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User Guide
Allmaterial2007Chemstations,Inc.
Table of Contents
CHEMCADFeaturesbyModule...................................................................................................... 4 UnitOpsbyModule............................................................................................................................ 5 Chapter2GettingStartedwithCHEMCAD..................................................................................... 7 InstallingtheSoftware ........................................................................................................................... 7 LicensingCHEMCAD ......................................................................................................................... 10 TypesofCHEMCADLicenses........................................................................................................ 10 LicenseSettings ................................................................................................................................. 11 UpdatingaLicense ........................................................................................................................... 12 GettingHelpwithCHEMCAD .......................................................................................................... 14 OnlineHelp ....................................................................................................................................... 14 CHEMCADCoach............................................................................................................................ 15 ProcedureDemos.............................................................................................................................. 15 TheChemstationsWebSite............................................................................................................. 15 ContactingChemstationsTechnicalSupport ............................................................................... 15
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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........................................................................................................................................ 26 AdjustingYourViewoftheWorkspace........................................................................................ 27 TheCHEMCADCoachPane .......................................................................................................... 27 Chapter4WorkingwithSimulationFiles ...................................................................................... 29 AboutCHEMCADSimulationFiles.................................................................................................. 29 UserComponentsinCHEMCAD .................................................................................................. 30 ExampleFiles..................................................................................................................................... 30 OpeninganExistingSimulation ........................................................................................................ 31 CreatingaNewSimulation................................................................................................................. 31 SavingaSimulation.............................................................................................................................. 32 SavingDifferentCasesfortheSameSimulation.......................................................................... 32 EmailingaSimulation ........................................................................................................................ 33 WorkingwithCHEMCADFilesfromPreviousVersions .............................................................. 33
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Chapter5BuildingandUsingaBasicSimulation ........................................................................ 35 StartingaNewSimulation .................................................................................................................. 35 SelectingEngineeringUnits................................................................................................................ 36 DrawingtheFlowsheet........................................................................................................................ 36 AddingUnitOps ............................................................................................................................... 36 SelectingaDefaultIconforaUnitOp ............................................................................................ 37 ManipulatingUnitOpIcons ............................................................................................................ 38 DrawingandConnectingaStream ................................................................................................ 38
Choosing a Stream Route ................................................................................................................................39 Rerouting a Stream ..........................................................................................................................................39
OtherDrawingTools........................................................................................................................ 40
The Text Tool ..................................................................................................................................................40 Simple Drawing Tools: Rectangle, Ellipse, and Line ......................................................................................40 Complex Drawing Tools: Multi-line and Polygon ..........................................................................................40
SelectingChemicalComponents........................................................................................................ 41 FindingaComponent ...................................................................................................................... 41 AddingaComponent....................................................................................................................... 42 ChangingtheOrderofSelectedComponents .............................................................................. 43 RemovingItemsfromtheSelectedComponentsList ................................................................. 43 SelectingKvalueandEnthalpyOptions .......................................................................................... 44 UsingtheThermodynamicsWizard .............................................................................................. 44
Selecting Components to Ignore......................................................................................................................44 Specifying Process Conditions ........................................................................................................................44 How the Thermodynamics Wizard Makes Suggestions ..................................................................................44 Should the Thermodynamics Wizard be trusted to make design decisions? ...................................................45
ManuallySelectingThermodynamicsSettings ............................................................................ 45 DefiningStreams .................................................................................................................................. 46 ThermodynamicProperties............................................................................................................. 46 StreamComposition ......................................................................................................................... 46 TotalFlowProperties ....................................................................................................................... 47 SpecifyingEquipmentParameters..................................................................................................... 47 RunningtheSimulation....................................................................................................................... 48 ReviewingtheResults.......................................................................................................................... 48
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Pumps,Compressors,andExpanders ........................................................................................... 52
Low-fidelity .....................................................................................................................................................52 High-fidelity ....................................................................................................................................................52
VesselsandTanks............................................................................................................................. 52
Low-fidelity .....................................................................................................................................................52 Sizing...............................................................................................................................................................53 High-fidelity ....................................................................................................................................................53
Valves ................................................................................................................................................. 53
Low-fidelity .....................................................................................................................................................53 Sizing...............................................................................................................................................................54 High-fidelity ....................................................................................................................................................54
Columns ............................................................................................................................................. 54
Low-fidelity .....................................................................................................................................................54 Sizing...............................................................................................................................................................54 High-fidelity ....................................................................................................................................................55
HeatExchangers ............................................................................................................................... 56
Low-fidelity .....................................................................................................................................................56 Sizing...............................................................................................................................................................56 High-fidelity ....................................................................................................................................................56
ReliefDevices .................................................................................................................................... 57
Low-fidelity .....................................................................................................................................................57 High-fidelity ....................................................................................................................................................58
LicensingConsiderationsforHighfidelityModeling.................................................................... 58 LicenseSettings ................................................................................................................................. 58 Chapter7BuildingandUsingaDynamicSimulation ................................................................. 59 Whatdowemeanbydynamics? ....................................................................................................... 59 LicensingConsiderations .................................................................................................................... 59 LicenseSettings ................................................................................................................................. 60 AdditionalInputforDynamicOperation......................................................................................... 60 StrategiesforDynamicSimulations ............................................................................................... 61
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SettingUpDynamicOperation .......................................................................................................... 61 SwitchingtoDynamics .................................................................................................................... 61 SettingtheRunTime ........................................................................................................................ 63 SelectingStreamsandUnitOps ...................................................................................................... 65 RunningaDynamicSimulation ......................................................................................................... 66 RunfromInitialState ....................................................................................................................... 66 RunfromCurrentState.................................................................................................................... 66 RunOneStepataTime ................................................................................................................... 67 OtherDynamicCommands ................................................................................................................ 67 ResettoInitialState .......................................................................................................................... 67 SaveAsInitialState .......................................................................................................................... 68 OutputfromDynamicSimulations ................................................................................................... 68 ReviewingtheFlowsheetSpecifications........................................................................................ 68 PlottingDynamicResults ................................................................................................................ 69 TextbasedDynamicReports .......................................................................................................... 69 Chapter8OutputandReports........................................................................................................... 71 TextReports .......................................................................................................................................... 71 ReportSetup ...................................................................................................................................... 71 StreambasedReports....................................................................................................................... 72
Stream Groups .................................................................................................................................................72 Stream Compositions.......................................................................................................................................74 Stream Properties.............................................................................................................................................75 Particle Size Distribution.................................................................................................................................76 Pseudocomponent Curves................................................................................................................................76
UnitOpbasedReports...................................................................................................................... 76
UnitOp Groups ................................................................................................................................................76 Select UnitOps.................................................................................................................................................77 Spec Sheet........................................................................................................................................................77 Distillation .......................................................................................................................................................78
FlowsheetbasedReports ................................................................................................................. 78
Topology..........................................................................................................................................................78 Thermodynamics .............................................................................................................................................78 Mass and Energy Balances ..............................................................................................................................79
