle modeling, calculation
parallelization potential, higher accuracy solutions, difficult recycle
and highly interacting flowsheets, independent of solver technology,
easier model code maintenance, online applications (optimization)
• EO Weaknesses/SM Strengths
- Difficult thermos
- Diagnostics for solver failures
- Limited use of logic in model code
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Motivation for EO Development
• Modeling uses in the future is also being looked at broadly by the
manufacturing industry
- See “Implementing 21st Century Smart Manufacturing - Workshop
Summary Report
- https://smartmanufacturingcoalition.org/
• Expand UniSim into Online Model Based Applications (OMBAs)
- Process Monitoring
- Operator Advisory/Decision Support
- Early Event Detection
- Optimization (Offline and Online)
• Business Cases for OMBAs are improving as issues continue to
be addressed
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim EO History
• UniSim EO (Equation Oriented) was referred to as Genesis
• Genesis was a development of Hyprotech to implement a next
generation simulation system with life cycle modeling capabilities
• Honeywell continued this development after acquisition of Hysys from
Aspen which became UniSim
• Honeywell marketing conducted VOC that indicated there was no
pressing need for EO capability, although it is common knowledge
there are classes of problems not well-handled by sequential modular
architectures
• UniSim EO development currently moving forward based on joint
funding from UniSim budget and customer inputs
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim EO
• UniSim EO (Equation Oriented) is a new functionality in UniSim to
use a better modeling approach for complex flowsheets and
problems with an optimization aspect (parameter estimation,
economic optimization)
• EO architecture separates modeling from the solution procedure,
thus simplifying model development and offering more solver
options
• Limited functionality released in UniSim Design so far
• Equation Oriented capability compliments sequential solution
strategies
• More capability under development in projects for customers
• Current version allows embedding a Unisim EO flowsheet into a
Unisim design model as a subflowsheet
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim EO Functionalities
• Enable more powerful optimization capability
• Enable solution of highly integrated complex
flowsheets
• Enable specification flexibility
• Potential to realize “lifecycle” modeling goals
- Same model for multiple applications/uses
• Create flowsheet models suitable for external applications
- Model deployment architecture
- Performance monitoring, model based optimal control
• Simple custom model integration capability
• Solver Library/Framework (NOVA, others)
• Powerful Modeling Language (4GL)
- MATLAB (like)
- Access to properties, streams, etc
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim EO Views
UniSim EO
Element
UniSim EO
Sub flowsheet
UniSim EO
Ops
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UniSim EO Specification Views
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim EO Blowdown
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
2005
2013
2015
UniSim Design R350
Depressuring Dynamics
(Legacy)• Code identical to the Aspen
HYSYS Depressuring Utility
After the IP acquisition by
Honeywell
• Equilibrium calculations
• Need to link to stream in the
main flowsheet in order to
configure
Blowdown Utility Predecessors
UniSim Design R430
Blowdown Utility• Introduced non-equilibrium
calculations
• Improvements to the heat
transfer between phases
• Improvements to the vessel
geometry
• Still need to link to stream in
the main flowsheet in order to
configure
UniSim Design R440
EO Blowdown Utility• Transferred utility to EO environment
(single vessel + RO only)
• Introduced blowdown scheduling
• Link to stream no longer needed
• Migration from R430 at click of button
• Improved reporting
UniSim Design R442
EO Blowdown Utility• Introduced flowsheet customisation on
EO environment
• Extended blowdown scheduling to the
flowsheet environment
• Allowed for 2D heat conduction in the
vessel walls and heads
• Implemented the fire method based on
the API 521 6° edition industry standard
2015
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
EO Blowdown - Background
• Earlier versions of UniSim Design had a depressuring utility called “Depressuring – Dynamics (Legacy)”
• Starting with UniSim Design R440, the Legacy utility is being phased out and is being replaced by two more rigorous and powerful depressuring utilities called “Blowdown Utility” and “EO Blowdown Utility”.
Depressuring – Dynamics
(Legacy) Utl. (R350)
Blowdown Utl.
(R430)
EO Blowdown Utl.
