Process Manual Internet Version 2006.5 User Guide
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Who Should Read this Guide?
This guide details the Internet Process Manual features and how to use them, and may be read by end-users requiring more information on the operation of the software. Further information about the Process Manual and functionality is contained in the on-line help available from the Help menu option within the application.
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Contents INTRODUCING THE INTERNET PROCESS MANUAL........................................... 5 The Process Manual.................................................................................................. 5 The Technical Areas ................................................................................................. 6 Applied Rheology ................................................................................................ 6 Bulk Solids Handling ............................................................................................ 6 Crystallization..................................................................................................... 7 Drying ............................................................................................................... 7 Gas Cleaning ...................................................................................................... 7 Slurry Handling................................................................................................... 7 Solid Liquid Separation ........................................................................................ 8 Solvent Extraction ............................................................................................... 8 Waste Water Treatment ....................................................................................... 8 Mini Manual Series .............................................................................................. 9 Manual Development ........................................................................................... 9
THE INTERNET PROCESS MANUAL................................................................. 10 Before You Start .................................................................................................... 10 Connecting and Registering ..................................................................................... 11 Registration by an Administrator ......................................................................... 11 Self-registration ................................................................................................ 11 Connecting....................................................................................................... 11
USING THE INTERNET PROCESS MANUAL ..................................................... 12 News items ........................................................................................................... 12 Feedback .............................................................................................................. 12 Administration ....................................................................................................... 12
ADMINISTRATION......................................................................................... 13 Introduction ..................................................................................................... 13 Settings........................................................................................................... 13 Email .............................................................................................................. 13 IP Address ....................................................................................................... 13 Users .............................................................................................................. 13 Usage.............................................................................................................. 14 Account ........................................................................................................... 14
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Contents
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Named ............................................................................................................ 14
GENERAL INFORMATION............................................................................... 15 Copyright.............................................................................................................. 15 Related Documentation........................................................................................... 16
TECHNICAL SUPPORT.................................................................................... 17 Online Technical Support Center .............................................................................. 17 Phone and E-mail................................................................................................... 18
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Contents
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Introducing the Internet Process Manual
The Process Manual The Process Manual is a knowledge management tool for the process industries. It enables chemists and chemical engineers in either plant operation, engineering contracting or equipment supply companies to access valuable chemical engineering knowledge from their desk. The Process Manual is derived from the considerable body of knowledge that has been developed by the SPS (Separation Processes Service) Consultants over 25 years of industrial problem solving and research. The Process Manual is composed of nine Technical Areas: •
Applied Rheology
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Bulk Solids Handling
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Crystallization
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Drying
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Gas Cleaning
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Slurry Handling
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Solid Liquid Separation
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Solvent Extraction
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Waste Water Treatment
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Mini Manual Series
The Process Manual is not only a unique collection of chemical engineering manuals located on your intranet for all of your technical staff to access. It is also a knowledge repository that allows your organization to capture and reuse its own chemical engineering knowledge. As the Process Manual is located on your server behind your firewall, your chemists and chemical engineers are free to place whatever information they believe will be valuable to your company without fear of giving away your company's competitive advantage. The content of the Process Manual can be delivered to any PC with a browser that is connected to your network. Each Technical Area includes information on the fundamental technologies, data correlation techniques, through
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equipment selection and design, to plant operation, troubleshooting and recommended procedures. The Manual comes with a powerful search tool that enables you to rapidly find the information you need. It also has literature databases, tables, figures and also a `live equation' facility to perform the calculations on the page that you are reading. To enable better communication across a potentially large network of staff, there is a `who's who', `links' and `news' capability in addition to the ability to attach notes to and links from the specific Process Manual pages to include your own in house knowledge resources.
The Technical Areas Applied Rheology Rheology fundamentals. Summary of typical data for wide range of industrial materials. Estimation of viscosity data. Review of, and recommended procedures for, five widely-used viscometric geometries for viscosity and flow curve measurement. Estimation of shear rate and shear stress for specific industrial applications to ensure relevance of viscosity and flow measurement with respect to application. Review of flow curve models and fitting data to selected model. Yield stress definition, measurement and application. Definitions of time-dependent flow behaviour. Review of, and recommendations for, methods for measuring and modelling thixotropy. Description of linear and non-linear viscoelasticity, including transient dynamic properties (creep compliance, recoil function, stress relaxation modulus, stress growth coefficient and stress decay coefficient) and oscillatory dynamic properties (complex rigidity modulus, complex shear viscosity, complex shear compliance and loss tangent). Normal stress and elongational (extensional) viscosity. Review and selection of commerciallyavailable laboratory and on-line viscometers and rheometers. Review of commercially-available index viscometers and possible applications. Effect of key physical and chemical properties on suspension, polymer and emulsion rheology. Use of rheology as a tool for process engineering design, plant troubleshooting, quality control and product formulation. Industrial case studies on use of rheological data.