DynamicsReports............................................................................................................................. 79
Batch Results ...................................................................................................................................................79 Dynamics .........................................................................................................................................................79
ConsolidatedReport......................................................................................................................... 79
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UsingtheLayersFeatureforSelectiveViewingandPrinting ................................................... 85
Scenarios for Using Layers..............................................................................................................................85 Creating a New layer .......................................................................................................................................86 Assigning Objects to a Layer...........................................................................................................................87 Hiding and Viewing Layers.............................................................................................................................88 Removing an Object from a Layer ..................................................................................................................88 Deleting an Entire Layer..................................................................................................................................88
PrintingaProcessFlowDiagram ................................................................................................... 88 Chapter9CustomizingCHEMCAD ................................................................................................ 91 FlowsheetTemplates ........................................................................................................................... 91 CreatingaTemplate ......................................................................................................................... 92 ViewingaTemplatesProperties.................................................................................................... 92 ApplyingaTemplate........................................................................................................................ 92 RenamingorDeletingaTemplate.................................................................................................. 92
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PseudocomponentRange ................................................................................................................ 96 ImportingaNeutralFile .................................................................................................................. 97 CreatingaCustomSymbol ................................................................................................................. 98 CustomizedCostingCalculations.................................................................................................... 100 CreatingCustomUnitOps ................................................................................................................ 100 CreatingaCustomUnitOpDialogBox ....................................................................................... 101 CustomizingThermodynamics ........................................................................................................ 102 CreatingaCustomKvalueorEnthalpyModel......................................................................... 102 CreatingaCustomMixingRule ................................................................................................... 104 VisualBasicApplications(VBA)...................................................................................................... 104 DefiningaReaction,MixingRule,orUnitOp ............................................................................ 104 UsingaVBAdefinedReaction ..................................................................................................... 105 UsingaVBAdefinedMixingRule............................................................................................... 106 UsingaVBAdefinedUnitOp ....................................................................................................... 106 Chapter10DataInterfaces ............................................................................................................... 107 ExcelDataMapping........................................................................................................................... 107 CreatinganExcelDataMap.......................................................................................................... 108 DataMapExecutionRules ............................................................................................................ 111 CreatingExcelUnitOps ..................................................................................................................... 113 SpecificationSheets ............................................................................................................................ 113 UsingCHEMCADasanOPCServer .............................................................................................. 114 OPCApplications ........................................................................................................................... 114 OPCCompliance............................................................................................................................. 114 EnablingCHEMCADasanOPCServer ..................................................................................... 115 ReadingandWritingValuestoCHEMCADUsingOPC ......................................................... 115 OPCServerOperations.................................................................................................................. 115 CHEMCADOPCNamespace ....................................................................................................... 116 COMInterfaces ................................................................................................................................... 117 ConnectingExcelandCHEMCAD:ASimpleCOMInterface ................................................. 117
Using the VBClient Example ........................................................................................................................118 A Peek under the Hood..................................................................................................................................118
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Chapter11CHEMCADTutorials ................................................................................................... 121 CCSTEADYSTATETutorial ........................................................................................................... 122 Overview.......................................................................................................................................... 122 StartingaNewSimulation ............................................................................................................ 123 SelectingEngineeringUnits .......................................................................................................... 123 DrawingtheFlowsheet .................................................................................................................. 123
Placing UnitOps.............................................................................................................................................123 Drawing Streams ...........................................................................................................................................126
CCTHERMTutorial .......................................................................................................................... 144 OverviewoftheHeatExchangerSizingProcess ....................................................................... 145 IdentifytheTubesideStream....................................................................................................... 145 GeneratetheHeatCurve ............................................................................................................... 146 DefineGeneralSpecifications ....................................................................................................... 147 SetTubeSpecifications................................................................................................................... 148 SetShellSpecifications ................................................................................................................... 148 SetBaffleSpecifications.................................................................................................................. 149
Baffle Spacing ...............................................................................................................................................149 Baffle Cut Percent .........................................................................................................................................149
SetNozzleSpecifications ............................................................................................................... 149 SetClearanceSpecifications .......................................................................................................... 150 SetMaterialSpecifications............................................................................................................. 151 SetMiscellaneousSpecifications................................................................................................... 151 RunSizingCalculations ................................................................................................................. 151
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ReviewResultsandCreatePlots .................................................................................................. 152 CCBATCHTutorial .......................................................................................................................... 154 DescriptionoftheProblem............................................................................................................ 154 OverviewoftheBatchDistillationProcess ................................................................................. 155 CreatingaNewSimulation ........................................................................................................... 156 SelectingEngineeringUnits .......................................................................................................... 156 DrawingtheFlowsheet .................................................................................................................. 156
Placing UnitOps.............................................................................................................................................156 Drawing Streams ...........................................................................................................................................157
SelectingComponents.................................................................................................................... 158 SelectingThermodynamicOptions.............................................................................................. 158 SpecifyingPotCharge.................................................................................................................... 160 SpecifyingtheDistillationColumn .............................................................................................. 162 DefiningtheOperatingSteps........................................................................................................ 163
Operating Step 1 ............................................................................................................................................163 Operating Step 2 ............................................................................................................................................164 Operating Step 3 ............................................................................................................................................164 Operating Step 4 ............................................................................................................................................165 Operating Step 5 ............................................................................................................................................165 The Run Time Information Dialog Box.........................................................................................................165
SimpleFlowExample..................................................................................................................... 176
Problem Statement.........................................................................................................................................176 Creating the Simulation .................................................................................................................................176 Using Controllers to Simplify the Problem ...................................................................................................178 Calculating NPSHA.......................................................................................................................................179
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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
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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.
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Chapter 2
CHEMCADVersion6UserGuide
Note: IfyouinsertthediscandclosetheCDmediadrivedoor,butnothinghappens
ClickInstalltocontinue.Followthepromptsonallotherscreensuntilyousee theCHEMCADSuiteInstallShieldWizardscreen,showninFigure202.
Note:DependingonhowmanysoftwarecomponentsInstallShieldidentifies,there
CHEMCADVersion6UserGuide
TheDestinationFolderscreenappearsnext,displayingthenameofthefolder intowhichtheCHEMCADfileswillbeinstalledbydefault.Normally,this destinationisC:\ProgramFiles\Chemstations\CHEMCAD,anditisrecommended thatyouusethislocationunlessyouhaveaspecificneedtoinstalltheprogram elsewhere.ClicktheChangebuttonifyouwanttochangethefiledestination,or clickNexttoacceptthesuggesteddestinationandproceed. TheSetupTypescreennowappears,offeringachoicebetweencompleteand custominstallation.Eachtypeofinstallationisdescribedonthescreen.Eitheraccept thedefaultsettingofCompleteorclickCustomtoselectspecificcomponentsto install,thenclickNexttoproceed.
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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,thatscreenisreplacedbytheLicenseSettingsscreen.
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Note:Ifyouareusingoneofthenetworklicensingmethods(NetSentinel,SuperPro
Net,orLicenseManager),youllneedtochecktheappropriateboxbeforeclicking OK.Youcanalsoclicktheotherboxestocleartheircheckmarksandspeedup CHEMCADssearchforyourlicense. Ontherightsideofthescreen,theNetworkdeviceproductcheckoutarealets networkuserschoosewhetherornottorequestlicensesforspecificCHEMCAD modules.Foreachlistedproduct,youcanelecttosecurealicenseAlways,As needed,orNever. ThedefaultsettingforalloftheseslidercontrolsisAsneeded,whichsecuresa licenseonlywhenyoubegintouseaspecificCHEMCADfeaturecontrolledbya certainproduct.Thissettingisidealinmostsituations,asitleavesunneededlicenses availableforotherusers.Tochangeanymodulescheckoutsetting,simplyclickto theleftorrightofthecurrentsettingtomovetheslider. Inmostcases,youwontneedtomakeanychangesontheLicenseSettings screen,althoughyoumaywanttocleartheAlwaysshowthisscreenatstartupcheck box,toavoidseeingthisscreeneachtimeyoustartCHEMCAD.
Note:Ifyouveturnedoffthischeckbox,youcanstillopentheLicenseSettings
Updating a License
CHEMCADdonglesrequirereprogrammingonaregularbasis,eitheronceayear ormoreoftendependingonyourlicensingagreement.Thisisasecuritymeasureto reducethelikelihoodthatyourdonglewillbestolenandmisused. Thedonglethatyouuseisprogrammedtoworkonlythroughthelicensedtime period,andwhenthattimehaselapsed,thedonglemustbeupdatedbeforeyoucan continueusingCHEMCAD. Updatingadongleisarelativelysimpleprocedure.Beforeyourlicense expiration,youoryoursoftwareadministratorshouldreceiveanemailfrom Chemstations,withwhatsknownasaconfigurationfileincludedasanattachment. YoushouldsavethisfiletoyourWindowsdesktopassoonasyoureceiveit.
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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. StarttheCHEMCADprogram;youshouldseetheLicenseSettingsdialog boxappearautomatically.Ifnecessary,youcanopenthisdialogboxusing eitherTools>Options>LicenseSettings(withasimulationopen)or License>LicenseSettings(withnosimulationopen). 2. WithintheLicenseSettingsdialogbox,clickthetabwiththesamenameas thetypeofhardwaredonglethatyouuse:SentinelScribe,NetSentinel, SuperPro,orSuperProNet. 3. Onthetabyouveselected,findtheReprogrambuttonReprogram SentinelSuperPro,forexample.Clickthisbuttontobeginthere programmingprocedure.
