industry
- Design and optimisation of industrial processes
- Fluidodynamic consultancy
- Design and execution of experimental studies and pilot plants
Design and optimisation of industrial processes
SIMPPLE offers technological products and services based on its broad experience and knowledge in industrial chemical processes and fluid mechanics. Such knowledge is materialised in the development of R+D+i projects outsourced by the industrial sector, the design, diagnosis and improvement of production processes, including technical and environmental improvements or the development of new chemical processes.
To execute these projects SIMPPLE employs computational and experimental methods.
The numerical simulation services offered are:
- Process simulation
- Kinetic modelling of chemical reactions
- Detailed calculation of process equipment using CFD
Process Simulation
This group of computational studies includes simulations based on the resolution of macroscopic balances of materials and energy in the various unitary operations of a chemical plant.
Examples of equipment that is often calculated in this manner include:
- Ideal reactors: perfect mixture, for discontinuous (batch) or continuous (CSTR) operations, tubular reactors (PFR, PBR)
- Equipment for separation processes: flash separators, distiller, absorption and stripping columns, etc.
- Heat exchangers
- Pumping, compression and similar systems: pumps, compressors, turbines
- Residual water treatment processes: oxidisation, clarification, adsorption, filtration, etc.
- Instrumentation and intelligent control systems
This is the most frequent type of simulation in the chemical industry, since it allows most of the required calculations to be made in the ambit of chemical processes: basic design of equipment, optimisation of operating conditions, viability studies, etc.
The calculations may be performed in a stationary or non-stationery state. The latter allows the evaluation and optimisation of the transitory states of a plant, and to carry out What-If analysis, the optimisation of control strategies, etc.
Kinetic modelling of chemical reactions
SIMPPLE has specific software for the development of kinetic models, with particular emphasis on complex reactions:
- Polymerisation processes, either in solution, emulsion, suspension or mass; batch or continuous
- Ziegler-Natta catalysis and metalocenes (HDPE, LLDPE, PP...)
- Free-radical polymerisation (PS, SAM, PVC, PMMA, LDPE, PVA...)
- Ionic polymerisation (PS, SBR...)
- Chain growth polymerisation (PET, PBT, PC...)
- Homogeneous and heterogeneous catalytic reactions, enzymatic reactions
- Multi-phase reactions
As a result, not only is the average speed of the reaction obtained (consumption of monomers and catalyser) but also the structural characteristics of the product (average molecular weight, polydispersity, ramification index, tacticity, composition of copolymers and terpolymers, particle sizes, etc.), all based on a relatively small quantity of experimental data.
Once a suitable kinetic model has been obtained, manufacturing processes may be optimised through increased productivity or improvements to product quality (reduction in polydispersity, etc.)
Detailed calculation of process equipment using CFD
Computational Fluid Dynamics (CFD) has countless applications in the industrial sector, especially, although not limited to, chemical and similar sectors (pharmacy, energy, paper, cement, etc.). In general terms, CFD allows the detailed design, optimisation and diagnosis of:
Process equipment:
- Agitated tanks (mixing tanks, chemical reactors).
- Fixed-bed and fluidised-bed catalytic reactors: gas-liquid, gas-solid, liquid-solid.
- Separators: decanters, filters, cyclones, membranes, etc.
- Heat transfer equipment: exchangers, ovens, boilers, dryers, etc.
- Rotary equipment: extruders, pumps, compressors, turbines, etc.
- Static mixers, gas/liquid distributors, pipes, valves, etc.
Other industrial processes involving fluids:
- Metallurgy: metal casting processes.
- Plastic transformation industry: design of injection moulds.
- Glass moulding.
- Formation of synthetic fibres.
- Lubrication processes.
- Process intensification: micro-reactors and micro-devices.
Fluid Dynamics Consultancy
In this line of activity, two clearly differentiated types of projects are executed.
- Problem solving: Carrying out studies and analysis of problems that exist in equipment and installations that have already been designed but not optimised. We isolate and identify the causes and solve the problem, proposing modifications and alternatives, subject to the limitations imposed by the process and the client. The solutions we propose have a direct impact on the efficiency of the process and immediate benefits will be obtained.
- Process and equipment design: Conceptual design of a process or idea which the client has in mind but does not know how to implement. The study and consultancy of such turnkey solutions normally offer even greater efficiency, since the entire design is carried out by the same team from the outset.
The type of problems that are solved are of a conceptual and design nature in systems or process that involve fluids, liquids or gases, with the transfer of quantities of movement, heat and species, single or multi-phase, in laminar or turbulent flows, with or without chemical reaction or phase changes and even combustion. The type of technique, experimental or numeric, and the level of detail with which each problem is studied obviously depends on its complexity.
The methodologies and techniques that are used for the execution of projects are:
Since 2000, SIMPPLE has been a pioneer in Spain in the use of CFD applied to industry, which has given it broad experience and knowledge in this field, as well as national recognition as an innovating company by applying this tool to the chemical industry.
Experimental studies and pilot plants
One of the company’s lines of activity is the design and execution of experimental studies aimed at research and development centres, and the engineering, production and environmental departments of companies for the purposes of designing new products and processes, optimising existing processes and solving problems by employing the transversal skills and experience of SIMPPLE’s highly qualified workforce.
Laboratory studies
- Preliminary and viability studies in the laboratory
- Diverse analytical tools
Design and construction of mini-plants and laboratory-scale plants
- Polymerisation reactions
- Catalytic hydrogenation – agitated and fixed-bed reactors – and hydrotreatment
- Steam reforming
- Batch and continuous distilling
- Oxidation and hydrolysis with super-critical water
- Residual water treatment
Projects that require a high level of development, or public R+D+i grants, may count on the participation of the CTQ of the Autonomous Government of Catalonia’s IT Network of Innovating Technology Support Centres.
