Operator training simulator process model implementation of a batch processing unit in a packaged simulation software

In chemical industry, especially in the case of continuous processes, operator training simulators (OTS) are becoming widely used. With the help of these systems several operation and safety issues can be analysed, and the operating staff of the plant can be trained for handling different plant failures. The main part of the OTS is the process model that replaces the real technology. Hence, in control development the simulated process variables are required to be reasonably accurate. The paper presents the structure of the process model of a batch processing unit in UniSim Design, different model constructions of a jacketed batch reactor and the identification of the parameters affecting its hydrodynamic and thermal behaviour. Construction of the process model is the first step in developing the OTS of the pilot plant located in the authors’ laboratory. It can be an effective tool in the development of model-based control systems.

► Different commonly used flowsheeting simulation software was tested.
► The process model was built in packaged flowsheeting simulation software.
► Different batch reactor model constructions were tested.
► Better results can be achieved using a temperature-dependent heat transfer coefficient.
► The models of measuring instruments are necessary for reliable simulation results.