Process Simulation and Control Using Aspen 1st Edition

astern
PROCESS SIMULATION
AND CONTROL USING
METHANOl
BUTENES
RDCOLUMN CCS
AMIYA K. JANA
Rs. 295.00
PROCESS SIMULATION AND CONTROL USING ASPEN
Amiya K. Jana
@ 2009 by PHI Learning Pnvate Limited, New Delhi. All rights reserved. No part of this book may
be reproduced In any form, by mimeograph or any other means, without permission in writing from
the publisher.
ISBN-978-81-203-3659-9
The export rights of this book are vested solely with the publisher.
Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
r
Preface
"
The future success of the chemical process industries mostly depends on the ability to
design and operate complex, highly interconnected plants that are profitable and that
meet quality, safety, environmental and other standards
"
. To achieve this goal, the software
tools for process simulation and optimization are increasingly being used in industry.
By developing a computer program, it may be manageable to solve a model structure
of a chemical process with a small number of equations. But as the complexity of a plant
integrated with several process units increases, the solution becomes a challenge. Under
this circumstance, in recent years, we motivate to use the process flowsheet simulator to
solve the problems faster and more reliably. In this book, the Aspen software package
has been used for steady state simulation, process optimization, dynamics and closed-
loop control.
To improve the design, operability, safety, and productivity of a chemical process
with minimizing capital and operating costs, the engineers concerned must have a solid
knowledge of the process behaviour. The process dynamics can be predicted by solving
the mathematical model equations. Within a short time period, this can be achieved
quite accurately and efficiently by using Aspen flowsheet simulator. This software tool is
not only useful for plant simulation but can also automatically generate several control
structures, suitable for the used process flow diagram. In addition, the control parameters,
including the constraints imposed on the controlled as well as manipulated variables.
are also provided by Aspen to start the simulation run. However, we have the option to
modify or even replace them.
This well organized book is divided into three parts. Part I (Steady State Simulation
and Optimization using Aspen Plus ) includes three chapters. Chapter 1 presents the
introductory concepts with solving the flash chambers. The computation of bubble point
and dew point temperatures is also focused. Chapters 2 and 3 are devoted to simulation
of several reactor models and separating column models, respectively.
Part II (Chemical Plant Simulation using Aspen Plus ) consists of only one chapter
(Chapter 4). It addresses the steady state simulation of large chemical plants. Several
individual processes are interconnected to form the chemical plants. The Aspen Plus
simulator is used in both Part I and Part II.
vii
Copyrighted maierlal
viii PREFACE
The Aspen Dynamics package is employed in Part III (Dynamics and Control using
Aspen Dynamics ) that comprises Chapters 5 and 6. Chapter 5 is concerned with the
dynamics and control offlow-driven chemical processes. In the closed-loop control study,
the servo as well as regulatory tests have been conducted. Dynamics and control of
pressure-driven processes have been discussed in Chapter 6.
The target readers for this book are undergraduate and postgraduate students of
chemical engineering. It will be also helpful to research scientists and practising engineers.
Amiya K. -Jana
Acknowledgements
It is a great pleasure to acknowledge the valuable contributions provided by many of my
well-wishers. 1 wish to express my heartfelt gratitude and indebtedness to Prof. A.N.
Samanta, Prof. S. Ganguly and Prof. S. Ray, Department of Chemical Engineering, IIT
Kharagpur. I am also grateful to Prof. D. Mukherjee, Head, Department of Chemical
Engineering, IIT Kharagpur. My special thanks go to all of my colleagues for having
created a stimulating atmosphere of academic excellence. The chemical engineering
students at IIT Kharagpur also provided valuable suggestions that helped to improve
the presentations of this material.
I am greatly indebted to the editorial staff of PHI Learning Private Limited, for their
constant encouragement and unstinted efforts in bringing the book in its present form.
No list would be complete without expressing my thanks to two most important people
in my life-my mother and my wife. I have received their consistent encouragement and
support throughout the development of this manuscript.
Any further comments and suggestions for improvement of the book would be
gratefully acknowledged.
rial
Contents
Preface vii
Acknowledgements ix
Part I Steady State Simulation and Optimization
using Aspen Plus
1
. Introduction and Stepwise Aspen Plus Simulation:
Flash Drum Examples 3-53
1
.1 Aspen: An Introduction 3
1
.2 Getting Started with Aspen Plus Simulation 4
1
.3 Stepwise Aspen Plus Simulation of Flash Drums 7
1
.
3
.
1 Built-in Flash Drum Models 7
13 2 Simulation nf a Flash nmm
, , , _
8
1
.3.
3 Computation of Bubble Point Temperature 28
1.3
.4 Computation of Dew Point Temperature 35
1
.
3
.5 T-xy and P-xy Diagrams of a Binary Mixture 42
Summary and Conclusions 50
Prnhlpms
, , , ,
50
Reference 53
2
,
Aspen Plus Simulation of Reactor Models 54-106
2
.
