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PROCESS SIMULATION
The SCC process modeling capability is unique in
the industry. It enables the most efficient unit operation design, and plant
integration.
TOOLS
The process simulation is done with a variety of tools which are, tailored
to the client’s needs and process. Some modeling tools are developed in
house, and others are off-the-shelf commercial packages. The SCC approach is
to use the most effective model for each part of the process; this often
requires multiple software packages be employed in one plant design.
“Tracked Species
Count Sample. The number in the star is the count of non-zero species
tracked in the stream or block. This flow sheet is an example of one
integration project that SCC worked on. The number of tracked species from
your project may vary depending on process conditions.”
PHYSICAL PROPERTIES
The SCC physical property library is likely the only one like it in the
world for modeling silicon containing chemicals. Many species of interest
for silicon processes are not contained in standard chemical databases. Some
of the chemical species in standard databases have incorrect information.
SCC has used experimental data to correct the standard database data, and
has generated data for missing compounds for all of the relevant chemical
species in the process.
DISTILLATION
The distillation modeling at SCC is a perfect marriage of thermodynamics and
experience. Based on experimental data from operating chemical plants, the
SCC distillation model has been validated and developed meticulously so that
it can track and model the removal of trace species. Some purification
columns in chlorosilane processing are complex and have a non-standard
operation. SCC understands how to run, model, and control such distillation
columns. The SCC purification philosophy is to understand the chemical forms
a final impurity takes throughout the process, then design the processes to
effectively remove it. This knowledge is incorporated into the
Nonequilibrium (rate-based) distillation model, because the column
separations are the primary contaminant removal pathway. SCC provides a
wealth of distillation column data customized to the client’s particular
process.
Such data includes:
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Tray-by-tray liquid and
vapor flow rates and composition
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Temperature and pressure
profiles in the column
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Reboiler and condenser
duties
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Tower diameter and tray
spacing
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Sampling ports and
strategy
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Furthermore the SCC
distillation modeling can
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Assist during start-up
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Minimize wasted energy
and material
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Design to handle upset
conditions
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Understand turn down and
alternate operation modes
“Liquid Phase
Tower Composition Profile. This plot shows the liquid phase compositions in
a tower separating trichlorosilane from silicon tetrachloride. Minor
constituents have been omitted from the chart for purposes of presentation
simplification.”
FLUIDIZED BED REACTOR
The fluidized bed reactor model is heavily experienced based. SCC has based
its reactor design on well proven technology with the fundamental principles
of safe operation, simple design, and reliable service. The SCC design
allows a high degree of on-stream time, superior chemical conversion
efficiency, and a lower construction expense compared with other designs.
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