DYNAMIC OPERATOR TRAINING SIMULATORS (OTS)
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<strong>DYNAMIC</strong> <strong>OPERATOR</strong> <strong>TRAINING</strong><br />
<strong>SIMULATORS</strong> (<strong>OTS</strong>)<br />
for Sulphuric Acid, Phosphoric Acid,<br />
and DAP Production Units<br />
Coral Siminovich, Sergio Joao
AGENDA<br />
› <strong>OTS</strong> Definition and Benefits<br />
› Scope and Simulators<br />
› DEMO<br />
2
WHAT IS<br />
AN <strong>OTS</strong>?<br />
Dynamic representation of the plant<br />
MODEL<br />
GRAPHICS<br />
<strong>TRAINING</strong><br />
› Datasheets, P&IDs,<br />
H&MB, operating data<br />
› Thermodynamics<br />
› Unit Ops<br />
› Controls and logic<br />
› DCS functionality<br />
› Manual operations<br />
› Exercises (upsets,<br />
start-up, shutdown)<br />
› Evaluation<br />
3
WHY USE<br />
AN <strong>OTS</strong>?<br />
Prediction<br />
R&D<br />
Increased safety<br />
and profitability<br />
Improved response to process upsets<br />
What-if scenarios<br />
Faster start-ups and shutdowns<br />
More efficient training<br />
Employee certification<br />
Improved skills<br />
Accurate diagnosis<br />
For the company<br />
For the operators<br />
Higher confidence level<br />
Better understanding<br />
4
SIMULATOR<br />
FEATURES<br />
Accurate steady state<br />
representation (
SCOPE AND DEVELOPED<br />
<strong>SIMULATORS</strong><br />
OCP Skill Program<br />
(registered trademark of OCP S.A.)<br />
BENEFICIATION<br />
(In Progress)<br />
ATTACK &<br />
FILTRATION<br />
(In Progress)<br />
ACID<br />
CONCENTRATION<br />
(Completed)<br />
DAP<br />
PRODUCTION<br />
(Completed)<br />
OCP Group<br />
Khouribga<br />
SULPHURIC<br />
ACID<br />
(Completed)<br />
6<br />
OCP Group<br />
Jorf Lasfar
CONCLUSION<br />
› <strong>OTS</strong>: key tool for training, cutting losses / incidents<br />
› Developed 3 high-fidelity simulators for OCP Group’s Jorf<br />
Lasfar complex:<br />
› Sulphuric Acid<br />
› Phosphoric Acid<br />
› DAP Production<br />
› Accurate representation of the plant<br />
› Training Exercises (start-up, shutdown, upsets)<br />
› Future work: MAP, NPK, phosphoric acid attack/filtration,<br />
and beneficiation simulators<br />
7
ACKNOWLEDGEMENTS<br />
OCP Group:<br />
Mr. Amine Louali<br />
Mr. Hicham El-Habti<br />
Mr. Youssef Lahmiti<br />
Mr. Alaoui Driss<br />
Mr. Mabrouk Kamal<br />
Mr. Noufoussi Hassan<br />
Mr. Abdelouahed Tari<br />
SNC-Lavalin:<br />
Mr. Jose Alamo<br />
Mr. Guillaume Perron<br />
E-learning & <strong>OTS</strong> teams<br />
8
DEMO<br />
DAP PRODUCTION UNIT<br />
9
DAP PRODUCTION <strong>OTS</strong><br />
› Developed high fidelity<br />
granulator module<br />
› PSD<br />
› Moisture content<br />
› NH3 and dust losses<br />
› Gas/solid temperatures<br />
› Reactions<br />
› Modeling of phosphoric acid<br />
quality variations<br />
10
DAP PRODUCTION <strong>OTS</strong><br />
› Crystallization (based on<br />
solubility curves, NP ratio)<br />
› NP ratio and temperature effect<br />
on NH 3 vapor pressure<br />
› Common upsets:<br />
› Poor distribution of NH 3<br />
and slurry in granulator<br />
› Obstruction of lines<br />
11
DAP PRODUCTION <strong>OTS</strong><br />
› Representation of key<br />
variables<br />
GRANULATOR<br />
Pre-neutralizer<br />
Plant data Model<br />
NP ratio 1.41 – 1.54 1.52<br />
Temperature (°C) 118 – 121 120<br />
Density (kg/m3) 1510 –1545 1540<br />
Product<br />
Plant data<br />
Model<br />
N % 17.45 – 18.54 17.89<br />
P % 45.53 – 47.97<br />
47.1<br />
Humidity % 1 – 2.2 1.1<br />
12
DAP PRODUCTION <strong>OTS</strong><br />
Ribbon Bar<br />
Active Tabs<br />
Navigation Pane<br />
13<br />
Status Bar
14<br />
DAP PRODUCTION <strong>OTS</strong>
15<br />
DAP PRODUCTION <strong>OTS</strong>
DAP PRODUCTION <strong>OTS</strong><br />
Simulation of lab results<br />
Granulator Output<br />
Final Product<br />
16
DAP PRODUCTION <strong>OTS</strong><br />
GRANULATOR<br />
AMMONIA FLOW<br />
Granulator step test<br />
› 50% increase<br />
ammonia feed flow<br />
17
DAP PRODUCTION <strong>OTS</strong><br />
Granulator step test<br />
•Product NP Ratio<br />
•Ammonia feed flow<br />
•Ammonia losses to treatment<br />
•Product humidity<br />
18
DAP PRODUCTION <strong>OTS</strong><br />
Granulator step test<br />
• PSD > 1.0 mm<br />
• PSD > 2.0 mm<br />
• PSD > 2.5 mm<br />
• PSD > 3.1 mm<br />
• PSD > 4.0 mm<br />
19
20<br />
DAP PRODUCTION <strong>OTS</strong>
21<br />
DAP PRODUCTION <strong>OTS</strong>
DEMO<br />
OTHER EXAMPLES<br />
22
SULPHURIC ACID<br />
<strong>OTS</strong><br />
› Run model 25X real time<br />
› 6 day start-up done in 1 day<br />
› New fluid package for<br />
sulphuric acid/oleum<br />
23
SULPHURIC ACID<br />
<strong>OTS</strong><br />
› Literature-based modeling<br />
› Converter beds<br />
› Absorption towers<br />
› Sulphur burner<br />
› Stack mist prediction<br />
24
SULPHURIC<br />
ACID <strong>OTS</strong><br />
› Representation<br />
of key variables<br />
Converter Temperatures (°C)<br />
Design data<br />
Model<br />
Bed 1 in/out 420 / 604 420 / 601<br />
Bed 2 in/out 454 / 545 451 / 539<br />
Bed 3 in/out 449 / 484 443 / 476<br />
Bed 4 in/out 425 / 455 420 / 450<br />
25
PHOSPHORIC ACID<br />
<strong>OTS</strong><br />
› Reconciliation of lab and<br />
real components<br />
› Impurities definition and<br />
effects<br />
› Fluid package<br />
adjustments for low<br />
pressure system<br />
26
PHOSPHORIC ACID<br />
<strong>OTS</strong><br />
› Availability of Results<br />
› Lab analysis (e.g. P 2 O 5 )<br />
› Real components (e.g. H 3 PO 4 )<br />
› Common upsets<br />
› Obstruction of evaporator heat<br />
exchanger filter<br />
› Heat exchanger fouling<br />
› Loss of vacuum<br />
27
28<br />
PHOSPHORIC<br />
ACID <strong>OTS</strong>
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