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CHEMCADVersion6UserGuide i
CHEMCAD Version 6 User Guide
Table of Contents
Chapter1IntroductiontoCHEMCAD .............................................................................................. 1
OverviewofCHEMCADandItsUses................................................................................................ 1
CHEMCADProductsandFeatures ................................................................................................. 3
CC-STEADY STATE .......................................................................................................................................3
CC-DYNAMICS ...............................................................................................................................................3
CC-BATCH.......................................................................................................................................................3
CC-THERM.......................................................................................................................................................3
CC-SAFETY NET.............................................................................................................................................3
CC-FLASH........................................................................................................................................................3
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
TableofContents
ii CHEMCADVersion6UserGuide
Chapter3TheCHEMCADInterface................................................................................................ 17
TheCHEMCADWindow ................................................................................................................... 17
TheWorkspace.................................................................................................................................. 18
TheCHEMCADExplorerPane ...................................................................................................... 18
The Recent Files Tab.......................................................................................................................................19
The Simulation Tab .........................................................................................................................................19
The Visual Basic Tab.......................................................................................................................................20
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
TheMainMenu................................................................................................................................. 23
TheToolbar........................................................................................................................................ 23
CustomizingtheCHEMCADScreen................................................................................................. 23
ViewingandHidingScreenElements ........................................................................................... 24
ResizingandMovingItems............................................................................................................. 24
Resizing a Pane................................................................................................................................................24
Moving a Pane.................................................................................................................................................25
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
TableofContents
CHEMCADVersion6UserGuide iii
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
TableofContents
iv CHEMCADVersion6UserGuide
Chapter6UsingCHEMCADforHighfidelityModeling........................................................... 49
Whatishighfidelitymodeling?......................................................................................................... 49
CriteriaforHighfidelityModeling................................................................................................... 50
IntroductiontoEquipmentSizing ..................................................................................................... 50
HighfidelityModelingandSizingforCommonUnitOps ............................................................ 51
Piping.................................................................................................................................................. 51
Low-fidelity.....................................................................................................................................................51
Sizing...............................................................................................................................................................51
High-fidelity ....................................................................................................................................................51
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
TableofContents
CHEMCADVersion6UserGuide v
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
TableofContents
vi CHEMCADVersion6UserGuide
GraphicalReports................................................................................................................................. 80
ThermophysicalDataGraphs ......................................................................................................... 80
TPXY...............................................................................................................................................................80
Binary LLE......................................................................................................................................................80
Binodal Plot .....................................................................................................................................................80
Binodal/Residue Curves ..................................................................................................................................80
Residue Curves ................................................................................................................................................80
FlowsheetbasedGraphs.................................................................................................................. 80
UnitOpbasedPlots .......................................................................................................................... 81
Tower Profiles .................................................................................................................................................81
Heat Curves .....................................................................................................................................................81
Plug Flow Reactor Profile ...............................................................................................................................81
Pipe Profile ......................................................................................................................................................81
Controller Convergence...................................................................................................................................81
DynamicPlots ................................................................................................................................... 81
UserspecifiedFile ............................................................................................................................ 81
PrintingCHEMCADReports ............................................................................................................. 82
ProcessFlowDiagrams ....................................................................................................................... 82
FlowsheetDataboxes........................................................................................................................ 82
Stream Boxes...................................................................................................................................................82
UnitOp Boxes ..................................................................................................................................................83
TP Boxes .........................................................................................................................................................83
Excel Range Boxes..........................................................................................................................................84
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
TableofContents
CHEMCADVersion6UserGuide vii
CreatingCustomComponents........................................................................................................... 93
AddingaSingleComponent........................................................................................................... 93
Creating the Component ..................................................................................................................................93
Regressing Data into the Component ..............................................................................................................95
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
TableofContents
viii CHEMCADVersion6UserGuide
Chapter11CHEMCADTutorials ................................................................................................... 121
CCSTEADYSTATETutorial ........................................................................................................... 122
Overview.......................................................................................................................................... 122
StartingaNewSimulation ............................................................................................................ 123
SelectingEngineeringUnits .......................................................................................................... 123
DrawingtheFlowsheet .................................................................................................................. 123
Placing UnitOps.............................................................................................................................................123
Drawing Streams ...........................................................................................................................................126
SelectingComponents.................................................................................................................... 126
SelectingThermodynamicOptions.............................................................................................. 128
DefiningtheFeedStreams............................................................................................................. 130
EnterUnitOpParameters .............................................................................................................. 132
First Heat Exchanger .....................................................................................................................................132
Second Heat Exchanger.................................................................................................................................133
Flash Drum....................................................................................................................................................133
Valve..............................................................................................................................................................133
Stabilizer Tower ............................................................................................................................................134
RuntheSimulation......................................................................................................................... 134
ReviewtheResultsandPrintasNeeded..................................................................................... 134
Checking the Cricondentherm Dewpoint.......................................................................................................134
Checking the Bottoms Stream Purity.............................................................................................................137
Re-running the Simulation.............................................................................................................................138
Producing a Text Report ................................................................................................................................139
Generating a Process Flow Diagram..............................................................................................................140
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
TableofContents
CHEMCADVersion6UserGuide ix
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
RunningtheSimulation................................................................................................................. 166
ReviewingandPrintingResults ................................................................................................... 167
Plotting the Results........................................................................................................................................167
Generating Text Reports................................................................................................................................168
Generating a Full Report ...............................................................................................................................168
PipingTutorial .................................................................................................................................... 170
ControlValveSizingExample...................................................................................................... 170
Problem Statement.........................................................................................................................................170
Rating Case....................................................................................................................................................171
Flow Rate as a Function of Pressure..............................................................................................................173
SimpleFlowExample..................................................................................................................... 176
Problem Statement.........................................................................................................................................176
Creating the Simulation .................................................................................................................................176
Using Controllers to Simplify the Problem ...................................................................................................178
Calculating NPSHA.......................................................................................................................................179
BranchedFlowExample ................................................................................................................ 180
Problem Statement.........................................................................................................................................180
Creating the Simulation .................................................................................................................................180
Running the Simulation .................................................................................................................................182
Selecting a Pump ...........................................................................................................................................183
Index ........................................................................................................................................ 185
TableofContents
x CHEMCADVersion6UserGuide
CHEMCADVersion6UserGuide 1
Chapter 1
Introduction to CHEMCAD
WelcometoCHEMCADVersion6.0,apowerfulandeffectivesoftwaretoolfor
chemicalprocesssimulation.WhetheryoureaneworexperiencedCHEMCADuser,
youllappreciatetheprogramsuserfriendly,featurerichinterface.Creating
flowsheetsandrunningsimulationsisfastandeasywithCHEMCAD,andthe
programishighlycustomizabletofityourneedsandthewayyouwork.
ThismanualwillhelpyougetupandrunningwithCHEMCAD,from
installationandlicensingtotutorialsthatwalkyouthroughrealworldexamples.
Overview of CHEMCAD and Its Uses
Todayschemicalprocessingindustry(CPI)facesnumerouschallenges:risingfuel
andfeedstockcosts,reducedengineeringstaff,shorterproductlifecycles,increased
globalcompetition,andincreasedregulation.ThesechallengesrequirethatCPI
companiesseekoutandusethebesttoolstoincreaseproductivityandimprove
engineeringdecisions.
CHEMCADisapowerfulandflexiblechemicalprocesssimulationenvironment,
builtaroundthreekeyvaluesofinnovation,integration,andopenarchitecture.
ThesevaluescreateimportantadvantagesforCHEMCADusers:
Thelatestchemicalengineeringtechniquesatyourfingertips
Allfunctionalityunitedinasinglesoftwareenvironment
Seamlessconnectiontothechemicalengineeringcomputingenvironment,with
linkstotoolssuchasMSExcelandWordandinterfacessuchasCOM,DCOM,
OPC,CAPEOPEN,andXML
IntroductiontoCHEMCAD
2 CHEMCADVersion6UserGuide
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
Nomatterhowcomplexyourprocess,CHEMCADiscapableofdeliveringthe
resultsyouneedtostaycompetitiveinanincreasinglyfastandfluidglobalmarket.
Easytolearnandhighlycustomizable,CHEMCADcanputfutureproofsolutions
withineasyreachofyourengineeringstaff.
IntroductiontoCHEMCAD
CHEMCADVersion6UserGuide 3
CHEMCAD Products and Features
TheCHEMCADsuiteconsistsofseveralmodulesthatservespecificpurposes.
Dependingonyourparticularneeds,youmayhavepurchasedsomeorallofthese
modules.ThefollowingarebriefdescriptionsofthevariousCHEMCADmodules
andtheirmostcommonuses.
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.
IntroductiontoCHEMCAD
4 CHEMCADVersion6UserGuide
CHEMCAD Features by Module
Thefollowingmatrixliststhefeaturesassociatedwitheachcomponentofthe
CHEMCADsuite.Foramoredetailedexplanation,ortoinquireaboutaparticular
componentorfeature,pleasecontactChemstationsoryourCHEMCADdistributor
(seecompletecontactinformationatwww.chemstations.net/contact.htm).
C
C
-
S
T
E
A
D
Y
S
T
A
T
E
C
C
-
D
Y
N
A
M
I
C
S
C
C
-
B
A
T
C
H
C
C
-
T
H
E
R
M
C
C
-
S
A
F
E
T
Y
N
E
T
C
C
-
F
L
A
S
H
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
CO
2
solid
Hydrates
Depress
TOC/COD
Pure regression
BIP regression
Electrolyte regression
Rate regression
Units calculator
Execute parser
Environmental report
Simple calculator
Spec sheet
IntroductiontoCHEMCAD
CHEMCADVersion6UserGuide 5
UnitOps by Module
Theavailabilityofcertainunitoperations,orUnitOps,inCHEMCADsimulationsis
afunctionofwhichmodulesyouhavelicensed.Thefollowingmatrixlistsall
availableUnitOpsandtheCHEMCADmodulesassociatedwiththem.
C
C
-
S
T
E
A
D
Y
S
T
A
T
E
C
C
-
D
Y
N
A
M
I
C
S
C
C
-
B
A
T
C
H
C
C
-
T
H
E
R
M
C
C
-
S
A
F
E
T
Y
N
E
T
C
C
-
F
L
A
S
H
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
IntroductiontoCHEMCAD
6 CHEMCADVersion6UserGuide
C
C
-
S
T
E
A
D
Y
S
T
A
T
E
C
C
-
D
Y
N
A
M
I
C
S
C
C
-
B
A
T
C
H
C
C
-
T
H
E
R
M
C
C
-
S
A
F
E
T
Y
N
E
T
C
C
-
F
L
A
S
H
Loop
Mixer
Node
Phase generator*
PID controller
Pipe simulator
Polymer reactor
Pump
Ramp controller
Recorder*
Run subflowsheet META unit
SCDS distillation column
Screen
Sedimentator
Shortcut column
Solids dryer
Solids washer
Stoichiometric reactor
Stream reference
Tank
Time delay
Time switch
Tower distillation column
Tower plus distillation column
User-added module
Vacuum filter
Valve
Venturi scrubber
Vessel*
* These UnitOps will be phased out eventually.