1 Built-in Rpartor Models 54
2
.2 Aspen Plus Simulation of a RStoic Model 55
2.3 Aspen Plus Simulation of a RCSTR Model 65
2
.4 Aspen Plus Simulation of a RPlug Model 78
2
.5 Aspen Plus Simulation of a RPlug Model using LHHW Kinetics 93
Prohlpms 704
Reference 106
v
VI CONTENTS
3
. Aspen Plus Sinmlation of Distillation Models 107-185
3 1 Rnilt-in nistillntinn Mndols 107
3
.2 Aspen Plus Simulation of the Binary Distillation Columns 108
3 2 1 Simulation of a DSTWTT Mnripl IQfl
3 9. 9 Simulation of a RaHFrnr MoHpI 122
3
.3 Aspen Plus Simulation of the Multicomponcnt Distillation Columns 136
3
.
3 1 Simnlnt.ion of a RaHFrar MoHpI 13fi
3
.
3
.2 Simulation of a PetroFrac Model 148
3
.4 Simulation and Analysis of an Absorption Column 164
3
.5 Optimization using Aspen Plus 178
Problems ff l2
Part II Chemical Plant Simulation using Aspen Plus
4
. Aspen Plus Simulation of Chemical Plants 189-226
4 1 TntrnHnrtion
4
.2 Aspen Plus Simulation of a Distillation Train 189
4
.3 Aspen Plus Simulation of a Vinyl Chloride Monomer (VCM)
Production Unit 203
Prnhlpms
; , -
220
References 226
Part III Dynamics and Control using Aspen Dynamics
5
. Dynamics and Control of Flow-driven Processes 229-284
5J Tnt.roHiirt.ion 229
5.2 Dynamics and Control of a Continuous Stirred
Tank Reactor (CSTR) 230
5
.3 Dynamics and Control of a Binary Distillation Column 255
Prnhlpms
, , ,..
279
References 284
6
. Dynamics and Control of Pressure-driven Processes 285-313
fil Tnt.rndnrtinn
285
6
.2 Dynamics and Control of a Reactive Distillation (RD) Column 286
Problems 31J
References 313
Index 315-317
Copyrlghled maierlal
Part I
Steady State Simulation and
Optimization using Aspen Plus
Copyrigf
CHAPTER
Introduction and Stepwise
Aspen Plus Simulation:
Flash Drum Examples
1
.
1 ASPEN: AN INTRODUCTION
By developing a computer program, it may be manageable to solve a model structure of
a chemical process with a small number of equations. However, as the complexity of a
plant integrated with several process units increases, solving a large equation set
becomes a challenge. In this situation, we usually use the process flowsheet simulator,
such as Aspen Plus (AspenTech). ChemCad (Chemstations), HYSYS (Hyprotech)
and PRO/II (SimSci-Esscor). In 2002, Hyprotech was acquired by AspenTech.
However, most widely used commercial process simulation software is the Aspen
software.
During the 1970s, the researchers have developed a novel technology at the
Massachusetts Institute of Technology (MIT) with United States Department of Energy
funding. The undertaking, known as the Advanced System for Process Engineering
(ASPEN) Project, was originally intended to design nonlinear simulation software
that could aid in the development of synthetic fuels. In 1981, AspenTech, a publicly
traded company, was founded to commercialize the simulation software package.
AspenTech went public in October 1994 and has acquired 19 industry-leading companies
as part of its mission to offer a complete, integrated solution to the process industries
(http://www.aspentech.eom/corporate/careers/faqs.cfm#whenAT).
The sophisticated Aspen software tool can simulate large processes with a high
degree of accuracy. It has a model library that includes mixers, splitters, phase
separators, heat exchangers, distillation columns, reactors, pressure changers,
manipulators, etc. By interconnecting several unit operations, we are able to develop a
process flow diagram (PFD) for a complete plant. To solve the model structure of either
a
i
Copynghled material
4 PROCESS SIMULATION AND CONTROL USING ASPEN
a single unit or a chemical plant, required Fortran codes are built-in in the Aspen
simulator. Additionally, we can also use our own subroutine in the Aspen package.
The Aspen simulation package has a large experimental databank for
thermodynamic and physical parameters. Therefore, we need to give limited input data
for solving even a process plant having a large number of units with avoiding human
errors and spending a minimum time.
Aspen simulator has been developed for the simulation of a wide variety of
processes, such as chemical and petrochemical, petroleum refining, polymer, and coal-
based processes. Previously, this flowsheet simulator was used with limited
applications. Nowadays, different Aspen packages are available for simulations with
promising performance. Briefly, some of them are presented below.
Aspen Plus-This process simulation tool is mainly used for steady state simulation of
chemicals, petrochemicals and petroleum industries. It is also used for performance
monitoring, design, optimization and business planning.
Aspen Dynamics-This powerful tool is extensively used for dynamics study and closed-
loop control of several process industries. Remember that Aspen Dynamics is integrated
with Aspen Plus.
