Simplified Process Simulator Using Empirical Correlations

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Solution Overview

Problem

Complex process simulators are not feasible for small or remote process units due to high costs, technical expertise requirements, and significant computing power needs, making them inaccessible for day-to-day operations.

Innovation Solution

A novel process simulator using simplified mathematical correlations developed from operating data to predict equipment performance, allowing for real-time evaluation and decision-making by operating personnel, and can be run on personal or control system computers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If complex process simulators with physical property models are used, then measurement precision and reliability are improved, but device complexity and cost increase significantly

Engineering Contradiction:

Improvesimulation accuracyVSAvoidsimulator complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent transforms complex physical property models into simplified mathematical correlations by changing the parameters from fundamental physical properties to empirically derived correlation parameters. These correlations maintain sufficient accuracy for operational decisions while dramatically reducing computational complexity and making the simulator accessible to operating personnel without extensive technical expertise.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces expensive, complex simulation software with simplified mathematical correlations that can be implemented in affordable spreadsheet applications. This approach sacrifices some measurement precision but achieves sufficient accuracy for operational decision-making at a fraction of the cost, making simulation accessible to small and remote process units.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If complex process simulators are deployed, then simulation reliability is improved, but ease of operation deteriorates due to technical expertise requirements

Engineering Contradiction:

Improvesimulation reliabilityVSAvoidoperational ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent simplifies the input parameters from complex physical property requirements to basic operational parameters that operating personnel already understand and use daily. The mathematical correlations are designed to accept readily available process data and produce reliable results without requiring specialized simulation expertise.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The simplified simulator enables operating personnel to perform their own simulation and optimization analyses without requiring external expert assistance. The system is designed to be self-sufficient for operational decision-making, allowing personnel to evaluate alternative operating conditions and make informed decisions independently.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If complex process simulators are used, then measurement precision is improved, but use of energy increases due to significant computing power requirements

Engineering Contradiction:

Improveprediction accuracyVSAvoidcomputing energy

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent replaces computationally intensive physical property calculations with simplified mathematical correlations that require minimal computing resources. The correlations are designed to provide sufficient accuracy for operational decisions while consuming negligible computational energy, enabling real-time simulation on standard personal computers or control system computers.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If simplified mathematical correlations are used, then ease of operation and affordability are improved, but measurement precision may deteriorate

Engineering Contradiction:

Improveoperational accessibilityVSAvoidprediction precision

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent carefully selects and formulates mathematical correlations that maintain sufficient precision for operational decision-making while achieving simplicity and accessibility. The correlations are validated against actual plant data to ensure they provide accurate predictions for the specific operating range and conditions, balancing precision requirements with ease of use.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7464012B2Simplified process simulator

Publication Date: 2008.12.09 LAIR LIQUIDE SOC ANOMYME A DIRECTOIRE & CONSEIL DE SURVEILLANCE LETUD & LEXPL DES PROCEDES GEORCLAUDE

AI summary

Process simulators, including a novel process simulator that utilizes simplified mathematical correlations to predict the performance of equipment or subsystems in a process unit. The process simulator comprises a process correlation that is a mathematical response model for a discrete process system in a process unit. The process correlation is developed by obtaining operating data over a range of operating conditions of the process unit and regressing the operating data to form the mathematical response model. The process simulator calculates a number of output parameters using a number of input parameters. The process simulator outputs the output parameters so they can be used by operating personnel to evaluate the current operations of the process plant and make operating decisions.