Professional Documents
Culture Documents
User Guide
Allmaterial2007Chemstations,Inc.
Table of Contents
CHEMCADFeaturesbyModule...................................................................................................... 4 UnitOpsbyModule............................................................................................................................ 5 Chapter2GettingStartedwithCHEMCAD..................................................................................... 7 InstallingtheSoftware ........................................................................................................................... 7 LicensingCHEMCAD ......................................................................................................................... 10 TypesofCHEMCADLicenses........................................................................................................ 10 LicenseSettings ................................................................................................................................. 11 UpdatingaLicense ........................................................................................................................... 12 GettingHelpwithCHEMCAD .......................................................................................................... 14 OnlineHelp ....................................................................................................................................... 14 CHEMCADCoach............................................................................................................................ 15 ProcedureDemos.............................................................................................................................. 15 TheChemstationsWebSite............................................................................................................. 15 ContactingChemstationsTechnicalSupport ............................................................................... 15
CHEMCADVersion6UserGuide i
TableofContents
ThePalettePane ................................................................................................................................ 20
Selecting a Palette............................................................................................................................................20 Customizing Palettes .......................................................................................................................................21
TheMessagesPane ........................................................................................................................... 22
The Errors and Warnings Tab..........................................................................................................................22 The Run Trace Tab ..........................................................................................................................................22 The Notes Tab .................................................................................................................................................23
PinningandUnpinningPanes........................................................................................................ 25 OtherUsefulInterfaceHints............................................................................................................... 26 UndoandRedo ................................................................................................................................. 26 VisibleGrid........................................................................................................................................ 26 AdjustingYourViewoftheWorkspace........................................................................................ 27 TheCHEMCADCoachPane .......................................................................................................... 27 Chapter4WorkingwithSimulationFiles ...................................................................................... 29 AboutCHEMCADSimulationFiles.................................................................................................. 29 UserComponentsinCHEMCAD .................................................................................................. 30 ExampleFiles..................................................................................................................................... 30 OpeninganExistingSimulation ........................................................................................................ 31 CreatingaNewSimulation................................................................................................................. 31 SavingaSimulation.............................................................................................................................. 32 SavingDifferentCasesfortheSameSimulation.......................................................................... 32 EmailingaSimulation ........................................................................................................................ 33 WorkingwithCHEMCADFilesfromPreviousVersions .............................................................. 33
ii
CHEMCADVersion6UserGuide
TableofContents
Chapter5BuildingandUsingaBasicSimulation ........................................................................ 35 StartingaNewSimulation .................................................................................................................. 35 SelectingEngineeringUnits................................................................................................................ 36 DrawingtheFlowsheet........................................................................................................................ 36 AddingUnitOps ............................................................................................................................... 36 SelectingaDefaultIconforaUnitOp ............................................................................................ 37 ManipulatingUnitOpIcons ............................................................................................................ 38 DrawingandConnectingaStream ................................................................................................ 38
Choosing a Stream Route ................................................................................................................................39 Rerouting a Stream ..........................................................................................................................................39
OtherDrawingTools........................................................................................................................ 40
The Text Tool ..................................................................................................................................................40 Simple Drawing Tools: Rectangle, Ellipse, and Line ......................................................................................40 Complex Drawing Tools: Multi-line and Polygon ..........................................................................................40
SelectingChemicalComponents........................................................................................................ 41 FindingaComponent ...................................................................................................................... 41 AddingaComponent....................................................................................................................... 42 ChangingtheOrderofSelectedComponents .............................................................................. 43 RemovingItemsfromtheSelectedComponentsList ................................................................. 43 SelectingKvalueandEnthalpyOptions .......................................................................................... 44 UsingtheThermodynamicsWizard .............................................................................................. 44
Selecting Components to Ignore......................................................................................................................44 Specifying Process Conditions ........................................................................................................................44 How the Thermodynamics Wizard Makes Suggestions ..................................................................................44 Should the Thermodynamics Wizard be trusted to make design decisions? ...................................................45
