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User Guide
Allmaterial2011Chemstations,Inc.
Table of Contents
CHEMCADFeaturesbyModule...................................................................................................... 4 UnitOpsbyModule............................................................................................................................ 5 Chapter2GettingStartedwithCHEMCAD..................................................................................... 7 InstallingtheSoftware ........................................................................................................................... 7 LicensingCHEMCAD ......................................................................................................................... 10 TypesofCHEMCADLicenses........................................................................................................ 10 LicenseSettings ................................................................................................................................. 11 UpdatingaLicense ........................................................................................................................... 13 GettingHelpwithCHEMCAD .......................................................................................................... 15 OnlineHelp ....................................................................................................................................... 15 CHEMCADCoach............................................................................................................................ 15 ProcedureDemos.............................................................................................................................. 16 TheChemstationsWebSite............................................................................................................. 16 ContactingChemstationsTechnicalSupport ............................................................................... 16
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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........................................................................................................................................ 27 AdjustingYourViewoftheWorkspace........................................................................................ 27 TheCHEMCADCoachPane .......................................................................................................... 27 Chapter4WorkingwithSimulationFiles ...................................................................................... 29 AboutCHEMCADSimulationFiles.................................................................................................. 29 UserComponentsinCHEMCAD .................................................................................................. 30 ExampleFiles..................................................................................................................................... 30 OpeninganExistingSimulation ........................................................................................................ 31 CreatingaNewSimulation................................................................................................................. 31 SavingaSimulation.............................................................................................................................. 32 SavingDifferentCasesfortheSameSimulation.......................................................................... 32 EmailingaSimulation ........................................................................................................................ 33 WorkingwithCHEMCADFilesfromPreviousVersions .............................................................. 34
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DrawingandConnectingaStream ................................................................................................ 39
Choosing a Stream Route ................................................................................................................................39 Rerouting a Stream ..........................................................................................................................................40 Stream ID Numbers .........................................................................................................................................40
OtherDrawingTools........................................................................................................................ 41
The Text Tool ..................................................................................................................................................41 Simple Drawing Tools: Rectangle, Ellipse, and Line ......................................................................................41 Complex Drawing Tools: Multi-line and Polygon ..........................................................................................41
SelectingChemicalComponents........................................................................................................ 42 FindingaComponent ...................................................................................................................... 43 AddingaComponent....................................................................................................................... 44 ChangingtheOrderofSelectedComponents .............................................................................. 45 RemovingItemsfromtheSelectedComponentsList ................................................................. 45 SelectingKvalueandEnthalpyOptions .......................................................................................... 46 UsingtheThermodynamicsWizard .............................................................................................. 46
Selecting Components to Ignore......................................................................................................................46 Specifying Process Conditions ........................................................................................................................46 How the Thermodynamics Wizard Makes Suggestions ..................................................................................46 Should the Thermodynamics Wizard be trusted to make design decisions? ...................................................47
ManuallySelectingThermodynamicsSettings ............................................................................ 47 DefiningStreams .................................................................................................................................. 48 ThermodynamicProperties............................................................................................................. 48 StreamComposition ......................................................................................................................... 49 TotalFlowProperties ....................................................................................................................... 49 SpecifyingEquipmentParameters..................................................................................................... 49 RunningtheSimulation....................................................................................................................... 50 ReviewingtheResults.......................................................................................................................... 51 Chapter6UsingCHEMCADforHighfidelityModeling ........................................................... 53 Whatishighfidelitymodeling?......................................................................................................... 53 CriteriaforHighfidelityModeling ................................................................................................... 54
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Pumps,Compressors,andExpanders ........................................................................................... 56
Low-fidelity .....................................................................................................................................................56 High-fidelity ....................................................................................................................................................56
VesselsandTanks............................................................................................................................. 56
Low-fidelity .....................................................................................................................................................56 Sizing...............................................................................................................................................................57 High-fidelity ....................................................................................................................................................57
Valves ................................................................................................................................................. 57
Low-fidelity .....................................................................................................................................................57 Sizing...............................................................................................................................................................58 High-fidelity ....................................................................................................................................................58
Columns ............................................................................................................................................. 58
Low-fidelity .....................................................................................................................................................58 Sizing...............................................................................................................................................................58 High-fidelity ....................................................................................................................................................60
HeatExchangers ............................................................................................................................... 60
Low-fidelity .....................................................................................................................................................60 Sizing...............................................................................................................................................................60 High-fidelity ....................................................................................................................................................60
ReliefDevices .................................................................................................................................... 61
Low-fidelity .....................................................................................................................................................61 High-fidelity ....................................................................................................................................................62
LicensingConsiderationsforHighfidelityModeling.................................................................... 62 Chapter7BuildingandUsingaDynamicSimulation ................................................................. 63 Whatdowemeanbydynamics? ....................................................................................................... 63 LicensingConsiderations .................................................................................................................... 63 AdditionalInputforDynamicOperation......................................................................................... 64 StrategiesforDynamicSimulations ............................................................................................... 65 SettingUpDynamicOperation .......................................................................................................... 65 SwitchingtoDynamics .................................................................................................................... 65 SettingtheRunTime ........................................................................................................................ 66 SelectingStreamsandUnitOps ...................................................................................................... 68 RunningaDynamicSimulation ......................................................................................................... 69 RunfromInitialState ....................................................................................................................... 69
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RunfromCurrentState.................................................................................................................... 69 RunOneStepataTime ................................................................................................................... 70 OtherDynamicCommands ................................................................................................................ 70 ResettoInitialState .......................................................................................................................... 70 SaveAsInitialState .......................................................................................................................... 71 OutputfromDynamicSimulations ................................................................................................... 71 ReviewingtheFlowsheetSpecifications........................................................................................ 72 PlottingDynamicResults ................................................................................................................ 72 TextbasedDynamicReports .......................................................................................................... 72 Chapter8OutputandReports........................................................................................................... 75 TextReports .......................................................................................................................................... 75 ReportOutputSetup ........................................................................................................................ 75 StreambasedReports....................................................................................................................... 76
Stream Groups .................................................................................................................................................76 Stream Compositions.......................................................................................................................................78 Stream Properties.............................................................................................................................................79 Particle Size Distribution.................................................................................................................................80 Pseudocomponent Curves................................................................................................................................80
UnitOpbasedReports...................................................................................................................... 80
UnitOp Groups ................................................................................................................................................80 Select UnitOps.................................................................................................................................................81 Spec Sheet........................................................................................................................................................82 Distillation .......................................................................................................................................................82
FlowsheetbasedReports ................................................................................................................. 83
Topology..........................................................................................................................................................83 Thermodynamics .............................................................................................................................................83 Mass and Energy Balances ..............................................................................................................................83
DynamicsReports............................................................................................................................. 83
Batch Results ...................................................................................................................................................83 Dynamics .........................................................................................................................................................83
ConsolidatedReportsandtheCHEMCADReportWriter......................................................... 84
Choosing and Ordering Report Sections..........................................................................................................84 Selecting Flowsheet Elements .........................................................................................................................85 Formatting Report Sections .............................................................................................................................85 Naming the Report and Choosing a Destination..............................................................................................86
CHEMCADVersion6UserGuide
UsingtheLayersFeatureforSelectiveViewingandPrinting ................................................... 93
Scenarios for Using Layers..............................................................................................................................93 Creating a New layer .......................................................................................................................................94 Assigning Objects to a Layer...........................................................................................................................95 Hiding and Viewing Layers.............................................................................................................................95 Removing an Object from a Layer ..................................................................................................................96 Deleting an Entire Layer..................................................................................................................................96
PrintingaProcessFlowDiagram ................................................................................................... 96 Chapter9CustomizingCHEMCAD ................................................................................................ 99 FlowsheetTemplates ........................................................................................................................... 99 CreatingaTemplate ....................................................................................................................... 100 ViewingaTemplatesProperties.................................................................................................. 100 ApplyingaTemplate...................................................................................................................... 100 RenamingorDeletingaTemplate................................................................................................ 100 CreatingCustomComponents ......................................................................................................... 101 AddingaSingleComponent......................................................................................................... 101
Creating the Component ................................................................................................................................101 Regressing Data into the Component ............................................................................................................104
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CustomizedCostingCalculations.................................................................................................... 109 CreatingCustomUnitOps ................................................................................................................ 109 CreatingaCustomUnitOpDialogBox ....................................................................................... 110 CustomizingThermodynamics ........................................................................................................ 111 CreatingaCustomKvalueorEnthalpyModel......................................................................... 111 CreatingaCustomMixingRule ................................................................................................... 112 VisualBasicApplications(VBA)...................................................................................................... 113 DefiningaReaction,MixingRule,orUnitOp ............................................................................ 113 UsingaVBAdefinedReaction ..................................................................................................... 113 UsingaVBAdefinedMixingRule............................................................................................... 114 UsingaVBAdefinedUnitOp ....................................................................................................... 115 Chapter10DataInterfaces ............................................................................................................... 117 ExcelDataMapping........................................................................................................................... 118 CreatinganExcelDataMap.......................................................................................................... 118 DataMapExecutionRules ............................................................................................................ 121 CreatingExcelUnitOps ..................................................................................................................... 123 SpecificationSheets ............................................................................................................................ 124 UsingCHEMCADasanOPCServer .............................................................................................. 125 OPCApplications ........................................................................................................................... 125 OPCCompliance............................................................................................................................. 125 EnablingCHEMCADasanOPCServer ..................................................................................... 125 ReadingandWritingValuestoCHEMCADUsingOPC ......................................................... 126 OPCServerOperations.................................................................................................................. 126 CHEMCADOPCNamespace ....................................................................................................... 127 COMInterfaces ................................................................................................................................... 128 ConnectingExcelandCHEMCAD:ASimpleCOMInterface ................................................. 128
Using the VBClient Example ........................................................................................................................129 A Peek under the Hood..................................................................................................................................129
Chapter11CHEMCADTutorials ................................................................................................... 131 CCSTEADYSTATETutorial ........................................................................................................... 132 Overview.......................................................................................................................................... 132 StartingaNewSimulation ............................................................................................................ 133 SelectingEngineeringUnits .......................................................................................................... 133 DrawingtheFlowsheet .................................................................................................................. 133
Placing UnitOps.............................................................................................................................................133 Drawing Streams ...........................................................................................................................................136
SelectingComponents.................................................................................................................... 136
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CCTHERMTutorial .......................................................................................................................... 153 OverviewoftheHeatExchangerSizingProcess ....................................................................... 154 IdentifytheTubesideStream....................................................................................................... 154 GeneratetheHeatCurve ............................................................................................................... 155 DefineGeneralSpecifications ....................................................................................................... 156 SetTubeSpecifications................................................................................................................... 157 SetShellSpecifications ................................................................................................................... 157 SetBaffleSpecifications.................................................................................................................. 158
Baffle Spacing ...............................................................................................................................................158 Baffle Cut Percent .........................................................................................................................................158
SetNozzleSpecifications ............................................................................................................... 159 SetClearanceSpecifications .......................................................................................................... 159 SetMaterialSpecifications............................................................................................................. 160 SetMiscellaneousSpecifications................................................................................................... 160 RunSizingCalculations ................................................................................................................. 161 ReviewResultsandCreatePlots .................................................................................................. 161 CCBATCHTutorial .......................................................................................................................... 164 DescriptionoftheProblem............................................................................................................ 164 OverviewoftheBatchDistillationProcess ................................................................................. 165 CreatingaNewSimulation ........................................................................................................... 166 SelectingEngineeringUnits .......................................................................................................... 166 DrawingtheFlowsheet .................................................................................................................. 166
Placing UnitOps.............................................................................................................................................166 Drawing Streams ...........................................................................................................................................167 viii CHEMCADVersion6UserGuide
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SelectingComponents.................................................................................................................... 168 SelectingThermodynamicOptions.............................................................................................. 168 SpecifyingPotCharge.................................................................................................................... 170 SpecifyingtheDistillationColumn .............................................................................................. 172 DefiningtheOperatingSteps........................................................................................................ 173
Operating Step 1 ............................................................................................................................................173 Operating Step 2 ............................................................................................................................................174 Operating Step 3 ............................................................................................................................................174 Operating Step 4 ............................................................................................................................................175 Operating Step 5 ............................................................................................................................................175 The Run Time Information Dialog Box.........................................................................................................175
SimpleFlowExample..................................................................................................................... 186
Problem Statement.........................................................................................................................................186 Creating the Simulation .................................................................................................................................186 Using Controllers to Simplify the Problem ...................................................................................................188 Calculating NPSHa........................................................................................................................................189
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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.
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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 CHEMCADVersion6UserGuide
CC-FLASH
IntroductiontoCHEMCAD
UnitOps by Module
Theavailabilityofcertainunitoperations,orUnitOps,inCHEMCADsimulationsis afunctionofwhichmodulesyouhavelicensed.Thefollowingmatrixlistsall availableUnitOpsandtheCHEMCADmodulesassociatedwiththem.
CC-STEADY STATE CC-SAFETY NET
CC-DYNAMICS
CC-THERM
CC-BATCH
Baghouse filter Batch column Batch reactor Calculator Centrifuge Component separator Compressor Control valve Controller Crusher/grinder Crystallizer Cyclone Divider Dynamic vessel Electrostatic precipitator Equilibrium reactor Excel unit Expander Fired heater Flash Gibbs reactor Heat exchanger Hydrocyclone Kinetic reactor Liquid/liquid extractor LLV flash* LNGH exchanger
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IntroductiontoCHEMCAD
CC-STEADY STATE
CC-SAFETY NET
CC-DYNAMICS
CC-THERM
CC-BATCH
Loop Mixer Node Phase generator* PID controller Pipe simulator Polymer reactor Pump Ramp controller Recorder* Run subflowsheet META unit SCDS distillation column Screen Sedimentator Shortcut column Solids dryer Solids washer Stoichiometric reactor Stream reference Tank Time delay Time switch Tower distillation column Tower plus distillation column User-added module Vacuum filter Valve Venturi scrubber Vessel* * These UnitOps will be phased out eventually.
CHEMCADVersion6UserGuide
CC-FLASH
Chapter 2
CHEMCADVersion6UserGuide
GettingStartedwithCHEMCAD
Note: IfyouinsertthediscandclosetheCDmediadrivedoor,butnothinghappens
ClickInstalltocontinue.Followthepromptsonallotherscreensuntilyousee theCHEMCADSuiteInstallShieldWizardscreen,showninFigure202.
Note:DependingonhowmanysoftwarecomponentsInstallShieldidentifies,there
CHEMCADVersion6UserGuide
FollowingthestandardCHEMCADlicenseagreement,asimilarscreenappears withthelicensetermsoftheMicrosoftVisualStudiotools.Again,youllneedtoclick theIacceptthetermsinthelicenseagreementbuttonandthenclickNexttoproceed. TheDestinationFolderscreenappearsnext,displayingthenameofthefolder intowhichtheCHEMCADfileswillbeinstalledbydefault.Normally,this destinationisC:\ProgramFiles\Chemstations\CHEMCAD,anditisrecommended thatyouusethislocationunlessyouhaveaspecificneedtoinstalltheprogram elsewhere.ClicktheChangebuttonifyouwanttochangethefiledestination,or clickNexttoacceptthesuggesteddestinationandproceed. TheSetupTypescreennowappears,offeringachoicebetweencompleteand custominstallation.Eachtypeofinstallationisdescribedonthescreen.Eitheraccept thedefaultsettingofCompleteorclickCustomtoselectspecificcomponentsto install,thenclickNexttoproceed. TheReadytoInstalltheProgramscreennowappears.Notethatonthisscreen, andinfactonanyscreenintheinstallationprocess,youcanclickBacktoreturntoa previousscreenandverifyorchangeyourinstallationsettings.Ifyouaresatisfied withyoursettingsastheyare,clickInstalltostarttheinstallation. TheInstallingCHEMCADSuitescreenappears,showingtheprogressofyour installationwithagreenstatusbar.
Licensing CHEMCAD
BeforeyoucanuseCHEMCAD,youllneedtosetupalicensingschemeofsome type.Dependingonyourparticularlicensingagreement,youwilluseoneofseveral typesoflicensestorunCHEMCAD.
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License Settings
TorunCHEMCADforthefirsttime,makesurethatyourdongle(ifapplicable)is pluggedinproperly,andthenstarttheprogram.FromtheWindowsStartmenu, selectAllPrograms>Chemstations>CHEMCAD. Theprogramopens,displayingaCHEMCADsplashscreen.Afterafew moments,thatscreenisreplacedbytheCHEMCADLicenseMonitordialogbox, whichdisplaysinformationaboutthelicense(s)thatyourcomputerisusingtorun CHEMCAD.
Note:Insomecases,theCHEMCADscreenthatappearsmaydisplayaNoLicense
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GettingStartedwithCHEMCAD
Normally,thisdialogboxremainsinviewforonlyafewseconds,listingall productlicensesthatCHEMCADhasobtained.Duringthattime,youcanclick anywhereinthedialogboxtokeepitopen.Ifyoudonotclickinthedialogbox,it disappearsfromview,butyoucanbringitbackupatanytimebyselectingTools> Options>Licensing. WhiletheCHEMCADLicenseMonitordialogboxisopen,youcanviewthe variousCHEMCADlicensesdetectedforyoursystemandseewhatmethod(and whereapplicable,whichserver)isbeingusedtoobtainthoselicenses.Ifyour organizationusesRMSLicenseManageroraSuperProNethardwarekey,youcan alsoseewhichotheruserscurrentlyholdvariousproductlicenses. Fornetworklicenses,youcanrightclickaservernameunderaparticular productandselectalicensingpreference(ondemand,always,ornever)asshown below.
