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Simulation-driven engineering to reduce risk and cost
Compass Minerals: A new crystallizer and compaction plant in Ogden, Utah, USA
Challenge
Integrate new and existing processes
American leading minerals producer Compass Mineral was planning a sulfate of potash (SOP) project, including a new crystallizer and compaction plant. Compass Minerals wanted its new SOP operation ready for production with minimum start-up delays, a quick ramp-up to full production, and minimal impact to existing operations.
Commissioning new equipment alongside the existing operation required finding innovative ways to program the controls, train operators, and provide power. The aggressive schedule and need to integrate equipment from several vendors led Compass Minerals to ANDRITZ.
ANDRITZ had previous experience dynamically modeling crystallizers and demonstrated this capability to Compass Minerals’ management team.
Based on this and on ANDRITZ’s record of successfully delivering simulation, advanced process control, power distribution, and training solutions to its clients, ANDRITZ was awarded the contract.
Solution
Simulation-driven engineering that reduces project risks
Drawing on its prior potash experience and focus on simulation-driven engineering, ANDRITZ offered an innovative way to minimize start-up risks, reduce implementation costs, and predict impact on the existing operation. In addition to modeling the compaction process, ANDRITZ proposed simulating the SOP crystallizer (including the saturation curves) using the IDEASTM process simulator in order to accurately predict the crystallizer’s behavior.
The simulator was also used for P&ID validation, operator training, and development of the process controls. The latter included configuration of BrainWave, which is a patented advanced control system that uses an adaptive internal model and predictive control to automatically stabilize and optimize complex industrial plant operations more effectively than traditional PID controllers. Operators were trained on the new equipment and control system using the simulator before start-up, effectively minimizing the impact to existing operations.
ANDRITZ validated the process design, designed and supplied the control system, supplied the power distribution (E-house), motor control equipment, patented BrainWave advanced controller for the SOP crystallizer, and developed a simulation-based operator training program.
The total scope of the project included:
• Dynamic modeling of SOP processes using the IDEAS
simulator
• P&ID validation of processes and control concepts
• Simulation-based operator training
• Complete control system supply
• Model-based control logic staging
• BrainWave advanced control of the new crystallizer
• Power distribution center (E-House)
• On-site commissioning and start-up support
Results
Accurate prediction and fully automated integration
ANDRITZ’s IDEAS simulator predicted how the new SOP plant (and crystallizer) would behave from a dynamic process and control standpoint. The simulation was interfaced with the control system to test all control logic, and the control system was later debugged with difficult control loops in automatic control. Upon startup, Compass Minerals had a fully integrated control system that was ready for operation from day one.
“There is payback after payback with the ANDRITZ simulation-based engineering approach.”