Figure 2-06: Re-programming a SuperPro dongle from the License Settings dialog box
Figure 2-07: Selecting the location where the configuration file resides
5. CHEMCADreprogramsthedongleandthendisplaysasuccesspopup window.
Online Help
AtanytimewhilerunningCHEMCADinanactivewindow,youcanpressthe[F1] keytobringuptheCHEMCADHelpscreenthatsmostappropriatetothetaskyou arecurrentlyperformingorthedialogboxcurrentlydisplayed. Insomesituations,pressing[F1]willbringupthemainCHEMCAD6Help windowinsteadofaparticularhelpscreen.Fromthere,youcanclicktheContents, Index,orSearchtabintheupperleftcorneroftheCHEMCAD6Helpwindow,and usethesetoolstofindtheinformationyouneed. YoucanalsogodirectlytothemainCHEMCAD6Helpwindowbyselecting Help>HelpTopicsfromtheCHEMCADmainmenu.Regardlessofhowyouopen CHEMCADHelp,italwaysopensinaseparatewindowthatdoesnotinterferewith theoperationoftheCHEMCADprogram.
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CHEMCAD Coach
TheCHEMCADCoachpaneisatoolthatyoucanopenwithinCHEMCADtoview conciseinstructionsforcommonprocedures.Toseealistofavailabletopics,select Help>CHEMCADCoach.ThenclickonanylinkintheCHEMCADCoachwindow toviewtheinstructionsforaspecifictask.
Procedure Demos
Animateddemonstrationsofcommontasksareavailabletohelpyougetstarted usingtheCHEMCADprogram.Topicscoveredincludethevariousstepsinvolvedin creatingabasicsimulation;proceduresforsimulationsinvolvingbatchreactors,heat exchangersizing,andpiping;controlvalveratingandsizing;creatinganExcelData Map;andupdatingalicensingdongle. ThedemofilesareinstalledalongwithCHEMCAD.Toaccessthesedemos, selectStart>AllPrograms>Chemstations>Demos,andthenbrowsethelistof availabletopics.ClickthebuttonforthedemoyoudliketoviewandthenclickPlay torunthedemo.
OutsideoftheUnitedStates,pleaseseewww.chemstations.comforregional contactinformation.
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Chapter 3
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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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.
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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.
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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.
Figure 3-08: The two-headed arrow cursor used for resizing panes
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CHEMCADVersion6UserGuide
TheCHEMCADInterface
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
Bydefault,allCHEMCADpanesareinitiallypinnedinplace.Youcanchooseto unpinapaneifyouprefertohavesomeextraspaceonthescreen.Tounpinapane,
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TheCHEMCADInterface
Figure 3-10: An unpinned pane in use; note the sideways pin icon
Visible Grid
Youcanturnonaworkspacegridtouseasaguidewhilecreatingyourflowsheet. SelectView>GridVisibletotogglethisfeatureonoroff.
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TheCHEMCADInterface
isthelocationofthemousepointer.
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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.
BuildingandUsingaBasicSimulation
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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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.
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Notethatyoucanholddownthe[SHIFT]keywhileusingthePolygontoolto createarighttriangle.
Finding a Component
BecauseofthelargenumberofcomponentsintheCHEMCADcomponentdatabase, scrollingupanddownthelistofavailablecomponentscanbetimeconsuming.To findaspecificcomponentquickly,usetheSearchboxatthebottomoftheSelect Componentsdialogbox. TypethenameofthechemicalyouwanttofindintheSearchbox.Witheach letterthatyoutype,CHEMCADsuggestspossiblematchesintheAvailable
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Componentslist.Inthefollowingexample,typingtheletterswaintheSearchfield hashighlightedtheWatercomponent.
Figure 5-05: Using the Search box to locate the Water component
Note:YoucanaddyourowncustomcomponentstotheCHEMCADcomponent
database.Formoredetailsaboutthisfeature,seeChapter10ofthismanual.
Adding a Component
OnceyouvelocatedthecomponentyouwantintheAvailableComponentslist, simplydoubleclickthecomponenttoaddittotheSelectedComponentslistforyour simulation. YoucanalsoselectmultiplecomponentsintheAvailableComponentslistand thenclicktherightarrowbutton,locatedbetweenthetwocolumns,toaddthe componentstoyoursimulation.Toselectmultiplecomponents,useWindows standardselectionmethodsofholdingdown[SHIFT]toselectcontiguousitemsor holdingdown[CTRL]toselectnoncontiguousitems.
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Figure 5-07: Adding multiple components using the right arrow button
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2. ThisopenstheThermodynamicSettingsdialogbox.Startbydetermining, basedonyourprocessknowledge,whetheryoursystemhastwoliquid phasesorasingleliquidphase.IntheGlobalKValueOptionfield,selecta methodthatcancalculatethephasebehaviorrelevanttoyoursystem. 3. Basedonthespecificcircumstancesofyourprocess,makeanyneeded alterationstotheoptionsdisplayedontheKvalueModelstab.Notethatthe optionsappropriatetoyourselectedKvaluemethodaredisplayedinblack, whileirrelevantoptionsaredisplayedingray. 4. ClickEnthalpyModelstab,selectthemostappropriatemodelintheGlobal EnthalpyOptionfield,andmakeanyotherchangestotheoptionsonthistab asneededforyourprocess. 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: TempF Prespsia VaporFraction
CHEMCADwillcalculatethethirdvariableandenthalpy,basedonthetwo variablesyouspecifyandthethermodynamicsmethodyouveselected.
Stream Composition
Todefinethestreamcomposition,youllneedtospecifyacompositionunitandthe amountofeachcomponentthatispresentinthestream. SelectaunitfromtheCompunitdropdownlist,andthenbasedonthat selection,populatethefieldforeachcomponentwiththeappropriateamount, percentage,orfraction. Forstreamcompositionsexpressedasapercentageorfraction,youcanenter valuesthatdonottotal100%.Inthiscase,CHEMCADwillnormalizethe
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compositiontofractionalvaluesthattotal1.Topreviewthenormalizedvaluesthat CHEMCADassignstothecomponents,clickFlash.
Figure 5-09: Two different UnitOps that require very different amounts of input
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selectRun>Run>RunSelectedUnitOp(s).
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
High-fidelity
Inhighfidelitypipingmodels,PipeUnitOpsinteractwithNodeUnitOpstobalance pressureandflowrateshydraulicallyamongconnectedpiecesofflowbased
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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. Theresultingdialogboxespromptyoutoenterinformationaboutyourtraysor packingandthecalculationmethodsyouwanttouseforcolumnsizing.Youwill
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generallyneedtoentersomegeometryandhydraulicparameterstocomplete columnsizing.
Figure 6-04: Specifying high-level tray data for distillation column sizing
oftheflowsheetsimulation.
High-fidelity
Toperformhighfidelitymodelingofadistillationcolumninsteadystate,usethe SCDSUnitOpandselecteitherofthemasstransfersimulationmodelsforthe column.
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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 6-07: Selecting the rigorous integral analysis method for relief device design
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High-fidelity
YoucanperformhighfidelityreliefdevicemodelingfortheBatchReactorand DynamicVesselUnitOps.Youcanspecifythereliefdevicenozzlearea,aswellas otherspecificationsforyourreliefscenario.Thisenablesyoutostudythedynamic reliefofthevessel.
License Settings
IfyouvejustaddedmodulestoyourCHEMCADlicense,youshouldreturntothe LicenseSettingsscreentochangesettingsbeforeproceeding. SelectTools>Options>LicenseSettings(ifasimulationisopen)orLicense> LicenseSettings(ifnosimulationisopen)tobringuptheLicenseSettingsscreen. MovethesliderforeachnewlyinstalledmoduletoAsNeededandthenclickOKto applyyourchanges. YoumayseeaTraceMessageswindow;ifoneappears,clickOKtocloseit.The nextscreenthatappearsistheLicensesinUsescreen,whereyoucanreviewthelist ofCHEMCADproductsforwhichyoucurrentlyhavelicenses.ClickOKtoclosethis screenandreturntothemainCHEMCADwindow.