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CHEMCADVersion6UserGuide
Updating a License
CHEMCADdonglesrequirereprogrammingonaregularbasis,eitheronceayear ormoreoftendependingonyourlicensingagreement.Thisisasecuritymeasureto reducethelikelihoodthatyourdonglewillbestolenandmisused. Thedonglethatyouuseisprogrammedtoworkonlythroughthelicensedtime period,andwhenthattimehaselapsed,thedonglemustbeupdatedbeforeyoucan continueusingCHEMCAD. Updatingadongleisarelativelysimpleprocedure.Beforeyourlicense expiration,youoryoursoftwareadministratorshouldreceiveanemailfrom Chemstations,withwhatsknownasaconfigurationfileincludedasanattachment. YoushouldsavethisfiletoyourWindowsdesktopassoonasyoureceiveit.
Note:Ifyouveupdatedthesamedongleinthepast,thenewconfigurationfile
shouldhavetheexactsamefilenameasthepreviousone.If,whilesavingthefileto yourdesktop,youseeaWindowsmessageaboutanexistingfilewiththesame name,youshouldoverwritetheoldfile(whichinanycasecannotbeusedagain), replacingitwiththenewone. Itsimportanttoensurethatyourconfigurationfilematchesyourdongle.The configurationfileshouldbea.DNGfilewhosenameincludesafourorfivedigit code;thiscodemustmatchthenumberstampedontoyourdongle.Ifthenumbers dontmatch,contactyoursoftwareadministratororChemstationssupporttoresolve theissue. Theupdateemailalsospecifiesthedateonwhichyoullneedtoupdateyour dongle.Beforethatdatearrives,followthisproceduretoperformtheupdate: 1. StarttheCHEMCADprogramandselectTools>Options>Licensing.This bringsuptheCHEMCADLicenseMonitordialogbox,whichdisplaysthe statusofallapplicableCHEMCADproductlicenses,alongwithyourdongle typeandnumber.
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2. ClicktheSetupbuttontobringuptheLicenseSetupdialogbox,thenclick Updatedongleasshownbelow.
Figure 2-08: Clicking Update dongle within the License Setup dialog box
Figure 2-10: Updating the dongle with the selected update file
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GettingStartedwithCHEMCAD
6. CHEMCADreprogramsthedongle,andthendisplaysapopupwindow statingthattheupdateiscomplete.
andrestarttheWindowsservicecalledSentinelProtectionServeronthelicensing serverafterauserupdatesadongle.
Online Help
AtanytimewhilerunningCHEMCADinanactivewindow,youcanpressthe[F1] keytobringuptheCHEMCADHelpscreenthatsmostappropriatetothetaskyou arecurrentlyperformingorthedialogboxcurrentlydisplayed. Insomesituations,pressing[F1]willbringupthemainCHEMCADHelp windowinsteadofaparticularhelpscreen.Fromthere,youcanclicktheContents, Index,orSearchtabintheupperleftcorneroftheCHEMCADHelpwindow,and usethesetoolstofindtheinformationyouneed. YoucanalsogodirectlytothemainCHEMCADHelpwindowbyselectingHelp >HelpTopicsfromtheCHEMCADmainmenu.Regardlessofhowyouopen CHEMCADHelp,italwaysopensinaseparatewindowthatdoesnotinterferewith theoperationoftheCHEMCADprogram.
CHEMCAD Coach
TheCHEMCADCoachpaneisatoolthatyoucanopenwithinCHEMCADtoview conciseinstructionsforcommonprocedures.Toseealistofavailabletopics,select Help>CHEMCADCoach.ThenclickonanylinkintheCHEMCADCoachwindow toviewtheinstructionsforaspecifictask.
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Procedure Demos
Animateddemonstrationsofcommontasksareavailabletohelpyougetstarted usingtheCHEMCADprogram.ThedemofilesareinstalledalongwithCHEMCAD. Toaccessthesedemos,selectStart>AllPrograms>Chemstations>Demos,and thenbrowsethelistofavailabletopics.Whenyouselectademofromthemenu,it willstartplayingautomatically.
OutsideoftheUnitedStates,pleaseseewww.chemstations.comforregional contactinformation.
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Chapter 3
transformation.Forthisreason,usersupgradingfromCHEMCAD5willbenefit fromareviewoftheprogramsscreenlayoutandthelocationofimportantfeatures.
Messages pane
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TheCHEMCADInterface
The Workspace
Theareainthemiddleofthescreenisknownastheworkspace.Thisisthemainfocus oftheCHEMCADwindow,theplacewhereyoullbuildandeditflowsheets,view graphs,andrunandtweakprocesssimulations. WhenyoufirstlaunchCHEMCAD,theworkspaceissolidwhite.Whenyoustart tobuildaflowsheetoropenanexistingsimulation,theflowsheetdisplaysinthe workspace. Theworkspaceusestabstoenableyoutoswitchbetweenyouropensimulation andanyopenExcelDataMapsand/ordataplots.Atthebottomoftheworkspace area,youllseeoneormoretabswheneverasimulationisopen.Eachtabincludesa buttonmarkedwithanX;tocloseanytab,firstclickthetabandthenclicktheX button.
Figure 3-01: The bottom of the workspace area, showing several tabs and their
buttons
Notethatanytimeyouveclosedasimulationandhaventyetopenedanother one,theworkspacedisplaysasablankgrayspace.
TheCHEMCADExplorertabsarepresentedinwhatsknownasatreeformat, withitemsorganizedintoamultilevelhierarchy.Thedefaultviewshowsonlytop levelitems,butyoucanexpandeachitemtoviewsecondlevelitems,thirdlevel items,andsoforth. Attheleftofeachtoplevelitemisasmallboxwithaplussign.Toexpandan item,clicktheplussign.Twothingshappensimultaneouslywhenyouclick:thetree expandstoshowthatitemscontents,andtheplussignbecomesaminussign.You canhide(orcollapse)thelowerlevelitemsagainbyclickingtheminussign,which thenturnsbackintoaplussign.Figure303showsanexampleofaCHEMCAD Exploreritemincollapsedandexpandedview.
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CHEMCADVersion6UserGuide
TheCHEMCADInterface
Figure 3-03: Clicking the plus sign to expand an item (left); the resulting view (right)
ExpandingandcollapsingitemsintheCHEMCADExplorertabsisonewaythat youcanmakethebestuseofyourscreenspacewhenworkinginCHEMCAD.
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TheCHEMCADInterface
Expandanyoftheseitemstoseeandusespecificfeatures,whicharedescribedin furtherdetailintheappropriatechaptersofthisuserguide.
Selecting a Palette
TheseUnitOpiconsandtoolsaregroupedintopalettesaccordingtofunctionor equipmenttype.ThedefaultpaletteiscalledAllUnitOps,anditincludesevery availableUnitOpiconanddrawingtool.Toselectadifferentpalette,simplyclickits titlebar.Theselectedpaletteexpandsinplace,asshowninFigure304.
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CHEMCADVersion6UserGuide
TheCHEMCADInterface
Customizing Palettes
AtthetopofthePalettepaneisafieldcalledSearchforUnitOp(s).Typeasearch termhereandthenclickGo!tolocatealloftheUnitOpiconsassociatedwiththat term.TheresultsfromthesearchappearinanewpaletteatthebottomofthePalette pane.Figure305showsthesearchresultsforthewordvessel.
CHEMCADVersion6UserGuide
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TheCHEMCADInterface
Youcandothefollowingwithuseraddedpalettes: Renameanyuseraddedpalettebyrightclickingitstitlebarandselecting Rename.Intheresultingdialogbox,typethenameyouwantandthenclick OK. Deleteauseraddedpaletteatanytimebyrightclickingandselecting Remove. AddindividualUnitOpsortoolstoanexistinguseraddedpalette.Simply rightclicktheiconfortheitemyouwanttoadd,selectInsertintoPalette, andthenclickthenameoftheuseraddedpalette. Removeanitemfromauseraddedpalettebyrightclickingtheiconand selectingRemovefromPalette. Createauseraddedpalettewithoutasearch.Rightclickthefirsticonthat youdliketoincludeonanewpaletteandselectInsertintoPalette>New Palette.TypeanameintheresultingdialogboxandclickOK.Thenaddas manyothericonsasyoudlikeusingthemethoddescribedjustabove.
TheCHEMCADInterface
The Toolbar
TheCHEMCADtoolbarprovidesbuttonsthatarecommontomostWindows applications,suchasNew,Open,Save,andPrint,alongwithbuttonsthatare specifictochemicalprocesssimulation. Todiscovertheuseofaparticularbutton,simplypointyourmousecursoratthe buttonandwatchforthetooltiptoappear,asshowninFigure307.
Toolbarbuttonsprovidequick,oneclickaccesstofrequentlyusedcommands thatarealsoavailableviatheCHEMCADmenus.
CHEMCADVersion6UserGuide
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TheCHEMCADInterface
Resizing a Pane
Thesimplestwaytoaltertheappearanceofapaneistoresizeit.Youcanmakethe CHEMCADExplorerandPalettepaneswiderornarrower,ormaketheMessages paneshorterortaller,bymovingtheinsideedge,orwall,ofthepanetowardor awayfromtheedgeofthemainwindow. Toresizeapane,startbypositioningyourmousecursorattheinsidewallofthe panethatis,therightedgeoftheCHEMCADExplorerpane,theleftedgeofthe Palettepane,orthetopedgeoftheMessagespane.Whenthecursorisinthecorrect positionforresizing,thenormalpointerwillbereplacedwithatwoheadedarrow asshowninFigure308.
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CHEMCADVersion6UserGuide
TheCHEMCADInterface
Figure 3-08: The two-headed arrow cursor used for resizing panes
Moving a Pane
Inadditiontoresizing,youcanalsomoveanyofthepanesintheCHEMCAD window,eithertoadifferentedgeofthescreenortothemiddleofthescreen.You canalsomovegroupsofbuttonsfromtheirdefaultpositionsonthetoolbar. Initially,allofthepanesandbuttongroupsaredocked,meaningthattheyare snappedintoanedgeofthescreenorthetoolbararea.Whenyouundockanitem, youcanputitinthelocationofyourchoosing,awayfromthescreenedge. Toundockapane,clickanddragthepanestitlebar,thatis,thebluebaratthe topofthepanethatshowsthepanename.Toundockabuttongroup,youllneedto clickanddragtherowoffourdotsrunningalongtheleftedgeoftheleftmostbutton inthegroup.
Note:InthecaseoftheMessagespane,thetitlebarrunsalongtheleftedgeofthe
TheCHEMCADInterface
Figure 3-10: An unpinned pane in use; note the sideways pin icon
TheCHEMCADInterface
Visible Grid
Youcanturnonaworkspacegridtouseasaguidewhilecreatingyourflowsheet. SelectView>GridVisibletotogglethisfeatureonoroff. OthergridoptionsincludeView>SnaptoGrid,whichhelpswithalignmentof objectsontheflowsheet,andView>ChangeGridSize,whichenablesyouto customizethehorizontalandverticalspacingofgridlines.
TheCHEMCADInterface
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CHEMCADVersion6UserGuide
Chapter 4
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WorkingwithSimulationFiles
Example Files
EspeciallyifyourenewtoCHEMCAD,itsagoodideatoopenandpractice workingwithsomeexamplefilesbeforecreatingyourownsimulations.Forthis purpose,wevecreatednumerousexamplesofsimulationsfortypicalchemical processes.Youcanopen,view,andeditanyexamplefile,andevensaveacopyin anotherlocationtojumpstartasimulationofyourown. TheCHEMCADexamplefilesareautomaticallycopiedtoyourcomputerwitha completeCHEMCADinstallation.Theexamplesareorganizedbyprocesstypeand locatedinthe\MyDocuments\MySimulations\Examplesdirectory.
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Ifyoushouldhavetroublelocatingaparticularsimulation,youcansearchyour harddriveornetworkforallfileswitha.CC6fileextension.
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Saving a Simulation
Tosaveallchangesinasimulationthatyouhavealreadynamed,selectFile>Save orclicktheSavebuttononthetoolbar.
Note:Insomecases,suchasthebuiltinCHEMCADexamplefiles,existingfilesmay
Note:UnlikepreviousversionsofCHEMCAD,thechangesyoumaketoasimulation
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E-mailing a Simulation
WithCHEMCAD6,emailingasimulationisasimplematterofaddingafile attachment.Justopenyourpreferredemailprogram,createanewmessage,choose yourrecipientsandaddyourtext,thenusetheprogramscommandforattachinga file.Navigatetothefolderwherethesimulationislocated,selecttheappropriate .CC6file,andaddthefileasanattachment.
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AlthoughthetypesofsimulationsyoucancreateusingCHEMCADaremanyand varied,thebasicprocedureforcreatingasimulationcanbebrokendownintothe followingcommonsteps: 1. Startanewsimulation. 2. Selectengineeringunitsforthesimulation. 3. Createaflowsheetwiththeappropriatestreamsandunitoperations. 4. Selectchemicalcomponentsfortheprocess. 5. SelectKvalueandenthalpyoptionsfortheprocess. 6. Definethefeedstreamsusedintheprocess. 7. Enterspecificationsfortheunitoperations. 8. Runthesimulation. 9. Reviewtheresultsofthesimulation.
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Adding UnitOps
ToplaceaUnitOpicononyourflowsheet,followthesesteps: 1. OntheAllUnitOpspalette,findtheappropriateUnitOpiconforthe equipmentyouwanttorepresent.Whenyoupointtotheiconwiththe mouse,theboxaroundtheiconlightsup.ClicktheicontoselecttheUnitOp. 2. Moveyourmousecursortotheworkspacearea,notingthatthepointer displaysanoutlineoftheUnitOpiconyouveselected.Pointtothelocation
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Figure 5-01: Black triangle showing that the Divider UnitOp offers a choice of icons
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UnitOp ID Numbers
WhenyouplaceUnitOpsonyourflowsheet,CHEMCADassignseachoneaUnitOp IDnumberthatisuniquewithinthesimulation.TheUnitOpIDnumberisan importantidentifierfortheunit,andisusedinvariousreportsandchartsasyou workwiththesimulation.Bydefault,yourUnitOpswillbenumbered,startingat1, intheorderinwhichyoucreatethem;alltypesofequipmentsharethesamepoolof IDnumbers. IfyouwanttogroupyourUnitOpsnumericallybyequipmenttype,youcanuse theStartingIDsfeaturetoaccomplishthis. SelectFormat>StartingIDs,whichbringsuptheStreamandUnitOpStarting IDsdialogbox.HereyoullseeeachtypeofUnitOpavailableinCHEMCAD,each withadefaultsettingof1.ThismeansthatanynewUnitOpwillbeassignedanID fromthesamenumberpoolthenextnumber(1orgreater)thathasnotbeenused yetinthissimulation. Tosetupseparaterangesofnumbersfordifferentequipmenttypes,youcanedit thevaluesintheStreamandUnitOpStartingIDsscreen.Forexample,youcouldset theHeatExchangervalueto200,thePumpvalueto300,thePipevalueto400,and soon,usinganystartingvaluesthataremeaningfultoyou.AnyUnitOptypeyou dontassignastartingvaluewillpullIDnumbersfromthepoolstartingwith1, skippinganynumbersthatarealreadyassigned.
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Figure 5-03: Stream 2 with automatic routing (above) and deliberate routing (below)
Rerouting a Stream
Evenafteryouvecompletedyourflowsheetandaddeddetailedinformationabout yourstreams,youcanstillrerouteastreamifneeded.Todothis,clickthestreamto selectit,thenrightclickandselectReroutestream.Theoldstreamdisappears, replacedbythebeginningofanewstreamoriginatingatthesameoutlet. Youcannowclicktocreate90turns,thesamewayyouwouldwithanew stream,toroutethestreamexactlywhereyouwantit.Yourlastclickmustcomplete thestreamatthesameinletyouusedbefore.Afterastreamisrerouted,itretainsall ofthestreamdetailthatyouhadpreviouslyentered.
Stream ID Numbers
Whenyoudrawstreamsinyourflowsheet,CHEMCADassignseachoneastream IDnumberthatisuniquewithinthesimulation.Thestreamnumberisanimportant identifierforthestream,andisusedinvariousreportsandchartsasyouworkwith thesimulation.Bydefault,yourstreamswillbenumbered,startingat1,intheorder inwhichyoucreatethem. IfyouwanttocreateaseriesofstreamswithaseparaterangeofIDnumbers fromtherestofyoursimulation,youcanusetheStartingIDsfeaturetoaccomplish this. SelectFormat>StartingIDs,whichbringsuptheStreamandUnitOpStarting IDsdialogbox.ThenscrolldowntotheStreamoptionandclicktheadjacentnumber column.EnterthenumberthatwillbethestartofyourseparatestreamIDpool,and
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youwanttostartdrawing.Thenmovethecursorandclickagaintocreatethe shapesfirstline.Keepclickingandmovingthemouseuntilyouvecreatedthe shapeyouwant,andthendoubleclicktocompletetheshapeandturnofftheMulti linetool. Tocreateanirregularclosedpolygon,selectthePolygontoolandthenmove yourcursortotheworkspace.Clickwhereyouwanttostartdrawing,andthenclick asecondtimetocreatethefirstsideofyourpolygon.Afterthesecondclick,youll begintoseetheopenareabeingcreated.Continuemovingthecursorandclicking untilyouarereadytoplaceyourlastpoint,andthendoubleclicktocompletethe shapeandturnoffthePolygontool. Notethatyoucanholddownthe[SHIFT]keywhileusingthePolygontoolto createarighttriangle.
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Finding a Component
BecauseofthelargenumberofcomponentsintheCHEMCADcomponentdatabase, scrollingupanddownthelistofavailablecomponentscanbetimeconsuming.To findaspecificcomponentquickly,usetheSearchfieldatthebottomoftheSelect Componentsdialogbox. TypethenameofthechemicalyouwanttofindintheSearchfield.Witheach letterthatyoutype,CHEMCADsuggestspossiblematchesintheAvailable Componentslist.Inthefollowingexample,typingtheletterswaintheSearchfield hashighlightedtheWatercomponent.