Aspen BatchCAD-This simulator is typically used for batch processing, reactions and
distillations. It allows us to derive reaction and kinetic information from experimental
data to create a process simulation.
Aspen Chromatography-This is a dynamic simulation software package used for both
batch chromatography and chromatographic simulated moving bed processes.
Aspen Properties-It is useful for thermophysical properties calculation.
Aspen Polymers Plus-It is a modelling tool for steady state and dynamic simulation,
and optimization of polymer processes. This package is available within Aspen Plus or
Aspen Properties rather than via an external menu.
Aspen HYSYS-This process modelling package is typically used for steady state
simulation, performance monitoring, design, optimization and business planning for
petroleum refining, and oil and gas industries.
It is clear that Aspen simulates the performance of the designed process. A solid
understanding of the underlying chemical engineering principles is needed to supply
reasonable values of input parameters and to analyze the results obtained. For example, a
user must have good idea of the distillation column behaviour before attempting to use
Aspen for simulating that column. In addition to the process flow diagram, required input
information to simulate a process are: setup, components, properties, streams and blocks.
1
.
2 GETTING STARTED WITH ASPEN PLUS SIMULATION
Aspen Plus is a user-friendly steady state process flowsheet simulator. It is extensively
used both in the educational arena and industry to predict the behaviour of a process
by using material balance equations, equilibrium relationships, reaction kinetics, etc.
Using Aspen Plus, which is a part of Aspen software package, we will mainly perform
in this book the steady state simulation and optimization. For process dynamics and
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 5
closed-loop control, Aspen Dynamics (formerly DynaPLUS) will be used in several
subsequent chapters. The standard Aspen notation is used throughout this book. For
example, distillation column stages are counted from the top of the column: the
condenser is Stage 1 and the reboiler is the last stage.
As we start Aspen Plus from the Start menu or by double-clicking the Aspen Plus
icon on our desktop, the Aspen Plus Startup dialog appears. There are three choices
and we can create our work from scratch using a Blank Simulation, start from a
Template or Open an Existing Simulation. Let us select the Blank Simulation option
and click OK (see Figure 1.1).
MM
MM 'Ml I I-
FIGURE 1.1
The simulation engine of Aspen Plus is independent f rom its Graphical User
Interface (GUI). We can create our simulations using the GUI at one computer and run
them connecting to the simulation engine at another computer. Here, we will use the
simulation engine at
'
Local PC'. Default values are OK.
Hit OK in the Connect to Engine dialog (Figure 1.2). Notice that this step is specific
to the installation.
The next screen shows a blank Process Flowsheet Window. The first step in
developing a simulation is to create the process flowsheet. Process flowsheet is simply
defined as a blueprint of a plant or part of it. It includes all input streams, unit
operations, streams that interconnect the unit operations and the output streams.
Several process units are listed by category at the bottom of the main window in a
toolbar known as the Model Library. If we want to know about a model, we can use the
Help menu from the menu bar. In the following, different useful items are highlighted
briefly (Figure 1.3).
Copyrighted material
Connect to Engine
Serve type
Liter Into
Node name:
Uset name
Password
Working dfedory:
Local PC
QSave as Default Cormeciion
OK Exit
FIGURE 1.2
Help
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Next button
Data Browser button Solver Settings button
Material STREAMS icon
H / lfcMM/5ilnt | Sipiram | HrfEKtwgvt | Calm | Rmovi | PmtutO*no*i | MrauMeti | Sat* | UmtUoM j
Status bar
s 1 mhb rsiK sscn
Model Library toolbar
PatntMrtH'l
FIGURE 1.3
INTRODUCTION AND STKPWISK ASPEN PI.US SIMULATION 7
To develop a flowsheet, first choose a unit operation available in the Model Library.
Proprietary models can also be included in the flowsheet window using User Models
option. Excel workbook or Fortran subroutine is required to define the user model. In
the subsequent step, using Material STREAMS icon, connect the inlet and outlet streams
with the process. A process is called as a block in Aspen terminology. Notice that clicking
on Material STREAMS, when we move the cursor into the flowsheet area red and blue
arrows appear around the model block. These arrows indicate places to attach streams
to the block. Red arrows indicate required streams and blue arrows are optional.
When the flowsheet is completed, the status message changes from Flowsheet Not
Complete to Required Input Incomplete. After providing all required input data using
input forms, the status bar shows Required Input Complete and then only the simulation
results are obtained. In the Data Browsery we have to enter information at locations
where there are red semicircles. When one has finished a section, a blue checkmark
appears. In subsection 1.3.2. a simple problem has been solved, presenting a detailed
stepwise simulation procedure in Aspen Plus. In addition, three more problems have
also been discussed with their solution approaches subsequently.
1
.
3 STEPWISE ASPEN PLUS SIMULATION OF FLASH DRUMS
1
.
3
.
1 Built-in Flash Drum Models
In the Model Library, there are five built-in separators. A brief description of these
models is given below.