CHEMCADVersion6UserGuide 7
Chapter 2
Getting Started with CHEMCAD
NowthatyouhaveCHEMCADinhand,youprobablywanttogetstartedright
away.Letsgetdirectlytothepoint,withstepbystepinstructionsforinstallingand
licensingtheprogram.
Installing the Software
StartbyensuringthatyourPCmeetstheminimumsystemrequirements,aslisted
below.Itsalsoagoodideatofindoutbeforeyoubeginwhetheryourcopyof
CHEMCADwillrelyonanetworklicense;ifitwill,makesuretoaskyournetwork
administratorforallthe
informationthatyoullneed
wheninstallationiscompleteand
itstimetosetuplicensing.
Onceyouveestablishedthat
yourcomputerisreadyfor
installation,insertthe
CHEMCAD6.0discintoan
availableCDmediadriveand
watchfortheCHEMCADsplash
screentoappear.
Figure 2-06: Re-programming a SuperPro dongle from the License Settings dialog box
4. WhentheBrowseforFolderdialogboxappears,navigatetothelocation
whereyousavedthe.DNGconfigurationfile.Normally,thisistheWindows
desktop;ifyousavedyourconfigurationfilethere,clickDesktoptotell
CHEMCADwheretolookforthefile,thenclickOK.
Getting Started with CHEMCAD
14 CHEMCADVersion6UserGuide
Figure 2-07: Selecting the location where the configuration file resides
5. CHEMCADreprogramsthedongleandthendisplaysasuccesspopup
window.
CHEMCADVersion6UserGuide 17
Chapter 3
The CHEMCAD Interface
WiththereleaseofVersion6.0,theCHEMCADinterfacehasundergonequitea
transformation.Forthisreason,evenlongtimeusersofCHEMCADwillbenefit
fromareviewoftheprogramsscreenlayoutandthelocationofimportantfeatures.
ThischaptertakesyouonatouroftheCHEMCADscreen,includingthemenus
andtoolbars,themainareasofthescreen,andtheflowsheetdrawingtools.Italso
showsyousomewaysthatyoucancustomizethescreenlayoutsothatitbestsuits
yourownwayofworking.
The CHEMCAD Window
WhenyoulaunchtheCHEMCADprogramforthefirsttime,youllseeascreenwith
alargewhiteareainthemiddleandvariouspanes,orspecializedareas,attheedges
ofthescreen.
Workspace
CHEMCAD
Explorer pane
Palette pane
Messages pane
TheCHEMCADInterface
18 CHEMCADVersion6UserGuide
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 X buttons
Notethatanytimeyouveclosedasimulationandhaventyetopenedanother
one,theworkspacedisplaysasablankgrayspace.
The CHEMCAD Explorer Pane
AlongtheleftedgeoftheCHEMCADwindow,youllseeanareawithatitlebarat
thetopthatreadsCHEMCADExplorer.AtthebottomoftheCHEMCADExplorer
panearethreetabscalledRecentFiles,Simulation,andVisualBasic.Toviewthe
contentsofatab,simplyclickitsname.
Figure 3-03: Clicking the plus sign to expand an item (left); the resulting view (right)
ExpandingandcollapsingitemsintheCHEMCADExplorertabsisonewaythat
youcanmakethebestuseofyourscreenspacewhenworkinginCHEMCAD.
The Recent Files Tab
TheRecentFilestabisselectedbydefaultwhenyoufirstlaunchCHEMCAD.This
tablistsallofthesimulationfilesthatyouhaveopenedlately,startingwiththemost
recent.WhenyoufirstinstallCHEMCAD,thelistisempty,butwithevery
simulationthatyouopennewfilesorexistingonessuchasbuiltinexamplesthe
listwillgrow,providingconvenientaccesstofilesthatyouusefrequently.
ToopenasimulationfromtheRecentFileslist,simplydoubleclickonthefile
nameinthelist.
The Simulation Tab
TheSimulationtabdisplaysbydefaultanytimeasimulationisopen.Itprovidesa
seriesofshortcutstocommoncommandsandsettings,including:
Components:Includesoneclickaccesstocomponent,electrolyte,andsolids
selection,aswellasdistillationcurves
Thermodynamics:Providesquickaccesstothermodynamicsettingsand
transportproperties
Flowsheet:AllowsquickeditingofUnitOpandstreamdata
DataMaps:EnablesyoutocreateorsetexecutionrulesforaDataMap
withoutusingthemenu
TheCHEMCADInterface
20 CHEMCADVersion6UserGuide
Groups:ProvidesaneasywaytocategorizeUnitOps,streams,and
components
Layers:Allowsselectedpartsoftheflowsheettobedisplayedorhiddenfor
viewingandprinting
Templates:StoresandorganizesstreamandUnitOpspecificationsthatyou
cancloneforreuse
Expandanyoftheseitemstoseeandusespecificfeatures,whicharedescribedin
furtherdetailintheappropriatechaptersofthisuserguide.
The Visual Basic Tab
IfyouuseVisualBasictocustomizeCHEMCAD,thistabprovidesquickandeasy
accesstoyourVisualBasiccode.YoucanexpandtheReactions,Properties,or
UnitOpsitemtoviewavailablesubroutinesforthatcategory.Clickingthenameofa
subroutineopensaVisualBasiceditorinaseparatewindow.
The Palette Pane
AlongtherightsideoftheCHEMCADwindowisapanetitledPalette,whichisa
repositoryforthevariousunitoperationiconsandothertoolsneededtodraw
flowsheets.
Selecting a Palette
TheseUnitOpiconsandtoolsaregroupedintopalettesaccordingtofunctionor
equipmenttype.ThedefaultpaletteiscalledAllUnitOps,anditincludesevery
availableUnitOpiconanddrawingtool.Toselectadifferentpalette,simplyclickits
titlebar.Theselectedpaletteexpandsinplace,asshowninFigure304.
Figure 3-08: The two-headed arrow cursor used for resizing panes
TheCHEMCADInterface
CHEMCADVersion6UserGuide 25
Whenyouseethetwoheadedarrow,clickanddraginthedirectionyouwantto
movethepanewall.Athickgraylineshowsapreviewofthenewpanesize;when
youreleasethemousebutton,theresizedpaneappears.
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
pane,andthenameisnotvisiblewhenthepaneisdocked.
Ifyoudragthepaneorbuttongroupintotheworkspacearea,youllseeagray
boxrepresentingthepositiontheitemwilloccupywhenyoureleasethemouse
button.Ifyoudontlikethenewposition,youcanclicktheitemstitlebaranddrag
itelsewhere,includingitsoriginalposition.
Youcanalsodockapanetoadifferentedgeofthescreen,ormovebutton
groupsaroundwithinthetoolbararea,insteadofundockingtheseitems.
Pinning and Unpinning Panes
Inadditiontomovingandresizingthevariouspanes,theresanotherwaythatyou
cancustomizeyourCHEMCADscreen:pinningandunpinningtheCHEMCAD
ExplorerandPalettepanes.
Thesetwopanescantakeupafairamountofhorizontalscreenspace,and
makingthemverynarrowisntanidealwaytowork.Pinningandunpinning
provideawaytoviewfullwidthCHEMCADExplorerandPalettepaneswhenyou
needthesetools,whilealsofreeingupspacewhenyouarentusingthem.
Whenevereitherofthesepanesisdockedatanedgeofthescreen,itisinoneof
twostates:
Pinned,meaningthatthepaneisalwaysvisible
Unpinned,meaningthatthepaneismostlyhiddenfromview,andappearsonly
ondemand
Bydefault,allCHEMCADpanesareinitiallypinnedinplace.Youcanchooseto
unpinapaneifyouprefertohavesomeextraspaceonthescreen.Tounpinapane,
TheCHEMCADInterface
26 CHEMCADVersion6UserGuide
findthetinypushpiniconinthepanestitlebar,nexttotheXiconthatenablesyou
toclosethepane.Ifthepaneisstationary,youllseethatthepinisuprightwithits
pointdown.
Figure 3-10: An unpinned pane in use; note the sideways pin icon
Torepinanunpinnedpane,pointtothetabtomakethepaneappearandthen
clickthepinicon.Thepinturnssothatitisonceagainupright,andthepaneisonce
againapermanentfixtureontheCHEMCADscreen.
Other Useful Interface Hints
ThefollowingarehelpfulitemsthatcanhelptomakeyourCHEMCADexperience
easierandmoreefficient.
Undo and Redo
AswithmostWindowsbasedprograms,CHEMCADallowsyoutobackoutof
actionsyouhavejusttakenwhileworkingwithafile.YoucanusetheUndo
commandtonegatethelastchangeyoumade;simplyselectEdit>Undo,orusethe
keycombination[CTRLZ].
YoucanusetheUndocommandtoretractuptothelast99actionsthatyou
performedsincethelasttimeyouopenedthecurrentsimulationfile.
Visible Grid
Youcanturnonaworkspacegridtouseasaguidewhilecreatingyourflowsheet.
SelectView>GridVisibletotogglethisfeatureonoroff.
TheCHEMCADInterface
CHEMCADVersion6UserGuide 27
OthergridoptionsincludeView>SnaptoGrid,whichhelpswithalignmentof
objectsontheflowsheet,andView>ChangeGridSize,whichenablesyouto
customizethehorizontalandverticalspacingofgridlines.
Adjusting Your View of the Workspace
TheView>ZoomOptionsmenuoffersawholeseriesofoptionsformovingand
resizingyourviewoftheCHEMCADworkspace.
SelectIntoviewtheworkspacefromcloserin,orOuttoviewfromfartheraway.
SelecteitherInataPointorOutataPoint,andthenclickapointonthe
workspace,tozoominoroutwiththatpointasafocus.
SelectZoomRectangle,andthenclickanddragontheworkspace,todesignatea
specificareathatyouwanttoview.
SelectZoomPercentagetochooseaspecificdisplaysizefortheworkspace.
SelectZoomtoFittoviewatthelargestsizethatstillpermitsalloftheexisting
flowsheetelementstoremaininthevisibleworkspace.
