Improving Plant Performance and Operational Readiness by the Application of Numerical Process Simulation

The interest in the application of numerical process simulation has constantly been growing over the last decade, also in sulfuric acid and wet gas cleaning plants of metallurgical production complexes. While the approval process to invest into a simulation model is often lengthy, the advantages of having such models are obvious. A virtual copy of the plant or separate units thereof allows a close look onto the plant performance and how it deviates from the optimum operational windows. Analysis can be broken down to single equipment or control loops to allow for detailed investigation and optimization. In this regard, not only are standard operating conditions in the focus, but also transitional or upset plant conditions. As a result, the more economic use of raw materials and utilities, as well as an increased lifetime of the equipment is achieved. Continuous performance monitoring provides valuable data about the condition of catalysts and equipment, allowing for realization of enhanced predictive maintenance concepts. Applying simulation models for operator training purposes and troubleshooting completes the list of benefits.