Flash 2: It is used for equilibrium calculations of two-phase (vapour-liquid) and three-
phase (vapour-liquid-liquid) systems. In addition to inlet stream(s), this separator can
include three product streams: one liquid stream, one vapour stream and an optional
water decant stream. It can be used to model evaporators, flash chambers and other
single-stage separation columns.
Flash 3: It is used for equilibrium calculations of a three-phase (vapour-liquid-liquid)
system. This separator can handle maximum three outlet streams: two liquid streams
and one vapour stream. It can be used to model single-stage separation columns.
Decanter: It is typically used for liquid-liquid distribution coefficient calculations of a
two-phase (liquid-liquid) system. This separator includes two outlet liquid streams along
with inlet stream(s). It can be used as the separation columns. If there is any tendency
of vapour formation with two liquid phases, it is recommended to use Flash3 instead of
Decanter.
Sep 1: It is a multi-outlet component separator since two or more outlet streams can
be produced from this process unit. It can be used as the component separation columns.
Sep 2: It is a two-outlet component separator since two outlet streams can be
withdrawn from this process unit. It is also used as the component separation columns.
At this point it is important to mention that for additional information regarding a
built-in model, select that model icon in the Model Library toolbar and then press Fl
on the keyboard.
1
.
3
.
2 Simulation of a Flash Drum
Problem statement
A 100 kmol/hr feed consisting of 10, 20, 30, and 40 mole% of propane, r c-butane,
n
-pentane, and n-hexane, respectively, enters a flash chamber at 15 psia and 50oF.
The flash drum (Flash2) is shown in Figure 1.4 and it operates at 100 psia and 200oF.
Applying the SYSOP0 property method, compute the composition of the exit streams.
3
-
FLASH
FIGURE 1.4 A flowsheet of a flash drum.
Simulation approach
From the desktop, select Start button followed by Programs, AspenTech, Aspen
Engineering Suite, Aspen Plus Version and Aspen Plus User Interface. Then choose
Template option in the Aspen Plus Startup dialog (Figure 1.5).
I 1- l-MHM*
FIGURE 1.5
As the next window appears after hitting OK in the above screen, select General
with English Units (Figure 1.6).
INTRODUCTION AND STEPVV1SE ASPEN PLUSIM SIMULATION 9
-Hi
1
1 #
;1
L -
.
'
I
i.-
.
I i -
FIGURE 1.6
Then click OK. Again, hit OK when the Aspen Plus engine window pops up and
subsequently, proceed to create the flowsheet.
Creating flowsheet
Select the Separators tab from the Model Library toolbar. As discussed earlier, there
are five built-in models. Among them, select Flash2 and place this model in the window.
Now the Process Flowsheet Window includes the flash drum as shown in Figure 1.7. By
default, the separator is named as Bl.
nia*lHl mU -JM ??1 r a-i-m * -ai-o "d 3 I l-l SI Hi
'
bl'
3
0
0 9 =>. 8 - C .
-I --i
1
FIGURE 1.7
Copyrlghled
10 PROCESS SIMULATION AND CONTROL USING ASPEN1
To add the input and output streams with the block, click on Streams section (lower
left-hand comer). There are three different stream categories (Material, Heat and Work),
as shown in Figure 1.8.
3
-
O,
XQ.o
-
,
Q
-
l
lr
, 1 Ma I J--
FIGURE 1.8
Block Bl includes three red arrows and one blue arrow as we approach the block
after selecting the Material STREAMS icon. Now we need to connect the streams with
the flash chamber using red arrows and the blue arrow is optional. The connection
procedure is presented in Figure 1.9.
-
i- - rl ...iil il a ! 1
rmfT -1 "| LV
-
I .(Bit ( - 11 iwl
- - - I
.III MM .- . I -.
FIGURE 1.9
Copyrighled material
INTRODUCTION AND STFPWISK ASPEN PLUS SIMULATION 11
Clicking on Material STREAMS, move the mouse pointer over the red arrow at the
inlet of the flash chamber. Click once when the arrow is highlighted and move the
cursor so that the stream is in the position we want. Then click once more. We should
see a stream labelled 1 entering the drum as a feed stream. Next, click the red arrow
coming out at the bottom of the unit and drag the stream away and click. This stream
is marked as 2. The same approach has been followed to add the product stream at the
top as Stream 3. Now the flowsheet looks like Figure 1.10. Note that in the present
case, only the red arrows have been utilized.
... ,
0
-
a
.
>
-
Of.
1
.
<o-e-a.o.ir-
FIGURE 1.10
We can rename the stream(s) and block(s). To do that highlight the object we want
to rename and click the right mouse button. Select Rename Block and then give a new
name, as shown in Figure 1.11 for Block Bl.
-
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0 %
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'
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'
FIGURE 1.11
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Copynghied material
Alternatively, highlight the object, press Ctrl + M on the keyboard, change the
name, and finally hit Enter or OK. After renaming Stream 1 to F, Stream 2 to L,
Stream 3 to V and Block Bl to FLASH, the flowsheet finally resembles Figure 1.12.