ManuallySelectingThermodynamicsSettings ............................................................................ 45 DefiningStreams .................................................................................................................................. 46 ThermodynamicProperties............................................................................................................. 46 StreamComposition ......................................................................................................................... 46 TotalFlowProperties ....................................................................................................................... 47 SpecifyingEquipmentParameters..................................................................................................... 47 RunningtheSimulation....................................................................................................................... 48 ReviewingtheResults.......................................................................................................................... 48
CHEMCADVersion6UserGuide
iii
TableofContents
Pumps,Compressors,andExpanders ........................................................................................... 52
Low-fidelity .....................................................................................................................................................52 High-fidelity ....................................................................................................................................................52
VesselsandTanks............................................................................................................................. 52
Low-fidelity .....................................................................................................................................................52 Sizing...............................................................................................................................................................53 High-fidelity ....................................................................................................................................................53
Valves ................................................................................................................................................. 53
Low-fidelity .....................................................................................................................................................53 Sizing...............................................................................................................................................................54 High-fidelity ....................................................................................................................................................54
Columns ............................................................................................................................................. 54
Low-fidelity .....................................................................................................................................................54 Sizing...............................................................................................................................................................54 High-fidelity ....................................................................................................................................................55
HeatExchangers ............................................................................................................................... 56
Low-fidelity .....................................................................................................................................................56 Sizing...............................................................................................................................................................56 High-fidelity ....................................................................................................................................................56
ReliefDevices .................................................................................................................................... 57
Low-fidelity .....................................................................................................................................................57 High-fidelity ....................................................................................................................................................58
LicensingConsiderationsforHighfidelityModeling.................................................................... 58 LicenseSettings ................................................................................................................................. 58 Chapter7BuildingandUsingaDynamicSimulation ................................................................. 59 Whatdowemeanbydynamics? ....................................................................................................... 59 LicensingConsiderations .................................................................................................................... 59 LicenseSettings ................................................................................................................................. 60 AdditionalInputforDynamicOperation......................................................................................... 60 StrategiesforDynamicSimulations ............................................................................................... 61
iv
CHEMCADVersion6UserGuide
TableofContents
SettingUpDynamicOperation .......................................................................................................... 61 SwitchingtoDynamics .................................................................................................................... 61 SettingtheRunTime ........................................................................................................................ 63 SelectingStreamsandUnitOps ...................................................................................................... 65 RunningaDynamicSimulation ......................................................................................................... 66 RunfromInitialState ....................................................................................................................... 66 RunfromCurrentState.................................................................................................................... 66 RunOneStepataTime ................................................................................................................... 67 OtherDynamicCommands ................................................................................................................ 67 ResettoInitialState .......................................................................................................................... 67 SaveAsInitialState .......................................................................................................................... 68 OutputfromDynamicSimulations ................................................................................................... 68 ReviewingtheFlowsheetSpecifications........................................................................................ 68 PlottingDynamicResults ................................................................................................................ 69 TextbasedDynamicReports .......................................................................................................... 69 Chapter8OutputandReports........................................................................................................... 71 TextReports .......................................................................................................................................... 71 ReportSetup ...................................................................................................................................... 71 StreambasedReports....................................................................................................................... 72
Stream Groups .................................................................................................................................................72 Stream Compositions.......................................................................................................................................74 Stream Properties.............................................................................................................................................75 Particle Size Distribution.................................................................................................................................76 Pseudocomponent Curves................................................................................................................................76
UnitOpbasedReports...................................................................................................................... 76
UnitOp Groups ................................................................................................................................................76 Select UnitOps.................................................................................................................................................77 Spec Sheet........................................................................................................................................................77 Distillation .......................................................................................................................................................78