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Licensing Considerations
Tousethefunctionalitydescribedinthischapter,youmusthaveavalidlicensefor theCCDYNAMICSmoduleofCHEMCAD. IfyoudontcurrentlyhaveaccesstothedynamicsfeaturesandwanttoaddCC DYNAMICStoyourcopyofCHEMCAD,contactthepersonwithinyour organizationwhohandlessoftwarelicensing,orifappropriate,youcancontact ChemstationsoraCHEMCADdistributordirectly.Foracompletelistof
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ChemstationscontactsandCHEMCADdistributorsforallpartsoftheglobe,seeour website(www.chemstations.com/contact.htm).
License Settings
IfyouvejustaddedCCDYNAMICStoyourCHEMCADlicense,youllneedto returntotheLicenseSettingsscreentochangeasettingbeforeyoucanrundynamic simulations. SelectTools>Options>LicenseSettings(ifasimulationisopen)orLicense> LicenseSettings(ifnosimulationisopen)tobringuptheLicenseSettingsscreen. MovethesliderforCCDYNAMICStoAsNeededandthenclickOKtoapplyyour change. YoumayseeaTraceMessageswindow;ifoneappears,clickOKtocloseit.The nextscreenthatappearsistheLicensesinUsescreen,whereyoucanreviewthe CHEMCADproducts(includingCCDYNAMICS)forwhichyoucurrentlyhave licenses.ClickOKtoclosethisscreenandreturntothemainCHEMCADwindow.
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).
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11. Runthesimulationindynamics. 12. Reviewtheresults. 13. Rerunorextendthesimulationasneeded. 14. Generateplotsandreportsasneeded. Beforeyoustartworkingonadynamicsimulation,itsimportanttohaveas muchinformationaboutyourprocessaspossible,aclearideaofwhatyouwantto findout,andastrategyforproducingtheresultsyouneed.
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.
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YoucannowselectRun>DynamicstobringuptheDynamicsMenu.This windowprovidesconvenientaccesstoalldynamicssettingsandcommands.
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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:FortheDynamicStreamHistoryandDynamicUnitOpHistoryplots,besure
torecordthestreamsandUnitOpsthatyouwanttostudy.Youcanonlyrequest theseplotsforrecordedstreamsorUnitOps.
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Note:FortheDynamicStreamHistoryandDynamicUnitOpHistoryreports,besure
torecordthestreamsandUnitOpsthatyouwanttostudy.Youcanonlyrequest thesereportsforrecordedstreamsorUnitOps.
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Chapter 8
Text Reports
CHEMCADcanproduceawidearrayofcustomizabletextbasedsimulationreports, basedonstreamdata,UnitOpdata,flowsheetdata,ordynamics.Ifyouprefer,you canproduceoneconsolidatedreportincorporatingalloftheavailabletextreport data.
Report Setup
Beforeyourun,view,orprintreports,youshouldcheckthesettingsthatdetermine whichprogramsCHEMCADwillusetodisplayandprintyourreports. Forindividualtextreports,youcanchoosetouseeitherWordPadorExcel.By default,CHEMCADusesWordPad.ToswitchtoExcel,selectTools>Options> ReportViewerSettingsandthenchecktheboxcalledUseMicrosoftExcelinsteadof WordPad.ClickOKtoreturntothemainCHEMCADworkspace. Fortheconsolidatedreport,youcanuseeitherWordorExcel.Tochoosea programtodisplayandprintthisreport,selectReport>ConsolidatedReport,then clickReportFormatatthetopoftheConsolidatedReportmenu.Thisbringsupthe ReportFormatdialogbox.Choosewhetheryouwantyourconsolidatedreport
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resultstoappearinaWorddocumentoranExcelworkbookfile,andthenclickOK toapplyyourchange.
Stream-based Reports
AnumberofCHEMCADreportsareavailabletoanalyzestreamdatafroma simulation.Toaccessanyofthefollowingreports,selecttheappropriateitemfrom theReportmenu.TheresultswilldisplayineitherWordPadorExcel,dependingon howyouveconfiguredCHEMCADtohandletextreports.
Note:Bydefault,thesereportswillusetheengineeringunitsyouselectedwhen
Stream Groups
Forstreamcompositionandpropertyreports,youcancreatecustomstreamgroups withinasimulationtostreamlineyourreportrequests. Forexample,ifyouhaveaprocessthatinvolvestendifferentfeedstreams,and youfrequentlyrunreportsonthisgroupofstreams,youcansetupagroup consistingofjustthosestreams.Then,wheneveryouwanttoobtaincompositionor propertydataforthosestreams,yourejustafewclicksawayanytimethesimulation isopen. ThequickestwaytosetupanygroupistousetheCHEMCADExplorer.Follow thesestepstocreateastreamgroup: 1. IntheCHEMCADExplorerpane,findthetoplevelitemcalledGroups.Click theplussignnexttoGroupstoexpandthisitem.
2. NowrightclicktheStreamsitemunderGroupsandselectNew.
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3. IntheNewGroupdialogbox,replacethedefaultname(suchasGroup1) withadescriptivenameforyourgroup,thenclickOK.
4. IntheEditStreamGroupdialogbox,selectthestreamsforthisgroup,either bytypinginthestreamnumbers(oneperline)orbyclickingonstreamsin theflowsheet.ClickOKtoclosethedialogbox. 5. Assoonasyoufinishcreatingthegroup,itsnameappearsunderStreamsin theCHEMCADExplorer.Fromhere,youcanrightclickthegroupnameand selectanyofthefollowing: View/Edit:OpentheEditStreamGroupdialogbox,whereyoucanadd ordeletestreamnumberstoincludeinthegroup. Rename:OpentheRenameGroupdialogbox,whereyoucantypeanew nameforthestreamgroup. Copy:OpentheCopyGroupdialogbox,whereyoucantypeanew groupnametomakeanexactcopyofthestreamgroup.Afteryouclick OK,youcantheneditthenewcopyofthegrouptofityourneeds. Delete:Removethisstreamgroupfromthesimulation.Ifyouresure aboutdeletingthegroup,clickYesinthedialogboxthatappears. Composition:Runaninstantstreamcompositionreportforthestreams inthegroup.
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Properties:Runaninstantstreampropertiesreportforthestreamsinthe group.
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. FeedStreams:Thisreportdisplaysstreamcompositiondataonlyforstreams issuingfromaFeediconontheflowsheet. ProductStreams:Thisreportdisplaysstreamcompositiondataonlyfor streamsterminatinginaProducticonontheflowsheet.
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Stream Properties
Beforerunningreportsonstreamproperties,youllneedtospecifywhichproperties toinclude.Todothis,selectReport>StreamProperties>SelectProperties.This openstheViewPropertyOptionsdialogbox,whereyoucanreviewwhich propertiesarecurrentlyselected. Ifyouwanttoaddanyproperties,checktheappropriateboxes;toremove properties,clickoncheckedboxestoclearthem.Ifapplicable,clicktheCrude/Solids tab,andmakeanychangestothepropertiesonthattab.ClickOKtoreturntothe mainCHEMCADwindow. 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 data.IfyouselectaUnitOpiconbeforerunningthereport,thedatawill displaywithoutfurtherinput.
Youcanquicklydisplaystreampropertiesforasinglestreamatanytime,simply byrightclickingthestreamintheflowsheetandselectingViewProperties.
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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
3. IntheEditUnitOpSequenceGroupdialogbox,selecttheUnitOpsforthis group,eitherbytypingintheUnitOpIDs(oneperline)orbyclickingon
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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.