-
~
-
c-Q-
0
a
-=
Si . , S
jjH*
- <*- i -ja---md.n -fw
FIGURE 1.12
In order to inspect completeness for the entire process flowsheet, look at the status
indicator. If the message includes Flowsheet Not Complete, click on Material STREAMS.
If any red arrow(s) still exists in the flowsheet window, it indicates that the process is
not precisely connected with the stream(s). Then we need to try again for proper
connection. To find out why the connectivity is not complete, hit the Next button on the
Data Browser toolbar. However, if we made a mistake and want to remove a stream
(or block) from the flowsheet, highlight it. right click on it. hit Delete Stream (or Delete
Block), and finally click OK.
Anyway, suppose that the flowsheet connectivity is complete. Accordingly, the status
message changes from Flowsheet Not Complete to Required Input Incomplete.
We have defined the unit operation to be simulated and set up the streams into
and out of the process. Next we need to enter the rest of the information using several
input forms required to complete the simulation. Within Aspen Plus, the easiest way to
find the next step is to use one of the followings:
1
. click the Next button
2
.
find Next in the Tools menu
3
. use shortcut key F4
As a consequence. Figure 1.13 appears.
Copynghied material
INTRODUCTION AND STKPWISK ASPEN PLUS SIMULATION 13
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FIGURE 1.13
Configuring settings
As we click OiC on the message. Aspen Plus opens the Data Browser window containing
the Data Browser menu tree and Setup/Specifications/Global sheet.
Alternatively, clicking on Solver Settings and then choosing Setup /Specifications in
the left pane of the Data Browser window, we can also obtain this screen (Figure 1.14).
;
.
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rr.Fi F
OQ-o-O-it-
FIGURE 1.14
14 PROCESS SIMUIvVTION AND CONTROL USING ASPEN
Although optional, it is a good practice to fill up the above form for our project giving
the Title (Flash Calculations) and keeping the other items unchanged (Figure 1.15).
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-
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-
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FIGURE 1.15
. !
In the next step (Figure 1.16), we may provide the Aspen Plus accounting information
(required at some installations). In this regard, a sample copy is given with the followings:
User name: AKJANA
Account number: 1
Project ID: ANYTHING
Project name: AS YOU WISH
\ r i-i i-f si
.
iO-Oo.Q.I.
m -
FIGURE 1.16
We may wish to have streams results summarized with mole fractions or some other basis
that is not set by default. For this, we can use the Report Options under Setup folder. In the
subsequent step, select Stream sheet and then choose Mole fraction basis,
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FIGURE 1.17
As filled out, the form shown in Figure 1.17, final results related to all inlet and
product streams will be shown additionally in terms of mole fraction. Remember that all
values in the final results sheet should be given in the British unit as chosen it previously.
Specifying components
Clicking on Next button or double-clicking on Components in the column at the left side
and then selecting Specifications, we get the following opening screen (Figure 1.18).
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FIGURE 1.18
Copynghi
16 PROCESS SIMULATION AND CONTROL USING ASPEN1"
Next, we need to fill up the table as suggested in Figure 1.18. A Component ID is
essentially an alias for a component. It is enough to enter the formulas or names of the
components as their IDs.
Based on these component IDs, Aspen Plus fills out the Type
,
Component name and Formula columns. But sometimes Aspen Plus does not find an
exact match in its library. Like, in the present simulation, we have the following screen
(Figure 1.19) after inserting chemical formulas of the components in the Component ID
column.
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FIGURE 1.19
Obviously, only for Component ID C3H8, Aspen Plus provided the Component name
(PROPANE) and Formula (C3H8). This simulator does not recognize the other three
components by their IDs. Therefore, we have to search in the following way
(Figure 1.20) to obtain their names and formulas. Click on a component ID (say, N-C4H10),
then hit Find button.
Now, we have to give a hint with Component name or formula (butane) and then
hit Enter or Find now button (Figure 1.21). Apart from component name or formula,
we can also search a component by giving component class or molecular weight (range)
or boiling point (range) or CAS (Chemical Abstracts Service) number. Click on Advanced
button in the following screen to get these options.
INTRODUCTION AND STKPWISE ASPEN PLUS SIMULATION 17
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I
FIGURE 1.21
Aspen Plus suggests a number of possibilities. Among them, select a suitable
component name (N-BUTANE) and then click on Add. Automatically, the Component
name and Formula for Component ID N-C4H10 enter into their respective columns.
For last two components, we follow the same approach. When all the components are
completely defined, the filled component input form looks like Figure 1.22.
- u
I
let >.-
Si - ~
m m: vr
r-
rai--l|i|-4|
,
*-| "l .) i"! -I vj ttl
I " i I I M -leal : ! !
"
8
j s- I
n tt-
FIGURE 1.22
The Type is a specification of how Aspen calculates the thermodynamic properties.