Bulk Solids Handling Metering and feeding and pumps for wet cakes. Survey of screw and vibratory conveyors, design guide for screw conveyors and selection guide for mechanical conveyors. Review of vacuum and pressurized air systems. State of the art and design guide for gravity transfer chutes. Survey & selection guide for valves. Review of moisture measurement methods, selection of moisture measurement methods & survey of level measurement. Techniques to improve bulk solids handling and a review of powder mixing. Survey of storage options for bulk solids & design guide for wet or dry bulk solids in hoppers, silos, bins and bunkers. State-of-the-art review of laboratory measurement and a survey of shear testers for bulk solids.
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Crystallization An overview of industrial crystallization, crystal nucleation and growth, habit modification, agglomeration and organic solvent selection. Data needed for equipment selection, process design, operation and troubleshooting. Concentration and supersaturation. Crystal size and shape, crystallization kinetics. Selecting the equipment to use and integration with up-stream and downstream plant. Selecting batch or continuous operation, and supersaturation generation route. Batch and continuous equipment, scale-up, pumps, agitators and control. Simulation of batch and continuous crystallizers. Tailoring the crystal size distribution. Crystal purity, encrustation in crystallizers. Chiral crystallization, sonocrystallization and other novel developments. Solubility measurement, crystal size and shape, measurement and literature searching, development techniques.
Drying Fundamentals of drying theory, industrial drying practice and equipment. Dryer selection: rules and algorithm, small-scale tests, heat and mass balances, approximate sizing procedures. Equipment description, detailed theoretical background and design/performance calculation guide for: fluidized bed dryers (including fluid bed granulation & vibro-fluidization), rotary dryers, spray dryers and atomization, pneumatic conveying (flash) dryers, layer and contact dryers (including tray, plate, agitated, tumbling and vacuum types), RF and microwave dryers. Drying kinetics and equilibria: theory and practical application. Product quality and powder stickiness. Safety, control, instrumentation and troubleshooting. Recommended procedures.
Gas Cleaning Selection of equipment type, cyclones, wet dedusters, electrostatic precipitators, depth and rigid filters, fabric filters, mist removal. Types, operation, science and design of: cyclones, wet dedusters, electrostatic precipitators, fabric filters and mist removal. VOC abatement, dioxin and furan formation, adsorbent selection, SOx and NOx removal. Fire and explosion, hostile & difficult conditions, stringent conditions, high temperature and pressure, sampling and measurement, optical dust monitors, troubleshooting. Fans, dampers, ducts, hoods and compressors.
Slurry Handling Review and selection of pumps for slurries and pastes including metering pumps. Review of pipeline design for slurries and pastes and methods for settling and non-settling slurries, pipeline-cleaning techniques. Vacuum and pressurized air systems for slurry transport, design guide for non-settling slurry transport using vacuum or air. Review of slurry flow in open channels and launders. Selection and state of the art review of valves for slurry. Minimization of wear in slurry systems. Level measurement techniques, viscosity and other rheological techniques, slurry flowmeters, moisture measurement, density & passive acoustic emission monitoring. State of the
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art review and selection/design guide for powder-liquid mixing. Review of slurry tank design, commercially available slurry agitators & design of slurry storage systems. Equipment and methods for measuring relevant properties of slurries for handling applications.
Solid Liquid Separation Selection and sizing of the optimum equipment type for a specific separation, instrumentation, flocculation & coagulation, discharge of cakes, filter aids, filter media. Nutsche, drum and disc, belt, tipping pan and table, tank, continuous pressure, filter presses, batch compression, continuous compression, control, ancillary equipment, and performance improvement. Crossflow filtration including microfilters, ultrafilters & dynamic filters. Thickeners & clarifiers, classifiers, hydrocyclones, reslurry washing, efficiency of separations, prediction of particle settling rates in different equipment environments. Sedimenting centrifuges, filtering centrifuges & mechanical design. Flotation, magnetic, electrical & sonic separations. Different types of media, including their properties, selection and applications.
Solvent Extraction Principles of selecting solvent systems, mass transfer, modes of operation, equipment selection and design. Mass transfer and chemical reaction fundamentals, phase equilibrium, interfacial phenomena, coalescence and phase separation. Contactor classification, column design, mixer-settlers, gravity settlers, tank reactors, supercritical and high pressure processes, membrane and liquid membrane processes, scale-up, design and simulation, safety, environmental impact. Methodology for organics, metals and inorganics and biotechnology applications. Recommended procedures in: process development, phase equilibrium, interfacial tension, drop size measurement, contactor selection, mixer batch kinetics, settler prediction, scaling batch mixer- settlers, diffusivity measurement, mass transfer data & extractor troubleshooting. Metals recovery processes, metals extraction, effluent treatment.
