Development and Use of Computer Simulation of Fertiliser Granulation

Development and Use of Computer Simulation of Fertiliser Granulation.

Keywords: granulation model, dynamics, operator training, validation, fertiliser.

Summary:

This paper describes the development and use of a dynamic fertiliser granulation model within DSM. The objective is to use the model for dynamic optimisation of the plant, to investigate control strategies and to perform operator training. The model can also be used for equipment optimisation when it is run in steady state mode. The paper consists of the following sections: description, implementation, validation and use of the model.

First a description is given of the modelling of the different unit operations occurring within a fertiliser plant. The unit operations described are granulator, cooler/dryer, breakers and sieves. The simulation model has been implemented on a personal computer and provisions have been made so that process parameters can be changed during a simulation. This allows the opportunity of using the model for operator training. The model has been validated using three types of measurements: single equipment measurements, steady state production test runs and a dynamic production test run where a start-up of the granulation plant was monitored. The use of the model is demonstrated by simulating the effect of reducing the feed to the installation and monitoring the effect on the flows, moisture content of the product and granule size.

This investigation shows that dynamic fertiliser granulation models can be used in a real-time environment and have an added value for the use in a modern production organisation.

Dr.ir. Pieter Vonk and Dr.ir. Stefan Schaafsma, Centre for Technology and Analysis, Advanced Chemical Engineering Solutions, Centre for Particle Technology, DSM Research, P.O. Box 18, 6160 MD Geleen, Netherlands.

15 Pages, 11 Figures, 4 References.