For fluid processing of organic chemicals, it is usually suitable to use 'Conventional*
option. Notice that if we make a mistake adding a component, right click on the row
and then hit Delete Row or Clear.
Specifying property method
Press Next button or choose Properties I Specifications from the Data Browser. Then if
we click on the down arrow under Base method option, a list of choices appears. Set the
SYSOPO' method as shown in Figure 1.23.
A Property method defines the methods and models used to describe pure component
and mixture behaviour. The chemical plant simulation requires property data. A wide
variety of methods are available in Aspen Plus package for computing the properties.
Each Process type has a list of recommended property methods. Therefore, the Process
type narrows down the choices for base property methods. If there is any confusion, we
may select
'
All' option as Process type.
Specifying stream information
In the list on the left, double click on Streams folder or simply use Next button. Inside
that folder, there are three subfolders, one for each stream. Click on inlet stream F, and
enter the temperature, pressure, flow rate and mole fractions. No need to provide any
data for product streams L and V because those data are asked to compute in the present
problem (see Figure 1.24).
This property method assumes ideal behaviour for vapour as well as liquid phase.
C ll
INTRODUCTION AND STEI'WISK ASPEN PLUS SIMULATION 19
cina
Tiers r
"
3
i
0 samii (Ham
AFU
Co
f> . FBI
P j miD
UVUM .
-
par-
r
-
I t4 -I - I . - |M
-
a
-
HO-e-o-i-it.
!
FIGURE 1.23
Ha 'ssH I
0]t*lMI
_
rmr i~i-..t>-rv
f5~
f, .rilll
'
I JIU-*"- I'M-
Im7V=
31
nns Dt
-
.
, ri.ttn it:
*
.1. -.. .11. : ...
h o e czd- @ - it.
FIGURE 1.24
Specifying block information
Hitting Next button or selecting Blocks/FLASH in the column at the left side, we get
the block input form. After inserting the operating temperature and pressure, one
obtains Figure 1.25.
20 PROCESS SIMULATION AND CONTROL USING ASPRN
i :r
~
.- u>i"i-
Toob Ron Piol Lfciaiy Wmdow Help
~
D - I I 'I -isil I lai alS*l
U3SE
did -J a M
UNIFAC Gioup 3
_) UN1FAC G<oup
.
__J
Cl 0ot ,
_J A sJyBJ
- PMP>SMi
O K>OE5I<iN
0 tMCPMAL
(#> TXPOftT
O VIE
*.
ilj Advanced
JQ
-
Lifl >=
-
Input
/Spc>rioalion>{ Floih.Ophwn | ErJ
EO varial
IS FLASH
| Be
i
Conv Opnoj
EO Conv Option*
O Setup
DMOBasK
49 DMOAdv
-
gp-n=-3
-
i
Input CompteK
[1 Mbcwt/SpBtsit Sopjuato.. j HmI Exciwigsi t Columni | FtMclnt | Pfonuio Chonoe
:
H 0 - 9 -CD-
STREAMS
'
Flh2 FlaihS Deca/Kei Sep 5ep2
FIGURE 1.25
Now the Status message (Required Input Complete) implies that all necessary
information have been inserted adequately. Moreover, all the icons on the left are blue.
It reveals that all the menus are completely filled out. If any menu is still red, carefully
enter the required information to make it blue.
Running the simulation
Click on Next button and get the following screen (see Figure 1.26). To run the
simulation, press OK on the message. We can also perform the simulation selecting
Run from the Run pulldown menu or using shortcut key F5.
r
Tl SJ b li"" 1 1 ] all*- -lj
"
cjJ_
Cl ~-T
-
Zl I - * I .IPI . I > in rnim
8
! 7.1 CarrvOpllam
33 to Conv Option*
3
=1
.TfUAMt ' FWttJ SgM L -o>i S p "fJ
3
FIGURE 1.26
The Control Panel, as shown in Figure 1.27, shows the progress of the simulation.
It presents all warnings, errors, and status messages.
jNIRODUCTlON AND STEPW1SE ASPEN PLUS SIMULATION
4 21
Q rtm eai vw DM* roota Lih..i..
I 1"! _=J 3?) H -iroh L_jih
-
3 I
,
QhrjAj*i j-j an .| ihi .j
M
"
3 r
"
3 r
. loch:
Pt.iofva and PoU<** Soipti
p" l t*i * *S'- f" '.. i ' r..:.
Command Lr |
AI bkK+ hv bean .
0 6 -ciD
STREAMS FU>K3
Fl<nH3 Dcanl- Sup Sp2
FIGURE 1.27
Viewing results
HittingATex button and then clicking OK, the Run Status screen appears first (see Figure 1.28).
yil l .i.l.lJIII.II..IIHIII.I.IMItMIIIIH.HI II.Wl'ltlll.Ml.llltHW
I
-
I Ffe Edt VKm Data Tools Rvxi Mot Lbtoty Window htetp
ItflHI -I v| daHal
-
3 m I _iJ_iMi_L
BRu-i Slatut
3 sQg r
S i Streams
QU RaMiU Swranarv
-
Run Statu*
Streams
Convergence
Atpen Plui Vetswn
Lite
prrr
[fLash CALCULATIONS
Dale and lime [JUNE 5. 2007 1 23621 Pm
"
Uminam [AOMINIS TRATOB
S*\D |TEAM_EAT
Machnelypo [WIN32 Hott iCONTROLLAB
Use << and >> robiowie testitt
MBW./Scfcie.. S* . ) Hal E-changst | CcWa | Beclor.
e Chang** i Man j Sobd. | U>Mo4* |
(0-9 o 8 .