Waste Water Treatment Legislation, wastewater characterization, water minimization and wastewater toxicity. A methodology for selection and live equations for estimating capital and operating costs. Heavy metals, trace organics, anion removal, volatile organic compounds, odor control, oil/water separation, saline streams, sludge treatment and disposal, transport of slurries. Process selection, aerobic and anaerobic processes, recent technical developments, `difficult' waste streams. Precipitation, electrical processes, adsorption and ion exchange, low temperature oxidation/reduction processes and incineration, radiation processes. Solid-liquid separation, membrane processes and pre-treatment techniques.
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General Solids Processing Gas & Particle Properties: detailed practical advice on equipment and techniques for measurement of important physical properties of gases and solids. Adsorption: technology, available materials and underlying science of physical bonding of liquid (adsorbate) to the surface of a microporous solid (adsorbent). Comminution: review and practical description of particle size reduction techniques. Classification: separation of particle flows into two or more streams according to particle size. Overall Process Design: overview of how to develop a solids processing flowsheet, interactions between separate unit operations. Pumping: detailed descriptions of over 60 different pump types with many diagrams, graphs, charts and tables. This area was formerly known as the Mini-Manuals series.
Manual Development We realize that knowledge needs to be refreshed and so the content of the Process Manual is annually updated. The SPS Consultants, with the close involvement of our customers and the academic community continue to update and add to the content of the Process Manual.
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The Internet Process Manual
This section will use Internet Explorer 6 as the demonstration platform for examples; if you have a different browser, it may use different conventions for how you operate it.
Installation The Internet Process Manual in most cases requires no installation on client machines. You just browse to the URL, as given below.
Before You Start The Internet Process Manual requires: •
Internet Explorer version 5.0 or later.
•
Javascript enabled.
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ActiveX controls configured for: − Binary and script behaviours set to Enable. − Download signed ActiveX controls set to Enable or Prompt. − Run ActiveX controls and plug-ins set to Enable. − Script ActiveX controls marked safe for scripting set to Enable.
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First-party cookies must be configured to allow session cookies, and we would recommend accepting stored cookies too.
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MSXML 4.0 is required for some ActiveX controls. Most modern systems have this already installed, alternatively is can be obtained from the Microsoft web site, or installed from the Aspen ONE discs.
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If your account uses client-side SLM licensing, you need to install the Aspen Software License Manager. This can be done from the AspenONE disc or from a link on the Process Manual.
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Connecting and Registering To access the Internet Process Manual, you need a user id and a password. Your company email address is used as your user id. There are two ways of registering with the Internet Process Manual.
Registration by an Administrator A user in your company with administrator access can register additional company users. In this case, you will receive a notification of your registration by email, and notification of your initial password.
Self-registration Some company accounts are configured to allow you to register yourself. You will need to obtain the correct URL address for your registration page, and this would normally be supplied by your local company contact. Browse to this page, and supply additional details as required. In particular, you should use your company email address as your user id. When you have completed the registration, a random password will be generated and sent to you by email.
Connecting Connect to the site by browsing to http://internet.processmanual.com select the Log-in button, then give your email address and password. Make sure that you are aware of the terms and conditions of use of the system. Once you have connected, you can use the Account menu to adjust your registration details and password as required.
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Using the Internet Process Manual
The Internet Process Manual is used in much the same way as the Intranet Process Manual. For more information on the features, refer to the Process Manual User Guide for the Intranet version. Major differences are noted below:
News items From time to time, news items may be posted to the Internet site. These will appear on the home page after you have logged in; click on an item to read additional details.
Feedback The Account menu has a Feedback option where you can enter comments and suggestions which will be relayed back to the appropriate Aspen contact.
Administration The Admin menu is not present in the Internet Process Manual. To access administrative functions for your company, you need to enter an administration code on the login page, and click on the Administrator login button. This is described further in the next section.
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Administration
To access administrative functions for your company, you need to enter an administration code on the login page, and click on the Administrator login button. This will display the administration page. This pages has a tab strip giving access to several sub-pages with various information and functions.
Introduction This sub-page summarizes the use of the other pages.
Settings This sub-page displays the configuration settings for your company account, and allows you to change them. Each setting has an explanation describing what it does.
Email This sub-page lists the restrictions on email address configured for your company. All user ids must conform to one of the patterns defined here. You cannot change the settings here; if you wish to adjust your email restrictions, contact support using the link in the top right of the banner.
IP Address This sub-page lists the restrictions on IP address configured for your company. All client connections must conform to one of the patterns defined here. You cannot change the settings here; if you wish to adjust your email restrictions, contact support using the link in the top right of the banner.
Users This sub-page lists the details of the users current registered on your company account. You can enable or disable accounts from here, and generate new (random) passwords for users (which will be emailed to them).
