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PROCESS SIMULATION CUP 2018Anna Wolna1,2, Jan C. Schöneberger1, Armin Fricke1,2 1 Chemstations Europe GmbH, Lindencorso, Unter den Linden 21, 10117 Berlin, Germany | info@chemstations.eu2 CGC Capital-Gain Consultants GmbH, Poststraße 12, 10178 Berlin, Germany

REAL-LIFE SIMULATION TRAINING FOR PROCESS ENGINEERING STUDENTS

BIOTECHNOLOGY: THE SCIENTIFIC REVOLUTION OF THE FUTUREBiotechnology is the cornerstone of the modern world and constantly evolves in the scope of its application, the range and power of its techniques. Innovation in biotechnology has the capacity to address

global problems, such as food and energy security or human diseases.

CHALLENGES IN ENGINEERING COURSES

→ Lack of real-life industry data → Reliance on textbook problems → Need for innovative teaching methods → Student’s readiness to enter the industry → Technology of commercial simulators

→ Theory meets practice → Replication of complex real world aspects → Hands-on teaching method → Industry focused skills development → Enhance student’s technical knowledge

WHY TEACH WITH SIMULATIONS

PSC AS A UNIQUE PROCESS SIMULATION TEACHING TOOLPSC tasks emulate the modern demands and challenges relevant to engineering professionals. Students apply knowledge gained in the classroom in a real-work environment. PSC benefits:

TEACHERS → Real industry data simulation training → Practical student/class assessment tool → Motivating and challenging teaching tool → Active teaching method → Increased learning outcome for students

STUDENTS → Critical and problem solving skills test → Understanding of the essence of the

simulated phenomenon → Technical software knowledge → Industry relevant skills acquisition

PSC2018 CHALLENGE

CHALLENGE BACKGROUND The simulation task is set in the context of one of the first world scale bacteria-based PDO production facilities. The plant is grouped into the process units: Fermentation, Filtration, Ion Exchange and Distillation. A change in the fermenter output caused by an unforeseen bacteria behaviour turned the company profit negative.

DESIGN VARIABLES: F01: Air flowrateF02: Cane juice feed rateF03: Ammonia feed rateF04: Acetic acid feed rateD01: Flowrate of dilution waterD02: Split of dilution water to MF1D03: Split of dilution water to MF2

D04: Pre-heating of dilution water to MF1D05: Flowrate of recycled head productD06: Evaporator pressureD07: Evaporator vapor fractionD08: Condenser pressureD09: Condenser temperatureD10: Column 1 pressure

D11: Column 1 reflux ratio D12: Column 1 bottom temp. D13: Column 2 pressure D14: Column 2 reflux ratio D15: Column 2 bottom temp. MF: Micro Filtration

The graph shows the reactor content during the cycle time of 30 hours. After this time the reactor content is transferred to the intermediate storage tank.

Reac

tor C

onte

nt (k

g)

200000

180000

160000

140000

120000

100000

80000

60000

40000

20000

0

Time (h)0 5 10 15 20 25 30

GlucoseBiomassDead biomassPDO

MODEL OF THE BACTERIA-BASED PDO PRODUCTION PROCESS

FED-BATCH RESULTS

It is in the interest of educators to arrange teaching methods and  assessments which reflect aspects of the real world in an interactive fashion. PSC is a modern process simulation training tool designed to meet the demands of today’s engineering education. Real-life based simulation problems bring broad-spectrum benefits to academia, students and the industry.

SUMMARY

FED

-BAT

CH

FER

MEN

TATI

ON

PRO

CES

SC

ON

TIN

UO

US

DO

WN

STRE

AM P

ROC

ESS

FERMENTATION SECTION

FILTRATION SECTION

Distillation Section Ion Exchanger

Product

IntermediateStorage Tank

HOW TO JOIN PSC

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REGISTER ONLINE

DOWNLOADCHEMCAD & FLOWSHEET

CRUNCH NUMBERS

SUBMIT VARIABLES

CHECK HIGHSCORE TABLE FOR RESULTS

TASKThe participants are required to restore company’s balance sheet by finding the optimal set of design variables to generate maximum profit. To find solutions, students use the process simulation software CHEMCAD and the provided flowsheet. The contestants submit their set using an online form and are not asked to upload their flowsheets.

→ Open to bachelor, masters, Ph.D. students → Open to CHEMCAD users and non-users  → Tasks developed with real industry data → Fully automated online contest → Worldwide entry all year long  → Unlimited number of participants → Unlimited number of submissions   → Calculations displayed in real-time → Full process description and flowsheets provided

PSC FEATURES PSC AWARDS → Professional CHEMCAD Training → Certificates & Vouchers → Recognition on PSC website

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