Ifyourcomputermouseisequippedwithascrollwheelbetweentheleftand
rightmousebuttons,youcanzoominandoutontheCHEMCADworkspacewitha
touchofyourfinger.Tozoomin,rollthewheelupthatis,pushyourfingertip
away,towardthetopedgeofthemouse.Tozoomout,rollthewheeldowntoward
thebottomofyourmouse,pullingyourfingertiptowardyourpalm.
Note:Whenyouzoominandoutusingthescrollwheel,thefocalpointforthezoom
isthelocationofthemousepointer.
The CHEMCAD Coach Pane
TheCHEMCADCoachpaneisnotdisplayedbydefault,butyoucanaccessitatany
timebyselectingHelp>CHEMCADCoach.ThepurposeofCHEMCADCoachisto
provideconciseinstructionsforcommonprocedures.Ifyouvelearnedhowto
performacommonprocedureinCHEMCADbuthaveforgottentheexactmenu
commandtouse,CHEMCADCoachcanhelpjogyourmemoryandputyouonthe
righttrack.
YoucandragtheCHEMCADCoachwindowtoanylocationonthescreen,
simplybyclickinganddraggingthetitlebaratthetopofthewindow.
IfyouhavefinishedusingtheCHEMCADCoachtoolandwanttocloseit,just
clicktheClosebutton(theredX)intheupperrightcorneroftheCHEMCADCoach
window.NotethatifthemainCHEMCADwindowwasmaximizedbeforeyou
openedtheCHEMCADCoachtool,youmayneedtomaximizetheCHEMCAD
windowagaintorestoreittofullscreensize.
TheCHEMCADInterface
28 CHEMCADVersion6UserGuide
CHEMCADVersion6UserGuide 29
Chapter 4
Working with Simulation Files
AlloftheworkthatyoudowithCHEMCADisstoredinsimulationfiles.Withthe
adventofCHEMCAD6,eachdiscretesimulationispackagedintoasinglefilethatis
portableandeasytohandle.AllthedetailsofthesimulationfromUnitOp
specificationstostreamcompositiontothermodynamicsareincludedinthisfile.
ThischapterdescribesthevariouswaysthatyoucanaccessandmanageCHEMCAD
simulationfiles.
About CHEMCAD Simulation Files
SimulationscreatedinCHEMCAD6usethefileextension.CC6,whichdistinguishes
themfromotherfilesonyourcomputer,includingsimulationfilescreatedusing
earlierversionsofCHEMCAD.
Oneofthemostnotabledifferencesbetween.CC6filesandpredecessorssuchas
.CCXfilesistheirportability.A.CC6simulationfileisaseasytoworkwith,
transport,andshareasanMSWorddocumentoranExcelspreadsheet.Whereas
CHEMCADsimulationsoncerequiredextrastepsbeforetheycouldbeemailedor
moved,simulationscreatedwithCHEMCAD6canbehandledasstandalonefiles.
WorkingwithSimulationFiles
30 CHEMCADVersion6UserGuide
Figure 5-01: Black triangle showing that the Divider UnitOp offers a choice of icons
ToselectanewdefaulticonforaUnitOp,clicktheblacktriangletoseeapopup
selectionboxwithallavailableicons.Clicktheiconyouwanttouse;thaticon
replacesthepreviouslydisplayedicononthepalette.Youcanchangethedefault
iconforaUnitOpasoftenasyoulike.
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.
BuildingandUsingaBasicSimulation
40 CHEMCADVersion6UserGuide
Other Drawing Tools
InadditiontotheStreamtoolandthevariousUnitOpicons,thePalettepaneoffersa
texttool,aswellastoolsfordrawingrectangles,ellipses,lines,multipartlines,and
polygons.
The Text Tool
Toplacetextonaflowsheet,selecttheTexttool(whichdisplaysalargeletterT)on
theAllUnitOpspalette.Whenyoumoveyourcursorovertheworkspace,youll
nowseethatyourpointerhasbecomeaverticalline.Clickthemousetoplacea
blinkingcursorontheflowsheet.
Starttypingthetextthatyouwanttoadd.Youwillseethetextappearwherever
youclickedthemouse.Whenyoufinish,clickanywhereintheworkspacetoturnoff
theTexttool.
Youcannowclickanddragyournewblockoftextaroundtheworkspace.You
canalsoselectFormat>ColororFormat>Fonttoaccessvariousstandardtextand
objectformattingtools.
Simple Drawing Tools: Rectangle, Ellipse, and Line
Youcandrawvariousshapesasneededonaflowsheet.Thesimplestoftheseshapes
todrawarerectangles,ellipses,andlines.
Toaddanyoftheseshapestoaflowsheet,simplyclickthecorrespondingtoolin
theAllUnitOpspalette.Then,thenclickanddragintheworkspacetodrawthe
shape,releasingthemousebuttonwhenyouhaveachievedthedesiredsizeand
shape.
Notethattomakeaperfectsquareorcircle,youcanholddownthe[SHIFT]key
asyoudrawwiththeRectangleorEllipsetool,respectively.
Complex Drawing Tools: Multi-line and Polygon
Inadditiontothesestraightforward,clickanddragshapes,youcanalsocreatemore
complexshapesandlinesonaflowsheet.
Tocreateanyopenfigurewithanirregularshape,selecttheMultilinetoolin
theAllUnitOpspalette.Moveyourcursortotheworkspaceandclickinthearea
whereyouwanttostartdrawing.Thenmovethecursorandclickagaintocreatethe
shapesfirstline.Keepclickingandmovingthemouseuntilyouvecreatedthe
shapeyouwant,andthendoubleclicktocompletetheshapeandturnofftheMulti
linetool.
Tocreateanirregularclosedpolygon,selectthePolygontoolandthenmove
yourcursortotheworkspace.Clickwhereyouwanttostartdrawing,andthenclick
asecondtimetocreatethefirstsideofyourpolygon.Afterthesecondclick,youll
begintoseetheopenareabeingcreated.Continuemovingthecursorandclicking
untilyouarereadytoplaceyourlastpoint,andthendoubleclicktocompletethe
shapeandturnoffthePolygontool.
BuildingandUsingaBasicSimulation
CHEMCADVersion6UserGuide 41
Notethatyoucanholddownthe[SHIFT]keywhileusingthePolygontoolto
createarighttriangle.
Selecting Chemical Components
Youcanselectchemicalcomponentsforyoursimulationatanypointwhilecreating
theflowsheet,oryoucanwaituntilyouvedrawntheentireflowsheetbeforeadding
components.Beforeyoucanrunthesimulation,youwillneedtolistevery
componentinvolvedinyourchemicalprocesssothatCHEMCADcanworkwith
thosecomponentsproperties.
ThesechemicalcomponentsarepulledfromCHEMCADscomponentdatabase,a
masterlistofthousandsofchemicalswiththeirassociatedproperties.Whenyoure
readytolistcomponentsforyoursimulation,selectThermophysical>Select
ComponentstoopentheSelectComponentsdialogbox.
Figure 5-05: Using the Search box to locate the Water component
TheSearchfieldacceptsbothtextandnumericentries.Bydefault,CHEMCAD
willsearchforyourentryamongallchemicalnames,chemicalformulas,
CHEMCADdatabaseIDs,andCASnumbers.Ifyouwouldprefernottosearchthis
broadly,clicktheOptionsbutton.Thisbringsupadialogboxthatenablesyouto
optoutofincludinganyoftheseitemsinyoursearches.
Figure 5-07: Adding multiple components using the right arrow button
Ifyouwouldliketoduplicatethecomponentlistfromanexistingsimulation,
clickCopyFromAnotherSimulation.IntheresultingOpendialogbox,navigateto
thedesiredsimulation,selectthatsimulation,andclickOpen.TheSelected
Componentslistisnowpopulatedwiththecomponentsusedinthesimulationyou
selected;youcanaddordeleteitemstocustomizethelist.
Changing the Order of Selected Components
WhenyourSelectedComponentslistforasimulationisparticularlylong,youmay
findithelpfultoplacecertaincomponentsateitherthetoporthebottomofthelist.
Youcanaddcomponentsinanyorder,andthenmovethemaroundinthelistas
needed.
TomoveacomponenttoanewpositionintheSelectedComponentslist,click
thecomponenttoselectitandthen:
ClickToptomoveittothefirstpositiononthelist.
ClickUptomoveituponeposition.
ClickDowntomoveitdownoneposition.
ClickBottomtomoveittothelastpositiononthelist.
Removing Items from the Selected Components List
ToremoveasinglecomponentfromtheSelectedComponentslist,clickthe
componenttoselectitandthenclickDeleteinthebottomrightareaoftheSelect
Componentsdialogbox.
ToremoveallcomponentsfromtheSelectedComponentslistandbeginagain,
clickClear,justtotherightofDelete.Ifyouhavechangedyourmindaboutadding
componentsatthistime,youcansimplyclickCanceltobackoutofcomponent
selection.
BuildingandUsingaBasicSimulation
44 CHEMCADVersion6UserGuide
Selecting K-value and Enthalpy Options
ThefirsttimeyoucompletetheComponentSelectiondialogbox,youllbetakento
theThermodynamicsWizarddialogbox.Atthispoint,youcaneitherclickCancelto
skipthewizardandenterthermodynamicsmanually,orenterparametersinthe
dialogboxandclickOKtoseewhichmethodsthewizardsuggests.
Using the Thermodynamics Wizard
Properselectionofthermodynamicsisgenerallythemostimportantstepina
processsimulation.Apoorthermodynamicsselectionmayleadtounrealistic
simulationresults.
TheThermodynamicsWizardmakesgeneralsuggestions,basedonyour
componentlistandthespecifiedrangesfortemperatureandpressure.
Selecting Components to Ignore
Intheupperportionofthewizardscreen,usethedropdownboxestoindicateany
componentsthattheThermodynamicsWizardshouldnotconsider.Thismayaffect
theresultsformodelsuggestion.Forexample,ifyouareusingwaterasacoolant
andyourothercomponentsarealkanes,theThermodynamicsWizardwillchoose
UNIFAC.Ifyouspecifythatwatershouldbeignored,thewizardwillignorethe
waterandselectSRK.
Specifying Process Conditions
Inthelowerportionofthewizardscreen,specifytheapproximatetemperatureand
pressurerangesforthisprocess.Enteringaccurateinformationinthesefieldswill
helptheThermodynamicsWizardreturnamoreusefulrecommendation.
IntheBIPDataThresholdfield,entertheminimumpercentageofpossible
binaryinteractionparameters(BIPs)whichmustbepresentinaBIPactivity
coefficientmodel(NRTL,Wilson,etc).WithoutBIPs,activitycoefficientmodels
simplifytoRaoultslaw.