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Figure 5-06: Using the Search field to locate the Water component
Notethatinsomesituations,thefirstresultmaynotbetheoneyouwant.For example,typingethaneintheSearchfieldbringsuptheMethanecomponentat first.Toseethenextmatchforyourtext,clickNext;continueclickingthisbuttonas neededuntilyoufindthedesiredcomponent. TheSearchfieldacceptsbothtextandnumericentries.Bydefault,CHEMCAD willsearchforyourentryamongallchemicalnames,chemicalformulas,and CHEMCADdatabaseIDs;ifyoulike,youcanalsosearchbyCASnumber.Toturn anyofthesesearchoptionsonoroff,clicktheOptionsbuttonbelowtheSearchfield. ThisbringsuptheSearchOptionsdialogbox,whereyoucanspecifywhichdatato includeinyourcomponentsearches.
Note:YoucanaddyourowncustomcomponentstotheCHEMCADcomponent
database.Formoredetailsaboutthisfeature,seeChapter10ofthismanual.
Adding a Component
OnceyouvelocatedthecomponentyouwantintheAvailableComponentslist, simplydoubleclickthecomponenttoaddittotheSelectedComponentslistforyour simulation. YoucanalsoselectmultiplecomponentsintheAvailableComponentslistand thenclicktherightarrowbutton,locatedbetweenthetwocolumns,toaddthe
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Figure 5-08: Adding multiple components using the right arrow button
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2. ThisopenstheThermodynamicSettingsdialogbox.Startbydetermining, basedonyourprocessknowledge,whetheryoursystemhastwoliquid phasesorasingleliquidphase.IntheGlobalKValueModelfield,selecta methodthatcancalculatethephasebehaviorrelevanttoyoursystem. 3. Basedonthespecificcircumstancesofyourprocess,makeanyneeded alterationstotheoptionsdisplayedontheKvalueModelstab.Notethatthe optionsappropriatetoyourselectedKvaluemethodaredisplayedinblack, whileirrelevantoptionsaredisplayedingray. 4. ClicktheEnthalpyModelstab,selectthemostappropriatemodelinthe GlobalEnthalpyModelfield,andmakeanyotherchangestotheoptionson thistabasneededforyourprocess. 5. ClicktheTransportPropertiestabandverifythatthesettingsthereare appropriateforthissimulation.Changeanysettingsasneededandthenclick OKtoclosetheThermodynamicSettingsdialogbox. 6. Ifyouvemadeanychanges,amessageboxappears:Allstreamsshouldbe reinitialized.Proceedwithreinitialization?ClickYestoreinitializeallstreams now,orNoifyoudprefertowaitandreinitializethestreamslater.
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Defining Streams
Thestreamsthatyouhavedrawnonyourflowsheetarestilljustlineswithnodata behindthem,sothenextstepistoeditthesestreams,populatingthemwith compositiondataandotherproperties.
Note:Inmostsituations,thestreamsyoullneedtodefinewillbethefeedstreamsin
Thermodynamic Properties
Youmustspecifyexactlytwoofthefollowingthreevariables: Temperature Pressure Vaporfraction
CHEMCADwillcalculatethethirdvariableandenthalpy,basedonthetwo variablesyouspecifyandthethermodynamicsmethodyouveselected.
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Stream Composition
Todefinethestreamcomposition,youllneedtospecifyacompositionunitandthe amountofeachcomponentthatispresentinthestream. SelectaunitfromtheCompunitdropdownlist,andthenbasedonthat selection,populatethefieldforeachcomponentwiththeappropriateamount, percentage,orfraction. Forstreamcompositionsexpressedasapercentageorfraction,youcanenter valuesthatdonottotal100%.Inthiscase,CHEMCADwillnormalizethe compositiontofractionalvaluesthattotal1.Topreviewthenormalizedvaluesthat CHEMCADassignstothecomponents,clickFlash.
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Figure 5-10: Two different UnitOps that require very different amounts of input
selectRun>Run>RunSelectedUnitOps,orrightclickanyUnitOponthe flowsheetandselectRunthisUnitOp.
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Chapter8,OutputandReports.
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Using CHEMCAD for High-fidelity Modeling
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Highfidelity:YouspecifyenergyandequipmentparametersandCHEMCAD calculatestheactualresults.
Figure 6-01: The Sizing menu, showing heat exchanger sizing options
UsingCHEMCADforHighfidelityModeling
Piping
Youcanuseeitherloworhighfidelitymodelingforpipinginyoursimulation. Pipelinesizingisdonebasedonthecompositionofaselectedstream.
Low-fidelity
Forlowfidelitymodelingofpiping,youarerequiredtospecifypipediameterand lengthinmostmodes;designmodesthatcalculatediameteraretheobvious exceptiontothis.Thepressuredropthroughthepipeiscalculatedbasedon diameter,length,andflowratethroughthepipe.
Sizing
Toperformsizingcalculations,selectSizing>Piping.Selectoneormorestreams, theninthePipeSizingdialogbox,selectasizingoptionandclickOKforlinesizing results.Youcanusetheseresults,suchassuggestedpipethicknessanddiameter,to specifygeometryforaPipeUnitOp,orsimplyreviewthemfortheinformationyou need.
Figure 6-02: Line sizing results from the Pipe Sizing dialog box
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High-fidelity
Inhighfidelitypipingmodels,PipeUnitOpsinteractwithNodeUnitOpstobalance pressureandflowrateshydraulicallyamongconnectedpiecesofflowbased equipment.NodesmustbeplacedonbothsidesofallPipeUnitOpstobeincluded inhydraulicbalance;pressureandflowconstraintsaresetatthenodes,notinthe pipes. Ahighfidelitypipingmodelcanshowchangesinflowratebasedonback pressurewheretwopipesmix,whereasalowfidelitymodelwouldsimplyassign theloweroftwospecifiedpressurestotheoutletwithoutconsiderationforback pressure.
Low-fidelity
Fortheseequipmenttypes,CHEMCADcalculatespowerusageandthermaleffects onthefluid,basedonspecifiedoutputpressureorpressureincrease.Other parameters,suchasefficiency,areoptionalbutdoaffectresults.
High-fidelity
Toproduceahighfidelitymodelfortheseequipmenttypes,youmustselectthe operationmodeinwhichyouspecifyperformancecurvesthatis,pressurechange asafunctionofvolumetricflowrate.Thisperformanceinformationisgenerally availablefromtheequipmentvendor.Basedonthevolumetricflowenteringthe UnitOp,CHEMCADcalculatesoutletpressure. Aswithpiping,highfidelitymodelingforpumps,compressors,andexpanders canbeusedwithnodesaspartofahydraulicflowbalancednetwork.
Low-fidelity
Withlowfidelitymodelingofavesselortank,astreamenterstheFlashUnitOpand separatesintovaporandliquid;CHEMCADdoesnotconsiderholduporliquid levelinthetank.Ifyouwanttotakeasteadystatesnapshotofthevessel,youcan manuallyadjusttheflowrateand/orthermalconditionstomakevolumetricflow ratesmatchthevolumeofthevessel.
Note:TheTankUnitOpisspecificallyintendedforusewiththeBatchColumn
UnitOp.Itdoesnotrepresentastandardstoragetankforgeneralpurposes.
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Sizing
Tocalculatesizingforavessel,selectaFlashUnitOpandthenselectSizing>Vessel. ChooseeitherLVVessel(liquidvaporvessel)orLLVVessel(liquidliquidvapor vessel),dependingonyourneeds.Intheresultingdialogboxes,enterthe appropriatevaluesforyourvesselandclickOK.
High-fidelity
Youcanperformhighfidelitymodelingonlyonbatchreactorsanddynamicvessels, andonlywithaCCDYNAMICSlicense(fordynamicvessels,aCCSAFETYNET licensewillsuffice).IfyouspecifythegeometryofyourvesselanduseCHEMCADs dynamicsmode,youcanstudywhathappensinthevesselovertimeasmaterialis addedorwithdrawn. Unlikesimpleflashvessels,batchreactorsanddynamicvesselsdoconsider holdup,liquidlevel,andvariablepressureovertime.
Valves
ValvemodelinginCHEMCADcanbeeitherlowfidelityorhighfidelity.Youcan sizeacontrolvalvebasedonanyflowsheetstream.
Low-fidelity
TheVALVUnitOpisusedforlowfidelitymodelingofavalve.Forthistypeof UnitOp,youspecifyoutletpressureorpressuredecreasethroughthevalve.
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Sizing
SelectSizing>ControlValve,thenselectastream.IntheControlValveSizing dialogbox,specifytheoutletpressureforthetheoreticalvalve,andenterother specificationsasappropriate.WhenyouclickOK,CHEMCADreturnsinformation suchascapacitycoefficient(Cv)andvalvesize.
High-fidelity
TheCVALUnitOpisusedforhighfidelityvalvemodeling.Decidewhichvalues youwillprovideandwhichvaluesCHEMCADwillcalculate,andselectthe appropriateoperatingmodeintheControlValvedialogbox.ProvidethevalvesCv value,andanyotherspecificationsasneeded. Controlvalvescanbeusedwithnodesaspartofahydraulicflowbalanced network.
Columns
ColumnsinCHEMCADcanbemodeledaseitherlowfidelityorhighfidelity.You canperformsizingonanyconvergedcolumn.
Low-fidelity
Forlowfidelitymodelingofcolumns,usetheTower,TowerPlus,orSCDSUnitOps. Specifyidealstagesandtheconditionsatthereboilerandcondenser,asapplicable. Alowfidelitycolumnmodeldoesnotconsidermasstransfereffectsorcolumn internals. Differentcolumnspecificationscanprovidemorerealismwithouttaking geometryintoaccount.Specifyingtoppurityisaverylowfidelitymodel,while specifyingrefluxratioorcondenserdutycanbringyourresultsclosertoreality.
Sizing
Afterrunningyoursimulation,clicktheUnitOprepresentingthedistillationcolumn andselectSizing>Distillation;chooseeitherTraysorPacking,basedonthetypeof column.
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Figure 6-05: Specifying high-level tray data for distillation column sizing
oftheflowsheetsimulation.
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High-fidelity
Toperformhighfidelitymodelingofadistillationcolumninsteadystate,usethe SCDSUnitOpandselecteitherofthemasstransfersimulationmodelsforthe column. Youwillneedtospecifygeometryforthecolumnandchooseacalculation methodfortheselectedmasstransfermodel.CHEMCADcalculatescolumn performancebasedonyourpackingortrayspecifications. Forcolumns,masstransferbasedmodelingperformsrigorousnonequilibrium mixingofvaporandliquid,whereaslowfidelitymodelingassumesidealmixing. Toperformhighfidelitymodelingofadistillationcolumnindynamics,specify thegeometryofthecolumnanddetailsaboutthecontrolsystem.Thisdynamic distillationcanconsidercolumnholdupandtheeffectofvariableschangingover time.
Note:TheShortcutColumnUnitOpisnotarigorouscalculationmodel.Unlessyour
systemsatisfiestheconstantmolarunderflowassumption,youshouldconsider usingadifferenttypeofdistillationcolumn.
Heat Exchangers
Whenspecifyingaheatexchangerinasimulation,youcanuseeitherloworhigh fidelitymodelingaswellassizing,dependingonthetypeofheatexchanger involved.
Low-fidelity
Whencreatingasimulation,youcanusealowfidelityapproachbysimply specifyingthethermalconditionscomingoutoftheexchanger.Specifyingheatduty insteadofmerelyanoutlettemperaturebringsyourresultsclosertoreality,butthis approachstilldoesntconsidergeometry.
Sizing
YoucanusetheCCTHERMmoduleforrigorouscalculationofheattransfer coefficient(U)basedonheatexchangergeometry.Inratingmode,CCTHERM determineswhethertheuserspecifiedheatexchangeriscapableoftheflowsheet heatexchangerperformance.Indesignmode,CCTHERMcalculatesanexchanger designthatiscapableoftheflowsheetperformance.
High-fidelity
Forsomeexchangercategoriesspecificallyshellandtubeanddoublepipeyou canusetherigorousCCTHERMmodeltocalculateheatexchangerperformance. TheflowsheetresultsarebasedonrigorouslycalculatedUvalueandthespecified exchangergeometry.Youcanalsodetermineapproximatefoulingofaunitifactual outlettemperaturesareknown.
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Relief Devices
Forreliefdevices,sizingisnotnecessarilydistinctfromlowfidelitymodeling.To modeldynamicreliefofavessel,youcaninsteadusehighfidelitymodeling.
Low-fidelity
Tomodelasteadystatesnapshotofareliefdevice,selectSizing>ReliefDevice, specifyratingordesignmode,andselecttheappropriateoptionsforyourrelief scenario.WhenyouclickOK,CHEMCADreturnsareliefdevicecalculation summary. IfyouselecttheRigorousintegralanalysisdesignmethodwhensizingarelief device,youwillobtainamoredynamicresult.
Figure 6-08: Selecting the rigorous integral analysis method for relief device design
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High-fidelity
YoucanperformhighfidelityreliefdevicemodelingfortheBatchReactorand DynamicVesselUnitOps.Youcanspecifythereliefdevicenozzlearea,aswellas otherspecificationsforyourreliefscenario.Thisenablesyoutostudythedynamic reliefofthevessel.
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Licensing Considerations
Tousethefunctionalitydescribedinthischapter,youmusthaveavalidlicensefor theCCDYNAMICSmoduleofCHEMCAD.Tovieworchangethedispositionof yourCCDYNAMICSproductlicense,seetheCHEMCADLicenseMonitorscreen (Tools>Options>Licensingwhenasimulationisopen,orLicense>Licensing whennosimulationisopen).
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Thebasicstepsforadynamicsimulationarelargelythesameasthosefora steadystatesimulation,withafewvitaldifferences: 1. Createanewsimulation. 2. Selectengineeringunits. 3. Drawtheflowsheet. 4. Selectcomponents. 5. Selectthermodynamicsoptions. 6. Specifyfeedstreamsandinitialstreamconditions. 7. SetspecificationsforUnitOps. 8. Runthesimulationinsteadystatetoobtaintimezerovalues. 9. Switchthesimulationtodynamics. 10. Specifydynamicssettings,suchasruntimeandinitialcharge(s). 11. Runthesimulationindynamics. 12. Reviewtheresults. 13. Rerunorextendthesimulationasneeded. 14. Generateplotsandreportsasneeded. Beforeyoustartworkingonadynamicsimulation,itsimportanttohaveas muchinformationaboutyourprocessaspossible,aclearideaofwhatyouwantto findout,andastrategyforproducingtheresultsyouneed.
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Switching to Dynamics
Followthesestepstoswitchasimulationfromsteadystatetodynamicoperation: 1. OpenthesimulationandselectRun>Convergence.Thisbringsupthe ConvergenceParametersdialogbox. 2. Inthelowerrightportionofthedialogbox,clickintheSteady State/DynamicsfieldandselectDynamics.
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3. ClickOKtosavethechangesandclosethedialogbox. Afteryouswitchtodynamics,youllnoticethatafewthingshavechangedon theCHEMCADscreen: ThestatusbaratthebottomofthemainCHEMCADwindowchanges.Afew inchesfromtherightedgeofthescreen,insteadofthewordsSteadyState, youllnowseeDTimeandatimecounterdisplayingthenumberofminutes yoursimulationhasrun.Beforeyourunthesimulation,theDTimesetting displays0:00min. ThesteadystateRunAllbuttononthetoolbarisdisabled,andthedynamics buttonsarenowactivated.Thesebuttons,showninFigure702,are(leftto right)SetRunTime,ResettoInitialState,RunDynamicSimulation,Plot DynStreams,andPlotDynUnitOps.
YoucannowselectRun>DynamicstobringuptheDynamicsMenu.This windowprovidesconvenientaccesstoalldynamicssettingsandcommands.
BuildingandUsingaDynamicSimulation
Figure 7-04: The General tab on the Dynamic Run Time Schedule dialog box
Figure 7-05: The Step 1 tab on the Dynamic Run Time Schedule dialog box
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Note:InboththeRecordStreamsandRecordUnitOpsdialogboxes,youcanusethe
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shouldbeusedwithextremecautiontoavoidconfusionandunintendedresults. ThisfeatureiscontrolledbyacheckboxontheConvergenceParametersdialogbox.
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Note:FortheStreamHistoryandDynamicUnitOpHistoryplots,besuretorecord
thestreamsandUnitOpsthatyouwanttostudy.Youcanonlyrequesttheseplots forrecordedstreamsorUnitOps.
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Toaccesstextbaseddynamicreports,selectReport>Dynamicsandthenselect oneofthefollowingreports: DynamicColumnHistory:Thisreportprovidesdynamiccolumnresultsfor aselectedcolumn.ThePrintReportOptionsdialogboxoffersthemost relevantitemsfordynamiccolumnreporting. DynamicStreamHistory:Thisreportprovidesstreamhistoriesforaspecific streamthatyouselect,basedontheintervalthatyouspecifyandincluding thecompositions,components,andstreampropertiesthatyouselect. DynamicUnitOpHistory:Thisreportprovidesdetailedinformationabouta dynamicUnitOpinthesimulation,basedontheintervalthatyouspecifyand includingtheUnitOpparametersthatyouselect.
Note:FortheDynamicStreamHistoryandDynamicUnitOpHistoryreports,besure
torecordthestreamsandUnitOpsthatyouwanttostudy.Youcanonlyrequest thesereportsforrecordedstreamsorUnitOps.
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Chapter 8
Text Reports
CHEMCADcanproduceawidearrayofcustomizabletextbasedsimulationreports, basedonstreamdata,UnitOpdata,flowsheetdata,ordynamics.Youcanalsouse CHEMCADspowerfulReportWriterfeaturetoproducecustomizedconsolidated reportsincorporatinganycombinationofavailabletextreports.
