Background
Dynamic simulation is the time-based simulation of an operating plant or process such as a copper smelter. Computer-based dynamic simulation has become an increasingly power tool over the last two decades aimed at optimization of complex industrial operations. The ability to dynamically simulate a given plant or process over time, such as a week or a year of operation including running times and potential downtimes, can provide invaluable insight to the understanding of a plant. This can help in projects to increase throughput, plant de-bottlenecking exercises, or in brownfield expansion projects (discrete event modelling).
Without having a high level look at how your systems are all working together, it's difficult to make decisions. Understanding your bottlenecks, capacity constraints, and other issues, will allow you to make informed decisions to improve your day to day operations. This plant was facing exactly this issue and needed a tool to understand their opportunities.
Solution
By implementing Arena Simulation Software to develop a model, the team was able to understand the system from raw materials entering to final products leaving. The clarity into their systems allowed them to identify bottlenecks and other key areas of improvement. Using this data, they were able to implement changes quickly and efficiently.
Results
- Understanding and resolving a number of plant bottlenecks to allow full plant entitlement to be reached
- Determining plant capacity under certain upset conditions (such as maintenance situations, unexpected shutdowns, etc.).
- Optimizing operating schedules
- Overall flow-sheet optimization