FIGURE 1.28
From the Data Browser, choose Results Summary /Streams and get the following
screen that includes the final results of the given problem (see Figure
1
.
29).
Save the work by choosing File/Save As/...from the menu list on the top.
We can
name the file whatever we want. Note that an Aspen Plus
Backup file (*.bkp) takes
much less space than a normal Aspen Plus Documents fi
le ( .apw).
1j Fto '. ,-V . - Took Run P
: JSbd JMSj-d HIP jsJ . j . i
J/l Block*
I I
1 fo. * r
"
3 5l<amTblf[
r rjj 1 - 3
50 0 2000 200 0
i f. nr i ion oo ion on
Vapo* Froc 0016 0 000 1 000
Mote Flow f cmot/hi 220 462 1 Tf 971 42 492
Mas* Ftow b/h. 15906 41* 13312.698 2593 716
v. l:...- Flow culler 1039 561 382.439 3008 065
lE.Hhlpy MMBtu/hi 16 583 1243? 2 236
Mole Flow bmolVIv
C3H8 22 046 9 275 12 771
NC4H10 44092 30124 13 969
66139 56 242 9 896
N.C6H14 eeies 82 329 5856
(V Mixw pMto! SoiMralof* { Heal Enchangon | Column* | Recto.. \ P-eume Chongeij \ Mo puMw* | So*. | Um. Models )
HO 0 cd
STREAMS ' FVwh2 Flaih3 D>came> 3ep Sep2
For H*te, press Fi
" ""
*
Start}} Aspen Pkn - Simulatl_
C.\- .g Pol<tou\Ajper. PK 11,1 ! NUM i - .. ..
Av,4,>:-
FIGURE 1.29
If we click on Stream Table button, the results table takes a place in the Process
Flowsheet Window, as shown in Figure 1.30.
Fie Edt View Data Tocfc Run Ffevaheet Librvy Whdow Help
1 global j |e.| . I lai
F L V
Temptntuit F 50 0 200 0 200.0
Pttiiun pri 15 00 100 00 100.00
V*poi Fnc 0.018 0 000 1000
HoUFtow fcrnoVhi 220462 177 971 42 492
fcftu 15906 414 13312 698 2593 716
VokuntFlw 1639 561 382439 3008 065
EnlhJpy MMBtu/hi -16583 -12.499 -2236
Hole Flw
C3H8 22 046 9-275 12 771
H-C4H10 44 092 30 124 13569
K-C5H12 66139 56 242 9996
H-C6H14 88 185 82.329 5 856
Mok Trie
C3K8 0.100 0053 0 301
HX4HI0 0.200 0.169 0329
H-C5H12 OJOO 0 316 0233
H-C6H14 0 400 0 463 0.138
Mm/Spitlan Sflprntms { Heat Eicchangeit { Cdum | Reactori | PrMtue Chmgeii j Mmpdalai | Soldi j Use. Models j
-
D-
<0-8-o
1
C:V.oF<*lefs\ApenMun.l
?1 1
FIGURE 1.30
INTRODUCTION AND STKPWISK ASPKN PI.US,M SIMUI.ATION 23
Viewing input summary
To obtain the input information, press Ctrl + Alt + I on the keyboard or select Input
Summary from the View pulldown menu. The supervisor may ask to include the results,
shown in Figure 1.30, along with the input summary in the final report on the present
project (see Figure 1.31).
Fl Ml ft >W He
linput swimtrf crvaccd bv upen Plus "el. U.l tt tiiMtiS rrf jun a, 2007 ~
;Dlrctory CtSproarur 11 TBc\Aspanrai:n\WDrklng Polaei ' j' iveft Plus 11.1 tllnnm*
mMPuis
DPLUS RCSULTS-ON
TITLE 'PlHh Calculations '
IN-UNir lii.
DEC-STRESS CONVtlt ALl
CCOUNI-tKEO KC0UNT>1 PROJECT-ID*MtTHING 4
ff>0)6C'OU WISH 0SE('-H**S-"J/f'
DGKRIPriON '
General Sl*u1al1e*< w<th English unl s :
F, dsI, Ib/hf, lEfol/. oiu/hr, eirft/hr,
Propariy Haihooi wona
eln* M*l for Incur: NOll
"
i r j - report : '. . Mola *lo
PUBCII / AQUCOUS / SOLIDS / UttROANIC / t
tOASPENPCO
PROP-IOURCES CUBEll / MJUCOUS / SOCIOl / INC>Ra"IC
CJm8 C3h8 /
N-camo caxio-z /
N-cenW CftHH-l
"lOWSHEET
bicc> flash ih-e aut-v l
PROPERTIES SY5OP0
SUOSTRCAH -EO TEWB.lo. PBE5-11, MLE-PLOB-i00. -ktcVr>->
.*
xe-fbc ana o.i / w kio o.j / n-cihi? o. t /
N-c6nl4 0
.