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OutputandReports
Inadditiontoindividualreports,youcancreateconsolidatedreports,whichare customizablecombinationsofdifferentindividualreports.Foranygiven consolidatedreport,youcanusethedestinationoptionyouvesetupinthe Preferencesdialogbox,orchangetoanyviableoutputformat:CHEMCADsinternal reportviewer,MSWord,WordPad,orExcel. Tochooseadefaultprogramforconsolidatedreportoutput,selectReport> FormatConsolidatedReport.OntheFormattab,chooseanoptioninthe Destinationdropdownlist.ClickOKtoapplyyourchange.Notethatyouwillhave theoptiontooverridethisdefaultdestinationforanygivenconsolidatedreportthat youcreate.
Stream-based Reports
AnumberofCHEMCADreportsareavailabletoanalyzestreamdatafroma simulation.Toaccessanyofthefollowingreports,selecttheappropriateitemfrom theReportmenu.Theresultswilldisplayaccordingtothewayyouhaveconfigured CHEMCADtohandletextreports.
Note:Bydefault,thesereportswillusetheengineeringunitsyouselectedwhen
Stream Groups
Forstreamcompositionandpropertyreports,youcancreatecustomstreamgroups withinasimulationtostreamlineyourreportrequests. Forexample,ifyouhaveaprocessthatinvolvestendifferentfeedstreams,and youfrequentlyrunreportsonthisgroupofstreams,youcansetupagroup consistingofjustthosestreams.Then,wheneveryouwanttoobtaincompositionor propertydataforthosestreams,yourejustafewclicksawayanytimethesimulation isopen.
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3. IntheEditStreamGroupdialogbox,selectthestreamsforthisgroup,either bytypinginthestreamnumbers(oneperline)orbyclickingonstreamsin theflowsheet.ClickOKtoclosethedialogbox. 4. Assoonasyoufinishcreatingthegroup,itsnameappearsunderStreamsin theCHEMCADExplorer.Fromhere,youcanrightclickthegroupnameand selectanyofthefollowing: View/Edit:OpentheEditStreamGroupdialogbox,whereyoucanadd ordeletestreamnumberstoincludeinthegroup. Rename:OpentheRenameGroupdialogbox,whereyoucantypeanew nameforthestreamgroup.
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Note:Thecommandstocreate,edit,andremovestreamgroupsarealsoofferedon
theReportmenu,underbothStreamCompositionsandStreamProperties.
Stream Compositions
Youcanrunastreamcompositionreportbasedonallstreams,oryoucanspecify whichstreamstoinclude.Torunastreamcompositionreport,selectReport> StreamCompositionsandthenselectfromthefollowingoptions: SelectStreams:ChoosethestreamsyouwanttoincludeintheSelectStreams dialogbox,eitherbytypinginthestreamnumbers(oneperline)orby clickingonstreamsintheflowsheet.ClickOKtoclosethedialogboxand displaythereport. AllStreams:Thisreportdisplaysallstreamcompositiondatafortheentire flowsheet.
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FeedStreams:Thisreportdisplaysstreamcompositiondataonlyforstreams issuingfromaFeediconontheflowsheet. ProductStreams:Thisreportdisplaysstreamcompositiondataonlyfor streamsterminatinginaProducticonontheflowsheet. UnitStreams:Thisreportdisplaysallinletandoutletstreamcomposition dataforaspecifiedUnitOpontheflowsheet.IfnoUnitOpiconisselected whenyourunthereport,youllseetheSelectUnitOpsdialogbox;typethe UnitOpIDorclicktheUnitOpontheflowsheetandthenclickOKtodisplay thedata.IfyouselectaUnitOpiconbeforerunningthereport,thedatawill displaywithoutfurtherinput.
Stream Properties
Beforerunningreportsonstreamproperties,youllneedtospecifywhichproperties toinclude.Todothis,selectReport>StreamProperties>SelectProperties.This openstheViewPropertyOptionsdialogbox,whereyoucanreviewwhich propertiesarecurrentlyselected. Ifyouwanttoaddanyproperties,checktheappropriateboxes;toremove properties,clickoncheckedboxestoclearthem.BesuretoclickthePage2taband makeanyappropriatechangesthereaswell.Whenyouarefinished,clickOKto returntothemainCHEMCADwindow. Torunastreampropertiesreportforthepropertiesyouvespecified,select Report>StreamPropertiesandthenselectfromthefollowingoptions: SelectStreams:ChoosethestreamsyouwanttoincludeintheSelectStreams dialogbox,eitherbytypinginthestreamnumbers(oneperline)orby clickingonstreamsintheflowsheet.ClickOKtoclosethedialogboxand displaythereport. AllStreams:Thisreportdisplaysallstreampropertydatafortheentire flowsheet. FeedStreams:Thisreportdisplaysstreampropertydataonlyforstreams issuingfromaFeediconontheflowsheet. ProductStreams:Thisreportdisplaysstreampropertydataonlyforstreams terminatinginaProducticonontheflowsheet. UnitStreams:Thisreportdisplaysallinletandoutletstreampropertydata foraspecifiedUnitOpontheflowsheet.IfnoUnitOpiconisselectedwhen yourunthereport,youllseetheSelectUnitOpsdialogbox;typetheUnitOp IDorclicktheUnitOpontheflowsheetandthenclickOKtodisplaythe
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Pseudocomponent Curves
Foratextreportonpseudocomponentcurves(alsoknownasdistillationcurves), selectReport>PseudocomponentCurves.Selectoneormorestreamscontaining hydrocarbons,eitherbytypinginstreamnumbers(oneperline)orbyclickingon streamsintheflowsheet.ClickOKtodisplaythereport.
UnitOp-based Reports
CHEMCADcanalsorunreportstoanalyzeUnitOpdata.Toaccessthesereports, selecttheappropriateitemfromtheReportmenu.Theresultswilldisplayineither WordPadorExcel,dependingonhowyouveconfiguredCHEMCADtohandletext reports.
UnitOp Groups
FortheUnitOpsreport,youcancreatecustomUnitOpgroupswithinasimulation. Muchliketheirstreambasedcounterparts,UnitOpgroupscansaveyoutimeand effortwhenrequestingreports;inaddition,youcanusethesegroupswhenrunning yoursimulation,toisolateandrunonlyselectedUnitOpsfordiagnosticorother reasons.
Note:BecauseofthisotherfunctionalityofUnitOpgroups,theorderinwhichyou
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3. IntheEditUnitOpSequenceGroupdialogbox,selecttheUnitOpsforthis group,eitherbytypingintheUnitOpIDs(oneperline)orbyclickingon UnitOpiconsintheflowsheet.AddUnitOpsintheordertheyruninthe simulation.ClickOKtoclosethedialogbox. Assoonasyoufinishcreatingthegroup,itsnameappearsunderUnitOpsinthe CHEMCADExplorer.Fromhere,youcanrightclickthegroupnameandselectany ofthefollowing: View/Edit:OpentheEditUnitOpSequenceGroupdialogbox,whereyou canaddordeleteUnitOpsorreordertheexistinglist. Rename:OpentheRenameGroupdialogbox,whereyoucantypeanew nameforthegroup. Copy:OpentheCopyGroupdialogbox,whereyoucantypeanewgroup nametomakeanexactcopyoftheUnitOpgroup.AfteryouclickOK,you cantheneditthenewcopyofthegrouptofityourneeds. Delete:RemovethisUnitOpgroupfromthesimulation.Ifyouresureabout deletingthegroup,clickYesinthedialogboxthatappears. Run:RunthesimulationonlyforthoseUnitOpsincludedinthisgroup. View:DisplayasummaryreportoftheUnitOpsincludedinthisgroup. Specifications:BringuptheUnitOpspecificationdialogboxesforeachitem intheUnitOpgroup,startingwiththefirstUnitOplisted.
Note:Thecommandstoadd,edit,andremoveUnitOpgroupsarealsoofferedonthe
ReportmenuunderUnitOps.
Select UnitOps
TorunareportthatcoversjusttheUnitOpsyouspecify,selectReport>UnitOps> SelectUnitOps.IntheSelectUnitOpsdialogbox,specifytheUnitOpsyouwantto includeinthereport,eitherbytypingintheUnitOpIDs(oneperline)orbyclicking onUnitOpsintheflowsheet.ClickOKtoclosethedialogboxanddisplaythereport. IfyouselectaUnitOpiconbeforerunningthereport,thedatawilldisplay withoutfurtherinput.
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Spec Sheet
TheSpecSheetcommandexportsdetailedinformationaboutaUnitOpintoa preformattedExcelworksheet.Thisreportisusefulfortaskssuchassolicitinga manufacturingquoteforapieceofequipment. TocreateaspecsheetforallUnitOpsontheflowsheet,selectReport>Spec Sheet>AllUnits. TocreateaspecsheetonlyforspecificUnitOps,selectReport>SpecSheet> SelectUnit.ChoosetheUnitOpsyouwanttoincludeintheSelectUnitOps dialogbox,eitherbytypingintheUnitOpIDs(oneperline)orbyclickingon UnitOpiconsintheflowsheet.ClickOKtoclosethedialogboxanddisplay thespecsheet. ForasingleUnitOpspecsheet,youcanselecttheUnitOpiconbefore runningthereport;Excelwillopenandthedatawilldisplaywithoutfurther input.
Note:ForspecsheetsthatincludemultipleUnitOps,CHEMCADcreatesaseparate
worksheetforeachUnitOpsdatawithintheExcelfilethatCHEMCADcreates.
Distillation
Torunadistillationreport,selectReport>Distillationandthenselectoneofthe following: TowerProfiles:Generatesareportdetailingtemperature,pressure,andflow rateforadistillationcolumn TrayCompositions:Createsareportthatshowsthevaporflowrate,liquid flowrate,andKvalueofeachcomponentoneachstageofadistillation column TrayProperties:Reportsoncurrentlyselectedstreampropertiesforeach stageofadistillationcolumn TowerMassTransfer:ForanSCDSdistillationcolumnthatusesamass transfermodel,providesmasstransfercoefficients,heightoftransferunits, andestimatedheightoftheoreticalplates(HETP) DynamicColumnHistory:Providesdatafromasingledynamicrunofa column(describedindetailinChapter7,BuildingandUsingaDynamic Simulation) ColumnDiagnosis:Forcolumnsthathavenotsuccessfullyconverged, providesrecommendationsforchangingcolumnsettingstoachieve convergence
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Flowsheet-based Reports
InadditiontoreportsthatfocusonparticularUnitOpsandstreams,CHEMCAD offerstextreportsthatprovideinformationaboutthesimulationasawhole.To accessanyofthesereports,selecttheappropriateitemfromtheReportmenu.
Topology
ThisreportprovidesalistingofallUnitOpsintheflowsheet,aswellasallstream originsanddestinations.
Thermodynamics
Thisreportlistsallcomponentsusedinthesimulationandprovidesvital informationaboutthethermodynamicsmethodsused.
Dynamics Reports
TheReportmenuprovidesaccesstotheBatchResultsandDynamicscommands, whichprovidereportsaboutnonsteadystateprocesses.
Batch Results
Thisreportsummarizestheresultsofabatchdistillationcolumnsimulationatthe endofeachoperatingstep.
Dynamics
YoucanaccessthreedifferentreportsbyselectingReport>Dynamics:Dynamic ColumnHistory,DynamicStreamHistory,andDynamicUnitOpHistory.These reportsaredescribedindetailinChapter7,BuildingandUsingaDynamicSimulation.
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Fromhere,youcanclickGeneratetobringupadefaultconsolidatedreportthat includestopology,convergence,massandenergybalances,andtheotherreports listedinthedialogboxsleftcolumn.Ifthisreportisadequatetoyourneeds,simply clickCancelaftergeneratingtheconsolidatedreport,toclosetheReportWriter dialogbox. Ifyouwantsomethingotherthanthedefaultconsolidatedreport,youcanalso usetheReportWritertocustomizewhichindividualreportstoinclude,whatorder toputthemin,whichflowsheetelementstoinclude,andmuchmore.Youcanfine tuneyourreportsettingswithoutclosingthisdialogbox,andthensaveyourreport configurationwithanewnamesothatyoucanrunitagaininthefuture.
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Figure 8-06: Results of typing a new name into the Report Name field
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Notethattogenerateoraccessagloballysavedreport,youcanselectReport> Global/PoolReports.
Graphical Reports
Inadditiontotextbasedreports,CHEMCADoffersawidevarietyofgraphicalplots thatyoucanviewonscreenorprintforreview.
TPXY
Thisselectiongeneratesvaporliquidequilibriumcurvesbetweenanytwo components,withanoptionalthirdcomponent.YoucanincludeTPXY,TXY,activity coefficient,andfugacitycoefficientcurves.
Binary LLE
Thisselectiongeneratesliquidliquidequilibriumcurvesbetweenanytwo components.
Binodal Plot
Thisselectiongeneratesaternaryphasediagramshowingthedistributionofthree selectedcomponentsintwoliquidphases,includingtielinesandplaitpoint.
Binodal/Residue Curves
Thisselectioncreatesaplotthatcombinesthecurvesfromabinodalplotanda residuecurveplot.Thisisusefulwhenworkingwithheterogeneousazeotropic distillation.
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Residue Curves
Thisselectiongeneratesandplotsagraphicaldisplayofdistillationzones, azeotropes,andresiduecurvesassociatedwithauserspecifiedternarymixture.
Solid/Liquid Equilibrium
Thisselectiongeneratessolidliquidequilibriumcurvesbetweenanytwo components.
Flowsheet-based Graphs
Toviewgraphicalreportsthatreflectyouroverallsimulation,selectoneofthe followingfromthePlotmenu: StreamProperties:Plotsoneselectedstreampropertyforaselectedstreamin theflowsheet PhaseEnvelopes:Plotsaphaseenvelopeforagivenstream,highlightingthe criticalpointofthemixture;canincludeplotsatvaporfractionsotherthan0 (bubblepointcurve)and1(dewpointcurve) CompositeCurves:Plotscompositeheatcurvesfortheentireflowsheet,as wellasoptionalheatcurvesforindividualUnitOps PseudocomponentCurves:Displaysaplotofoneormoredistillationcurves forastream
UnitOp-based Plots
CHEMCADoffersseveralplotsthatdisplaydataforasingleUnitOp.Toaccessany oftheseplots,selectPlot>UnitOpPlotsandthenselectoneofthefollowing options.
Tower Profiles
Thisselectionplotscompositions,temperature,andflowprofilesfordistillation columns.
Heat Curves
Thisselectionplotsheatingandcoolingcurvesforaselectedheatexchanger.
Pipe Profile
ThisselectionplotsfluidpropertiesforpipeUnitOpsalongtheaxiallengthofthe pipe.Thisplotrequiresthatthepipecontainmultiplesegments.
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Controller Convergence
Forcontrollersthathavenotconverged,thisplotenablesyoutodiagnosethe controllerbehaviorthatispreventingconvergence.Theplotshowshowthe controllererrorfunctionchangeswithiteration.
Dynamic Plots
CHEMCADoffersaseriesofplotsforusewithdynamicoperations.SelectPlot> DynamicPlotstoaccessanyofsixgraphicaldynamicsreports. TheseplotsaredescribedindetailinChapter7,BuildingandUsingaDynamic Simulation.
User-specified File
IfyouhavecustomizedCHEMCADusingVBA,C++,orotherprogramming languages,youcansaveplotdataintoatextfileandusethisfeaturetodisplaythat dataasacurve. SelectPlot>UserSpecifiedFiletobringupamessageboxthatprovides instructionsonhowtoformatthetextfile.ClickOKtocontinuetoanOpendialog box,whereyoucanselectthetextfileyouwanttouse.WhenyouclickOpen,the curveisplottedanddisplayed.
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Flowsheet Databoxes
CHEMCADoffersfourtypesofdataboxes: StreamBox:Liststhestreamsthatyouselectinasingletable,alongwiththe streampropertiesthatyouchoosetoinclude UnitOpBox:GeneratesaseparatedataboxforeachselectedUnitOp TPBox:Generatesseparatesummarydataboxesforselectedstreams ExcelRangeBox:ReferencesarangeofcellsfromanExcelworksheet
Stream Boxes
Tocreateastreamdatabox,startbyselectingFormat>AddStreamBox.Fromthe SelectStreamsdialogbox,followthesesteps: 1. Determinewhichstreamstoincludeinthedatabox,usingoneofthree methods: ChecktheAllstreamsboxtoincludeallstreamsonyourflowsheet,then clickOK. Typethenumbersofthestreamsyouwanttoincludeintotheboxes provided(onenumberperline),thenclickOK. Choosethestreamsyouwanttoincludebyclickingtheactualstream lineswithyourprimarymousebutton.Streamnumbersthatyouselect willappearintheSelectStreamsdialogbox;totoggleaselectedstream off,justclickitagain.Whenyouveselectedallthestreamsyouwant, clickOKtocontinue.
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UnitOp Boxes
TheprocedureforcreatingUnitOpdataboxesissimilartothatusedtocreatestream databoxes,withthechiefdifferencebeingthatthereisnoselectionofUnitOp properties. BeginbyselectingFormat>AddUnitOpBox,andtheneithertypeinUnitOp IDsorclickUnitOpsontheflowsheet.Notethatyoudonthavetheoptionof automaticallyincludingallUnitOps,asyoudidwithstreams;toincludeallUnitOps inthedatabox,clickablankareaoftheflowsheetandthenpress[CTRLA]toaddall UnitOpIDstothelist. WhenyoucompleteyourselectionsandclickOK,theDataboxSettingsdialog boxappears,withthesameformattingoptionsthatareavailableforstream databoxes.Changeanysettingsyouwanthere,andthenclickOKtoplacethe requesteddataboxesonyourworkspace. Unlikeastreamdatabox,whichdisplaysdataformultipleitemsinasinglebox,a UnitOpdataboxdisplaysdataonlyforasingleUnitOp.Ifyouselectedthree UnitOpsintheUnitOpIDsdialogbox,youllseethreeseparatedataboxesappear whenyouclickOK.Ifyouseeonlyonedataboxatfirst,trymovingthatboxto anotherpartofthescreentoseeiftheothersarehiddenbehindit.