Spec Sheet
ThiscommandexportsdetailedinformationaboutaUnitOpintoapreformatted Excelworksheet.Thisreportisusefulfortaskssuchassolicitingamanufacturing quoteforapieceofequipment. TocreateaspecsheetforallUnitOpsontheflowsheet,selectReport>Spec Sheet>AllUnits. TocreateaspecsheetonlyforspecificUnitOps,selectReport>SpecSheet> SelectUnit.ChoosetheUnitOpsyouwanttoincludeintheSelectUnitOps dialogbox,eitherbytypingintheUnitOpIDs(oneperline)orbyclickingon
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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
Flowsheet-based Reports
InadditiontoreportsthatfocusonparticularUnitOpsandstreams,CHEMCAD offerstextreportsthatprovideinformationaboutthesimulationasawhole.To accessanyofthesereports,selecttheappropriateitemfromtheReportmenu.
Topology
ThisreportprovidesalistingofallUnitOpsintheflowsheet,aswellasallstream originsanddestinations.
Thermodynamics
Thisreportlistsallcomponentsusedinthesimulationandprovidesvital informationaboutthethermodynamicsmethodsused.
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Dynamics Reports
TheReportmenuprovidesaccesstotheBatchResultsandDynamicscommands, whichprovidereportsaboutnonsteadystreamprocesses.
Batch Results
Thisreportsummarizestheresultsofabatchdistillationcolumnsimulationatthe endofeachoperatingstep.
Dynamics
YoucanaccessthreedifferentreportsbyselectingReport>Dynamics:Dynamic ColumnHistory,DynamicStreamHistory,andDynamicUnitOpHistory.These reportsaredescribedindetailinChapter7,BuildingandUsingaDynamicSimulation.
Consolidated Report
Youcanrunanycombinationofthetextbasedreportsdescribedaboveasasingle operation,byselectingReport>ConsolidatedReport.Thisbringsupthe ConsolidatedReportmenu.
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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.
Residue Curves
Thisselectiongeneratesandplotsagraphicaldisplayofdistillationzones, azeotropes,andresiduecurvesassociatedwithauserspecifiedternarymixture.
Flowsheet-based Graphs
Toviewgraphicalreportsthatreflectyouroverallsimulation,selectoneofthe followingfromthePlotmenu: StreamProperties:Plotsoneselectedstreampropertyforaselectedstreamin theflowsheet PhaseEnvelopes:Plotsaphaseenvelopeforagivenstream,highlightingthe criticalpointofthemixture;canincludeplotsatvaporfractionsotherthan0 (bubblepointcurve)and1(dewpointcurve) CompositeCurves:Plotscompositeheatcurvesfortheentireflowsheet,as wellasoptionalheatcurvesforindividualUnitOps
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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.
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,thenclickOK. ChecktheSelectstreamsfromflowsheetbox,clickOK,andthenchoosethe streamsyouwanttoincludebyclickingtheactualstreamlineswithyour primarymousebutton.Streamnumbersthatyouselectwillappearinthe SelectStreamsdialogbox;totoggleaselectedstreamoff,justclickit
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createastreamdataboxforthissimulation. InadditiontothemainGeneraltab,notetheCrude/Solidtab,whichyoucan clicktoselectcrudeoilstreampropertiesorsolidstreamproperties.When youveselectedthestreampropertiesyouwant,clickOKtocontinue. 3. IntheDataboxSettingsdialogbox,youcanchoosethefontstyleandsizefor yourdataboxtext,aswellaswhethertoincludehorizontallinesorhorizontal sectiondividersinthedatabox.ClickOKtoplacethedataboxonyour workspace. Aswithflowsheetelements,youcanmove,stretch,orresizeadataboxusing yourmouse.
UnitOp Boxes
TheprocedureforcreatingUnitOpdataboxesissimilartothatusedtocreatestream databoxes,withthechiefdifferencebeingthatthereisnoselectionofUnitOp properties. BeginbyselectingFormat>AddUnitOpBox,andtheneitherenterUnitOpIDs orchecktheboxtoselectUnitOpsfromtheflowsheet.Notethatyoudonthavethe optionofautomaticallyincludingallUnitOps,asyoudidwithstreams. 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.
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ToaddTPdataboxes,selectFormat>AddTPBox.IntheTPBoxSettingsdialog box,firstselectanoptionatthetop,todeterminewhethertoaddTPboxesforall streamsoronlyforthestreamsyouselect. IntheDisplaycolumn,selectitemsfromthedropdownlistineachfieldto determinewhichstreampropertiestodisplayandinwhatorder.UseNoselection asappropriateifyouwanttodisplayfewerthanfourproperties. IntheNumberformatcolumn,makeaselectionineachfieldtodeterminehow numberswilldisplayintheTPboxes.IntheDigitscolumn,typethenumberof digitstodisplayafterthedecimalpoint.Youcanalsochangethefontstyleandsize fortheTPboxtext,andchoosewhethertodisplaystreamIDsandengineeringunits. ThePreviewboxdisplaysadynamicsampleofhowtheitemsyouveselected willappearintheTPboxes.Notethatthepreviewareadoesnotreflectchangesyou maketothefontsize. WhenyoufinishmakingyourselectionsintheTPBoxSettingsdialogbox,click OK.IfyouvechosentomakeTPboxesforallstreams,theTPboxeswillappearon theflowsheetrightaway.Ifyouveoptedtoselectthestreamsfromtheflowsheet, youllseeaSelectStreamsdialogbox;typethestreamnumbers(oneperline)orclick onthestreamlinesintheflowsheettoselectstreams,andthenclickOKtocreatethe TPboxes.
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3. IntheWorksheetnamefield,typethenameoftherelevantworksheetwithin theworkbookthatyouveindicated. 4. Inthecenterportionofthedialogbox,specifythestartingandending columnandrowcoordinatesthatyouwanttoreferencewithintheselected worksheet. 5. Inthelowerportionofthedialogbox,changeanyformattingsettingsas desiredandthenclickOKtocreatethedatabox. AnExcelrangeboxisadynamiclinkbetweenCHEMCADandtheExcel worksheet.Asdataisupdatedandsavedintheselectedcellrange,therangeboxcan automaticallyupdatetoreflectthosechanges.Toviewthemostuptodatedatain yourExcelrangeboxesatanytime,selectView>RefreshDataBoxes.
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whateverotheritemsyouneed.Createasmanydifferentlayersasyoulike, andeachtimeyougotoprintthediagram,viewonlythelayersthatyou wanttoprint. Youneedtoemailasimulationtodifferentrecipientswhowanttoview differentdataboxes.Createsetsofdataboxesassignedtomultiplelayers,and thenviewjustthelayersthatyouwantyourfirstrecipienttoseeupon openingthefile.Saveandclosethesimulationbeforeattachingittoanemail message.Openthesimulationagainforthenextrecipient,selectthelayers youwantthatpersontosee,savethefile,andattachittoanotheremail message. Youhaveaverylargeflowsheetthatencompassesanumberofdiscrete processes.Youcancreateseparatelayersforvariousportionsoftheoverall flowsheet,andviewonlytheportionsyoureworkingwithatagiventime. Youcanalsohideunneededportionsoftheflowsheetforprinting. Ifyouaretroubleshootingaprocess,orforwhateverreasonneedtomark upaprocessflowdiagram,youcandrawshapessuchasellipsesor rectanglesaroundcertainUnitOpsorgroupsofUnitOps,usingtextorbright colorstodrawextraattention.Thenassignallofthesemarkupitemstoa singlelayersothatyoucanchoosetovieweitherthemarkedupversionor thecleanversionoftheflowsheetatanytime.
IntheNewLayerdialogbox,replacethedefaultlayernamewithadescriptive nameofyourownandthenclickOK.
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Figure 8-10: Visible and hidden layers as they appear in CHEMCAD Explorer
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assignedtotwoormorelayers,however,itwillbedisplayedunlessallofits associatedlayersarehidden.
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unpinoneormorepanesaswell,togiveyourselfmoreworkspacewhileyou preparetoprint. Next,considerwhetheryourprocessflowdiagramshoulddisplayajobbox, UnitOporstreamdataboxes,textnotes,orotheritemsinadditiontotheflowsheet itself.Ifyouhavealreadycreatedtheneededitems,makesurethattheyare currentlyvisibleandplacedwhereyouwantthem. Whenalloftheitemsyouwanttoprintarevisible,checkoncemoretoensure thateverythingfallswithintheCHEMCADworkspace.ThenselectFile>Print,or clickthePrintbuttononthetoolbar.ThisbringsupthePrintSetupdialogbox, whereyoucanselectprintingoptionsorsimplyclickOKtoprinttheprocessflow diagram.