(R442 on)
Top/Bottom
DepressuringLimited Yes Yes
Geometry of
Vessel HeadsLimited Good
Good – further
enhanced
Rigorous Heat
TransferNo Yes
Yes– further
enhanced
Multiple Vessels
and PipingNo No Yes
Non-Equilibrium
holdup modelNo Yes Yes
Robustness Fair Good Good
Rigor Limited Good Good
Validated against
real dataNo Yes Yes
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
EO Blowdown Utility Capabilities
• Works by creating a Dynamic sub-flowsheet within the steady state model - Defaults to a single vessel with a single Relief Orifice
- Additional Unit Ops can be added from the EO Unit Op library:
Mixers
Pipes
Non-equilibrium Vessels, and
Relief Orifices
• UniSim Design EO Dynamics Solver- NOVA solver (simultaneous Equation Oriented architecture)
- Uses UniSim thermo (clones FP as necessary)
- Robust solver for convergent Hydraulic network
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Blowdown of a of a single volume
• Single Vessel with a single Orifice (default flowsheet)- Utility will calculate transient and settle out conditions
• The utility considers up to 3 phases (V, L1, L2)
• Vessel characterisation- Orientation
- Head Type
- Length/Height and Diameter
- Discharge Nozzle
- Initial conditions
• Orifice characterisation- Diameter
- Discharge coefficient
- State (Open/Closed)
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Blowdown of a customized Flowsheet
• Modify the default PFD. Currently EO library has following Unit Ops:
Mixers
Pipes
Non-equilibrium Vessels, and
Relief Orifices
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Environment - Adiabatic or Fire mode
• Adiabatic mode- No external heat is applied so no parameters need to be entered in this section
• Fire Methods1. Analytical API 521
2. Basic API 521
3. Empirical
4. Enhanced API 521
5. Radiation
- Each Fire Method has its own Parameters
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Heat Transfer Model• Zoned model: up to 3 vessel zones and 3 Wall zones (V-L1-L2)
• Two Wall Model Types
- 1 D: 1 dimension temperature gradient
- 2 D: 2 dimensional temperature gradient
• Wall comprises vessel wall & insulation layers
- Material type & thickness specified
- Heat capacity, density & thermal conductivity could also be specified
• External Convection
- On
- Off
• User Heat Flux
- Vapor Zone
- Liquid Zone
• Heat transfer coefficients are calculated
Vapour and liquid to metal
Metal/insulation to environment
Between fluid phases
x
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Orifice Model
• Generic multi phase orifice model for- Subsonic flow
- Sonic flow (Choked Flow)
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Rating Mode Only
• Rating mode- User supplies orifice size and depressuring time
- UniSim Design calculates depressuring during given time
• For Orifice Sizing- Select a size, run Blowdown Utility and iterate until desired performance is achieved
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Dynamic Scheduling
• Allows dynamic scheduling- Specify events (variable values) at set times
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Effective use of EO Blowdown Utility
• Define Vessel
• Define Vessel contents & conditions
• Define Environment (Adiabatic or Fire)
• Define Wall layers
• Define Orifice
• Specify Back Pressure and Integration Parameters
• Run Utility
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Results
• Pre-configured strip charts for trends of variables of general interest
Vessel zone pressures & temperatures
Vessel hold ups and liquid level
Vessel wall temperatures
Orifice outlet velocity, mass flow, pressure, temperature and vapour fraction
• New strip charts can be created.
• Results can be viewed on strip charts or on tables.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Refinery Modelling Functionalities
Reactor Models
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
The Platform | Next Generation Refining Capabilities
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Refining
Reactor Models
• Equation Oriented
Reactor Models
• Validated by Honeywell
subject matter experts
• Flexible and easy
calibration with few
parameters
Easy to Tune
and Deploy by User
High Performance EO
Platform
• Equations Oriented
(EO) Platform
• Refining simulation and
optimization in the
same environment
Rapid Deployment &
Conversions of Large
Scale Flowsheets
Refining
Workflows
• Efficient Workflow
• LP vector generation
• Crude selection and
analysis,
• Heat exchanger
monitoring and
optimization
Improve Engineering
Effectiveness
Refinery Modelling
Infrastructure
• Refining Properties
• Crude Environment -
Assay Management
• Supply Chain
Integration - LP Vector
Generation
Best In Class
Technology-Design to
Optimization
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
UniSim Design Suite | Delivering Value to Refining Customers
Delivering Increased Refinery Profitability
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Supply Chain
Support
Ensure LP Vectors,
used in feedstock
planning, are updated
to accurately reflect
current refinery
capabilities
Unit Level
Monitoring
Real-time monitoring of
refinery units,
leveraging EO platform,
to support operations
Provides insight into
predicted performance
vs actual
Small
Debottlenecking
Projects
Supports process and
project engineers
doing sensitivity
analysis and project
option evaluation
Off-line
Optimization
Enables ‘what-if’
analysis to provide
unit optimization
across the refinery
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Refining Features in UniSim Design26
• Predictive Refining Reactors:
- Hydrocracker
- Hydrotreater
- Catalytic Reformer
- Isomerization
- Alkylation
• Predictive Refining Reactors:
- Fluid Catalytic Cracker
- Delayed Coker
- Visbreaker
Unit Mod. & Opt. -> More Unit Mod. & Opt. -> Refinery-Wide Mod. & Opt. -> Life-Cycle Support
• Assays & Refining
Properties
• Blending Rules
• Import from Spiral Crude
• Link with Haverly H/CAMS
• LP Vector Generation Tool
• Predictive Reactor Support
in Dynamics
• Modeling & Optimization
of Units without
Predictive Refining
Reactors
• Modeling & Optimization
of Brownfield Refineries
• Remote consulting
services for UOP units
• Modeling & Optimization
of Units containing the
above reactors for
Greenfield Refineries
• Modeling & Optimization of
all units of any refinery
• Refinery-Wide Optimization
• Refinery-Wide Production
Allocation
• Remote consulting
services for non-UOP units
by other technologists
• Life-cycle Simulation
Support
Featu
res
Cap
ab
ilit
ies
CONFIDENTIAL
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
• UniSim® Design allows engineers in refining study scenarios to process different crude feeds,
accurately predict yields for various refining products, and keep up-to-date their LP programs
for scheduling and planning purposes.