TP Boxes
CHEMCADcancreatedataboxes,calledTPboxes,whichdisplayanycombinationof temperature,pressure,andflowrateforallstreamsorselectedstreamsona flowsheet. ToaddTPdataboxes,selectFormat>AddTPBox.IntheTPBoxSettingsdialog box,firstselectanoptionatthetop,todeterminewhethertoaddTPboxesforall streamsoronlyforthestreamsyouselect. IntheDisplaycolumn,selectitemsfromthedropdownlistineachfieldto determinewhichstreampropertiestodisplayandinwhatorder.UseNoselection asappropriateifyouwanttodisplayfewerthanfourproperties. IntheNumberformatcolumn,makeaselectionineachfieldtodeterminehow numberswilldisplayintheTPboxes.IntheDigitscolumn,typethenumberof digitstodisplayafterthedecimalpoint.Youcanalsochoosewhethertodisplay streamIDsandengineeringunits.
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Youhaveaverylargeflowsheetthatencompassesanumberofdiscrete processes.Youcancreateseparatelayersforvariousportionsoftheoverall flowsheet,andviewonlytheportionsyoureworkingwithatagiventime. Youcanalsohideunneededportionsoftheflowsheetforprinting. Ifyouaretroubleshootingaprocess,orforwhateverreasonneedtomark upaprocessflowdiagram,youcandrawshapessuchasellipsesor rectanglesaroundcertainUnitOpsorgroupsofUnitOps,usingtextorbright colorstodrawextraattention.Thenassignallofthesemarkupitemstoa singlelayersothatyoucanchoosetovieweitherthemarkedupversionor thecleanversionoftheflowsheetatanytime.
IntheNewLayerdialogbox,replacethedefaultlayernamewithadescriptive nameofyourownandthenclickOK.
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Figure 8-11: Visible and hidden layers as they appear in CHEMCAD Explorer
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assignedtotwoormorelayers,however,itwillbedisplayedunlessallofits associatedlayersarehidden.
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Customizing CHEMCAD
AsyoubecomemorefamiliarwiththewaythatCHEMCADworksandthevarious optionsandtoolsthatareavailable,youmayfindyourselfwishingthatyoucould makeyourownadditionseitherforspecializeditemsorforthoseyouuse frequently.YoucaninfactcustomizeCHEMCADinseveralwaysthatsaveyoutime bystreamliningandsimplifyingyourworkflow.Theseinclude: CreatingstreamandUnitOptemplates AddingcustomcomponentstoCHEMCADscomponentdatabase MakingyourownsymbolsandaddingthemtotheUnitOpspalette BuildingcustomUnitOps CreatingcustomdialogboxesforUnitOpsettings Definingcustomthermophysicalrules
Flowsheet Templates
OneofthemosteffectivewaystosavetimewhencreatingCHEMCADsimulations istomakeuseofstreamandUnitOptemplates.Atemplateissimplyasetof characteristics,whichyouassignanameandsaveforlateruse.Whenyousetup streamorUnitOpspecificationsthatyouknowyoullneedtorecreateinthefuture, youcancreateatemplateofthatstreamorUnitOp.Youcanthenduplicatethatitem withinthesamesimulationorinanyothersimulationwithjustafewmouse clicks.
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Creating a Template
Tocreateastreamtemplate,firstcreatethestreamyouwanttocloneandgiveitall ofthecharacteristicsyouwanttoincludeinthetemplate. ThenfindthisstreamontheCHEMCADExplorersSimulationtab.Expandthe Flowsheetitem,thenexpandtheStreamitem,andfinallydoubleclickthe applicablestreamID.ThisbringsupanitemcalledSave.Doubleclicktheword SavetobringuptheEnterTemplateNamedialogbox,thentypeanameforyour newstreamtemplateandclickOK.Thenewstreamnameisnowlistedbeneaththe Saveitem. TocreateaUnitOptemplate,selecttheappropriateUnitOpIDinCHEMCAD Explorer,andthenfollowthesameprocedureusedtocreateastreamtemplate.
Applying a Template
Toapplyastreamtemplate,firstexpandtheCHEMCADExploreritemforthe streaminquestion,eitherbyclickingtheplussigntoitsleftorbydoubleclickingthe streamname. Whenthestreamitemisexpanded,youllseetheSaveitembelowit,followedby thenamesofallthestreamtemplatesthatyouhavecreated.Doubleclickthename ofthetemplateyouwanttouse,thenclickOKtoconfirmthatyouwanttoapply thisstreamtemplate.
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Note:AnystreamorUnitOptemplatethatyoucreateisavailableforusewithall
othersimulationsonthesameinstallationofCHEMCAD,untilandunlessyou deletethetemplate.
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6. Normally,youllneedtoclickCreate,whichbringsuptheSaveAsdialog box.Navigatetothelocationyouwantforyourcustomcomponentdatabase, givethedatabaseaname,andclickSave.Ifyouwanttoaddadatabasethat someoneelsehascreated(generallyinanetworklocation),youcanclick Connect,whichbringsupanOpendialogbox;navigatetothatdatabases location,highlightthedatabase,andclickOpen. 7. TheManageComponentDatabasesdialogboxnowliststhedatabasethat youcreatedorselected.ClickOKtocontinue. 8. IntheSelectDestinationDatabasedialogbox,thenewdatabaseyouhavejust namedisnowlisted;highlightitandclickOK. 9. TheView/EditComponentDatamenunowappears.Clickanyitemonthe menutoaccessadialogboxwithoptionsfordefiningyournewcomponent. Afterdefiningasmanycharacteristicsaspossible,clickExittoclosethe menu. Thenewcomponentisnowavailabletoaddtoyourcurrentsimulationandall futuresimulations.Toreturnatanytimetomakechangestoauserdefined component,dooneofthefollowing: SelectThermophysical>ComponentDatabase>View/EditDatabase ComponenttobringuptheSelectSingleComponentdialogbox,whichlists allavailablecomponents.Highlightthecomponentyouwantinthelistand clickOKtobringuptheView/EditComponentDatamenu. ClickComponentListonthetoolbar(orselectThermophysical> ComponentDatabase>View/EditSimulationComponent)tobringupthe listofcomponentsinthecurrentsimulation.Doubleclickthecomponentyou wantinthelisttobringuptheView/EditComponentDatamenu.
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2. SelecttheuseraddedcomponentthatyouwanttoregressandclickNew. ThisbringsuptheEditRegressionSetdialogbox.
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Pseudocomponent Range
Usingapseudocomponentcurveanothertermforthedistillationcurveportionofan assayyoucancutahydrocarbonstreamintopseudocomponents,orfractions.A pseudocomponentrepresentsagroupofcomponentsthatboilwithinanarrow temperaturerange.PseudocomponentrangesareusedinCHEMCADtomodel hydrocarbons. Whenyoudefineapseudocomponentrangeforastream,CHEMCADcreates entriesinthecomponentdatabaseforeachhydrocarboncut,andassignsthese componentscompositionstothestream.
Note:Beforeyoudefineapseudocomponentrange,makesurethatyouhave
CustomizingCHEMCAD
andenterthenumberofpointsthatyouwanttodefineasdiscrete pseudocomponentswithinthatrange.ClickOKtocontinue. 5. IntheBulkPropertiesdialogbox,specifyadistillationcurvetypeandentera totalflowrateandbulkgravityforthestream.Youcanmakeotherentries hereasneeded,butonlythesethreeitemsarerequired.Notethatifyouhave viscositydatathatyouwanttouse,youmustchecktheViscosityboxhere. ClickOKtocontinue. 6. Intheresultingdialogbox,enterthedistillationcurvefromyourassay, specifyingthevolumepercentageandboilingtemperatureforatleastfive datapoints.ClickOKtocontinue. 7. Thenextdialogboxisoptional.Enteragravitycurvefromyourassay,listing thevolumepercentageandspecificgravityforatleastfivedatapoints.Click OKtocontinue. 8. Thenextdialogboxisalsooptional.Ifyouhavelightendsandwaterdefined inyourassay,entervolumepercentagedatahereforallrelevantcomponents. ClickOKtocontinue. 9. IfyoucheckedtheViscosityboxontheBulkPropertiesdialog,youwillnow seetheViscosityDatadialogbox.EnteryourviscositydataandclickOK. 10. ThisbringsuptheEditDistillationCurvesmenu,showninFigure905.
11. ClickSaveandExit.Thepseudocomponentpropertiesnowdisplayinatab inthemainCHEMCADwindow.Youcanreviewandprinttheseresults,and leavethetabopenaslongasyoulike.Toreturntothemainworkspaceand yourflowsheet,simplyclickthefarlefttab,whichdisplaysthenameofyour simulation. 12. Toseethelistofpseudocomponentsthatyouhavecreated,editthe propertiesforthestreamyouselected.Thepseudocomponentswillbelisted afterpurecomponents,withnamesthatbeginwithNBP.
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Oncetheeditorisopen,youllseeagriddedworkspaceandasmall,freefloating toolpalette.
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Figure 9-07: The pump_1.sym file open in the Symbol Editor workspace
2. SelectFile>SaveAsandsavethefileinadifferentdirectory,usinga distinctivenametoavoidconfusionwiththeoriginalsymbol. 3. UsethetoolsavailableinSymbolEditortochangethesymbolasneeded: Toremoveoralteranyexistingpartofthesymbol,selectStructure> Ungrouptobreakthesymbolintoitsindividualcomponents. Toaddgraphicalcomponentstothesymbol,usethedrawingtoolsonthe toolpalette,suchasRectangleandEllipse. Toaddatextlabeltothesymbol,usetheTexttool. Toaddaninletoroutlet,clicktheappropriateitemonthetoolpalette andthenclicktoplacetheinletoroutletonthesymbol. Tobackoutofachangethatyouvemade,selectEdit>Undoorpress [CTRLZ].
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ThebasicproceduresforcreatingcustomExcelUnitOpsarecoveredinChapter 10,DataInterfaces.CalculatorUnitOpsaredefinedbyaprogramminglanguage calledParser,thesyntaxforwhichisdocumentedintheCHEMCADCalculator/Parser Moduleguide,availableontheChemstationswebsite. C++useraddedmodulesaredevelopedusingMicrosoftsVisualC++ developmenttool,thesametoolsthatwereusedinthecreationofCHEMCADsown UnitOps.TheproceduresforcreatingC++useraddedmodulesforusewith CHEMCADaredetailedintheUseraddedModulesGuide,whichisalsoavailableon theChemstationswebsite. VBAUnitOpsaredefinedbyVBAsubroutines,andaredescribedlaterinthis chapter. ThemethodyouchooseisanimportantfirststeptowardcreatingaUnitOp,but thechoiceisalmostentirelyuptoyou.CalculatorUnitOpscanbequickandeasyto setup,buttheycantdoeverythingtheothermethodscan.TheExcel/VisualBasic approachisverypowerfulandusesthefamiliarVisualBasiclanguagefor development.Adrawbacktothismethodisthatcalculationcansometimesbeslow duetotheuseofMicrosoftExceltodothecalculations.Themostpowerfuland fastestcalculatingmethodistheC++useraddedmodulemethod,butifyouarenew toC++,itmaybechallengingtouse.VBAUnitOpsareaspowerfulasthosecreated usingC++,andaremucheasiertobuild. WhichevermethodyouusetoprogramthecalculationsofyourUnitOp,youwill likelyneedtocreateadialogboxtoprovideauserinterface.Adialogboxenables userstosendinformationintoyourUnitOp,forexamplethenumberofstagesfora distillationUnitOp.NomatterwhatmethodyouusetoprogramyourUnitOp,you willusetheDialogEditorprogramtocreatetheuserinterface.
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TheDialogEditorprogramisseparatefromCHEMCAD.Tolaunchit,select Start>AllPrograms>Chemstations>Utilities>DialogEditor.
AdetaileddescriptionofhowtousetheDialogEditorisavailableonthe Chemstationswebsite,aswellasontheCHEMCADinstallationCDROM.
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Occasionally,youmayfindthatnoneofthethermodynamicmodelsbuiltinto CHEMCADserveyourneedsforaparticularsimulation.Ifthisshouldhappen,you cantakeoneoftwoapproachestohandlingthermodynamicsforthesimulation: eithercreateyourownKvalueorenthalpymodelorcreateyourownmixingrule.
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Note:Youcanalsousethe[ALTF11]keycombinationtotogglebetweenCHEMCAD
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Figure 9-12: Selecting a VBA-defined reaction in the Kinetic Data dialog box
4. Whenyouhavedefinedthelastreaction,clickOKtoreturntothemain CHEMCADwindow.
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Data Interfaces
CHEMCADenablesyoutoexchangedatawithotherprogramsthroughavarietyof methods.Thissavestime,effort,andthepotentialforkeystrokeerroranddata omissions.Insomecases,thesedatainterfacescanenableCHEMCADtolink directlyintoyourplantinformationsystemstorunsimulationswithouthuman intervention. ThedatainterfacesthatCHEMCADusesareasfollows: TheExcelDataMapinterface,whichcanlinkanyvalueinaCHEMCAD simulationtoanycellinanExcelworksheet,orviceversa(notethatrunning CHEMCADsimulationsfromExcelrequiresaCOMinterface,described below) TheVisualBasicApplicationinterface,whichenablesyoutobuildcustom reactions,mixingrules,andUnitOps TheOPCinterface,whichpermitsanyOPCClientapplicationtoaccess valuesinaCHEMCADsimulation COMinterfaces,whichallowanyCOMenabledprogram(suchasMATLAB) toaccessandcontrolaCHEMCADsimulation
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Figure 10-02: Selecting a Map Rule option in the Excel Data Map Editor
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Note:WhenyouareimportingcelldataintoCHEMCAD,thelistofparameter
Figure 10-03: Component-specific parameters marked with arrows on the Par ID list
9. ClickthecellbelowWrkShtCell/Range.Typethecelladdressorcellrange towhichyouwanttolink.Celladdressesshouldbeformattedwiththe columnletterandrownumber,e.g.,A1orD17.Cellrangesshouldbe formattedastwosuchaddresses(representingtherangesfirstandlast values)separatedbyacolon,e.g.,A1:A12orB5:E20. 10. Ifyouareperformingadatareconciliation,youcanusetheWeightcolumn togivecertainitemsinthereconciliationmoreimportancethanothers. 11. Repeattheprocedureuntilyouhavespecifiedallofthecellsorcellranges thatwilllinktoyoursimulation. 12. SavetheDataMapbyselectingFile>SaveAs.TypeanameforyourData MapandthenclickOK.ThenewlycreatedDataMapnowappearsonthe CHEMCADExplorerundertheDataMapsitem.
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2. ClickthesquarebuttonnexttothefirstfieldintheSelectDataMapscolumn tobringuptheSelectDataMapdialogbox.
3. SelectthenameoftheDataMapforwhichyouwanttosetrules,andclick OKtoreturntotheDataMapExecutionRulesdialogbox.Repeatthisstep forallotherDataMapswhoserulesyouwanttosetupatthistime. 4. IntheBeforeSimulationRunsfieldnexttoeachselectedDataMap,clickthe dropdownlisttochooseanactionforthatDataMaptoperformbefore calculationsbegin: DoNothingperformsnoactionbeforethesimulationisrun.Youmight usethisoptiontodisableaDataMaptemporarily. ToWorkbooksendstherequesteddatatoExcelbeforerunningthe simulation.Youmightusethisoptionwhenyouwanttopulldatafrom inletstreamsorUnitOpspecifications. ToCHEMCADsendstherequesteddatainExceltoCHEMCADbefore runningthesimulation.Youmightusethisoptionwhenyouwanttofeed datatoinletstreamsorUnitOpswithdatafromtheExcelworksheet.
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8. ClickOKtoreturntothemainCHEMCADwindow.
Specification Sheets
UsingtheinterfacewithMicrosoftExcel,CHEMCADallowsyoutooutput simulationdatatoanExcelspreadsheetresemblingavendorspecificationsheet,as discussedinChapter8,OutputandReports.Customizingthesespecsheetssavesyou timebyoutputtingdataintheformatrequiredbyyourcompanyorvendor. TocustomizethespecsheetforaspecificUnitOptype,editthecorresponding Excelspreadsheetinthefollowingdirectory: C:\ProgramFiles\Chemstations\CHEMCAD\Program\templates IftheUnitOptypeyouwantisnotrepresentedbytheExcelfilesinthisdirectory, youcancopythegenericspecsheet.xlsfileanduseitasatemplateforanewUnitOp spreadsheet. Placethecopyinthesamedirectory,andmakeitsfilenamethestandardfour characterabbreviationfortheUnitOptypeinquestion.Forexample,tocreateaspec sheettemplatefortheFlashUnitOp,youwouldneedtonamethefilecopyflas.xls. SeetheCHEMCADHelpinformationaboutyourspecificUnitOpifyouneedtolook upthisabbreviation. Beforeyoucontinue,youwillneedtoturnofftheReadonlyattributeforthe newspreadsheetfile.Thequickestwaytodothisistorightclickthefilewithinthe WindowsExplorer,selectProperties,andthencleartheReadonlycheckboxinthe Propertiesdialogbox. OncethecopyisrenamedandtheReadonlyattributeisturnedoff,youcan openthespreadsheetandedititasneeded.
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OPC Applications
OPCcanbeappliedasfollows: Inferentialsensors:Sometimescalledsoftsensors,inferentialsensorsuseone ormoremeasuredvariablestoestimateanothervariable.UsingCHEMCAD simulationsanddatafromyourplantsDCS,youcanembedsimulationsto providedatasuchasconcentrations,heatduty,andfoulingfactor,which wouldnotnormallybeavailable. Operatortraining:YoucancoupleanoperatorHMItoadynamicsimulation tocreateatrainingsimulatorthatcanhelptrainoperatorsinasafeand effectiveway.