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Chapter 9
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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2. Givethenewcomponentadescriptivename;itisstronglyrecommendedthat youmakethisnameunique.Allothercharacteristicshereareoptional,except fornormalboilingpoint,whichisrequiredforthepseudocomponent method. 3. SelectaCorrelationoptiontoindicatewhichoftheabovemethodsyouwill use,andclickOKtocontinue. 4. Intheresultingdialogbox,selecttheappropriateoptionsforyournew componentandspecifyasmanycharacteristicsasyoulike,asaccuratelyas possible.ClickOKtocontinue. 5. IntheSelectDestinationDatabasedialogbox,youwillseenodatabaseslisted ifthisisyourfirsttimetoaddacomponent.Ifthisisthecase,clickNewto bringuptheManageComponentDatabasesdialogbox. 6. Normally,youllneedtoclickAddNew,whichbringsuptheSaveAsdialog box.Navigatetothelocationyouwantforyourcustomcomponentdatabase, givethedatabaseaname,andclickSave.Ifyouwanttoaddadatabasethat someoneelsehascreated(generallyinanetworklocation),youcanclickUse Existing,whichbringsupanOpendialogbox;navigatetothatdatabases location,highlightthedatabase,andclickOpen. 7. TheManageComponentDatabasesdialogboxnowliststhedatabasethat youcreatedorselected.ClickOKtocontinue. 8. IntheSelectDestinationDatabasedialogbox,thenewdatabaseyouhavejust namedisnowlisted;highlightitandclickOK. 9. TheView/EditComponentDatamenunowappears.Clickanyitemonthe menutoaccessadialogboxwithoptionsfordefiningyournewcomponent. Afterdefiningasmanycharacteristicsaspossible,clickExittoclosethe menu.
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Thenewcomponentisnowavailabletoaddtoyourcurrentsimulationandall futuresimulations.Toreturnatanytimetomakechangestoauserdefined component,dooneofthefollowing: SelectThermophysical>ComponentDatabase>View/EditComponentto bringuptheSelectSingleComponentdialogbox,whichlistsallavailable components.HighlightthecomponentyouwantinthelistandclickOKto bringuptheView/EditComponentDatamenu. ClickComponentListonthetoolbartobringupthelistofcomponentsinthe currentsimulation.Doubleclickthecomponentyouwantinthelisttobring uptheView/EditComponentDatamenu.
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cellsinthisdialogbox. 6. Theregressiondataisdisplayedinatabularformatforreview.Whenyouare readytoviewtheregressioncurve,closetheWordPadorExcelwindow. 7. Theregressionresultsnowdisplayingraphicalformat.Reviewtheplotand decidewhethertheregressionadequatelyrepresentsyourexperimentaldata. IntheApplyComponentChangesdialogbox,eitherchooseanoptionand clickSaveorabandonyourregressionchangesbyclickingDontSave. 8. Repeatthisprocedureasneededtoregressotherpropertiesforyour component,andthenclickExittoclosetheRegressComponentProperties menu.
Pseudocomponent Range
Usingapseudocomponentcurveanothertermforthedistillationcurveportionofan assayyoucancutahydrocarbonstreamintopseudocomponents,orfractions.A pseudocomponentrepresentsagroupofcomponentsthatboilwithinanarrow temperaturerange.PseudocomponentrangesareusedinCHEMCADtomodel hydrocarbons. Whenyoudefineapseudocomponentrangeforastream,CHEMCADcreates entriesinthecomponentdatabaseforeachhydrocarboncut,andassignsthese componentscompositionstothestream.
Note:Beforeyoudefineapseudocomponentrange,makesurethatyouhave
specifiedinyourcomponentlist,asappropriate,waterandanylightendsthatexist intheassay. 1. SelectThermophysical>PseudocomponentCurves. 2. IntheDistCurveCharacterizationdialogbox,enterstreamnumber(s)and clickOK. 3. IntheHydrocarbonCorrelationdialogbox,selecttheappropriate correlationsforyourcurve,orusethedefaultselectionsandclickOK. 4. ThisbringsuptheCurveTemperatureCutRangesdialogbox.Foreachcut rangethatyouwanttodefine,provideabeginningandendingtemperature, andenterthenumberofpointsthatyouwanttodefineasdiscrete pseudocomponentswithinthatrange.ClickOKtocontinue.
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5. IntheBulkPropertiesdialogbox,specifyadistillationcurvetypeandentera totalflowrateandbulkgravityforthestream.Youcanmakeotherentries hereasneeded,butonlythesethreeitemsarerequired.ClickOKtocontinue. 6. Intheresultingdialogbox,enterthedistillationcurvefromyourassay, specifyingthevolumepercentageandboilingtemperatureforatleastfive datapoints.ClickOKtocontinue. 7. Thenextdialogboxisoptional.Enteragravitycurvefromyourassay, specifyingthevolumepercentageandgravityforatleastfivedatapoints. ClickOKtocontinue. 8. Thenextdialogboxisalsooptional.Ifyouhavelightendsandwaterdefined inyourassay,entervolumepercentagedatahereforallrelevantcomponents. ClickOKtocontinue. 9. ThisbringsuptheEditDistillationCurvesmenu,showninFigure903.
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Oncetheeditorisopen,youllseeagriddedworkspaceandasmall,freefloating toolpalette.
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Figure 9-05: 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].
4. Whenyourereadytosavethesymbol,makesurethatyouhavedeletedany unwanteditemsontheworkspace.SelectEdit>SelectAllorpress[CTRLA], andthenselectStructure>Group. 5. SelectFile>Savetosavethechangestoyournewsymbol. Tocreateatotallynewsymbol,simplystartfromablankworkspace,namethe file,andusethevariousdrawingtoolstocreatethedesiredcombinationofshapes andtext.Addinletsandoutletsasneeded,thengroupthesymbolscomponentsand savethefile. Onceyouvecreatedyournewsymbol,youneedtoassociateitwithaUnitOp typeandthenadditintotheappropriateUnitOpsubpalette. 1. WithintheSymbolEditorprogram,selectFile>EditUnitOpType.The SelectUnitOperationTypedialogboxappears.
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ThebasicproceduresforcreatingcustomExcelUnitOpsarecoveredinChapter 10,DataInterfaces.CalculatorUnitOpsaredefinedbyaprogramminglanguage
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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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Customizing Thermodynamics
Occasionally,youmayfindthatnoneofthethermodynamicmodelsbuiltinto CHEMCADserveyourneedsforaparticularsimulation.Ifthisshouldhappen,you cantakeoneoftwoapproachestohandlingthermodynamicsforthesimulation: eithercreateyourownKvalueorenthalpymodelorcreateyourownmixingrule.
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ClicktheViewCHEMCADbuttonatthefarleftendoftheVBAeditors toolbartoclosetheeditorwindow.
Note:Youcanalsousethe[ALTF11]keycombinationtotogglebetweenCHEMCAD
Figure 9-10: Selecting a VBA-defined reaction in the Kinetic Data dialog box
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4. Whenyouhavedefinedthelastreaction,clickOKtoreturntothemain CHEMCADwindow.
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Chapter 10
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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Note:Ifyouneedtoverifythenameoftheworksheet,youcanclicktheOpenbutton
tolaunchExcelandviewtheworkbook. 4. ClickthecellbelowMapRuletohighlightthatcell.Clickagaintoseeadrop downlistofmappingoptions: ToWorksheetOnlyenablesyoutosenddatafromstreamsorUnitOpsin CHEMCADtotheselectedworksheet. ToCCOnlyenablesyoutosenddatafromanycellontheworksheetto theselectedstreamorUnitOpparameterinyoursimulation. Fordatareconciliationenablesyoutomanipulatethedatausing CHEMCAD's Data Reconciliation feature.
Figure 10-02: Selecting a Map Rule option in the Excel Data Map Editor
optionsislimited,asmanyvaluesinaCHEMCADsimulationarecalculatedbased onothervalues.