FlowsheetbasedReports ................................................................................................................. 78
Topology..........................................................................................................................................................78 Thermodynamics .............................................................................................................................................78 Mass and Energy Balances ..............................................................................................................................79
DynamicsReports............................................................................................................................. 79
Batch Results ...................................................................................................................................................79 Dynamics .........................................................................................................................................................79
ConsolidatedReport......................................................................................................................... 79
CHEMCADVersion6UserGuide
TableofContents
UsingtheLayersFeatureforSelectiveViewingandPrinting ................................................... 85
Scenarios for Using Layers..............................................................................................................................85 Creating a New layer .......................................................................................................................................86 Assigning Objects to a Layer...........................................................................................................................87 Hiding and Viewing Layers.............................................................................................................................88 Removing an Object from a Layer ..................................................................................................................88 Deleting an Entire Layer..................................................................................................................................88
PrintingaProcessFlowDiagram ................................................................................................... 88 Chapter9CustomizingCHEMCAD ................................................................................................ 91 FlowsheetTemplates ........................................................................................................................... 91 CreatingaTemplate ......................................................................................................................... 92 ViewingaTemplatesProperties.................................................................................................... 92 ApplyingaTemplate........................................................................................................................ 92 RenamingorDeletingaTemplate.................................................................................................. 92
vi
CHEMCADVersion6UserGuide
TableofContents
PseudocomponentRange ................................................................................................................ 96 ImportingaNeutralFile .................................................................................................................. 97 CreatingaCustomSymbol ................................................................................................................. 98 CustomizedCostingCalculations.................................................................................................... 100 CreatingCustomUnitOps ................................................................................................................ 100 CreatingaCustomUnitOpDialogBox ....................................................................................... 101 CustomizingThermodynamics ........................................................................................................ 102 CreatingaCustomKvalueorEnthalpyModel......................................................................... 102 CreatingaCustomMixingRule ................................................................................................... 104 VisualBasicApplications(VBA)...................................................................................................... 104 DefiningaReaction,MixingRule,orUnitOp ............................................................................ 104 UsingaVBAdefinedReaction ..................................................................................................... 105 UsingaVBAdefinedMixingRule............................................................................................... 106 UsingaVBAdefinedUnitOp ....................................................................................................... 106 Chapter10DataInterfaces ............................................................................................................... 107 ExcelDataMapping........................................................................................................................... 107 CreatinganExcelDataMap.......................................................................................................... 108 DataMapExecutionRules ............................................................................................................ 111 CreatingExcelUnitOps ..................................................................................................................... 113 SpecificationSheets ............................................................................................................................ 113 UsingCHEMCADasanOPCServer .............................................................................................. 114 OPCApplications ........................................................................................................................... 114 OPCCompliance............................................................................................................................. 114 EnablingCHEMCADasanOPCServer ..................................................................................... 115 ReadingandWritingValuestoCHEMCADUsingOPC ......................................................... 115 OPCServerOperations.................................................................................................................. 115 CHEMCADOPCNamespace ....................................................................................................... 116 COMInterfaces ................................................................................................................................... 117 ConnectingExcelandCHEMCAD:ASimpleCOMInterface ................................................. 117
Using the VBClient Example ........................................................................................................................118 A Peek under the Hood..................................................................................................................................118
CHEMCADVersion6UserGuide
vii
TableofContents
Chapter11CHEMCADTutorials ................................................................................................... 121 CCSTEADYSTATETutorial ........................................................................................................... 122 Overview.......................................................................................................................................... 122 StartingaNewSimulation ............................................................................................................ 123 SelectingEngineeringUnits .......................................................................................................... 123 DrawingtheFlowsheet .................................................................................................................. 123
Placing UnitOps.............................................................................................................................................123 Drawing Streams ...........................................................................................................................................126