How the Thermodynamics Wizard Makes Suggestions
CHEMCADsThermodynamicsWizardfollowsalogictreetochooseamodel.The
logictreeassumesthatallyourcomponentsaremixedinavessel,withconditions
fallingintothespecifiedtemperatureandpressureranges.
Ifallcomponentsarehydrocarbons,thewizardwilllikelysuggestan
equationofstate.
Ifwaterispresent,thewizardwilllikelyselectanactivitycoefficientmethod.
Ifwaterandhydrocarbonsarepresent,thewizardwilllikelyselectUNIFAC.
Ifwaterandstrongelectrolytes(HCl,NaOH,etc.)aredetected,thewizard
willsuggestelectrolytemodels.
BuildingandUsingaBasicSimulation
CHEMCADVersion6UserGuide 45
Temperatureandpressurerangewillaffecttheselectionofmodel.Ifpressureis
high,CHEMCADismorelikelytosuggestanequationofstate.Ifpressureis
atmosphericandtemperatureisbelowthenormalboilingpointofallcomponents,
CHEMCADmaychoosealiquidactivitymodeloridealvaporpressure.
Should the Thermodynamics Wizard be trusted to make design decisions?
Usethewizardasastartingpointforyourdecision.Properselectionof
thermodynamicsistheengineersresponsibility.Yoursimulationmaycallforthe
useofadifferentthermodynamicmodelthanwhattheThermodynamicsWizard
suggests.
Manually Selecting Thermodynamics Settings
Tosetupthermodynamicsforyoursimulationmanually,followthesesteps:
1. SelectThermophysical>ThermodynamicSettings,orclickthebuttonbythe
samenameonthetoolbar.
Figure 5-09: Two different UnitOps that require very different amounts of input
BuildingandUsingaBasicSimulation
48 CHEMCADVersion6UserGuide
ThedetailedinformationaboutthespecificationsforeachtypeofUnitOpis
containedintheCHEMCADHelpsystem,whichyoucanaccessfromany
CHEMCADscreenbypressingthe[F1]key.
Thesespecificationscreensdo,however,havecertainrulesincommon:
Itemswithgreentextlabelsarerequiredentries.
Allotherentriesareoptional.
ClickingOKsavesyourspecificationchanges;clickingCanceldiscardsthem.
AfteryouclickOK,CHEMCADchecksyourdataforinternalconsistencyand
thenreturnserrorsorwarningsaswarranted.TheseitemsdisplayintheMessages
paneintheCHEMCADwindow.
Running the Simulation
NowthatyouvedrawntheflowsheetandaddeddetailtothestreamsandUnitOps
thatmakeuptheflowsheet,youcanrunthesimulation.YoucaneitherselectRun>
Run>RunAllorsimplyclicktheRunbuttononthetoolbar.
Whenyourunasimulation,CHEMCADcalculatesmaterialandenergybalances
throughouttheentireflowsheetandreturnsanyerrorsorwarningsdiscoveredin
theflowsheet.Iftheruncompletessuccessfully,aRunfinishedmessageappearsat
thefarleftofthestatusbar,attheverybottomoftheCHEMCADwindow.
Note:ForpreliminarychecksofindividualUnitOpsorgroupsofUnitOps,youcan
selectRun>Run>RunSelectedUnitOp(s).
Reviewing the Results
Afterasimulationhasrun,youcancallupanynumberofindividualtextbased
reportsorgraphicalplots,eitherforonscreenviewingorforprinting.Reportscan
providedataonanysinglestreamorUnitOp,oranygroupofstreamsorUnitOps,in
asteadystateordynamicsimulation.Youcanalsorequestaconsolidatedreportthat
providescomprehensivedataonthestreamsandUnitOpsyouselect.
Note:CHEMCADreports,plotting,andplotprintingarecoveredindetailin
Chapter8,OutputandReports.
CHEMCADVersion6UserGuide 49
Chapter 6
Using CHEMCAD for High-fidelity Modeling
UnitoperationspecificationsinCHEMCADvarygreatlyindetail,fromvagueand
conceptualtoextremelyspecificandrealistic.Dependingonthedemandsofyour
processandwhatyouretryingtoachievewithyoursimulation,youmayworkwith
whatwecalllowfidelitymodeling,highfidelitymodeling,orboth.
ThischapteraddressesCHEMCADscapacityforhighfidelitymodelingand
howtoachieveahighlevelofrealismwithyourUnitOps.
What is high-fidelity modeling?
Withlowfidelitymodeling,youspecifywhatyouwant,orwhatyouhaveobserved,
andCHEMCADmakesitscalculationsbasedontheassumptionthatyoucan
achievewhatyouvespecified.Itscommontospecifyobservedpropertiessuchas
temperatureand/orpressurecomingoutofaUnitOp,orcomponentpuritycoming
outofaseparationunit.Specifyingtemperaturecomingoutofaheatexchangerisan
exampleoflowfidelitymodeling.
Highfidelitymodeling,ontheotherhand,requiresthatyouenternumerous
extensivevariables.CHEMCADcalculatestheresultingconditionsbasedonthese
detailedentries.Withhighfidelitymodeling,youreoftenrequiredtospecify
geometryrelatedvariablesforaUnitOpsothatCHEMCADcancalculateprecise
conditionsattheequipmentsoutlet.
Heresthekeydistinctionbetweenlowfidelityandhighfidelitymodelingin
CHEMCAD:
Lowfidelity:YouspecifythedesiredresultsandCHEMCADassumesthatyou
canachievethoseresultswiththeequipmentyouhave.
UsingCHEMCADforHighfidelityModeling
50 CHEMCADVersion6UserGuide
Highfidelity:YouspecifyenergyandequipmentparametersandCHEMCAD
calculatestheactualresults.
Criteria for High-fidelity Modeling
TotakeadvantageofCHEMCADshighfidelitymodelingcapabilities,youmust
providedetailedspecificationsforyourequipment.Todothis,mostUnitOpsrequire
thatyouselectacalculationmodethatallowsforentryofhighfidelitycaliberdetail.
Forexample,ifyouhaveapumpthatissettothedefaultmodeofSpecifyoutlet
pressure,youllgetalowfidelityresultfromthispumpthatis,thesimulationwill
usetheoutletpressurethatyouspecify,butwithoutconsiderationforthesizeofthe
pump,theamountoffluidenteringthepump,orinletpressure.
IfyouswitchthepumptoSpecifyperformancecurve,ahighfidelitymode,youll
needtoenterdatapointsfromthepumpsperformancecurve,eitherforasingle
speedlineorformultiplespeedlines.Usingthismode,CHEMCADwillcalculate
thechangeofpressureheadbasedontheperformancedataandtheinletvolumetric
flowrate.Thisprovidesarealisticpressureincreasefortheactualpumpthatyour
processuses.
NoteverytypeofCHEMCADUnitOplendsitselftohighfidelitymodeling.The
followingsectionsdiscussvarioustypesofUnitOpsthatdoofferhighfidelity
calculationmodes,andprovidesomebasicinformationabouthowtousethose
modes.
Introduction to Equipment Sizing
EquipmentsizinginCHEMCADisoptional.ItentailsusingtheSizingmenu
options,generallyafterrunningasimulation,tocalculateapproximatesizesfor
pipes,vessels,valves,orifices,andotherequipment.
Figure 6-01: The Sizing menu, showing heat exchanger sizing options
Equipmentsizingcancomplementlowfidelityresults,andoftenprovidesan
excellentstartingpointforhighfidelitymodeling.Youcanusecertainsizingresults
asinputforhighfidelitymodelsofUnitOpsinyoursimulation.Specifying
geometricparametersforUnitOpscanhelpyouobtainmorerealisticresults.
Notethatforlowfidelitymodeling,sizingdoesnotchangeconvergedflowsheet
results.Also,forsomeUnitOps,certaingeometryparametersmustbeentered
regardlessoftheselectedcalculationmode.
UsingCHEMCADforHighfidelityModeling
CHEMCADVersion6UserGuide 51
High-fidelity Modeling and Sizing for Common UnitOps
HighfidelitymodelingdoesnotapplytoallCHEMCADUnitOps.Thissection
summarizesthoseUnitOpsforwhichyoucanusehighfidelitymodeling,and
comparesthatapproachforeachUnitOptypetolowfidelitymodeling.Where
applicable,UnitOpsizingisalsodiscussedasitrelatestolowfidelityversushigh
fidelitymodelingoftheseUnitOptypes.
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
UsingCHEMCADforHighfidelityModeling
52 CHEMCADVersion6UserGuide
equipment.NodesmustbeplacedonbothsidesofallPipeUnitOpstobeincluded
inhydraulicbalance;pressureandflowconstraintsaresetatthenodes,notinthe
pipes.
Ahighfidelitypipingmodelcanshowchangesinflowratebasedonback
pressurewheretwopipesmix,whereasalowfidelitymodelwouldsimplyassign
theloweroftwospecifiedpressurestotheoutletwithoutconsiderationforback
pressure.
Pumps, Compressors, and Expanders
Youcancreatepump,compressor,andexpanderUnitOpsusingeitherlowfidelity
orhighfidelitymodeling.
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.
Vessels and Tanks
Youcanaddvesselsandtankstoyoursimulationsusinghighfidelitymodeling,or
performlimitedapproximationoftheseequipmenttypeswithlowfidelityinsteady
state.Sizingisavailableforcertaintypesofvessels.
Low-fidelity
Withlowfidelitymodelingofavesselortank,astreamenterstheFlashUnitOpand
separatesintovaporandliquid;CHEMCADdoesnotconsiderholduporliquid
levelinthetank.Ifyouwanttotakeasteadystatesnapshotofthevessel,youcan
manuallyadjusttheflowrateand/orthermalconditionstomakevolumetricflow
ratesmatchthevolumeofthevessel.
Note:TheTankUnitOpisspecificallyintendedforusewiththeBatchColumn
UnitOp.Itdoesnotrepresentastandardstoragetankforgeneralpurposes.
UsingCHEMCADforHighfidelityModeling
CHEMCADVersion6UserGuide 53
Sizing
Tocalculatesizingforavessel,selectaFlashUnitOpandthenselectSizing>Vessel.
ChooseeitherLVVessel(liquidvaporvessel)orLLVVessel(liquidliquidvapor
vessel),dependingonyourneeds.Intheresultingdialogboxes,enterthe
appropriatevaluesforyourvesselandclickOK.
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
UsingCHEMCADforHighfidelityModeling
CHEMCADVersion6UserGuide 55
generallyneedtoentersomegeometryandhydraulicparameterstocomplete
columnsizing.