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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. Ifyouare performing a datareconciliation, youcanusethe Weightcolumntogivecertainitemsinthereconciliationmoreimportance thanothers. 11. Repeattheprocedureuntilyouhavespecifiedallofthecellsorcellranges thatwilllinktoyoursimulation. 12. SavetheDataMapbyselectingFile>SaveAs.TypeanameforyourData MapandthenclickOK.ThenewlycreatedDataMapnowappearsonthe CHEMCADExplorerundertheDataMapsitem.
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2. ClickthesquarebuttonnexttothefirstfieldintheSelectDataMapscolumn tobringuptheSelectDataMapdialogbox.
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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
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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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thatthecommandhascompletedsuccessfully,whileanegativereturnindicatesa problemofsomekind. Theavailablecommandsareasfollows: RefreshServertellsCHEMCADtorefreshalldatasenttotheOPCserver. RunSteadyStaterunsasteadystatesimulation.Whenthesimulation finishes,theflagwillbereseteitherto0(runconverged)ortoanegative numberindicatingthenumberoferrorsthatoccurredduringtherun.To 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.
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COM Interfaces
ComponentObjectModel(COM)isaMicrosoftstandardplatformthatenables programstosharecontentsuchasdataandcalculationroutines.Thisinterface makesitpossibleforotherprogramstocontrolaCHEMCADsimulation. CHEMCADactsasaCOMserver,soanyprogramthatcanactasaCOMclient canbemadetointerfacewithCHEMCADinthisway.Ifyouarentcertainwhether yourapplicationcanactasaCOMclient,checkwiththesoftwarevendor.
Note:UsingtheCOMinterfacetoCHEMCADisacomplicatedprocedurethat
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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 ThedocumentcalledCOMInterfaceReference.doc,availableonthe Chemstationswebsite,providesafullreferenceofthecommandsavailablethrough COM.
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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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9. NowthatyouhaveselectedtheappropriateTowericon,addthisUnitOpto theflowsheet.
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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 ValueOptionselection,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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8. ReturntothemainCHEMCADwindowbyselectingFile>Close.
4. SelectFile>Exitinthetabulardatawindowtoreturntothemain CHEMCADwindow.
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Nowthatyouhaveachievedtheresultsthatyousetouttoproduce,savethe simulation,usingeitherFile>SaveortheSavebuttononthetoolbar.
Becauseyouwantareportwithabroadrangeofinformationaboutyour simulation,usetheConsolidatedReportoption. 1. SelectReport>ConsolidatedReporttobringuptheConsolidatedReport menu.Fromhere,youcanspecifyexactlywhatyouwanttoincludeinyour report. 2. Startbyspecifyingwhichstreamsyouwanttoinclude.ClickSelectStreams toopentheSelectStreamsdialogbox. 3. ClicktheAllstreamsboxtoclearthedefaultcheckmark,thentypethe numbers1,5,8,and9intostreamIDboxes.ClickOKtoreturntothe ConsolidatedReportmenu. 4. NowselectwhichUnitOpsyouwanttoinclude.ClickSelectUnit OperationstoopentheSelectUnitOpsdialogbox. 5. ThePrintallUnitOpsoptionisselectedbydefault.Inthiscase,youdowant toincludeallUnitOpsinthereport,soverifythatthisboxischeckedand thenclickOKtoreturntotheConsolidatedReportmenu. 6. ClickStreamPropertiestoopenthePropertyOptionsdialogbox.Here,you canselectanycombinationofitemsontheGeneralandCrude/Solidtabsto determinewhatstreampropertieswillbeincludedinthereport.Checked
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itemswillbeincludedbydefault;totoggleanyitemonoroff,simplyclick thecorrespondingbox. Forthepurposeofthistutorial,usethedefaultsettingsinthisdialogbox. ClickCanceltoclosethedialogboxandreturntotheConsolidatedReport menu. 7. ClickStreamFlowrate/CompositionstoopentheFlow/CompositionOptions dialogbox.ClickthecheckedboxnexttoMoleflowratetoturnoffthis defaultoption.Then,clicktheMassflowrateandMolefractionsboxesto turnbothofthoseoptionson.ClickOKtosaveyoursettingsandreturnto theConsolidatedReportmenu. 8. Finally,specifywhichinformationtoprintforthecondensatestabilizer distillationcolumnbyclickingDistillationSummaries.IntheDistillation Optionsdialogbox,theinformationyourelookingtoprintTrayprofileis alreadyselected.ClickOKtoreturnforthelasttimetotheConsolidated Reportmenu. 9. Togeneratethereport,clickCalculateandGiveResults.Thereportdisplays inaseparatewindow,withaformatsuitableforprinting.Youcanedit,save, andprintthereportasneeded. 10. Whenyoufinishreviewingandworkingwiththereport,closethereport windowtoreturntothemainCHEMCADworkspace.
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dialogbox.Becauseyouwanttoincludeallstreams,leavethesettingsthe waytheyareandclickOKtocontinue. 3. IntheDataboxPropertyOptionsdialogbox,reviewthedefaultselections, indicatedbycheckedboxes.Forthepurposesofthistutorial,leavethe selectionsastheyareandclickOKtocontinue. 4. IntheDataboxSettingsdialogbox,youcancontrolthefontstyleandsizeof thedataboxtext,aswellastheuseofdividinglineswithinthebox.Accept thedefaultsettingshereandclickOK. 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.
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CC-THERM Tutorial
Thistutorialwalksyouthroughtheratingofaheatexchanger.Theexampleyoull workwithisthecondensatestabilizerexampledescribedintheCCSTEADYSTATE tutorial,whichlookslikethis:
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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seeifyoureturntoshellandtubesizingforthisexchangeratanytimeafterthis initialspecification.