OPC Compliance
ChemstationsisaMemberoftheOPCFoundation,anorganizationdevotedto maintainingtheOPCstandards.CHEMCADhasbeencertifiedfor,andinterop testedfor,OPCDAstandard2.05a.
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Everyvaluetaghasaunitstagassociatedwithit,whichshowstheengineering unitsusedtoreportthevalue.Tochangetheengineeringunits,selectFormat> EngineeringUnitswithinaCHEMCADsimulation. WhentheOPCserverfeatureisenabled,CHEMCADautomaticallyregisters itselfasanOPCserver.IfyouwanttounregisterCHEMCADandremoveitfromthe listofOPCservers,youcanselectStart>Runandtypethefollowingcommand: {program directory}\CC6.Exe unregister Forexample,ifyourprogramdirectorywereC:\Program Files\Chemstations\CHEMCAD\Program(thedefaultdirectory),youwouldtype thefollowing: C:\Program Files\Chemstations\CHEMCAD\Program\CC6.exe unregister
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viewtheerrormessagetext,youmustopentheCHEMCADinterface directly. Restoretoinitialstatereturnsadynamicsimulationtotimezero.Areturnof 0indicatessuccess;avalueof1indicatesfailure. RunDynamicstartsadynamicsimulation.Areturnof0indicatessuccess;a valueof1indicatesfailure. RunDynamicOneSteprunsasingletimestepofadynamicsimulation.A returnof0indicatessuccess;avalueof1indicatesfailure. SetInitialStatesetsthecurrentprocessconditionsasthetimezero conditions,overwritingtheprevioustimezeroconditions.Areturnof0 indicatessuccess;avalueof1indicatesfailure. StopSimulationstopsadynamicsimulation.Areturnof0indicatessuccess; avalueof1indicatesfailure.
them.Inthesecases,weusuallydefinetwoseparatetags,onecontainingthedata valueandtheothercontainingtheunitsstring.Allunitsstringsarereadonlyfrom OPC.Theunitsstringsaregovernedbythesettingsinsidethesimulation. ThegroupsinCHEMCADsOPCnamespaceareorganizedasfollows: CHEMCAD.SimulationServer:ThisistheOPCservername.Byconvention, thisnameisfollowedbyaversionnumber,e.g., CHEMCAD.SimulationServer.1,toindicatetheOPCServerversion.Thisis theservernametowhichOPCclientswillconnect. CHEMCADGroup:Thisgroupcontainsanyinformationthatisnot dependentonastreamorUnitOp,andallcommandsusedtorun CHEMCAD. StreamsGroup:Thisgroupcontainsaseriesofsubgroups,oneforeach streamontheflowsheetnumberedbystreamIDnumber. UnitOperationsGroup:Thisgroupcontainsaseriesofsubgroups,onefor eachunitoperationontheflowsheet,numberedbyUnitOpIDnumber.
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COM Interfaces
ComponentObjectModel(COM)isaMicrosoftstandardplatformthatenables programstosharecontentsuchasdataandcalculationroutines.Thisinterface makesitpossibleforotherprogramstocontrolaCHEMCADsimulation. CHEMCADactsasaCOMserver,soanyprogramthatcanactasaCOMclient canbemadetointerfacewithCHEMCADinthisway.Ifyouarentcertainwhether yourapplicationcanactasaCOMclient,checkwiththesoftwarevendor.
Note:UsingtheCOMinterfacetoCHEMCADisacomplicatedprocedurethat
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' load CHEMCAD Set CC6 = CreateObject("CHEMCAD.VBServer") If CC6 Is Nothing Then Dim msg As String msg = "Can not load CHEMCAD." MsgBox msg End If End Sub Themostimportantlineinthatwholesubroutineis: Set CC6 = CreateObject("CHEMCAD.VBServer") Inthatsingleline,ExcelloadsCHEMCADintomemory. Loadingasimulationisaccomplishedwiththissimpleline: retFlag = CC6.LoadJob(casePath) Runningasimulationcanbeassimpleasthis: retFlag = CC6.SSRunAllUnits TheCOMInterfaceReferencesectionoftheCHEMCADHelpfile(listedunder theheadingCustomization)providesafullreferenceofthecommandsavailable throughCOM.
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CHEMCAD Tutorials
AlthoughthesimulationsstoredinyourExamplesdirectoryareusefulformany scenarios,thebestwaytolearntouseCHEMCADistocreateandrunsimulations yourself.Thetutorialsinthischapterwalkyouthroughbasicsimulationbuilding stepbystep,usingarealisticexampleproblemthatwillhelpprepareyouforyour ownsimulations. Thefirsttutorialisforasimplesteadystatesimulation,whichisthenusedasthe basisforthesecondtutorial,inwhichyoulllearntousetheCCTHERMmoduleto rateaheatexchanger.Thethirdtutorialwalksyouthroughabatchdistillation problemusingCCBATCH,andthefinaltutorialcoversvariousscenariosforpiping systems.
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Overview
RunningaflowsheetsimulationinCHEMCADisessentiallyaninestepprocedure: 1. Startanewsimulation. 2. Selectengineeringunits. 3. Createaflowsheet. 4. Selectcomponents. 5. Selectthermodynamicsoptions. 6. Definethefeedstreams. 7. EnterUnitOpparameters.
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Placing UnitOps
1. Startyourflowsheetbyaddinganicontorepresenttheinitialfeedstream.In theAllUnitOpspalette,findtheFeedicon,whichisanarrowpointingtothe right.ClicktheFeedicon,thenclickintheworkspacewhereyouwantto placethefeedstream.Whenthefeedstreamarrowappears,goaheadand turnofftheFeeddrawingtoolbyrightclickinganyblankareaofthe workspace.
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Note:AtanytimeafterdrawingafeedstreamoranyUnitOpicon,youcanclickthe
Figure 11-02: The pop-up label that identifies the UnitOp icon
4. Pointthemousecursoraboutaninchtotherightofthefeediconandclick.A twosidedheatexchangericonappearsontheflowsheetwhereyouclicked.
Note:TheUnitOpIDlabelof1shouldappearinacirclenexttotheheatexchanger
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slightlydifferentlocation.WhenyouveclickedtocreatethethirdProduct icon,rightclicktoturnofftheProductdrawingtool.
Drawing Streams
NowthatalloftheUnitOpsareinplace,selecttheStreamtoolandconnectthe variousUnitOpsasappropriate.Rememberthateachstreammuststartatared outletpointontheupstreamUnitOp,andendatablueinletpointonthe downstreamUnitOp. ToavoidhavingtoreselecttheStreamtooleachtime,makesurethatassoonas youclicktocompleteonestream,youmovethecursortothenextlocationandclick tostartthenextstream. Drawstreamstoconnectthefollowing: Feedstreamtofirstheatexchangersleftsideinlet Firstheatexchangersrightsideoutlettosecondheatexchangersleftside inlet Secondheatexchangersrightsideoutlettoflashinletofyourchoice Flashtopoutlettofirstheatexchangerstopinlet Firstheatexchangersbottomoutlettonearestproducticon Flashbottomoutlettovalveinlet Valveoutlettotowerinletofyourchoice Towertopoutlettonearestproducticon Towerbottomreboileroutlettonearestproducticon
Selecting Components
Nowyouneedtoidentifythecomponentstobeusedinthissimulation.Startby selectingThermophysical>SelectComponents.ThisbringsuptheSelect Componentsdialogbox,showninFigure1107.
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Forthisexample,youllchoosecomponentsfromthestandardCHEMCAD database.IntheSelectComponentsdialogbox,findandaddeachneeded component,beginningwithnitrogen: 1. IntheSearchbox,starttypingthewordnitrogen. 2. Assoonasyouvetypedni,youshouldsee46NitrogenN2highlightedin theAvailableComponentsarea.Clicktherightarrowbuttontoaddnitrogento yoursimulation. 3. UsethescrollbarintheAvailableComponentsareatoreturntothetopofthe componentlist. 4. Holddownthe[CTRL]keyonyourkeyboardasyouclickeachofthe followingcomponentsinturn: 2 3 4 5 6 Methane Ethane Propane IButane NButane
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7. SaveyourcomponentselectionsbyclickingOK.
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thePengRobinsonmethodforboththeKvalueandenthalpycalculations.Follow thesestepstoselectyourthermophysicaloptions: 1. AcceptthedefaulttemperatureandpressurerangesintheThermodynamics WizardandclickOK. 2. ClickOKagaintoacceptthewizardssuggestedmethodofSRK. 3. WhentheThermodynamicSettingsdialogboxopens,findtheGlobalK ValueModelselection,intheupperleftcorneroftheKValueModelstab. ThecurrentsettingisSRK,butforthepurposesofthetutorial,youllneedto selectthePengRobinsonmodel.Clickthedownarrowattherightendofthe selectionboxtoviewalonglistofKvaluechoices,thenclickPeng Robinson.
Figure 11-09: The new K-value selection in the Thermodynamic Settings dialog box
knowhowtouseit,ifonlyasastartingpointforyoursimulations.Youcanrevisit thewizardatanytimebyselectingThermophysical>ThermodynamicsWizard.
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Youwillspecifythefeedstreamaccordingtothefollowingrules: TheStreamNamefieldcandisplayastreamlabelofupto16alphanumeric characters.Thisfieldisoptional,andyoucanuseanylabelyoulike. ThenextfourfieldsTempF,Prespsia,VaporFraction,andEnthalpy MMBtu/harethethermodynamicpropertiesofthestream.Accordingtothe GibbsPhaseRule,onceamixturescompositionisgiven,specifyinganytwo ofthesefourthermodynamicpropertieswilldefinetheothertwo.Assuch, definingthecomposition,temperature,andpressureforamixtureuniquely definesitsvaporfractionandenthalpy.Alternatively,definingthe composition,pressure,andenthalpywilluniquelydefinethemixtures temperatureandvaporfraction. Sinceenthalpiesarecalculatedrelativetoadatum,thecalculationofany givenstreamenthalpyisaninvolvedprocesswhichispronetoerrors.For thisreason,CHEMCADdoesnotpermityoutoenterstreamenthalpyasa constraint.
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Inadditiontodefiningthestreamscomposition,youmustdefineexactly twoofthefollowingproperties:temperature,pressure,andvaporfraction. Thetwovariablesthatyouspecifywilldisplayasredtext,whilethethird variableandthevalueenthalpywillbedisplayedinblackwhenyouflashthe stream. Anexceptiontothisconventionallowsyoutoaddheatdutywithanempty stream.Ifyouspecifyatotalcomponentflowrateofzero,youmayspecifya temperature,pressure,andenthalpyrate.Astreamdefinedthiswayis treatedasaheatduty,andisaddedtotheheatbalanceoftheunit.The temperatureandpressurearearbitraryforthissituation. TheTotalflowunitandCompunitfieldsworktogethertoprovideavariety ofwaystodefinestreamcompositions.Iftheselectedcompunitismole, mass,orvolumefraction(eithergloballyorlocally),thentheTotalflowunit selectionisavailable.Iftheselectedcompunitisafloworamountoption, thenthetotalflowratebecomesthesumofthecomponentflowrates,and theTotalflowunitselectionisnotavailable. IftheCompunitfieldselectionisanamountflowunit(asopposedtoa fractionalunit),thenthecomponentflowratevaluesareautomaticallyadded asyouenterthem.ThecurrentsumisdisplayedintheTotalflowfield. YoucanclicktheFlashbuttonatanytimetoperformaflashcalculation usingthecurrentlyspecifiedcompositionandthermodynamicproperties. Thisenablesyoutoobtainflashcalculationsquicklyandwithoutleavingthe dialogbox. Fractionsthatdonotaddupto1.0areautomaticallynormalizedwhenyou eitherclickFlashorexitthedialogbox.
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4. ClickOKtosavethisstreaminformationandreturntothemainCHEMCAD workspace.
purposesofthistutorial,wellusethequickestandsimplestmethod,doubleclicking eachUnitOptoaccessitsspecificationdialogbox.
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5. ClickOKtosavethespecificationsforthisUnitOpandclosethedialogbox.
3. ClickOKtosavethespecificationsforthisUnitOpandclosethedialogbox.
Flash Drum
Inthissimulation,theflashdrumisavaporliquidseparatorandrequiresno specification.
Valve
1. DoubleclickthevalveflowsheeticontobringuptheValvedialogbox. 2. Theoutletpressureforthisunitis125psia,soenter125intheOutletpressure field. 3. ClickOKtosavethespecificationsforthisUnitOpandclosethedialogbox.
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Stabilizer Tower
1. DoubleclickthetowericontoopentheTOWRDistillationColumndialog box.NotethatthesettingsforthisUnitOparedividedintofivetabs.
2.
ClickOKtosavethespecificationsforthisUnitOpandreturntothemain CHEMCADworkspace.
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Figure 11-13: Plotting vapor fraction lines along with the cricondentherm dewpoint
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4. Returntothemainsimulationwindowbyclickingthereporttabsredx button.
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Nowthatyouhaveachievedtheresultsthatyousetouttoproduce,savethe simulation,usingeitherFile>SaveortheSavebuttononthetoolbar.
Becauseyouwantareportwithabroadrangeofinformationaboutyour simulation,usetheConsolidatedReportoption. 1. SelectReport>ConsolidatedReporttobringuptheReportWriterdialog box.Fromhere,youcanspecifyexactlywhatyouwanttoincludeinyour report. 2. Startbyspecifyingwhichstreamsyouwanttoinclude.ClicktheSelect Streams&UnitOpstabandchecktheSelectStreams(OverrideDefaults) box.Thisprovidesaccesstotheotherstreamselectionsettings. 3. ClicktheSelectFromFlowsheetbutton,whichbringsuptheSelectStreams dialogbox.Eithertypeinthenumbers1,5,8,and9orclickthe correspondingstreamsontheflowsheettoaddthenumbers.ClickOKto returntotheSelectStreams&UnitOpstab. 4. TheAllUnitOpsoptionisselectedbydefault.Inthiscase,youdowantto includeallUnitOpsinthereport,soleavethesettingsontherightsideofthe tabastheyare. 5. ClickStreamPropertiesintheleftcolumntoviewthestreamproperties options.ThenclickthePropertiestab,whichlistsacollapsedlistofall availablestreamproperties.YoucanchecktheStreamProperties(Override
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Defaults)boxtoexplorethevariouspropertiesandseewhichonesare selected,butforthepurposeofthistutorial,usethedefaultsettingsonthis tab. 6. ClickStreamCompositionintheleftcolumntoviewthestreamcomposition options.ThenclicktheStreamCompositionstab,whichlistsavailableand selectedflowoptions.ClicktheStreamComposition(OverrideDefaults) boxtogainaccesstotheseoptions.KeeptheMassFlowRateoption,and doubleclickMoleFractionsintheleftcolumntoaddthisoptiontothelistof selectedflowoptionsatright. 7. Finally,verifythattheTrayprofilereportsectionisincludedinthe ConsolidatedReport.Youcanalsodeleteanyreportsectionsthatyoudont need,andreorderthedesiredsectionstosuityourneeds. 8. ClickGeneratetorunanddisplaythereport.Youcannowreviewthe results,rerunifdesired,savethereportforlateruse,andprintthereportas needed. 9. Whenyoufinishreviewingandworkingwiththereport,clickCancelto closetheReportWriterdialogboxandreturntothemainCHEMCAD workspace.
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3. IntheDataboxPropertyOptionsdialogbox,reviewthedefaultselections, indicatedbycheckedboxes.Forthepurposesofthistutorial,leavethe selectionsastheyareandclickOKtocontinue. 4. IntheDataboxSettingsdialogbox,youcanindicatewhethertousedividing lineswithinthebox.AcceptthedefaultsettingshereandclickOK. 5. ThestreamdataboxappearsintheupperleftcorneroftheCHEMCAD workspace,butyouwanttoplaceitbelowtheflowsheet.Thedataboxis alreadyselected,sopointyourmousecursoranywhereinsidetheboxand thenclickanddragtorepositionit.Movethedataboxuntilitiscentered belowtheflowsheetdiagram.
Note:Youcanalsoresizeadataboxbyselectingtheboxandthenclickingand
dragginganyofthesizinghandlesatthecorners.Dragintomakethedatabox smaller,orouttomakeitlarger;noticethatthetextadjustsinsizetofitthebox. 6. NowplaceatitleonthePFDtodescribetheprocess.IntheAllUnitOpsor DrawingSymbolspalette,findandselecttheTexttool. 7. Movethecursortoapointsomewhereabovetheflowsheetandclickthe primarymousebutton.Averticalinsertionpointlinebeginstoblinkwhere youhaveclicked.TypethewordsCondensateStabilizerPFDandthenclick anyblankspotontheCHEMCADworkspace. 8. Tomakethistextlarger,selectFormat>Font.IntheFontdialogbox,change theSizesettingto18andthenclickOK. 9. Clickanddragthenewheadingtocenteritabovetheflowsheetdiagram. 10. Finally,setupalayerforyourstreamdataboxandtitlesothatyoucan displayorhidetheseitemsasasingleunit.AtthebottomoftheCHEMCAD Explorerpane,clicktheSimulationtab,thenrightclicktheLayersitemand selectNew.
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11. IntheNewLayerdialogbox,typeanameforthenewlayer.Forthis example,namethelayerPFDElements,thenclickOKtocreatethelayer. 12. NowaddthetwoPFDelementstothelayer.Clickthetitlethatyouplaced abovetheflowsheet,thenholddownthe[SHIFT]keyandclickinsidethe streamdataboxthatyouplacedbelowtheflowsheet.Bothitemsshouldnow beselected,withsmallblackboxesvisibleineachcorner. 13. IntheCHEMCADExplorerpane,doubleclicktheLayersitemtoexpandit, thenrightclickonyournewlycreatedPFDElementslayerandclickAdd Selected.