• Allows variation in process parameters to predict performance of reactor units.
• Allows scenario studies for variations in feedstock, product yields & so on
• Provides refinery unit level optimization capabilities
• Generates LP vectors and the generated vectors can be used to tune scheduling and
optimization applications for production planning
• Capabilities to study reactor performance & its contribution to a wider combination of units
UniSim® Design capabilities
• UniSim Design capabilities fully meet Refinery Modelling objectives
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Refinery Reactor in UniSim R460
• UniSim® Hydrotreater for simulating Naphtha, Kerosene, Gas Oil, Slurry and Atmospheric
Residue Hydrotreater reactor models
• UniSim® Hydrocracker for simulating Hydrocracker/Mild Hydrocracker and Base oil production
• UniSim® Reformer for simulating Naphtha Reforming
• UniSim® Isomerization for simulating Light Naphtha Isomerization
• UniSim® Alkylation for simulation Alkylation
• Reactor modules part of UniSim R460 & R470
UniSim® Design | Refinery Reactor
Refinery Reactor in UniSim R470 (2019)
• UniSim® FCC Reactor for simulating FCC reactor models
• UniSim® Delayed Coker for simulating Delayed Coker
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Example: Hydroprocessing Reactor
• Predictive Kinetic reactor model
• Covers all aspects of Hydroprocessing (HCU & HDT)
• Implemented fully in the Next Generation Simulation Environment
Allows for switching of solver: Sequential, Simultaneous & Optimization
• Allows controlling distribution of light & heavy ends
• Catalyst Life Prediction
• Provides overall reactor
performance information
• Requires minimum
configuration & Calibration time
• Hydroprocessing Reactor module part of UniSim R460
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Refinery Reactor Parameter Calibration
• Refinery Reactor Parameter calibration helps tuning reaction kinetic parameter
• It allows to match results (component yields, outlet temp) with desired results
• The data input to parameter calibration can be pilot or real plant data
• Parameter Calibration allows
combination of optimizer & data
reconciliation
• Saves effort and time of
manual parameter tuning
• Parameter Calibration and Data Reconciliation within EO environment
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Refining Properties• Base environment stream properties required to support Refining
Flowsheet and Crude Environment
• RON, MON, RVP, conradson carbon rate, carbon to hydrogen
ratio, cetane index, refractive index, yield, Aniline, cloud, freeze,
pour, smoke, softening, wax congealing and flash points, X-ring
UV and IP391 Aromatics, Cx Asphaltenes, olefins, naphthalenes,
naphthenes, n-paraffins, paraffins, polynaphthenes,
mercaptans...
• Individual stream properties or multiple stream properties can be
visualized using the stream plot utility
Deeper Dive | Refining Infrastructure
Infrastructure & Unit Operations to Efficiently Create Complete Refining Flowsheet
3131
Crude Environment• Environment for managing Crude
Assay properties
• Direct link to Haverly H/CAMS
crude assay library, can also be read from
MS Excel files or manually entered
• Assays are mapped to components and
pseudo components and propagated to
flowsheet environment
Blending Rules• Pre-defined non proprietary
blending rules included
• Horizontal and vertical
mixing
• Fully customizable
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
© 2017 by Honeywell International Inc. All rights reserved. Restricted distribution.
Crude Assay Management
• UniSim Design links to Crude Assay Databases
• Haverly H/CAMS
• Spiral
• Other Databases
• Possible to also include proprietary assays
• Assays are imported under the UniSim Crude Manager
environment
• Assay Synthesis
Easy assay import into UniSim Design
32
USD R450/1
• The crude assay import facility makes it easy to import
and manage crude assays.
• This functionality increases engineering effectiveness,
eliminates room for manual data entry, and makes it
easier to model crude storage facilities and refining
processes.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
LP Vector Generation• Generate LP vectors from user-configured independent and
dependent variables using simulation model or plant data
• Tune and maintain business planning, scheduling and
optimization applications
• Easy workflow between process engineering and supply chain
ensures continuous improvement of planning models and
profitable refinery operation
• Reduce plan-vs-actual gaps, deliver lost opportunity with realistic
and optimal plans that successfully achieve targets
Delivering Value through Engineering and Operations Effectiveness
3333
High Performance Optimization• Proprietary NOVA solver for online,
real-time optimization across all
process industries
• Well suited for solving hundreds of
thousands of equations with up to a
thousand degrees of freedom
• Unlocks new value with existing assets
Crude Pre-Heat Exchanger Monitoring• Exchanger Network Design, Pinch Analysis and Operational
Analysis solution with UniSim ExchangerNet & ExchangerNet Ops
• Perform “what-if” scenarios,
retrofits, cost optimization and
cleaning cycle optimization
decisions
• Optimize energy consumption
while maintaining product
quality and yield
Deeper Dive | Refining Capabilities Delivering Results
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Thank you!
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