An Application of Discrete-Event Simulation for Batch-Process Chemical-Plant Design

Operating a batch-processing chemical-plant efficiently is difficult. Chemical processes require specialized equipment that is sensitive to precise operating conditions and subject to strict quality conformance. Chemical formulations having unique attributes require the simultaneous use of multiple resources to process and move products through the plant. One of our clients used a generic simulation model we developed to help design and operate a multimillion-dollar batch-process chemical facility. Our client used the model to evaluate the impact of many complex issues—such as scheduling policy, inventory policy, resource sizing and configuration, operator schedules, and processing capability—for a proposed process facility. The client used the model to identify throughput issues related to new plant designs and to evaluate proposed improvements prior to implementation, thus saving considerable cost and time.