14. ThetitleandstreamdataboxarenowpartofthePFDElementslayer.This layerisvisible,asindicatedbythegreencheckmarkonitsicon.Clickthis iconorthenamePFDElementstotogglethelayeroff,causingthetitleand streamdataboxtodisappear;thenclickagaintomakethemvisible. 15. WiththePFDelementsvisible,selectView>ZoomOptions>ZoomtoFit. ThiscustomfitstheentirePFDtotheavailableworkspaceforoptimal printing.Toprint,youcaneitherselectFile>PrintorclickthePrintbutton onthemainCHEMCADtoolbar.Followthepromptsforyourprinterto completetheprintingprocess. 16. TocloseCHEMCAD,selectFile>Close,orclicktheClosebuttoninthe upperrightcorneroftheCHEMCADwindow.ClickYesatthemessage askingwhetheryouwanttoexitCHEMCAD,thenclickYesagaintosave changestothesimulation.
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CC-THERM Tutorial
Thistutorialwalksyouthroughtheratingofaheatexchanger.Theexampleyoull workwithisthecondensatestabilizerexampledescribedintheCCSTEADYSTATE tutorial,whichlookslikethis:
WhileitsrecommendedthatanewCHEMCADuserbuildthissimulationfrom thegrounduptogainproficiencywiththesoftware,areadymadeexamplecalled CHEMCADTutorial.CC6isalsoavailable.Thisfileislocatedbydefaultinthe directorycalledMyDocuments\MySimulations\Examples\Tutorials. Yourobjectiveistoratethefirstheatexchangerinthisflowsheet.Theequipment youreworkingwithisacountercurrentgas/gasheatexchangerwiththefollowing geometryanddimensions: TEMAclass=R TEMAtype=BEM Foulingfactors=0.001bothsides Shellinsidediameter=27 Numberoftubes=646 Tubeoutsidediameter=0.75 Tubewallthickness=0.065 Tubelength=20 Tubepattern=rotatedtriangular(60) Tubepitch=0.9375 Baffles:10,equallyspaced Baffletype=singlesegmental Bafflecut=35%(diameter) Impingementplatepresent Shellsidenozzles=one,12
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Thedefaultsettingisthebubbledewpointoption.Foreithersegmentation method,youcanalsodecidehowmanyzonestocalculatefortheexchanger.The morezonesyouspecify,themoreaccuratethecalculationswillbe,butcalculations willalsobeslower.Theindustrystandardis10zones(11points),whichisthe defaultentryhere,butyoucanselectanynumberbymakinganentryinthe Numberofcuttingpointsfield.Bearinmindthatthenumberofpointsequalsthe numberofzonesplusone. Forthistutorial,leaveallthedefaultsettingsandclickOKtocontinue.CC THERMcalculatesthe11pointsneededfortheheatcurveanddisplaysaplotlike theoneshowninFigure1122.
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Thisplotenablesyoutoinspectthecalculatedheatcurveforanyobvious problemsinthesetupoftheanalysis.ClickOKtoclosethiswindowandcontinue.
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Enter646intheNumberoftubesfieldandclickOKtocontinue.
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Mostofthedefaultentrieshereareappropriateforthisexample;youdo, however,needtospecifythebafflespacingandbafflecut.
Baffle Spacing
Allthatyouknowforthepurposesofbafflespacingisthatthereare10baffles equallyspaced.Eraseanydefaultvaluesforspacingandenter10intheNumberof bafflesfield.CCTHERMwillcalculateequalspacingforthebaffles.
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CC-BATCH Tutorial
ThistutorialwalksyouthroughtheprocessofusingCCBATCHtosimulateabatch distillationcolumn.
Thefollowingaredetailedspecificationsforthisproblem: ThermodynamicSelections K-value:PengRobinson Enthalpy:PengRobinson ColumnSpecifications InitialChargeConditions Temperature:Calculated Pressure:16.7psia VaporFraction:0atbubblepoint Totalamountofcharge: 100lbmol InitialChargeComposition(molefrac) Propane: 0.1 N-Butane: 0.3 N-Pentane: 0.1 N-Hexane: 0.5 No.ofinternalstages:8 No.ofoperations:5 Internalstageholdup:0.01ft3 Condenserholdup:0.1ft3 Condenserpressure:14.7psia Columnpressuredrop:2psia
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OperatingStep1 OperatingStep3 Purpose:Butaneproduction Refluxratio:25 Distillatemolarflowrate:2 Stopwhen:Accumulatormole fractionofNButaneis0.99 Materialstobeaddedatstart:20 lbmolofmolefraction40%N Butane/60%NHexane,atits bubblepointat16.7psia OperatingStep4 Purpose:Pentaneremoval Refluxratio:15 Distillatemolarflowrate:2 Stopwhen:Distillatemolefractionof NHexaneis0.2 Materialstobeaddedatstart:None Purpose:Propaneremoval Refluxratio:5 Distillatemolarflowrate:2 Stopwhen:Distillatemole fractionofNButaneis0.2 Materialstobeaddedatstart: None OperatingStep2 Purpose:Propaneremoval Refluxratio:20 Distillatemolarflowrate:2 Stopwhen:Distillatemolefractionof NButaneis0.985 Materialstobeaddedatstart:None
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Placing UnitOps
BeginbyplacingtheBatchColumnunitonthescreen. 1. OntheAllUnitOpspalette,clicktheBatchcolumntool(seeFigure1135) andthenclickinthemainCHEMCADworkspace.Thebatchcolumnicon appearswhereyouclicked.
2. ClicktheTanktool(seeFigure1136).Ontheworkspace,clicktotherightof thebatchcolumntoplaceatankicon.Thenclickjustbelowthefirsttank,and
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clickagainbelowthesecondtank.Whenyouhaveplacedallthreetankson theflowsheet,rightclicktodeactivatetheTanktool.
Drawing Streams
NowthatalloftheUnitOpsareinplace,selecttheStreamtoolandconnecteach tanksoutlettothenearestproductarrow.Thesearetheonlystreamsthatyouneed forthistutorial.
Note:Inthissimulation,thebatchdistillationcolumntransfersproductstothetanks
baseduponbatchoperationparametersthatyouprovide.Streamconnections betweenthecolumnandthetanksarenotnecessary,andareambiguousgiventhe dynamicnatureofsuchstreams. Rememberthateachstreammuststartataredoutletpointontheupstream UnitOp,andendatablueinletpointonthedownstreamUnitOp.Toavoidhavingto reselecttheStreamtooleachtime,makesurethatassoonasyouclicktocomplete onestream,youmovethecursortothenextlocationandclicktostartthenext stream. Asyoudrawstreams,CHEMCADassignsstreamIDs,justasitassignedUnitOp IDswhenyoucreatedthoseitems.ThelabelsforstreamIDsaredisplayedin squares,todistinguishthemfromtheUnitOpIDsdisplayedincircles. Atthispoint,theflowsheetshouldlooksimilartoFigure1134.
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Selecting Components
Nowyouneedtoidentifythecomponentstobeusedinthissimulation.Startby selectingThermophysical>SelectComponents. Forthisexample,youllchoosecomponentsfromthestandardCHEMCAD database.IntheSelectComponentsdialogbox,findandaddeachneeded component. 1. Holddownthe[CTRL]keyonyourkeyboardasyouclickeachofthe followingcomponentsinturn: 4 6 8 10 Propane NButane NPentane NHexane
3. SaveyourcomponentselectionsbyclickingOK.
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3. Ifthemethodisanactivitymodel,theprogramthenlooksattheBIP databasetoseewhichmodelhasthemostdatasetsforthecurrentproblem. ItthencalculatesthefractionalcompletenessoftheBIPmatrix.Ifthatfraction isgreaterthantheBIPthresholdparameter,itusesthechosenactivity method;ifnot,itusesUNIFAC. TheThermodynamicsWizardisnoreplacementforengineeringjudgment.Thistool usesanalgorithmbasedongeneralrules,andisthereforefallible.Thesuggested modelmightnotalwaysbethebestmodelforthesystem. Selectingthermodynamicoptionsbasicallymeansselectingamodelormethod forcalculatingvaporliquid(orvaporliquidliquid)phaseequilibrium(calledtheK valuemodel)andselectingamethodormodelforcalculatingtheheatbalance(called theenthalpymodel).Thecommandsfortheseselectionsarelocatedonthe Thermophysicalmenu. CHEMCADhasalibraryofdozensofKvaluemodelswithavarietyofoptions andabout12enthalpymodels.Makingtheproperselectionfromtheselibrariescan sometimesbedifficult.Forthepurposesofthistutorial,assumethatyouwanttouse thePengRobinsonmethodforboththeKvalueandenthalpycalculations.Follow thesestepstoselectyourthermophysicaloptions: 1. AcceptthedefaulttemperatureandpressurerangesintheThermodynamics WizardandclickOK. 2. ClickOKagaintoacceptthewizardssuggestedmethodofSRK. 3. WhentheThermodynamicSettingsdialogboxopens,findtheGlobalK ValueModelselection,intheupperleftcorneroftheKValueModelstab. ThecurrentsettingisSRK,butforthepurposesofthetutorial,youllneedto selectthePengRobinsonmodel.Clickthedownarrowattherightendofthe selectionboxtoviewalonglistofKvaluechoices,thenclickPeng Robinson.
Figure 11-39: The new K-value selection in the Thermodynamic Settings dialog box
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knowhowtouseit,ifonlyasastartingpointforyoursimulations.Youcanrevisit thewizardatanytimebyselectingThermophysical>ThermodynamicsWizard.
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Withtheserulesandbehaviorsinmind,enterthedataforyourpotcharge: 1. DoubleclickthebatchcolumntoopentheEditBatchChargedialogbox.
2. InthePrespsiafield,type16.7,thenpress[TAB]andtype0intheVapor Fractionfield.
Note:Itsimportantthatyouactuallytypea0overtheexisting0entryintheVapor
5. ClickOKtosavethischargeinformationandcontinue.
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Whenyouhaveenteredtheseparameters,clickOKtosavethedataand continue.
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Inthisdialogbox,youlldefinetheparametersforeachoperatingstepofthe batchcampaign.Beforeyoubegin,youneedtounderstandhowCCBATCHhandles tankassignments. TheProductassignmentfieldsidentifytheaccumulatortowhichaproductor decantstreamwillbesent.Youcanusethisoptionevenifyoudonotplacetankson theflowsheet;simplydesignatingaUnitOpIDnumberissufficient.Inthiscase,its importantthatyoudesignateaUnitOpIDthatisnotalreadyinuse. SinceCCBATCHpermitsvaporliquidliquiddistillation,theremaybetwo liquidphasesinthecondenser,possiblygivingrisetodecantingofonephaseorthe other.TheDistillateTank#fieldentryrepresentsthetankthataccumulatesthe distillate.TheDecanterTank#fieldentryrepresentsthetankthataccumulatesthe decantedliquid,ifany.
Operating Step 1
Foroperatingstep1,makethefollowingentriesintheBatchOperationParameters dialogbox: ChangetheStartupoptionfieldto1Startwithtotalreflux. IntheProductassignmentarea,enter2intheDistillatetank#field. IntheFirstspecvaluefield,enter5asthevalueoftherefluxratio. IntheSecondspecvaluefield,enter2.
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Whenyouhavemadetheseentries,clickOKtomoveontothenextoperating step.
Operating Step 2
Foroperatingstep2,makethefollowingentriesintheBatchOperationParameters dialogbox: Enter2intheDistillatetank#field. Enter20intheFirstspecvaluefieldand2intheSecondspecvaluefield. StoptheoperationwhenthemolefractionofNButaneinthedistillateis 0.985.
Whenyouhavemadetheseentries,clickOKtomoveontothenextoperating step.
Operating Step 3
Followthesestepsforoperatingstep3: 1. MakethefollowingentriesintheBatchOperationParametersdialogbox: Enter3intheDistillatetank#field. Enter25intheFirstspecvaluefieldand2intheSecondspecvaluefield. StoptheoperationwhenthemolefractionofNButaneinthe accumulatoris0.99.
2. ClicktheAdditionalSettingstab.Hereyouwillspecifytheadditionof20 molesofmixturetothepot,withacompositionof40%butaneand60% hexane.ChecktheAddmaterialtopotboxandthenclickOKtobringupthe EditBatchChargedialogbox. 3. InthePrespsiafield,type16.7,thenpress[TAB]andtype0intheVapor Fractionfield. 4. Enterthefollowingcompositionsettings: SettheCompunitfieldtomolefrac. Enter0.4intheNButanefield. Enter0.6intheNHexanefield. Enter20intheTotalflowfield.
5. ClickOKtocontinuetothenextoperatingstep.
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Operating Step 4
Foroperatingstep4,makethefollowingentriesintheBatchOperationParameters dialogbox: Enter4intheDistillatetank#field. Enter15intheFirstspecvaluefieldand2intheSecondspecvaluefield. StoptheoperationwhenthemolefractionofNHexaneinthedistillateis0.2. IntheMin.runtimefield,enter0.5.
Whenyouhavemadetheseentries,clickOKtomoveontothefinaloperating step.
Operating Step 5
Foroperatingstep5,makethefollowingentriesintheBatchOperationParameters dialogbox: Enter4intheDistillatetank#field. Enter25intheFirstspecvaluefieldand2intheSecondspecvaluefield. StoptheoperationwhenthemolefractionofNHexaneintheresidual chargeatthebottomofthecolumnis0.9998. IntheMin.runtimefield,enter0.5.
Whenyouhavemadetheseentries,clickOKtocontinue.
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Assumingthatyoucorrectlyspecifiedthepotchargeandsubsequentoperation steps,youshouldseenomessages;theprogramwillproceeddirectlytothe calculation. Youwillseethedistillatemolefractionsplottedonthescreeninaplotwindow. Eachtimetheprogramproceedstothenextoperatingstep,anewplotwindowwill open,alongwithanewtabatthebottomofthemainCHEMCADworkspace. Duringtherun,onlythecurrentstepsplotisvisible.Whenthesimulationis finished,thedynamicplotwillquitscrollingandaRunfinishedmessagewillappear atthefarleftendoftheCHEMCADstatusbar. Aftertherun,youcanviewtheplotforaparticularoperatingstepbyclicking thecorrespondingtabatthebottomoftheCHEMCADworkspace.Tocloseany plotstab,clicktheClosebutton(markedwithanx)onthetab.Tocloseallofthe plottabsatthesametime,selectWindow>CloseAllCharts.
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4. ClickOKtoviewthecompositeplot,whichshouldresembleFigure1146.
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Revieworprinttheresultsasneeded,andthenclosetheplottabtoreturntothe simulation.
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Piping Tutorial
Apipingnetworkrepresentstheflowoffluidsthroughseveralpiecesofequipment. Ifsufficientvariables(flowrateandpressure)arespecifiedonthepipingnetwork, CHEMCADcalculatestheunknownvariables. Forfluidflowthroughequipment,flowratemaybecalculatedasafunctionof theinletandoutletpressure.Ifyouknowanytwoofthesethreevariables, CHEMCADcancalculatethethird. Inthistutorial,youwillworkwithCHEMCADspipingfeatures.Youwill performcontrolvalveandorificesizingandrating;simulatecomplexpiping networks;usefeedbackcontrollers;calculateNPSH;andmakeappropriate equipmentselections.
Problem Statement
Forthispartofthetutorial,referencetheflowsheetshowninFigure1148.This exampleiscalledExample1,anditslocatedintheMy Simulations\Examples\Pipingfolder.
D-1 -9F 225 psig
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AllthreestreamsinFigure1149areattheinletconditionsof9Fand225psig. Thedividersplitsthe226,000lb/hrflowintotwoequalflowsof113,000lb/hrof ammonia. Toperformtheinitialsizing,followthesesteps: 1. ClicktheRunAllbuttononthemainCHEMCADtoolbartocalculatethe flowinformationforstreams2and3.Bothstreamsshouldbeat9F,225 psig,and113,000lb/hrofammonia. 2. Clickstream2toselectit.Thestreamisselectedwhenitisshownbracketed byblacksquares.SelectSizing>ControlValvetobringuptheControlValve Sizingdialogbox.
Rating Case
Thenexttaskistoratethesevalvesinasimulation.Youneedtodeterminethevalve positionforthesevalvesinthisserviceat113,000lb/hr.Sincethistaskmodelsthe behaviorofthecontrolvalves,youwillneedaslightlylargerflowsheet,asshownin Figure1151.
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3 2 4
2 4 8
3 5 9
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2. IntheValveflowcoefficient(Cv)field,enter36.IntheDownstream pressurefield,enter15.SelecttheOperatingmodeoptioncalledFix flowrate,adjustvalveposition.ClickOK. 3. Nowdoubleclicktheiconforcontrolvalve#5.Forthisvalve,selectthesame operatingmodethatyouusedforvalve#4.Specifyavalveflowcoefficientof 54andadownstreampressureof0.2psig,andthenclickOK. 4. ClicktheRunAllbuttononthetoolbartorunthesimulation. 5. Toviewtheresults,firstclickablankareaoftheCHEMCADworkspaceto ensurethatnoUnitOpsarecurrentlyselected.ThenselectReport>UnitOps >SelectUnitOps. 6. IntheSelectUnitOpsdialogbox,type4,press[RETURN],andthentype5. ClickOKtobringupareportforthesetwovalves. Thereportshowsthatvalve#4isat72.5%open,andvalve#5isat53.3%open. Toseehowmuchvaporizationoccursacrossvalve#5,rightclickthevalveand selectViewStreamProperties.ThisvolumechangeiswhyCHEMCADchosea largervalveforthesecondstream.Withthevaporizationoccurringinthevalve,a smallertwoinchvalvebodywouldbeapproachingsonicvelocitythroughthevalve body.