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At the bottom of the page, you can create a new user account. Details are automatically emailed to the user.
Usage This sub-page displays information on the usage by users in your company. You can display this information in various ways using the selection boxes at the top.
Account This sub-page summarizes your licensing details, listing the technical areas available and licences currently in use.
Named If your account has specific named licences, this sub-page allows you to allocate named licences to specific users.
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General Information
This section provides Copyright details and lists any other documentation related to this release.
Copyright Version Number: 2006.5 November 2007 Copyright © 1981 - 2007 Aspen Technology, Inc. All rights reserved. Process Manual™ (Registered in England and Wales No. 4229618), Process Tools™, ProFES 2P Tran™, ProFES 2P Wax™, ProFES 3P Tran™, ProFES Tranflo™, STX™, TASC-Thermal™, TASC-Mechanical™, Aspen Zyqad™, ACOL™, ACX™, APLE™, Aspen Adsim™, Aspen Aerotran™, Aspen CatRef®, Aspen Chromatography®, Aspen Custom Modeler®, Aspen Decision Analyzer™, Aspen Dynamics®, Aspen Enterprise Engineering™, Aspen FCC®, Aspen Hetran™, Aspen Hydrocracker®, Aspen Hydrotreater™, Aspen Icarus Process Evaluator™, Aspen Icarus Project Manager™, Aspen Kbase™, Aspen Plus®, Aspen Plus® HTRI®, Aspen OLI™, Aspen OnLine®, Aspen PEP Process Library™, Aspen Plus BatchFrac™, Aspen Plus Optimizer™, Aspen Plus RateFrac™, Aspen Plus SPYRO®, Aspen Plus TSWEET®, Aspen Split™, Aspen WebModels™, Aspen Pinch®, Aspen Properties™, Aspen SEM™, Aspen Teams™, Aspen Utilities™, Aspen Water™, COMThermo®, COMThermo TRC Database™, DISTIL™, DISTIL Complex Columns Module™, FIHR™, FLARENET™, FRAN™, HX-Net®, HX-Net Assisted Design Module™, Hyprotech Server™, HYSYS®, HYSYS Optimizer™, ACM Model Export™, HYSYS Amines™, HYSYS Crude Module™, HYSYS Data Rec™, HYSYS DMC+ Link™, HYSYS Dynamics™, HYSYS Electrolytes™, HYSYS Lumper™, HYSYS Neural Net™, HYSYS Olga Transient™, HYSYS OLGAS 3-Phase™, HYSYS OLGAS™, HYSYS PIPESIM Link™, HYSYS Pipesim Net™, HYSYS RTO™, HYSYS Sizing™, HYSYS Synetix Reactor Models™, HYSYS Tacite™, HYSYS Upstream™, HYSYS for Ammonia Plants™, MUSE™, PIPE™, Polymers Plus®, the aspen leaf logo, and Enterprise Optimization are trademarks or registered trademarks of Aspen Technology, Inc., Cambridge, MA. All other brand and product names are trademarks or registered trademarks of their respective companies.
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This document is intended as a guide to using AspenTech's software. This documentation contains AspenTech proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the software and the application of the results obtained. Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE.
Corporate Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803-5501 USA Phone: (1) (781) 221-4300 Toll Free: (1) (888) 996-7100 URL: http://www.aspentech.com
Related Documentation In addition to this document, the following documents are provided to help users learn and use this application. Title
Content
User Guide (Intranet version)
This guide provides an overview of the Process Manual features and how to use them.
On-line Help
A comprehensive on-line help system detailing all aspects of the Process Manual application.
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Technical Support
Online Technical Support Center AspenTech customers with a valid license and software maintenance agreement can register to access the Online Technical Support Center at: http://support.aspentech.com You use the Online Technical Support Center to: •
Access current product documentation.
•
Search for technical tips, solutions, and frequently asked questions (FAQs).
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Search for and download application examples.
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Search for and download service packs and product updates.
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Submit and track technical issues.
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Search for and review known limitations.
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Send suggestions.
Registered users can also subscribe to our Technical Support e-Bulletins. These e-Bulletins proactively alert you to important technical support information such as: •
Technical advisories.
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Product updates.
•
Service Pack announcements.
•
Product release announcements.
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Phone and E-mail Customer support is also available by phone, fax, and e-mail for customers who have a current support contract for their product(s). Toll-free charges are listed where available; otherwise local and international rates apply. For the most up-to-date phone listings; please see the Online Technical Support Center at: http://support.aspentech.com Support Centers
Operating Hours
North America
8:00 – 20:00 Eastern time
South America
9:00 – 17:00 Local time
Europe
8:30 – 18:00 Central European time
Asia and Pacific Region
9:00 – 17:30 Local time
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