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Aspen HYSYS Process Simulation Guide

The document provides an overview of a chemical engineering simulation course taught by ChemicalEngineeringGuy.com. The course introduces students to process modeling and simulation using Aspen HYSYS software. It covers setting up a flowsheet, adding common unit operations like heat exchangers, distillation columns and reactors, running simulations, and analyzing the results of changes to process conditions. The course aims to give students basic proficiency in process modeling to support their chemical engineering studies.

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Hariajah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
1K views59 pages

Aspen HYSYS Process Simulation Guide

The document provides an overview of a chemical engineering simulation course taught by ChemicalEngineeringGuy.com. The course introduces students to process modeling and simulation using Aspen HYSYS software. It covers setting up a flowsheet, adding common unit operations like heat exchangers, distillation columns and reactors, running simulations, and analyzing the results of changes to process conditions. The course aims to give students basic proficiency in process modeling to support their chemical engineering studies.

Uploaded by

Hariajah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Introduction
  • Our Chemical Process
  • Physical Property Environment
  • Simulation Environment I - The Flowsheet
  • Simulation Environment II - Unit Operations
  • Running, Results & Analysis
  • Case Studies
  • Conclusion

Chemical Engineering Guy

[Link]
Change:

• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs

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 Makes us easier/faster work
 Multiple and Simultaneous Simulations
 Different Real-Life Scenarios
 Change on raw/feed materials scenario

 Pricing and Costs calculation


 Raw Materials
 Plant Cost
 Utilities

 How it would behave under different conditions


 High/Low Pressure
 Humidity Changes
 Temperature change (cool/warm days/seasons)

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 Mainly:
 Petrochemical
 Pharmaceutical
 Fine chemicals

 Other commodities such as:


 Sulfuric acids
 Chlorine/Caustic industry
 Solvents
 Coatings
 Many more…

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 Excelent for your curriculum as an engineer

 Perfect for analytical/numerical minds

 Good for debuging and fixing “what if” scenarios

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1. Introduction
2. Our Chemical Process!
3. Setting up the Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Running, Results & Analysis
7. Case Studies (A,B,C,D)
8. Conclusion

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 Introductory Knowledge of Processes Modeling
 Setting the adequate Physical Properties
 General Flowsheet Concepts
 Basic Flowsheet “manipulation”
 Common Unit Operations
 Minimum Requirements to set up & run a Simulation
 Analyze several changes in process conditions
 Create an interest in Process Modeling

[Link]
 Please contact me if required (doubts, questions, comments, suggestions)
 Contact@[Link]
 More courses…

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 Unit Operations
 Heat Exchange
 Heat Exchanger
 Reaction Kinetics
 Combustion Chamber / Reactor
 Momentum
 Pump
 Turbine / Expander
 Separation Process
 Flash Drum
 Distillation Columns

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 A stream of three hydrocarbons are to be treated as follows:
 Methane, Iso-Pentane and Dodecane must be separated.
 Methane is only useful as a fuel, must be separated in a flash drum and sent to stack
 Main separation is achieved in a Flash Drum
 P/T is adjusted to: 15°C, P = 456.6 kPa. Operation is Adiabatic

 Dodecane and isopentane are valuable, so they must be further separated


 P/T conditions are adjusted for the Column
 The distillation column operates with a partial condenser and reboiler
 The current operation states that:
 N = 20 stages, being fed at 10th stage. Reflux ratio is 2.5 approx., with 2.15 – 21.50 Gas-Distillate Ratio
 Dodecane is required at 150 kPa in the following Plant but Iso-Pentane is ready to ship to client.

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 The Combustion chamber has the following conditions:
 Approx. 100% conversion
 Q = adiabatic operation
 Air is used for oxidant
 T = 350°c, P = 405 kPa inlet conditions
 dP = 125 kPa approx.

 Turbine is used to decrease Pressure of the stack gas.

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 Requirements
 Model the plant using Aspen HYSYS in Steady State
 Verify Material/Energy Balances of the unit operations & processes
 Verify purity and composition of streams
 Verify conditions such as T, P and Flow rates.
 For specific unit operations, verify their relevant results
 Heater  Heat duty
 Combustion Chamber  T-max, Heat released by reaction
 Compressor/Pump  Required Work
 For the Columns  Reboiler & Condenser Duties

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 Landing Page

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 Min. Requirements:
 Adding Components to the Component List
 Selecting a Physical Property Method (Thermodynamic pack)

 If you want to further explore this environment 


 Aspen HYSYS - Petroleum Assays and Oil Characterization
 Different Types of Components
 Methods (EOS, Activity, Mixed)
 Modeling new/inexistent components
 Modeling Crude Oils & Petroleum Assays
 Blending & Installing Oils

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 Add the following to the list:
 Methane, CH4
 Iso-Pentane, iC5
 Dodecane, C12

 Later, we will add:


 CO2, H2O, O2, N2 (air)

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 For now, select a EOS Method
 Peng Robinson is excellent for this model.