Figure 6-04: Specifying high-level tray data for distillation column sizing
Figure 6-07: Selecting the rigorous integral analysis method for relief device design
UsingCHEMCADforHighfidelityModeling
58 CHEMCADVersion6UserGuide
High-fidelity
YoucanperformhighfidelityreliefdevicemodelingfortheBatchReactorand
DynamicVesselUnitOps.Youcanspecifythereliefdevicenozzlearea,aswellas
otherspecificationsforyourreliefscenario.Thisenablesyoutostudythedynamic
reliefofthevessel.
Licensing Considerations for High-fidelity Modeling
Tousetheheatexchangersizingfunctionality,youmustcurrentlyhaveavalid
licensefortheCCTHERMmoduleofCHEMCAD.Tousebatchreactors,youllneed
avalidlicensefortheCCDYNAMICSmodule.Fordynamicvessels,alicensefor
eitherCCDYNAMICSorCCSAFETYNETisrequired.
Ifyoudontcurrentlyhaveaccesstotheheatexchangersizingordynamics
featuresandwanttoaddanyofthesemodulestoyourcopyofCHEMCAD,contact
thepersonwithinyourorganizationwhohandlessoftwarelicensing,orif
appropriate,youcancontactChemstationsoraCHEMCADdistributordirectly.For
acompletelistofChemstationscontactsforallpartsoftheglobe,seeourwebsite
(www.chemstations.net/contact.htm).
License Settings
IfyouvejustaddedmodulestoyourCHEMCADlicense,youshouldreturntothe
LicenseSettingsscreentochangesettingsbeforeproceeding.
SelectTools>Options>LicenseSettings(ifasimulationisopen)orLicense>
LicenseSettings(ifnosimulationisopen)tobringuptheLicenseSettingsscreen.
MovethesliderforeachnewlyinstalledmoduletoAsNeededandthenclickOKto
applyyourchanges.
YoumayseeaTraceMessageswindow;ifoneappears,clickOKtocloseit.The
nextscreenthatappearsistheLicensesinUsescreen,whereyoucanreviewthelist
ofCHEMCADproductsforwhichyoucurrentlyhavelicenses.ClickOKtoclosethis
screenandreturntothemainCHEMCADwindow.
CHEMCADVersion6UserGuide 59
Chapter 7
Building and Using a Dynamic Simulation
Whilesteadystatemodelingcanprovidealloftheinformationyouneedformany
purposes,itsofteninformativetolookcloselyatthechangesovertimethataffect
yourstreamsandequipment.CHEMCADsCCDYNAMICSmodulemakesit
possibletosimulateaprocessovertime.
What do we mean by dynamics?
Weusethetermdynamicstodescribemodelingachemicalprocessoverasetperiod
oftime.Duringthecourseofarealworldchemicalprocess,factorssuchasutility
temperature,feedcomposition,andliquidlevelstendtochange.Modelingthe
responseofyourprocesstothesechangescanhelpyouunderstandandpredictwhat
mighthappenwithyourprocessovertime.
Givenaflowsheet,alengthoftimetorun,andthecalculationintervaltouse,
CHEMCADcanreturndetailedresultsthattakeintoaccountthesetypesofchanges.
Theprogramcanconsiderthematerialholdupwithinprocessequipmentsuchas
tanks,reactors,andpipes.ItalsoenablesyoutomodelcontrolsystemssuchasPID
controllers.
Licensing Considerations
Tousethefunctionalitydescribedinthischapter,youmusthaveavalidlicensefor
theCCDYNAMICSmoduleofCHEMCAD.
IfyoudontcurrentlyhaveaccesstothedynamicsfeaturesandwanttoaddCC
DYNAMICStoyourcopyofCHEMCAD,contactthepersonwithinyour
organizationwhohandlessoftwarelicensing,orifappropriate,youcancontact
ChemstationsoraCHEMCADdistributordirectly.Foracompletelistof
BuildingandUsingaDynamicSimulation
60 CHEMCADVersion6UserGuide
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.
Additional Input for Dynamic Operation
Beforeyoucreateadynamicsimulation,youllneedtogathertherelevant
informationaboutyourUnitOpsandstreams,asyouwouldwithanysimulation.In
addition,youneedtobeabletoanswerthefollowingdynamicsspecificquestions:
Howlongwillthesimulationrun?
Whatwillbetheinterval(deltatime/stepsize)betweencalculations?
Whatisthechangethatyouwanttostudyovertime?
Ifapplicable,whatistheinitialcompositionandchargeofanydynamic
vesselsorbatchreactors?
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).
BuildingandUsingaDynamicSimulation
CHEMCADVersion6UserGuide 61
11. Runthesimulationindynamics.
12. Reviewtheresults.
13. Rerunorextendthesimulationasneeded.
14. Generateplotsandreportsasneeded.
Beforeyoustartworkingonadynamicsimulation,itsimportanttohaveas
muchinformationaboutyourprocessaspossible,aclearideaofwhatyouwantto
findout,andastrategyforproducingtheresultsyouneed.
Strategies for Dynamic Simulations
Whenyoustartplanningadynamicsimulation,itsvitalthatyouknowwhat
questionorquestionsyouaretryingtoanswer.Togetuseful,informativeresults,
youshouldstartwithasimplequestionandthenrefinethesimulationandrunit
again.
Forexample,todiscoverhowheataffectsavesselstemperatureovertime,you
mightstartbyapplyingconstantheattothevesselforthedurationofyourdynamic
simulation.Youcanthensaveacopyofthatsimulation,changeittousevariable
heat,andreviewtheresultstoseehowtheydifferfromtheoriginal.Basedonthat
secondsimulation,youcanmakeanothercopy,andthistimetryvariableheatwitha
controlsystemtoattempttomaintainaconsistenttemperature.Eachofthese
dynamicsimulationswouldbringyouclosertowhatyouactuallywanttodiscover.
Eachsubsequentsimulationrequiresmoreinformationfromyoutorunandreturn
theresultsyouwant.
Whilethereisnorequirementthatyouapproachdynamicsproblemsthisway,
itsasoundpracticethatwillsaveyoutimeandfrustrationinthelongrun.
Setting Up Dynamic Operation
Beforeyoucanrunadynamicsimulation,youneedtoprovideparameterssuchas
runtimeandstepsize.First,however,youmustactivateCHEMCADsdynamics
mode.
Switching to Dynamics
Followthesestepstoswitchasimulationfromsteadystatetodynamicoperation:
1. OpenthesimulationandselectRun>Convergence.Thisbringsupthe
ConvergenceParametersdialogbox.
2. Inthelowerrightportionofthedialogbox,clickintheSteady
State/DynamicsfieldandselectDynamics.
BuildingandUsingaDynamicSimulation
62 CHEMCADVersion6UserGuide
Figure 7-04: The General tab on the Dynamic Run Time Schedule dialog box
2. OntheGeneraltab,setthenumberofoperationstepsyouplantouse,or
leavethedefaultsettingof1.Themaximumnumberofstepsthatyoucan
specifyis10.
Note:Whenyouinitiallysetupdynamicsforasimulation,theCurrenttimedisplay
fieldonthistabwillbeempty.Afterthesimulationhasrun,thisfielddisplaysthe
totaltimeofacompletedrunorthecurrenttimeofaninterruptedrun.
3. NowclicktheStep1tabandspecifytheparametersforthisportionofthe
dynamicrun.EnterthetotaltimeforthisdynamicstepintheRuntimefield,
andtheintervalinminutesintheStepsizefield.
Figure 7-05: The Step 1 tab on the Dynamic Run Time Schedule dialog box
4. Ifyouhaveotherstepstospecify,clickeachtabinturnandentertheRun
timeandStepsizeinformation.
5. Whenyouhavespecifiedallsteps,clickOKtoreturntothemain
CHEMCADwindow.
BuildingandUsingaDynamicSimulation
CHEMCADVersion6UserGuide 65
TheDynamicRunTimeScheduledialogboxalsoallowsforconditionsother
thantimetodeterminethedurationofadynamicoperationstep.Ifyouselect
StreamorEquipmentinsteadofthedefaultTimeoption,youcanspecifyastream
orUnitOpparameterthatwilltriggertheendofthisstep,ifthatparameteris
reachedbeforethestepsruntimeisup.
Selecting Streams and UnitOps
Nowthatyouhavespecifiedhowlongyourdynamicprocesswillrun,youneedto
tellCHEMCADwhatstreamandUnitOpdatatorecordduringtherun.
1. IftheDynamicsMenuisnotalreadyopen,selectRun>Dynamicstoopenit,
thenclicktheRecordStreamsbutton.
2. IntheRecordStreamsdialogbox,dooneofthefollowing:
ChecktheSelectstreamsfromflowsheetbox,clickOK,andthenusethe
mousetoaddstreamstotheSelectStreamsdialogbox.
TypethenamesofstreamsyouwanttorecordintheIDboxes.
Figure 8-10: Visible and hidden layers as they appear in CHEMCAD Explorer
Assigning Objects to a Layer
Nowthatyouhavelayers,youcanassignitemstothem.Startbyclickinganobject
tohighlightit;thismightbeanythingfromastreamIDlabeltoaUnitOptoaTP
box.Whatevertypeofobjectitis,whenyouhighlightityoullseethefourblack
boxesthatdefineitsouteredges.Withtheobjectselected,rightclickthenameofthe
desiredlayerintheCHEMCADExplorerandchooseAddSelected.
Tosavetime,youcanaddmultipleobjectstoalayeratonce.Justholddownthe
[SHIFT]keyasyouclickeachobjectinturn,thenrightclickthelayernameand
chooseAddSelected.
Note:Ifyoulike,youcanassignoneormoreobjectstoalayeratthesametimeyou
createthelayer.Todothis,simplyclickthedesiredobject(usethe[SHIFT]click
methodformultipleobjects),thenrightclickLayers,selectNew,andassignthe
layeraname.Theselectedobjectsareautomaticallyassignedtothenewlayer.
OutputandReports
88 CHEMCADVersion6UserGuide
Hiding and Viewing Layers
Assoonasyouveaddedatleastoneobjecttoalayer,youcantestthelayerby
hidingitandwatchingwhathappens.Tohidealayer,simplyclickthegreencheck
markediconnexttothatlayersname;theiconshouldchangetograyandallitems
assignedtothelayershoulddisappearfromview.
Atanytime,youcanhideorvieweachlayerinyoursimulationindependently.
TheiconsnexttothelayernamesintheCHEMCADExplorerprovideaconstant
reminderofwhichlayers,ifany,arecurrentlyhiddenfromview.
Eachtimeyouopenasimulationfile,CHEMCADdisplaysorhidesitslayers
accordingtothewaytheyweresetthelasttimeyousavedthesimulation.
Note:Itispossibleforanobjecttobeassignedtomorethanonelayer.Ifanobjectis
assignedtotwoormorelayers,however,itwillbedisplayedunlessallofits
associatedlayersarehidden.