Clickanyofthesebuttonstoviewvariousreportsoneverythingfrombaffle parameterstovibrationanalysis.Whenyouselectareport,thedatadisplaysina
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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 valueoption)andselectingamethodormodelforcalculatingtheheatbalance(called theenthalpyoption).Thecommandsfortheseselectionsarelocatedonthe Thermophysicalmenu. CHEMCADhasalibraryofdozensofKvaluemodelswithavarietyofoptions andabout12enthalpymodels.Makingtheproperselectionfromtheselibrariescan sometimesbedifficult.Forthepurposesofthistutorial,assumethatyouwanttouse thePengRobinsonmethodforboththeKvalueandenthalpycalculations.Follow thesestepstoselectyourthermophysicaloptions: 1. AcceptthedefaulttemperatureandpressurerangesintheThermodynamics WizardandclickOK. 2. ClickOKagaintoacceptthewizardssuggestedmethodofSRK. 3. WhentheThermodynamicSettingsdialogboxopens,findtheGlobalK ValueOptionselection,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. Enter0.6intheNButanefield. Enter0.4intheNHexanefield. 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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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 Efficiency 0.5 0.45 0.4 0.35 0.3 0 40 80 120 160 200 Flow (gpm)
Figure 11-62: Combined pump curves for a sample pump
1150 rpm
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Index
.CC6files,29 Addingasinglecomponent,93 Addingcomponentstoasimulation,42 AllUnitOpspalette,37 ApplyComponentChangesdialogbox,96 Applyingatemplate,92 Assigningobjectstoalayer,87 Attachingasimulationfiletoanemail,33 BatchReactor/DVSLHistoryplot,69 BatchResultsreport,79 BinaryLLEplot,80 BinodalPlot,80 Binodal/ResidueCurvesplot,80 Buildingabasicsimulation,35 BulkPropertiesdialogbox,97 C++,usingtocreateacustommixingrule,104 C++,usingtocreatecustomthermodynamics,102 CallingChemstations,15 Cases,saving,32 CCBATCHtutorial,154 CCDYNAMICS,59 CCSTEADYSTATEtutorial,122 CCTHERMtutorial,144 CHEMCAD Mainmenu,23 Toolbar,23 Tutorials,121 Gettinghelpwith,14 Installing,7 Interface,17 Licensing,10 Modules,3 Openingolderfiles,33 Overview,1 Productsandfeatures,3 Systemrequirements,7 Usercomponentsin,30
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Index
Customizingthermodynamics,102 DatainterfacestoCHEMCAD,107 DataMapExecutionRulesdialogbox,111 DataMaps,creating,108 Databoxes,82 DefaulticonforUnitOp,37 Definingstreams,46 DefiningUnitOps,47 Deletingatemplate,92 Dialogbox,customizing,101 DialogEditorutility,101 DistCurveCharacterizationdialogbox,96 Distillationreport,78 Dongle ForCHEMCADlicensing,10 Reprogramming,12
Chemicalcomponents,selecting,41 Chemstationswebsite,15 Coach,27 COMinterfaces,117 ComponentObjectModel(COM),117 Components Adding,42 Finding,41 Removing,43 Selecting,41
CompositeCurvesplot,80 ConnectingstreamstoUnitOps,38 Consolidatedreporting,79 ControlValveSizingdialogbox,54 ControllerConvergenceplot,81 ConvergenceParametersdialogbox,62 Costingcalculations,customized,100 CreatingacustomUnitOpdialogbox,101 Creatingalayer,86 Creatinganewsimulation,31 Creatingatemplate,92 CreatinganExcelDataMap,108 Creatingcustomcomponents,93 CreatingExcelUnitOps,113 CreatingcustomUnitOps,100 CurveTemperatureCutRangesdialogbox,96 Customcomponents,93 Customenthalpymodel,102 CustomKvaluemodel,102 Custommixingrule,creatingusingVBA,104 Customreaction,creatingusingVBA,104 CustomUnitOpicon Creating,98 Addingtoasubpalette,99
Drawingaflowsheet,36 Drawingstreamsonaflowsheet,38 Drawingtools,40 DynamicColumnHistoryplot,69 DynamicColumnHistoryreport,69 Dynamicoperation,settingup,61 Dynamicplots,81 DynamicRunTimeScheduledialogbox,64 Dynamicsimulation,running,66 Dynamicsimulations,strategiesfor,61 DynamicStreamHistoryplot,69 DynamicStreamHistoryreport,70 DynamicUnitOpHistoryreport,70 DynamicsMenu,63 Dynamicsreports,79 Dynamics Additionalinputfor,60 Defined,59 Output,68 Plottingresults,69 RecordingstreamsandUnitOps,65 Runningonestepatatime,67 Textbasedresults,69 Toolbarbuttonsfor,62
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Linetool,40 LockedforEditingdialogbox,31 Lowfidelitymodeling,defined,49 Mainmenu,23 ManageComponentDatabasesdialogbox,94 MassandEnergyBalancesreport,79 Messagespane,22 Movingapane,25 MovingUnitOpicons,38 Multilinetool,40 MySimulationsdirectory,32 Neutralfileimport,97 NewComponentdialogbox,93 Newsimulation,creating,31 Notestab,onMessagespane,23 OlderCHEMCADfiles,33 OleforProcessControl(OLE),114 OPC Applications,114 Compliance,114 Namespace,116 Serveroperations,115
Enthalpyoptions,selecting,44 Equipmentparameters,specifying,47 Equipmentsizing,introduction,50 ErrorsandWarningstab,onMessagespane,22 Examplefiles,30 ExcelDataMapEditor,108 ExcelDataMappingfeature,defined,107 ExcelDataboxSettingsdialogbox,84 Excelrangeboxes,84 ExcelUnitOps,creating,113 Flowsheetdataboxes,82 Flowsheettemplates,91 Flowsheets,drawing,36 Flowsheetbasedgraphs,80 GlobalEnthalpyOption,45 GlobalKValueOption,45 Graphicalreports,80 Grid,26 Groups Stream,72 UnitOp,76
OPCserver,usingCHEMCADas,114 Opencommand,31 Openinganexistingsimulation,31 OpeninganolderCHEMCADfile,33 Palettepane,introduced,20 Palettes,customizing,21 ParticleSizeDistributionreport,76 PFDprinting,88 PFDs,82 PhaseEnvelopesplot,80 Pinningandunpinningpanes,25 PipeProfileplot,81 Pipingtutorial,170 PlotsinCHEMCAD,80 Plots,dynamic,81 Plottingdynamicresults,69 PlugFlowReactorProfileplot,81 Polygontool,40 Printingaprocessflowdiagram,88 PrintingCHEMCADreports,82 Processflowdiagrams,82 Properties,ofstreams,46 PseudocomponentCurvesplot,81
HeatCurvesplot,81 Hidingalayer,88 Highfidelitymodeling,defined,49 HydrocarbonCorrelationdialogbox,96 Icons,creating,98 InstallingCHEMCAD,7 Jobfiles,29 Kvalueoptions,selecting,44 Layers,85 Assigningobjectsto,87 Creating,86 Deleting,88 Hidingandviewing,88 Removingobjectsfrom,88
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Index
PseudocomponentCurvesreport,76 Pseudocomponentrange,defining,96 RecordStreamsdialogbox,65 RecordingstreamsandUnitOpsfordynamics,65 Rectangletool,40 Redocommand,26 RegressComponentPropertiesmenu,95 Regressingdataintoauseraddedcomponent,95 Reliefdevicesizing,57 Removingcomponentsfromasimulation,43 Renamingatemplate,92 ReportFormatdialogbox,71 Reportsetup,71 Reportsfordynamicsimulations,69 Reports Dynamics,79 Printing,82 Streamcompositions,74 Streamproperties,75 UnitOpbased,76
Selectingcomponents,41 Selectingengineeringunits,36 SelectingKvalueandenthalpyoptions,44 Selectiveprinting,85 Settingruntimefordynamics,63 Simulationfiles Introduced,29 Creating,31 Emailing,33 Opening,31 Overviewofbuilding,35 Saving,32
Simulation,running,48 Singlecomponent,adding,93 Sizing,introduction,50 Specsheetreport,77 Specsheets,outputtoExcel,113 SpecifyingUnitOps,47 Startinganewsimulation,31 Streamboxes,82 Streamcompositionreports,74 Streamcomposition,viewing,75 Streamgroups,creating,72 StreamPropertiesplot,80 Streampropertyreports,75 Streams Drawingonaflowsheet,38 Defining,46 Rerouting,39
Reprogrammingadongle,12 Reroutingastream,39 ResettoInitialStatebutton,67 ResidueCurvesplot,80 Resizingapane,24 ResizingUnitOpicons,38 Results,reviewing,48 Reviewingrunresults,48 Routingstreams,39 RunfromCurrentStatebutton,66 RunfromInitialStatebutton,66 Runtime,setting,63 RunTracetab,onMessagespane,22 Runningadynamicsimulation,66 Runningasimulation,48 SaveAscommand,32 SaveasInitialStatebutton,68 Savingasimulation,32 Savingdifferentcases,32 SearchforUnitOp(s)field,21 SearchOptionsdialogbox,42 SelectComponentsdialogbox,41 SelectDataMapdialogbox,111 SelectDestinationDatabasedialogbox,94 SelectSingleComponentdialogbox,95
Switchingtodynamics,61 SymbolEditorutility,98 Symbols,creating,98 Technicalsupport,contacting,15 Templates Applying,92 Creating,92 Defined,91 Deleting,92 Renaming,92
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Thermodynamics,customizing,102 Thermophysicaldatagraphs,80 Toolbar,23 Topologyreport,78 TowerProfilesplot,81 TPboxes,83 TPXYplot,80 TraySizingdialogbox,55 Undocommand,26 UnitOpboxes,83 UnitOpdialogbox,customizing,101 UnitOpgroups,creating,76 UnitOpicons Creatingcustomized,98 Manipulating,38 Addingtoaflowsheet,36 Selectingdefaulticonfor,37 Listingofallavailable,5 Specifying,47
UnitOpbasedplots,81 UnitOpbasedreports,76 UpdateSimulationFormatdialogbox,34 UpdatingaCHEMCADlicense,12 Userspecifiedfile,plotting,81 ValveTraydialogbox,55 VBA Custommixingrules,104 Customreactions,104 CustomUnitOps,104 UsingtocustomizeCHEMCAD,104
UnitOps
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Allmaterial2007Chemstations,Inc.