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 The Simulation Environment Overview
 Manipulation of the flowsheet
 Adding Streams (Material / Energy)
 Input of data

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 Two raw-material streams:

 Stream Feed:
 100 kmol/h
 T = 30°C, P = 506.6 kPa

 Air (21% O2, 79% N2)


 300 kmol/h
 T = 350°C, 405 kPa

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 Adding Unit Operations
 Setting up Unit Operations
 Connectivity
 Running Simulation along…

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 Streams:
 Material  inlet: P-Feed
 Material  outlet: Feed
 Energy  outlet: Q-Chiller

 Conditions:
 dP = 50.66 kPa
 T = 15°C

 Tip  Setup up the temperature of the outlet stream

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 Streams:
 Material  inlet: Feed
 Material 
 outlet: Gas
 outlet: Liquid
 Energy  N/A

 Conditions:
 T = 15°C

 Tip  Setup up the temperature of the outlet stream

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 Streams:
 Material  inlet: Gas
 Material  outlet: Warm-Gas
 Energy  inlet: Q-Heater

 Conditions:
 dP = 50 kPa
 T = 350°C

 Tip  Setup up the temperature of the outlet stream

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 Streams:
 Material  inlet: Liquid
 Material  outlet: Col-Inlet

 Conditions:
 P-final= 1 atm

 Tip  Setup up the pressure of the outlet stream

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 Add Reactions in the Physical Property Environment
 Use  Equilibrium Reactions (Activity)
 CH4 + 2O2 → CO2 + 2H2O
 C5H12 +8O2 → 5CO2 + 6H2O
 C12H26 + 18.5O2 → 12CO2 + 13H2O

 NOTE  Add to FP

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 Streams:
 Material 
 inlet: Air
 inlet: Warm-Gas
 Material 
 outlet: Stack
 Outlet: Reactor-Liq

 Conditions:
 dP = 125 kPa
 Q = 0 (adiabatic)

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 Streams:
 Material  inlet: Stack
 Material  outlet: Off-Gas
 Energy  outlet: Mecha-Work

 Conditions:
 Efficiency (adiabatic) = 85.7%
 P-final  1 atm

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 Streams:
 Material  inlet: Liquid
 Material 
 outlet: Distillate
 outlet: Bototms
 Energy  Inlet: Q-Reb
 Energy  Outlet: Cond

 Conditions:
 Stages
 N = 20 stages
 Feed = 10th
 Default Reboiler
 dP = 0, Pcond = Pboil = 101 kPa
 No temperature estimates
 Condenser = partial
 Reflux = 2.5, molar
 Gas = 2.15 kmol/h
 Distillate = 21.50 kmol/h

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 Page (1/5)

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 Page (2/5)

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 Page (3/5)

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 Page (4/5)

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 Page (5/5)

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 Streams:
 Material  inlet: Bottoms
 Material  outlet: Decane
 Energy  Pump-Workload

 Conditions:
 P discharge = 150 kPa
 Tip  Setup up the pressure of the outlet stream

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 Workbook
 Streams
 Blocks

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 Workbook

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 Streams

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 Blocks

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 Let us now change some process conditions
 Verify the input/output of the new changes

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 Case Studies
 A) Change Air from 300 kmol/h to 350 kmol/h
 B) Effect of temperature in chiller (15°C  30°C)
 C) Effect of distillate-gas ratio (1:10 to 1:5)
 D) Effect of number of trays (20 to 30)

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 A) Change Air from 300 kmol/h to 350 kmol/h

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 B) Effect of temperature in chiller (15°C  30°C)

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 C) Effect of distillate-gas ratio (1:10 to 1:20)

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 D) Effect of number of trays (20 to 30)

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1. Introduction
2. Our Chemical Process!
3. Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Results & Analysis
7. Case Studies
8. Conclusion

[Link]
 Introductory Knowledge of Processes Modeling
 General Flowsheet Concepts
 Setting the adequate Physical Properties
 Basic Flowsheet “manipulation”
 Minimum Requirements to set up simulation
 Common Unit Operations
 Create an interest in Process Modeling

[Link]
Change:

• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs

[Link]
 Typically, you will follow your training with
 Basic Course

 What do you learn there:


 More on Aspen HYSYS
 More on Physical Property Environment
 Flowsheet techniques
 More Unit Operations
 Analysis Tools
 Plenty Workshops
 Process & Industry Case Studies

[Link]
 Aspen HYSYS – Basic Course!
 1 Month Free Trial then $8.00 USD/month

[Link]
 Aspen HYSYS – Training Bundle includes:
 Aspen HYSYS – Your First Simulation
 Aspen HYSYS – Basic Course
 Aspen HYSYS - Petroleum Assays and Oil Characterization
 All other new upcoming Aspen Plus courses

[Link]

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