Removing an Object from a Layer
Ifyounolongerwantaspecificobjectorgroupofobjectstobeassignedtoagiven
layer,youcanremovetheassignmentaseasilyasyoucreatedit.
Firstensurethatthelayerinquestionisvisible.Thenselectalltheobjectsthat
youwanttoremovefromthelayer,rightclickthelayernameinCHEMCAD
Explorer,andchooseRemoveSelected.Nowwhenyouhidethelayer,theobjector
objectsyouremovedshouldremaininview.
Deleting an Entire Layer
Ifforanyreasonyouwanttoremovealayerfromyourlist,simplyrightclickthe
layersnameinCHEMCADExplorerandselectDelete.Thelayerdisappearsfrom
thelist,andifthelayerwashiddenwhenyoudeletedit,theitemsassignedtoitnow
reappear.
Printing a Process Flow Diagram
WhenyouusethePrintcommandonthemainCHEMCADscreen,theresultisa
verbatimreproductionofyourvisibleworkspace.
Ifyourezoomedcloseintooneportionofyourflowsheetwhenyouprint,youll
getacloseupprintoutthatdoesnotincludetherestoftheflowsheet.Ifyouve
hiddenallofyourdataboxestokeepthemoutofyourwaywhileyoufixaproblem,
thosedataboxeswillnotappearontheprintout.IfthePalettepaneiscoveringupthe
productstreamscomingfromoneofyourUnitOps,thoseproductstreamswontbe
ontheprintouteither.
Forthisreason,thefirstthingyoushoulddowhenyourereadytoprinta
processflowdiagramistodecidewhatneedstobeincludedontheprintout.Ifyou
needtheentireflowsheettoappearontheprinteddiagram,selectView>Zoom
Options>ZoomtoFit,orzoommanuallyifyouprefer.Youmaywanttohideor
OutputandReports
CHEMCADVersion6UserGuide 89
unpinoneormorepanesaswell,togiveyourselfmoreworkspacewhileyou
preparetoprint.
Next,considerwhetheryourprocessflowdiagramshoulddisplayajobbox,
UnitOporstreamdataboxes,textnotes,orotheritemsinadditiontotheflowsheet
itself.Ifyouhavealreadycreatedtheneededitems,makesurethattheyare
currentlyvisibleandplacedwhereyouwantthem.
Whenalloftheitemsyouwanttoprintarevisible,checkoncemoretoensure
thateverythingfallswithintheCHEMCADworkspace.ThenselectFile>Print,or
clickthePrintbuttononthetoolbar.ThisbringsupthePrintSetupdialogbox,
whereyoucanselectprintingoptionsorsimplyclickOKtoprinttheprocessflow
diagram.
OutputandReports
90 CHEMCADVersion6UserGuide
CHEMCADVersion6UserGuide 91
Chapter 9
Customizing CHEMCAD
AsyoubecomemorefamiliarwiththewaythatCHEMCADworksandthevarious
optionsandtoolsthatareavailable,youmayfindyourselfwishingthatyoucould
makeyourownadditionseitherforspecializeditemsorforthoseyouuse
frequently.YoucaninfactcustomizeCHEMCADinseveralwaysthatsaveyoutime
bystreamliningandsimplifyingyourworkflow.Theseinclude:
CreatingstreamandUnitOptemplates
AddingcustomcomponentstoCHEMCADscomponentdatabase
MakingyourownsymbolsandaddingthemtotheUnitOpspalette
BuildingcustomUnitOps
CreatingcustomdialogboxesforUnitOpsettings
Definingcustomthermophysicalrules
Thischapterdiscussesallofthesetypesofcustomization,startingwiththe
simplestproceduresandthenmovingontomorecomplexcustomizationsthat
requiresomeprogrammingexperience.
Flowsheet Templates
OneofthemosteffectivewaystosavetimewhencreatingCHEMCADsimulations
istomakeuseofstreamandUnitOptemplates.Atemplateissimplyasetof
characteristics,whichyouassignanameandsaveforlateruse.Whenyousetup
streamorUnitOpspecificationsthatyouknowyoullneedtorecreateinthefuture,
youcancreateatemplateofthatstreamorUnitOp.Youcanthenduplicatethatitem
withinthesamesimulationorinanyothersimulationwithjustafewmouse
clicks.
CustomizingCHEMCAD
92 CHEMCADVersion6UserGuide
Creating a Template
Tocreateastreamtemplate,firstcreatethestreamyouwanttocloneandgiveitall
ofthecharacteristicsyouwanttoincludeinthetemplate.
ThenfindthisstreamontheCHEMCADExplorersSimulationtab.Expandthe
Flowsheetitem,thenexpandtheStreamitem,andfinallydoubleclickthe
applicablestreamID.ThisbringsupanitemcalledSave.Doubleclicktheword
SavetobringuptheEnterTemplateNamedialogbox,thentypeanameforyour
newstreamtemplateandclickOK.Thenewstreamnameisnowlistedbeneaththe
Saveitem.
TocreateaUnitOptemplate,selecttheappropriateUnitOpIDinCHEMCAD
Explorer,andthenfollowthesameprocedureusedtocreateastreamtemplate.
Viewing a Templates Properties
Toseewhatspecificationsanexistingtemplateincludes,lookitupinthe
CHEMCADExplorer.ExpandtheTemplatesitem,thenexpandtheUnitOpsitem,
andfinallyexpandthenameoftherelevantUnitOptype.Forexample,ifyoure
lookingupatemplatethatyoucreatedforatypeofpumpthatyoufrequentlyuse,
expandthePumpitemintheCHEMCADExplorer.
Whenyoufindyourtemplate,simplyclickthetemplatenametoopenits
specificationsdialogbox.
Applying a Template
Toapplyastreamtemplate,firstexpandtheCHEMCADExploreritemforthe
streaminquestion,eitherbyclickingtheplussigntoitsleftorbydoubleclickingthe
streamname.
Whenthestreamitemisexpanded,youllseetheSaveitembelowit,followedby
thenamesofallthestreamtemplatesthatyouhavecreated.Doubleclickthename
ofthetemplateyouwanttouse,thenclickOKtoconfirmthatyouwanttoapply
thisstreamtemplate.
Renaming or Deleting a Template
Torenameatemplate,simplyfinditunderTemplatesinCHEMCADExplorer,
rightclickthetemplatename,andselectRename.TypethenewnameandclickOK.
ThischangesthetemplatenamethroughoutCHEMCADExplorer.
Theprocedurefordeletingatemplateissimilartorenamingatemplate.Again,
findthetemplateyouwantunderTemplates,rightclickitsname,andselectDelete.
ClickOKtoconfirmthatyouwanttodeletethistemplate.Thetemplatename
disappearsfromCHEMCADExplorer,butstreamsorUnitOpsthatwerespecified
usingthetemplatearenotaffectedinanyway.
CustomizingCHEMCAD
CHEMCADVersion6UserGuide 93
Note:AnystreamorUnitOptemplatethatyoucreateisavailableforusewithall
othersimulationsonthesameinstallationofCHEMCAD,untilandunlessyou
deletethetemplate.
Creating Custom Components
TheCHEMCADcomponentdatabaseplacesdetailedinformationaboutthousands
ofchemicalsatyourfingertips.Ifforanyreasonyoufindthatyouneedtousea
chemicalcomponentthatdoesnotmatchanyitemcurrentlyintheCHEMCAD
database,youcancreateyourowncomponentforusewithyoursimulations.
Youcancreateasinglecomponent,definearangeofpseudocomponents,or
importacomponentsphysicalpropertiesfromanexternalsource.Theseprocedures
havesimilaraims,butdiffersignificantlyfromoneanother.
Adding a Single Component
CreatingapurecomponentintheCHEMCADcomponentdatabaseisatwopart
task.Youmustfirstcreatethecomponentandthenregressdataintothecomponent.
Creating the Component
Tocreateanewcustomcomponent,youcanuseanyoffivedifferentestimation
methods:
Createahydrocarbonpseudocomponent.Thisistreatedlikeapure
componentinthatcertainaspectsofhowitbehavesorreactsareknown.
UsetheJoback/Lydersonmethod.Withthismethodyouindicatebasic
characteristics,andselectmoleculargroups(knownasJobackgroups,called
GroupAssignmentsinCHEMCAD)fromalist,toindicatehowmanyofeach
moleculargrouparepresentinthecomponent.
UsetheUNIFACmethod.ThismethodisidenticaltoJoback/Lyderson,
exceptthatthegrouplistismorespecializedtowardorganiccomponents.
Createacombustionsolid.Thismethodisusedtosimulatesolid
componentsforwhichanelementalanalysisandheatingvalueareknown,
e.g.,coal.
Createanelectrolytecomponent.Thismethodcreatesacomponentthatyou
cansubsequentlyuseinanelectrolytesimulation.
Theprocedureforcreatingapurecomponentisasfollows:
1. SelectThermophysical>ComponentDatabase>CreateNewComponent.
ThisbringsuptheNewComponentdialogbox.
CustomizingCHEMCAD
94 CHEMCADVersion6UserGuide
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.
CustomizingCHEMCAD
100 CHEMCADVersion6UserGuide
Figure 9-10: Selecting a VBA-defined reaction in the Kinetic Data dialog box
CustomizingCHEMCAD
106 CHEMCADVersion6UserGuide
4. Whenyouhavedefinedthelastreaction,clickOKtoreturntothemain
CHEMCADwindow.
Using a VBA-defined Mixing Rule
Onceyouhavedefinedanewmixingrule,youcanincludeitinyourCHEMCAD
simulations:
1. SelectThermophysical>ThermodynamicSettings.
2. IntheThermodynamicSettingsdialogbox,dropdownthelistofoptionsfor
themixingrulethatyouusedasatemplateforyournewrule.Selectyour
rulefromthelist.
3. ClickOKtoreturntothemainCHEMCADwindow.
Using a VBA-defined UnitOp
OnceyouhavedefinedanewVBAUnitOp,youcanincludeitinyourCHEMCAD
simulations:
1. SelecttheVisualBasicUnitOptoolandplaceaniconontheflowsheet.Add
streamsintoandoutoftheUnitOpasyounormallywould.
2. DoubleclicktheicontodefinetheUnitOpsspecifications.
3. IntheVisualBasicUnitOpdialogbox,dropdowntheFunctionlisttoseethe
availableVBAUnitOps.SelecttheoneyouwanttouseandclickOK.