CCTHERMTutorial .......................................................................................................................... 144 OverviewoftheHeatExchangerSizingProcess ....................................................................... 145 IdentifytheTubesideStream....................................................................................................... 145 GeneratetheHeatCurve ............................................................................................................... 146 DefineGeneralSpecifications ....................................................................................................... 147 SetTubeSpecifications................................................................................................................... 148 SetShellSpecifications ................................................................................................................... 148 SetBaffleSpecifications.................................................................................................................. 149
Baffle Spacing ...............................................................................................................................................149 Baffle Cut Percent .........................................................................................................................................149
SetNozzleSpecifications ............................................................................................................... 149 SetClearanceSpecifications .......................................................................................................... 150 SetMaterialSpecifications............................................................................................................. 151 SetMiscellaneousSpecifications................................................................................................... 151 RunSizingCalculations ................................................................................................................. 151
viii CHEMCADVersion6UserGuide
TableofContents
ReviewResultsandCreatePlots .................................................................................................. 152 CCBATCHTutorial .......................................................................................................................... 154 DescriptionoftheProblem............................................................................................................ 154 OverviewoftheBatchDistillationProcess ................................................................................. 155 CreatingaNewSimulation ........................................................................................................... 156 SelectingEngineeringUnits .......................................................................................................... 156 DrawingtheFlowsheet .................................................................................................................. 156
Placing UnitOps.............................................................................................................................................156 Drawing Streams ...........................................................................................................................................157
SelectingComponents.................................................................................................................... 158 SelectingThermodynamicOptions.............................................................................................. 158 SpecifyingPotCharge.................................................................................................................... 160 SpecifyingtheDistillationColumn .............................................................................................. 162 DefiningtheOperatingSteps........................................................................................................ 163
Operating Step 1 ............................................................................................................................................163 Operating Step 2 ............................................................................................................................................164 Operating Step 3 ............................................................................................................................................164 Operating Step 4 ............................................................................................................................................165 Operating Step 5 ............................................................................................................................................165 The Run Time Information Dialog Box.........................................................................................................165
SimpleFlowExample..................................................................................................................... 176
Problem Statement.........................................................................................................................................176 Creating the Simulation .................................................................................................................................176 Using Controllers to Simplify the Problem ...................................................................................................178 Calculating NPSHA.......................................................................................................................................179
TableofContents
CHEMCADVersion6UserGuide
Chapter 1
Introduction to CHEMCAD
CHEMCADVersion6UserGuide
IntroductiontoCHEMCAD
CHEMCADcombinesastateoftheartgraphicaluserinterface(GUI),an extensivechemicalcomponentdatabase,alargelibraryofthermodynamicdata,and alibraryofthemostcommonunitoperationstogiveuserstheabilitytoprovide significantandmeasurablereturnsontheirinvestment.Inaddition,theprogramis customizabletoallowcustomchemicals,thermodynamics,unitoperations, calculations,andreportingallingredientsforapowerfuluserexperience. CHEMCADiscapableofmodelingcontinuous,batch,andsemibatchprocesses, anditcansimulatebothsteadystateanddynamicsystems.Thisprogramisused extensivelyaroundtheworldforthedesign,operation,andmaintenanceofchemical processesinawidevarietyofindustries,includingoilandgasexploration, production,andrefining;gasprocessing;commodityandspecialtychemicals; pharmaceuticals;biofuels;andprocessequipmentmanufacturing. Withinalloftheseindustries,chemicalengineersworkeverydaywith CHEMCADtoaddressavarietyofchallenges: Initialdesignofnewprocesses Optimizationordebottleneckingofexistingprocesses Performancemonitoringofprocesses Designandratingofprocessequipmentsuchasvessels,columns,heat exchangers,piping,valves,andinstrumentation Evaluationofsafetyreliefdevices Heatexchangersizing Pressureandflowbalancingofcomplexpipingnetworks Reconciliationofplantdata Economiccomparisonsofprocessalternatives Advancedprocesscontrol(APC),includingmodelpredictivecontrol(MPC), realtimeoptimization(RTO),andoperatortrainingsystems(OTS) Scaleupofprocessesfromlabscaletopilotscale,andfrompilotscaletofull scale Binaryinteractionparameter(BIP)regressionfromprocessorlabdata Batchreactionrateregressionfromprocessorlabdata
CHEMCADVersion6UserGuide
IntroductiontoCHEMCAD
CC-STEADY STATE
ThemainCHEMCADproduct,knownasCCSTEADYSTATE,enablesyouto designnewprocesses,rateexistingprocesses,andoptimizeprocessesinsteadystate.
CC-DYNAMICS
ThemoduleknownasCCDYNAMICSmakesitpossibletodesignandrateexisting processesusingadynamicsimulation.Thismoduleisfullyintegratedwith CHEMCADtomakeswitchingbetweensteadystateanddynamicseasyand intuitive.UsingCCDYNAMICS,youcaneasilysimulateeverythingfromsimple vesselaccumulationtocomplexcontrolsystemsoncolumns.Thismodulealso providestoolsforsimulationofcontinuousstirredtankreactors(CSTRs),including complexreactionrateandpressurecalculation.
CC-BATCH
TheCCBATCHproductenablesyoutodesign,rate,oroptimizeabatchdistillation column.CCBATCHincludesaschedulinginterfacetoallowanoperationstep approachtosimulationofbatchcolumns.
CC-THERM
TheCCTHERMproductletsyoudesignasingleheatexchanger,orvetavendors heatexchangerdesign.Itisalsoidealforcustomerswhowanttorateexisting exchangersinnewservice,ortoperformcalculationsonhypotheticalsituations.CC THERMcansimulateshellandtube,aircooled,plateandframe,anddoublepipe exchangers.FullintegrationwithCHEMCADmakesitpossibletocalculateexit conditionsfromexchangergeometryforhighfidelitysimulations.
CC-SAFETY NET
TheCCSAFETYNETproductprovidesthecapabilitytodesignorratepiping networksandsafetyreliefdevicesandsystems,inbothsteadystateanddynamic systems.ThesteadystatefeaturesofCCSAFETYNETareincludedwithCC STEADYSTATE.Thisproductenablesuserstomakesimultaneousflowand pressurebalancedsimulationseveninreverseflowsituationsforsingleor multiphaseflow.
CC-FLASH
TheCCFLASHmoduleprovidesphysicalpropertyandphaseequilibriumdata,as wellaspropertypredictionandregression.CCFLASHisasubsetofCCSTEADY STATE,andismeantforcustomerswhodonotneedfullflowsheetsimulationtools.
CHEMCADVersion6UserGuide 3
IntroductiontoCHEMCAD
CC-DYNAMICS
CC-THERM
CC-BATCH
VB/COM/OPC/Data Map Sensitivity/optimization Sizing (line/valve/orifice/vessel) Run steady state Run dynamics Run recycles Costing Reconciliation Sizing columns Sizing heat exchangers Economics Reports (incl. Excel) DIERS CO2 solid Hydrates Depress TOC/COD Pure regression BIP regression Electrolyte regression Rate regression Units calculator Execute parser Environmental report Simple calculator Spec sheet 4