Development of operator training simulator for isopropyl alcohol producing plant

• Published in: Education for chemical engineers Vol. 22; pp. 35 - 43
• Main Authors: Puskás, János, Egedy, Attila, Németh, Sándor
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.01.2018
• ISSN: 1749-7728; 1749-7728
• DOI: 10.1016/j.ece.2017.11.003

•A stationary and dynamic simulator of an IPA plant was created in UniSim.•With a HMI an OTS of the system was implemented in Microsoft Excel.•An optimisation and a scenario task was built to test the knowledge of the different operators.•The OTS was tested using groups with different educational background.•The developed OTS can be used in the chemical engineering education, and will be implemented next year. In this study, an operator training simulator was developed for an isopropyl-alcohol producing plant. The main product of this plant is isopropyl alcohol — water azeotrope, by-product is diisopropyl ether which are formed by direct hydrolyzation of propylene via strong acid cation exchange resins. Firstly, the steady-state simulator of the plant was developed. The next step was to develop the dynamic simulator and the control system of the process. Reference data – main parameters of the equipments and streams – for this simulator was provided by the stationary simulator. The simulator contains the preheater and the reaction subsystems. Finally, an operator screen was developed and connected to the dynamic simulator via UniSim Excel Interface Tool. This operator training simulator can be used for analysis and optimization of the process. The OTS, which was tested by students, can be applied by chemical engineering students in different tasks – analysis, optimization and scenario – hence it can be used in education. By the use of this OTS the students may acquire adequate knowledge to control, optimize a process and handle malfunctions. This knowledge will be useful for them to operate the control system of a chemical plant. Honeywell’s UniSim® Design was used in the present simulation and further studies.