CHEMCADVersion6UserGuide 107
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
Excel Data Mapping
TheExcelDataMappingfeatureallowsyoutolink,retrieve,andinsertdatafroman
ExcelspreadsheetintoaCHEMCADsimulation.Italsoletsyouinsertdatafroma
CHEMCADsimulationintoanExcelspreadsheetwithjustafewclicks.The
integrationofCHEMCADandExcelisapowerfulandeasytousetoolthatsaves
youtimeandwork.
DataInterfaces
108 CHEMCADVersion6UserGuide
WithExcelDataMapping,youcanquicklyandeasilygetthemostof
CHEMCAD/Excelintegration,evenifyouhavenoexperiencewithVisualBasicor
Excelprogramming.Infact,youcanuseandbenefitfromthisfeatureevenwithvery
littleknowledgeoftheExcelprogram.
TouseExcelDataMapping,youmustfirstcreateoneormoreDataMaps,and
thensetuprulesfortheexecutionofeachDataMapinuse.
Creating an Excel Data Map
ThetoolusedtocreateandeditDataMapsinCHEMCADistheExcelDataMap
Editor.ThistooldisplayswithintheCHEMCADworkspace,andresemblesanExcel
spreadsheet.IthasallyouneedtolinkstreamandUnitOpparameterstooneor
moreExcelspreadsheets.OneachExcelDataMap,youcanlinkupto500
parametersinasinglespreadsheet,andyoucanhaveuptotenDataMapsper
simulation.
TolinkyoursimulationtoanExcelspreadsheet,firstcreatethetargetExcel
workbook,makinganoteofthefilesname,itslocation,andthenameofthespecific
worksheettowhichyouwanttolink.Thenfollowthesestepstocreateanewdata
map:
1. OntheCHEMCADExplorer,expandtheDataMapsitemandthenclick
NewDataMap.AspreadsheetwillopenwithintheCHEMCADworkspace.
Figure 10-02: Selecting a Map Rule option in the Excel Data Map Editor
5. ClickthecellbelowCCObjTypetohighlightthatcell.Clickagaintoseea
dropdownlistofmappingoptions:
StreamenablesyoutolinkanExcelcellorcellrangetoastreamonthe
flowsheet.
UnitOpenablesyoutolinkanExcelcellorcellrangetoaUnitOponthe
flowsheet.
Miscenablesyoutochangedynamicflowsheetsettings.
6. ClickthecellbelowCCObjID.TypetheIDnumberofthestreamorUnitOp
towhichyouwanttolink.
7. ClickthecellbelowParIDtohighlightthatcell.Clickagaintoseeadrop
downlistofparametersfortheselectedUnitOporstream.Scrolldownand
selectanoptionfromthelist.
Note:WhenyouareimportingcelldataintoCHEMCAD,thelistofparameter
optionsislimited,asmanyvaluesinaCHEMCADsimulationarecalculatedbased
onothervalues.
DataInterfaces
110 CHEMCADVersion6UserGuide
8. Ifyouchoseaparameterthatisrelatedtoaspecificcomponent(e.g.,Comp
Molefraction,oranyitemmarkedwithanarrow),youwillneedtospecifythe
component.ClickthecellbelowComponenttohighlightthatcell,andclick
againtoseeadropdownlistofavailablecomponents.Selectacomponent
fromthelist.
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 data reconciliation, youcan use the
Weightcolumntogivecertainitemsinthereconciliationmoreimportance
thanothers.
11. Repeattheprocedureuntilyouhavespecifiedallofthecellsorcellranges
thatwilllinktoyoursimulation.
12. SavetheDataMapbyselectingFile>SaveAs.TypeanameforyourData
MapandthenclickOK.ThenewlycreatedDataMapnowappearsonthe
CHEMCADExplorerundertheDataMapsitem.
CHEMCADVersion6UserGuide 121
Chapter 11
CHEMCAD Tutorials
AlthoughthesimulationsstoredinyourExamplesdirectoryareusefulformany
scenarios,thebestwaytolearntouseCHEMCADistocreateandrunsimulations
yourself.Thetutorialsinthischapterwalkyouthroughbasicsimulationbuilding
stepbystep,usingarealisticexampleproblemthatwillhelpprepareyouforyour
ownsimulations.
Thefirsttutorialisforasimplesteadystatesimulation,whichisthenusedasthe
basisforthesecondtutorial,inwhichyoulllearntousetheCCTHERMmoduleto
rateaheatexchanger.Thethirdtutorialwalksyouthroughabatchdistillation
problemusingCCBATCH,andthefinaltutorialcoversvariousscenariosforpiping
systems.
CHEMCADTutorials
122 CHEMCADVersion6UserGuide
CC-STEADY STATE Tutorial
Thistutorialcreatesabasicsteadystatesimulationforacondensatestabilizerplant.
Inthisplant,gasentersthesystemwiththefeedconditionsshowninthefollowing
diagram:
Figure 11-02: The pop-up label that identifies the UnitOp icon
3. ClickthelowerrightcorneroftheHeatExchangericon,ontheblacktriangle,
toopenthesubpalette.Selectthetwosidedheatexchangericonasshownin
Figure1103.Theiconthatyouclickedinthesubpalettenowappearsonthe
mainAllUnitOpspalettetorepresenttheHeatExchangerUnitOp.
Figure 11-09: The new K-value selection in the Thermodynamic Settings dialog box
4. NowclicktheEnthalpyModelstab.ThePengRobinsonmethodhasalready
beenenteredastheGlobalEnthalpyOptionsselection;thiswasdone
automaticallybecauseyouchosePengRobinsonasyourKvaluemethod.
Whileyoudohavetheoptiontooverridethischoice,inthiscaseyoullneed
tokeepthePengRobinsonmodel;leaveallsettingsastheyareandclickOK
toreturntothemainCHEMCADworkspace.
Forthepurposeofthistutorial,thethermodynamicselectionsarenowcomplete.
Note:WhileyouarenotrequiredtousetheThermodynamicsWizard,youshould
knowhowtouseit,ifonlyasastartingpointforyoursimulations.Youcanrevisit
thewizardatanytimebyselectingThermophysical>ThermodynamicsWizard.
CHEMCADTutorials
130 CHEMCADVersion6UserGuide
Defining the Feed Streams
Nowitstimetodefineyoursimulationsfeedstream.Thereareseveralwaysthat
youcandothis,butthequickestandmostefficientwaytodefineasinglestreamis
todoubleclickthestreamline.
Note:Beforeyouproceed,verifythatyourengineeringunitsaresettoEnglishinthe
EngineeringUnitSelectiondialogbox,asdescribedearlierinthistutorial.
Doubleclickthelineforstream1,yourfeedstream,tobringuptheEditStreams
dialogbox.
Figure 11-13: Plotting vapor fraction lines along with the cricondentherm dewpoint
3. ClickOKtocontinue.CHEMCADperformtherequiredflashcalculationsto
generatethespecifiedphaseenvelope.Phaseenveloperesultsareproduced
intwoformats:
Anumericaltabulation(table)ofthetemperature,pressure,vapor
fraction,vaporcompressibilityfactor,andtheliquidcompressibility
factor
Agraphicalplotoftemperatureandpressureforeachvaporfractionline
requested
Thetabularresultswillappearfirst;sinceyoureinterestedinthegraphical
results,closethewindowdisplayingthetable.Thescreenwillnowlook
similartoFigure1114.NotethatthemainCHEMCADbuttontoolbaris
largelyunavailablenow,andthemenuitemshavechanged.
CHEMCADTutorials
136 CHEMCADVersion6UserGuide
WhileitsrecommendedthatanewCHEMCADuserbuildthissimulationfrom
thegrounduptogainproficiencywiththesoftware,areadymadeexamplecalled
CHEMCADTutorial.CC6isalsoavailable.Thisfileislocatedbydefaultinthe
directorycalledMyDocuments\MySimulations\Examples\Tutorials.
Yourobjectiveistoratethefirstheatexchangerinthisflowsheet.Theequipment
youreworkingwithisacountercurrentgas/gasheatexchangerwiththefollowing
geometryanddimensions:
TEMAclass=R
TEMAtype=BEM
Foulingfactors=0.001bothsides
Shellinsidediameter=27
Numberoftubes=646
Tubeoutsidediameter=0.75
Tubewallthickness=0.065
Tubelength=20
Tubepattern=rotatedtriangular(60)
Tubepitch=0.9375
Baffles:10,equallyspaced
Baffletype=singlesegmental
Bafflecut=35%(diameter)
Impingementplatepresent
Shellsidenozzles=one,12
CHEMCADTutorials
CHEMCADVersion6UserGuide 145
Tubesidenozzles=one,12
BaffletoshellI.D.clearance=0.3125(diameter)
ShellI.D.toOTLclearance=0.35433(diameter)
Tubetobaffleholeclearance=0.035(diameter)
Spaceattopofbundle=2.8
Carbonsteeltubes;allothermaterialsA285C
5rowspersealingstrip
Overview of the Heat Exchanger Sizing Process
TheCCTHERMmoduleenablesyoutogenerateheatcurvesandspecifyheat
exchangers.Thisprocessinvolvesthefollowingsteps:
1. Identifythetubesidestream.
2. Generateandfinalizetheheatcurveandpropertiesonbothsidesofthe
exchanger.
3. Definegeneralinformationabouttheexchanger.
4. Specifyanydesiredtubedata.
5. Specifyanydesiredshelldata.
6. Specifyanydesiredbaffledata.
7. Specifyanydesirednozzledata.
8. Specifyanydesiredspecificclearances.
9. Specifythematerialsusedintheconstructionoftheheatexchanger.
10. Specifyanydesiredmiscellaneousdata.
11. Runthesizingcalculations.
12. Reviewresultsandcreateplotsasneeded.
Identify the Tube-side Stream
OncethesimulationiscompleteinCCSTEADYSTATE,youcanstartsizingthefirst
heatexchangerbyidentifyingthetubesidestream:
1. ClickonthefirstheatexchangericonandthenselectSizing>Heat
Exchangers>Shell&Tube.
2. Amessageboxpromptsyoutoselectastreamenteringtheexchangerstube
side.ClickOKtocontinue.
3. AttheSelectStreamsdialogbox,eithertype1orclickstream1onthe
flowsheet,thenclickOK.
CHEMCADTutorials
146 CHEMCADVersion6UserGuide
4. CCTHERMdisplaysdataforallfourstreamsaroundtheexchangerina
separatereportwindow.Revieworprintthedataasneededandthenclose
thereportwindow.
Generate the Heat Curve
Oncethetubesidestreamisidentified,CCTHERMpromptsyouthroughthesetup
oftheheatcurve.TheHeatCurveParametersdialogboxdisplaysassoonasyou
closethereportfromthepreviousstep.
