Abstract
Digital twins are rigorous mathematical models that can be used to represent the operation of real systems. This connection allows for deeper understanding of the actual states of the analyzed system through estimation of variables that are difficult to measure otherwise. In this context, the present manuscript describes the successful implementation of a digital twin to represent a four-stage multi-effect evaporation train from an industrial sugar-cane processing unit. Particularly, the complex phenomenological effects, including the coupling between thermodynamic and fluid dynamic effects, and the low level of instrumentation in the plant constitute major challenges for adequate process operation. For this reason, dynamic mass and energy balances were developed, implemented and validated with actual industrial data, in order to provide process information for decision-making in real time. For example, the digital twin was able to indicate failure of process sensors and to provide estimates for the affected variables in real time, improving the robustness of the operation and constituting an important tool for process monitoring.
Highlights
The most important areas that affect evaporation systems in typical sugar mills are milling and crystallization
This paper focuses on the dynamic modeling of a real multi-effect evaporation (MEE) system
Independent hold up is considered for all effects; Perfect mixing is considered in the juice chamber, so that the juice that leaves the evaporator has the same properties of the juice present in the chamber; Steam does not accumulate within the calandria; The boiling-point of the juice is affected by brix, temperature and pressure; Thermodynamic parameters and densities vary with temperature and brix; Only the latent heat of the steam is transferred within the calandria; Energy loss is negligible as steam passes across a restriction, such as a steam valve; The evaporation process produces superheated steam as an effect of boiling-point elevation; The amount of heat stored in the chamber walls is negligible; Variations of ambient temperature can be ignored
Summary
The most important areas that affect evaporation systems in typical sugar mills are milling and crystallization. These decisions are driven by different abstract criteria, converging to simple and trivial actions that may lack the desired technical and methodological foundations and can be biased In this context, there certainly are many opportunities to improve process performance and market competitiveness in the sugar-energy industry, which may be accomplished through application of advanced process engineering tools, such as digital twins. Some authors developed steady-state models that could provide good fits of industrial data [4,5,6,7], but these tools have been used so far for off-line applications In these cases model and process are disconnected. This work presents the development and implementation of a customized digital twin to assist the production MEE operation in real time, connecting and synchronizing model and plant to build an integrated tool for process monitoring in real time. The model can be used in many applications, including operator training, fault identification, advanced process control and optimization
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