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D-1 -9 F 225 psig Cv =36 72.5 % open D-2 -1 F 30 psig (UPSET condition)
18 12 12 8 14 10 16 19
20
Figure 11-54: Nodes located upstream and downstream from control valves
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Thefixedpressureatthisnodeis225psig.TheinletflowmodeissettoFreeinlet stream,andthetwooutletstreamsaresettoFlowsetbyUnitOp.Theflowintoeach controlvalvewillbedeterminedbythecontrolvalveopeningpositionandthe pressuredifferenceacrossthevalve. Fornode#9,thefixedpressureissetto30psig,andfornode#10,thepressureis 0.2psig.Flowintoeachofthesenodesiscontrolledbythecontrolvalveusingthe FlowsetbyUnitOpmode;flowoutissettoFreeOutletstream. Thecontrolvalvesneedtobechangedtofixthevalvepositionandcalculateflow rate.Todothis,settheOperatingmodeforeachvalvetoFixvalveposition,adjust flowrate. Aftermakingthischange,clicktheRunAlltoolbarbuttontorunthesimulation. Afterrunning,youcanviewthestreamsaroundnode#6byrightclickingthenode andselectingViewstreamcomposition.Theresultingreport(Figure1156)shows thattheflowrateforstream11(upstreamfromD2)hasdroppedfrom113,000lb/hr to109,138lb/hr.Thisillustratestheeffectofbackpressureontheflowratesthrough thevalves.
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Problem Statement
Thepipingsystemshownmustbedesignedtotransport120gpmofglacialacetic acidat70140F.Thepressureattheinletisknownat20psia,andtheoutletmustbe nolessthan20psia.Thepipingsystemanditsindividualelementsmustbesizedfor designconditionsandthenratedatoperatingconditions.Thegoalistodetermine theNPSHaandheadrequirementsforfuturepumpselection.
ThisexampleiscalledExample2,anditslocatedinthelocatedintheMy Simulations\Examples\Pipingfolder.
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3. SelecttheTypicalsizingforsinglephaseoptionandusestandardschedule 40pipe.ClickOKtoviewalinesizingreportfortheselectedstream.
Note:Sincethefluidinthissystemissubcooledliquidandallflowsareconstant,
factoroftheorificeasshown:
C = Cd /( (1 4 )
1 2 Kr 2 4 C
TheorificesizingreportgivestheKrvalue,whichyouwilluselaterinthePipe SizingandRatingdialogbox. 5. Tosizethecontrolvalve,selectstream#1andthenselectSizing>Control Valve.IntheDownstreampressurefield,enter15,andselecttheSingleseat option.Sincestream#1isat20psia,youaresimplysizingacontrolvalveto produceapressuredropof5psi.ClickOKtoviewacontrolvalvesizing reportfortheselectedstream. 6. Doubleclickcontrolvalve#4toopentheControlValvedialogbox.Enterthe valveflowcoefficient(Cv)ofthevalvefromthesizingreport,setthevalve positionto50%,andsettheoperatingmodetoFixflowandposition, calculatePout.ClickOKtosavethesesettingsandclosethedialogbox.
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7. DoubleclicktheheatexchangericontoopentheSimpleHeatExchanger dialogbox.Enterapressuredropof2psiandsettheoutlettemperatureto 140F.ClickOKtocontinue. 8. Tabulateandspecifythevalves,fittings,pipelengths,andelevationchanges ofeachsectionofpipe.Forallofthesepipes,settheMethodfieldto2Single Phaseflow,settheSizingoptionto0Rating,anduseflangedfittings throughout. Pipe#1 1entrance,wellrounded 2ballvalves 4standardelbows,90degree 1tee,flowthroughbranch 35feetofpiping 8elevationchange Pipe#5(aftercontrolvalve) 2ballvalves 2tee,flowthroughrun 3standardelbows,90degree 1exitfrompipe 24feetofpiping 2footelevationchange Pipe#3(beforecontrolvalve) 1swingcheckvalve,clearway 2ballvalves 2tee,flowthroughrun 1orificeplate(aspreviouslydetermined) 14feetofpiping 14elevationchange Pipe#7(afterE1515) 1ballvalve 4standardelbows,90degree 1tee,flowthroughrun 1wellroundedentrance 1exitfrompipe 157feetofpiping 5elevationchange 9. Specifythepumpoutletpressureatsomearbitraryvalue(try25psia)and makeatrialrun.Checkthecalculatedoutletpressure.Youcantheniterateto findtherequiredpumphead.
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8 9
Calculating NPSHa
Thenetpositivesuctionhead,betterknownasNPSH,isdefinedasthetotalpressure availableatthepumpsuctionminusthepumpingfluidsvaporpressure.Itisalmost alwaysreportedinfeetofpumpedfluidorwater. EverypumphasaspecifiedNPSHrequirement(NPSHr)atagivenoperating speed.Toensurereliableoperation,theavailableNPSH(NPSHa)mustbegreater thantheNPSHr.Ifnot,cavitationandshortenedservicelifemayresult. Toselecttheappropriatepump,youneedtocalculateNPSHa.InCHEMCAD, thisisaneasytask.SimplychecktheCalculateNPSHaboxinthePumpdialogbox, andthenrunthesimulation.NowwhenyoupullupthePumpdialogbox,the calculatedNPSHaisdisplayed.
Note:ItisimportanttotheNPSHacalculationthattheinletpipingtothepumpbe
correctlyspecified.Ifthepipingspecificationsarenotcomplete,thepressureatthe inletmaynotbeaccurate,leadingtoaninaccurateNPSHacalculation.
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Problem Statement
Thepreviouspipingsystemhasbeenchanged.Duetothebranchedflowtothetwo heatexchangers,theproblemisnolongerasimpleone.
ThisexampleiscalledExample3,anditslocatedinthelocatedintheMy Simulations\Examples\Pipingfolder. Thebranchedflowisadifficultproblemtosolveusingthecontrollerapproach. Bothexchangershavedifferentpipingandthereforedifferentflowrates.Youneed anapproachwhereyousplitandrecombineflows,andhavethesimulationcalculate thepressureandflowratesinaniterativemanner.TheNodeUnitOpgivesyouthis flexibility. Rememberthatanodeisapointwherepressureisuniform.Theremaybe multipleinletsandoutlets.Theflowratesforeachstreamwillbebalancedby CHEMCADtoreachasinglepressure.Youcanspecifythepressureorallowitto vary.
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InCHEMCAD,PipeUnitOpsareusedtorepresententiresectionsofpiping, includingfittings.NodeUnitOpsareplacedwherepressureorflowrateare unknown. Forthisexample,assumeapressuredropof2psiacrosseachheatexchanger. Tabulatethevalves,fittings,pipelengths,andelevationchangesofeachsectionof pipe.Useflangedfittingsthroughout. Pipe#1 1entrance,wellrounded 2ballvalves 4standardelbows,90degree 1tee,flowthroughbranch 35feetofpiping Pipe#3(aftercontrolvalve) 1ballvalve 1tee,flowthroughrun 2standardelbows,90degree 10feetofpiping Pipe#2(beforecontrolvalve) 1swingcheckvalve,clearway 2ballvalves 2tee,flowthroughrun 1orificeplate(asdeterminedabove) 14feetofpiping Pipe#4(toE1514) 1tee,flowthroughbranch 1ballvalve 1exitfrompipe 3standardelbows,90degree 26feetofpiping
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Pipe#5(fromE1514) 1ballvalve 1wellroundedentrance 3standardelbows,90degree 1tee,flowthroughbranch 30feetofpiping Pipe#7(fromE1515) 1standardelbow,90degree 1ballvalve 1wellroundedentrance 1tee,flowthroughrun 10feetofpiping
Pipe#6(toE1515) 1ballvalve 1exitfrompipe 1tee,flowthroughrun 1standardelbows,90degree 14feetofpiping Pipe#8(toV1522) 3standardelbows,90degree 1exitfrompipe 147feetofpiping
Atthistimeyoudontknowthepumpspecifications,sosetthepumptoSpecify OutletPressureandleavethepressurespecificationblank.TheNodeUnitOpwill solveforthepressureincrease,andsetthepumpoutletpressureaccordingly. Setupthenodeswiththefollowinginformation: Node3:Variablepressure,usecurrentstreamrateforinlet,flowsetby UnitOpforoutlet,elevation=20feet Node5:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=34feet Node7:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=34feet Node9:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=34feet Node12:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=50feet Node16:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=38feet Node18:Variablepressure,flowsetbyUnitOpforbothinletandoutlet, elevation=42feet Node20(lastnode):Fixedpressure,20psia,flowsetbyUnitOpforinlet,free outletstreamforoutlet,elevation=43feet
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Selecting a Pump
Thefollowingpumpcurvedataisrepresentativeofthetypeofequipmentthat wouldbeappropriateforthisapplication.
Pump Curve
90 80 Head (ft) 70 60 50 40 30 20 0 40 80 120 160 200 Flow (gpm) 1150 rpm 1450 rpm 1750 rpm
0.6 0.55 1750 rpm Efficiency 0.5 0.45 1150 rpm 0.4 0.35 0.3 0 40 80 120 160 200 Flow (gpm)
Figure 11-62: Combined pump curves for a sample pump
1450 rpm
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forthenumberofspeedlinesandsetthepumpspeedto1750RPM.ClickOKto bringupthePerformanceCurvedialogbox.
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Index
.CC6files,29 Addingasinglecomponent,101 Addingcomponentstoasimulation,42 AllUnitOpspalette,37 Applyingatemplate,100 Assigningobjectstoalayer,95 Attachingasimulationfiletoanemail,33 BatchReactor/DVSLHistoryplot,72 BatchResultsreport,83 BinaryLLEplot,87 BinodalPlot,87 Binodal/ResidueCurvesplot,87 Buildingabasicsimulation,35 BulkPropertiesdialogbox,106 CallingChemstations,16 Cases,saving,32 CCBATCHtutorial,164 CCDYNAMICS,63 CCSTEADYSTATEtutorial,132 CCTHERMtutorial,153 CHEMCAD Mainmenu,23 Toolbar,23 Tutorials,131 Gettinghelpwith,15 Installing,7 Interface,17 Licensing,10 Modules,3 Openingolderfiles,34 Overview,1 Productsandfeatures,3 Systemrequirements,7 Usercomponentsin,30
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Index
DatainterfacestoCHEMCAD,117 DataMapExecutionRulesdialogbox,121 DataMaps,creating,118 Databoxes,90 DefaulticonforUnitOp,37 Definingstreams,48 DefiningUnitOps,49 Deletingatemplate,100 Dialogbox,customizing,110 DialogEditorutility,110 DistCurveCharacterizationdialogbox,105 Distillationreport,82 Dongle ForCHEMCADlicensing,10 Reprogramming,13
Chemicalcomponents,selecting,42 Chemstationswebsite,16 Coach,27 COMinterfaces,128 ComponentObjectModel(COM),128 Components Adding,44 Finding,43 Removing,45 Selecting,42
CompositeCurvesplot,88 ConnectingstreamstoUnitOps,39 Consolidatedreporting,84 ControlValveSizingdialogbox,58 ControllerConvergenceplot,89 ConvergenceParametersdialogbox,65 Costingcalculations,customized,109 CreatingacustomUnitOpdialogbox,110 Creatingalayer,94 Creatinganewsimulation,31 Creatingatemplate,100 CreatinganExcelDataMap,118 Creatingcustomcomponents,101 CreatingExcelUnitOps,123 CreatingcustomUnitOps,109 CurveTemperatureCutRangesdialogbox,105 Customcomponents,101 Customenthalpymodel,111 CustomKvaluemodel,111 Custommixingrule,creatingusingVBA,113 Customreaction,creatingusingVBA,113 CustomUnitOpicon Creating,107 Addingtoasubpalette,109
Drawingaflowsheet,36 Drawingstreamsonaflowsheet,39 Drawingtools,41 DynamicColumnHistoryplot,72 DynamicColumnHistoryreport,73 Dynamicoperation,settingup,65 Dynamicplots,89 DynamicRunTimeScheduledialogbox,67 Dynamicsimulation,running,69 Dynamicsimulations,strategiesfor,65 DynamicStreamHistoryplot,72 DynamicStreamHistoryreport,73 DynamicUnitOpHistoryreport,73 DynamicsMenu,66 Dynamicsreports,83 Dynamics Additionalinputfor,64 Defined,63 Output,71 Plottingresults,72 RecordingstreamsandUnitOps,68 Runningonestepatatime,70 Textbasedresults,72 Toolbarbuttonsfor,66
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LockedforEditingdialogbox,31 Lowfidelitymodeling,defined,53 Mainmenu,23 ManageComponentDatabasesdialogbox,102 MassandEnergyBalancesreport,83 Messagespane,22 Movingapane,25 MovingUnitOpicons,38 Multilinetool,41 MySimulationsdirectory,32 Neutralfileimport,106 NewComponentdialogbox,102 Newsimulation,creating,31 Notestab,onMessagespane,23 OlderCHEMCADfiles,34 OLEforProcessControl(OPC),125 OPC Applications,125 Compliance,125 Namespace,127 Serveroperations,126
Enthalpyoptions,selecting,46 Equipmentparameters,specifying,49 Equipmentsizing,introduction,54 ErrorsandWarningstab,onMessagespane,22 Examplefiles,30 ExcelDataMapEditor,118 ExcelDataMappingfeature,defined,118 ExcelDataboxSettingsdialogbox,92 Excelrangeboxes,92 ExcelUnitOps,creating,123 Flowsheetdataboxes,90 Flowsheettemplates,99 Flowsheets,drawing,36 Flowsheetbasedgraphs,88 GlobalEnthalpyModel,47 GlobalKValueModel,47 Graphicalreports,87 Grid,27 Groups Stream,76 UnitOp,80
OPCserver,usingCHEMCADas,125 Opencommand,31 Openinganexistingsimulation,31 OpeninganolderCHEMCADfile,34 Palettepane,introduced,20 Palettes,customizing,21 ParticleSizeDistributionreport,80 PFDprinting,96 PFDs,90 PhaseEnvelopesplot,88 Pinningandunpinningpanes,25 PipeProfileplot,88 Pipingtutorial,180 PlotsinCHEMCAD,87 Plots,dynamic,89 Plottingdynamicresults,72 PlugFlowReactorProfileplot,88 Polygontool,41 Printingaprocessflowdiagram,96 PrintingCHEMCADreports,89 Processflowdiagrams,90 Properties,ofstreams,48 PseudocomponentCurvesplot,88 PseudocomponentCurvesreport,80
HeatCurvesplot,88 Hidingalayer,95 Highfidelitymodeling,defined,53 HydrocarbonCorrelationdialogbox,105 Icons,creating,107 InstallingCHEMCAD,7 Jobfiles,29 Kvalueoptions,selecting,46 Layers,93 Assigningobjectsto,95 Creating,94 Deleting,96 Hidingandviewing,95 Removingobjectsfrom,96
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Index
Pseudocomponentrange,defining,105 RecordStreamsdialogbox,68 RecordingstreamsandUnitOpsfordynamics,68 Rectangletool,41 Redocommand,26 Regressingdataintoauseraddedcomponent,104 Reliefdevicesizing,61 Removingcomponentsfromasimulation,45 Renamingatemplate,100 ReportWriter,84 Reportsfordynamicsimulations,71 Reports CHEMCADReportWriter,84 Dynamics,83 Printing,89 Streamcompositions,78 Streamproperties,79 UnitOpbased,80
Selectingengineeringunits,36 SelectingKvalueandenthalpyoptions,46 Selectiveprinting,93 Settingruntimefordynamics,66 Simulationfiles Introduced,29 Creating,31 Emailing,33 Opening,31 Overviewofbuilding,35 Saving,32
Simulation,running,50 Singlecomponent,adding,101 Sizing,introduction,54 Specsheetreport,82 Specsheets,outputtoExcel,124 SpecifyingUnitOps,49 Startinganewsimulation,31 Streamboxes,90 Streamcompositionreports,78 Streamcomposition,viewing,79 Streamgroups,creating,76 StreamPropertiesplot,88 Streampropertyreports,79 Streams Drawingonaflowsheet,39 Defining,48 Rerouting,40
Reprogrammingadongle,13 Reroutingastream,40 ResettoInitialStatebutton,70 ResidueCurvesplot,88 Resizingapane,24 ResizingUnitOpicons,38 Results,reviewing,51 Reviewingrunresults,51 Routingstreams,39 RunfromCurrentStatebutton,69 RunfromInitialStatebutton,69 Runtime,setting,66 RunTracetab,onMessagespane,22 Runningadynamicsimulation,69 Runningasimulation,50 SaveAscommand,32 SaveasInitialStatebutton,71 Savingasimulation,32 Savingdifferentcases,32 SearchforUnitOp(s)field,21 SearchOptionsdialogbox,44 SelectComponentsdialogbox,43 SelectDataMapdialogbox,122 SelectDestinationDatabasedialogbox,102 SelectRegressionDataSetdialogbox,104 SelectSingleComponentdialogbox,103 Selectingcomponents,42
Switchingtodynamics,65 SymbolEditorutility,107 Symbols,creating,107 Technicalsupport,contacting,16 Templates Applying,100 Creating,100 Defined,99 Deleting,100 Renaming,100
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Thermophysicaldatagraphs,87 Toolbar,23 Topologyreport,83 TowerProfilesplot,88 TPboxes,91 TPXYplot,87 TraySizingdialogbox,59 Undocommand,26 UnitOpboxes,91 UnitOpdialogbox,customizing,110 UnitOpgroups,creating,80 UnitOpicons Creatingcustomized,107 Manipulating,38 Addingtoaflowsheet,36 Selectingdefaulticonfor,37 Listingofallavailable,5 Specifying,49
UnitOpbasedplots,88 UnitOpbasedreports,80 UpdateSimulationFormatdialogbox,34 UpdatingaCHEMCADlicense,13 Userspecifiedfile,plotting,89 ValveTraydialogbox,59 VBA Custommixingrules,113 Customreactions,113 CustomUnitOps,113 UsingtocustomizeCHEMCAD,113
UnitOps
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Index
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