ColumnSpecifications
No.ofinternalstages:8
No.ofoperations:5
Internalstageholdup:0.01ft
3
Condenserholdup:0.1ft
3
Condenserpressure:14.7psia
Columnpressuredrop:2psia
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
CHEMCADTutorials
CHEMCADVersion6UserGuide 155
OperatingStep1
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
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
OperatingStep5
Purpose:Pentaneremoval
Refluxratio:25
Distillatemolarflowrate:2
Stopwhen:Bottommolefraction
ofNHexaneis0.9998
Materialstobeaddedatstart:
None
Figure 11-39: The new K-value selection in the Thermodynamic Settings dialog box
CHEMCADTutorials
160 CHEMCADVersion6UserGuide
4. NowclicktheEnthalpyModelstab.ThePengRobinsonmethodhasalready
beenenteredastheGlobalEnthalpyOptionsselection;thiswasdone
automaticallybecauseyouchosePengRobinsonasyourKvaluemethod.
Whileyoudohavetheoptiontooverridethischoice,inthiscaseyoullneed
tokeepthePengRobinsonmodel;leaveallsettingsastheyareandclickOK
toreturntothemainCHEMCADworkspace.
Forthepurposeofthistutorial,thethermodynamicselectionsarenowcomplete.
Note:WhileyouarenotrequiredtousetheThermodynamicsWizard,youshould
knowhowtouseit,ifonlyasastartingpointforyoursimulations.Youcanrevisit
thewizardatanytimebyselectingThermophysical>ThermodynamicsWizard.
Specifying Pot Charge
Nowthatyouhavethermodynamicsandcomponentsdefinedforthissimulation,
andyouhaveabatchcolumnintheflowsheet,youcandefinethepotchargeforthe
column.
Youwillspecifythepotchargeaccordingtothefollowingrules:
TheTempF,Prespsia,VaporFraction,andEnthalpyMMBtu/hfieldsare
thethermodynamicpropertiesofthecharge.AccordingtotheGibbsPhaseRule,
onceamixturescompositionisgiven,specifyinganytwoofthesefour
thermodynamicpropertieswilldefinetheothertwo.Assuch,definingthe
composition,temperature,andpressureforamixtureuniquelydefinesits
vaporfractionandenthalpy.Alternatively,definingthecomposition,
pressure,andenthalpywilluniquelydefinethemixturestemperatureand
vaporfraction.
Sinceenthalpiesarecalculatedrelativetoadatum,thecalculationofany
givenenthalpyisaninvolvedprocesswhichispronetoerrors.Forthis
reason,CHEMCADdoesnotpermityoutoenterenthalpyasaconstraint.
Inadditiontodefiningthepotcomposition,youmustdefineexactlytwoof
thefollowingproperties:temperature,pressure,andvaporfraction.Thetwo
variablesthatyouspecifywilldisplayasredtext,whilethethirdvariable
andthevalueenthalpywillbedisplayedinblackwhenyouflashthecharge.
TheTotalflowunitandCompunitfieldsworktogethertoprovideavariety
ofwaystodefinechargecomposition.Iftheselectedcompunitismole,mass,
orvolumefraction(eithergloballyorlocally),thentheTotalflowunit
selectionisavailable.Iftheselectedcompunitisanamountoption,thenthe
totalchargebecomesthesumofthecomponentquantities,andtheTotal
flowunitselectionisnotavailable.
IftheCompunitfieldselectionisanamountunit(asopposedtoafractional
unit),thenthecomponentchargevaluesareautomaticallyaddedasyou
enterthem.ThecurrentsumisdisplayedintheTotalflowfield.
CHEMCADTutorials
CHEMCADVersion6UserGuide 161
YoucanclicktheFlashbuttonatanytimetoperformaflashcalculation
usingthecurrentlyspecifiedcompositionandthermodynamicproperties.
Thisenablesyoutoobtainflashcalculationsquicklyandwithoutleavingthe
dialogbox.
Fractionsthatdonotaddupto1.0areautomaticallynormalizedwhenyou
eitherclickFlashorexitthedialogbox.
Withtheserulesandbehaviorsinmind,enterthedataforyourpotcharge:
1. DoubleclickthebatchcolumntoopentheEditBatchChargedialogbox.
Figure 11-54: Nodes located upstream and downstream from control valves
Thefunctionofthedividertosplittheincomingflowisnowhandledbynode
#6.Thenodewillbalancetheflowratessothatallstreamsenteringandexitingthe
nodeareatthesamepressure.Nodesarealsoplacedbetweentheflashvesselsand
thecontrolvalves.Atthenodesyoucanfixthepressures,andlettheflowratevary
asafunctionofvalvepositionandpressuredifference.
Toseehowthesenodesaresetup,youcandoubleclicknode#6toopenthe
Nodedialogbox.
CHEMCADTutorials
CHEMCADVersion6UserGuide 175
C
Kr
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.
CHEMCADTutorials
178 CHEMCADVersion6UserGuide
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#3(beforecontrolvalve)
1swingcheckvalve,clearway
2ballvalves
2tee,flowthroughrun
1orificeplate(aspreviouslydetermined)
14feetofpiping
14elevationchange
Pipe#5(aftercontrolvalve)
2ballvalves
2tee,flowthroughrun
3standardelbows,90degree
1exitfrompipe
24feetofpiping
2footelevationchange
Pipe#7(afterE1515)
1ballvalve
4standardelbows,90degree
1tee,flowthroughrun
1wellroundedentrance
1exitfrompipe
157feetofpiping
5elevationchange
9. Specifythepumpoutletpressureatsomearbitraryvalue(try25psia)and
makeatrialrun.Checkthecalculatedoutletpressure.Youcantheniterateto
findtherequiredpumphead.
Using Controllers to Simplify the Problem
Whilemanuallychangingthepumpoutletpressurewillgetyouwhereyouneedto
be,itseasiertoletCHEMCADdothework.TheControllerUnitOpcanadjustthis
pressureforyou.
AfeedbackcontrollerinCHEMCADhasnothingtodowithprocesscontrol
valvesorPIDsettings.InaCHEMCADsteadystatemodel,thetermfeedbackcontrol
referstoamathematicalcontroller.Itsamathtoolusedtoadjustavariableona
flowsheetuntilatargetvaluereachesaspecifiedvalue.
Followthesestepstouseafeedbackcontrollertocalculatetherequiredoutlet
pressure:
CHEMCADTutorials
CHEMCADVersion6UserGuide 179
1. Rightclickstream#8andselectInsertunit.ClickOKatthepopupmessage
andthenclicktheControllertoolintheAllUnitOpspalette.
2. Clickneartheexistingstreamtoplaceacontrollericonontheflowsheet.The
streamautomaticallyreroutesthroughthisicon,asshowninFigure1159.
7
7
8
8
9
Pipe#2(beforecontrolvalve)
1swingcheckvalve,clearway
2ballvalves
2tee,flowthroughrun
1orificeplate(asdeterminedabove)
14feetofpiping
Pipe#3(aftercontrolvalve)
1ballvalve
1tee,flowthroughrun
2standardelbows,90degree
10feetofpiping
Pipe#4(toE1514)
1tee,flowthroughbranch
1ballvalve
1exitfrompipe
3standardelbows,90degree
26feetofpiping
CHEMCADTutorials
182 CHEMCADVersion6UserGuide
Pipe#5(fromE1514)
1ballvalve
1wellroundedentrance
3standardelbows,90degree
1tee,flowthroughbranch
30feetofpiping
Pipe#6(toE1515)
1ballvalve
1exitfrompipe
1tee,flowthroughrun
1standardelbows,90degree
14feetofpiping
Pipe#7(fromE1515)
1standardelbow,90degree
1ballvalve
1wellroundedentrance
1tee,flowthroughrun
10feetofpiping
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
Running the Simulation
Torunthesimulation,clicktheRunAllbuttononthemainCHEMCADtoolbar.
CHEMCADTutorials
CHEMCADVersion6UserGuide 183
Oncethesimulationhasrun,checkthePumpUnitOpspressureincrease.This
tellsyoutheheadrequirementsofthepump.Usingthisinformationandtheflow
rate(120gpm),youcanconsultapumphandbooktodeterminethecorrectpump
size.
Selecting a Pump
Thefollowingpumpcurvedataisrepresentativeofthetypeofequipmentthat
wouldbeappropriateforthisapplication.
Pump Curve
1750 rpm
1450 rpm
1150 rpm
20
30
40
50
60
70
80
90
0 40 80 120 160 200
Flow (gpm)
H
e
a
d
(
f
t
)
1750 rpm
1450 rpm
1150 rpm
0.3
0.35
0.4
0.45
0.5
0.55
0.6
0 40 80 120 160 200
Flow (gpm)
E
f
f
i
c
i
e
n
c
y
.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
CHEMCADCoachpane,27
CHEMCADDialogEditor,101
CHEMCADExplorer,introduced,18
Index
186 CHEMCADVersion6UserGuide
CHEMCADSymbolEditor,98
CHEMCADtutorials
CCBATCH,154
CCSTEADYSTATE,122
CCTHERM,144
Piping,170
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
CustomUnitOp,creatingusingVBA,104
CustomUnitOps,creating,100
Customizedcostingcalculations,100
CustomizingCHEMCAD,91
CustomizingtheCHEMCADscreen,23
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
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
EditDistillationCurvesmenu,97
EditFeedStreamsbutton,46
EditStreamGroupdialogbox,73
EditStreamsdialogbox,46
Ellipsetool,40
Index
CHEMCADVersion6UserGuide 187
Emailingasimulation,33
EngineeringUnitSelectiondialogbox,36
Engineeringunits
Changingforreports,72
Selecting,36
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
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
LicenseSettingsscreen,11
LicensingCHEMCAD,10
Licensing,fordynamics,59
Licensing,forhighfidelitymodeling,58
Linesizing,51
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
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
Index
188 CHEMCADVersion6UserGuide
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
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
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
Switchingtodynamics,61
SymbolEditorutility,98
Symbols,creating,98
Technicalsupport,contacting,15
Templates
Applying,92
Creating,92
Defined,91
Deleting,92
Renaming,92
Textreports,71
Texttool,40
ThermodynamicSettingsdialogbox,45
Thermodynamicsreport,78
Thermodynamicssettings,manuallyselecting,45
ThermodynamicsWizard,44
Index
CHEMCADVersion6UserGuide 189
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
UnitOps
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
VBAdefinedmixingrule,using,106
VBAdefinedreaction,using,105
VBAdefinedUnitOp,using,106
VesselSizingdialogbox,53
ViewPropertyOptionsdialogbox,75
View/EditComponentDatamenu,94
Viewingalayer,88
WebsiteforChemstations,15
ZoomOptionsmenu,27
Allmaterial2007Chemstations,Inc.