Modelling solutions for industrial crystallisation processes
Industrial crystallisation is a highly complex process in chemical engineering, and it is becoming increasingly important in the chemical and pharmaceutical sectors. In fact, numerous intermediates and fine chemicals, as well as bulk products like fertilisers, are solids obtained through crystallisation. However, unpredictable crystallisation mechanisms lead to non-reproducibility, unacceptably low product qualities and significant production inefficiencies. The aim of the SINC-PRO project was to increase both the efficiency and effectiveness of continuous and batch crystallisation processes through on-line control. For this purpose, it brought together the experience and expertise of a number of industrial end-users, research centres and developers of modelling and control software. The development of an advanced control scheme involved the implementation of a generic modelling toolbox which can supply the models required for model-based control. Process Systems Enterprise Ltd (PSE) developed a user-friendly, configurable modelling environment, based on rigorous and hybrid crystallisation models and covering a wide range of crystallisation processes. It provides unrivalled modelling and solutions capabilities, enabling users to estimate kinetics parameters on the basis of experimental data, either from laboratory scale experiments or industrial plant data. Steady state models can be used in off-line determination of the optimal trajectory, thus leading to the desired final state, whilst dynamic simulations as a routine part of control verification and tuning for real-time and time-critical tasks. This modelling toolbox can be used in conjunction with external physical property and fluid dynamic software via an open interface. Significant savings on process capital and operating costs thus emerge, and safety and environmental compliance is enhanced. The methodology used in its development and validation have been made available as published papers.
