Modular Processing Plant Layout for Faster Liquid Plant Reconfiguration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Designing and modifying complex liquid processing plants is time-consuming and error-prone due to the need for manual configuration of numerous controllable components, requiring extensive knowledge of the existing plant and often necessitating extensive redesign when changes are needed, such as adding new products or functionalities.
Innovation Solution
A module-based approach using a platform database and design element database to represent processing plants by functionality rather than physical structure, allowing for intelligent selection and modular addition of design elements with defined relationships, facilitating efficient design and redesign by converting functional representations into control logic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a processing plant is designed to handle multiple liquid products with various processing routes, then the plant's versatility and adaptability are improved, but the device complexity and control scheme complexity increase significantly
Solution Approach 1:
The processing plant is divided into modular functional units (e.g., heating unit, cooling unit, mixing unit, separation unit), each with standardized interfaces. This segmentation allows versatile configuration for different products while keeping individual module complexity manageable.
Solution Approach 2:
Standardized functional units are designed to perform multiple operations across different product lines. For example, a heating unit can serve multiple processing routes for different liquid products, reducing overall system complexity while maintaining versatility.
2Reliability
If each controllable component is programmed individually to ensure proper operation, then the reliability and operational precision are improved, but the design time and manual configuration effort increase significantly
Solution Approach 1:
Control logic for functional units is pre-configured and validated during module design. This preliminary action ensures operational reliability is built-in from the start, eliminating the need for extensive individual programming and testing during plant design and commissioning.
Solution Approach 2:
Multiple control functions are merged into integrated control modules that manage coordinated operation of equipment within functional units. This reduces the number of individual programming tasks while maintaining comprehensive control and reliability.
3Adaptability or versatility
If a processing plant is designed with comprehensive functionality to handle various products, then the plant's adaptability is improved, but the ease of manufacture and implementation of changes deteriorate
Solution Approach 1:
The plant is constructed from standardized functional modules that can be independently manufactured, tested, and assembled. This segmentation enables easy implementation of changes by simply replacing or reconfiguring specific modules without affecting the entire system.
Solution Approach 2:
The modular architecture allows dynamic reconfiguration of processing routes and functional unit assignments based on product requirements. Changes can be implemented by reprogramming control logic and reconfiguring module connections rather than physical redesign.
4Productivity
If design tools are used to facilitate the design procedure, then the productivity is improved, but the ease of operation and difficulty of implementing changes worsen due to excessive work and complex configurations
Solution Approach 1:
Design tools are structured to work with modular functional units rather than requiring comprehensive plant-wide configuration. This segmentation simplifies the design operation by allowing designers to work with individual modules and their standardized interfaces.
Solution Approach 2:
Standardized functional modules serve as reusable templates that can be copied and instantiated multiple times throughout the plant design. This copying approach maintains design productivity while reducing operational complexity through consistency and reusability.
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A method for a processing system is provided. The method comprises the steps of identifying at least one specific functionality of the processing plant, creating at least one design elements, each design element being associated with a specific functionality of the processing plant, and storing each design element as an item in a design element database, wherein each design element item comprises one or more attributes defining the relationship between the particular design element and other design elements.