4
- - plash Flash;
kabah rtwp- ao. "sr.-ic-j.
FIGURE 1.31
Creating report file
To create a detailed report of the work we have done, including input summary, stream
information, etc., select Export (Ctrl + E) from the File dropdown menu. Then save the
work as a report file (e.g., C/Program Files/AspenTech/Working Folders/Aspen Plus
Version/ Flash.rep). Subsequently, we may open the saved report file (Flash.rep) going
through My Computer with using a program, such as the Microsoft Office Word or
WordPad or Notepad. A report file for the present problem is opened below.
ASPEN PLUS IS A TRADEMARK OF HOTLINE:
ASPEN TECHNOLOGY. INC. U.S.A. 888/996-7001
TEN CANAL PARK EUROPE (32) 2/724-0100
CAMBRIDGE. MASSACHUSETTS 02141
617/949-1000
PLATFORM: WIN32
VERSION: 11.1 Build 192
INSTALLATION: TEAM
_
EAT
ASPEN PLUS PLAT: WIN32 VER: 11.1
JUNE 10, 2007
SUNDAY
11:23:23 A.M
.
06/10/2007 PAGE I
FLASH CALCULATIONS
ASPEN PLUS (R) IS A PROPRIETARY PRODUCT OF ASPEN TECHNOLOGY, INC.
(ASPENTECH), AND MAY BE USED ONLY UNDER AGREEMENT WITH ASPENTECH.
RESTRICTED RIGHTS LEGEND: USE, REPRODUCTION, OR DISCLOSURE BY THE
U
.
S
.
GOVERNMENT IS SUBJECT TO RESTRICTIONS SET FORTH IN
(i) FAR 52.227-14, Alt. Ill, (ii) FAR 52.227-19, (iii) DEARS
252.227-7013(c)(l)(ii), or (iv) THE ACCOMPANYING LICENSE AGREEMENT,
AS APPLICABLE. FOR PURPOSES OF THE FAR, THIS SOFTWARE SHALL BE DEEMED
TO BE "UNPUBLISHED" AND LICENSED WITH DISCLOSURE PROHIBITIONS.
CONTRACTOR/SUBCONTRACTOR: ASPEN TECHNOLOGY, INC. TEN CANAL PARK,
CAMBRIDGE, MA 02141.
TABLE OF CONTENTS
RUN CONTROL SECTION 1
RUN CONTROL INFORMATION 1
DESCRIPTION 1
FLOWSHEET SECTION 2
FLOWSHEET CONNECTIVITY BY STREAMS 2
FLOWSHEET CONNECTIVITY BY BLOCKS 2
COMPUTATIONAL SEQUENCE 2
OVERALL FLOWSHEET BALANCE 2
PHYSICAL PROPERTIES SECTION 3
COMPONENTS 3
U-O-S BLOCK SECTION 4
BLOCK: FLASH MODEL: FLASH2 4
STREAM SECTION 5
F L V 5
PROBLEM STATUS SECTION 6
BLOCK STATUS 6
ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 1
FLASH CALCULATIONS
RUN CONTROL SECTION
RUN CONTROL INFORMATION
THIS COPY OF ASPEN PLUS LICENSED TO
TYPE OF RUN: NEW
OUTPUT PROBLEM DATA FILE NAME:
_
1437xbh VERSION NO. 1
INPUT FILE NAME:
_
1437xbh.inm
LOCATED IN:
PDF SIZE USED FOR INPUT TRANSLATION:
NUMBER OF FILE RECORDS (PSIZE) = 0
NUMBER OF IN-CORE RECORDS - 256
PSIZE NEEDED FOR SIMULATION - 256
CALLING PROGRAM NAME: apmain
LOCATED IN: C:\PROGRA~ I\ASPENT~-1 \ASPENP~1.1 \Engine\xeq
SIMULATION REQUESTED FOR ENTIRE FLOWSHEET
DESCRIPTION
GENERAL SIMULATION WITH ENGLISH UNITS : F, PSI, LB/HR, LBMOL/HR,
BTU/HR, CUFT/HR. PROPERTY METHOD: NONE FLOW BASIS FOR INPUT: MOLE
STREAM REPORT COMPOSITION: MOLE FLOW
FLASH CALCULATIONS
FLOWSHEET SECTION
FLOWSHEET CONNECTIVITY BY STREAMS
STREAM SOURCE DEST STREAM SOURCE DEST
F FLASH V FLASH
L FLASH
FLOWSHEET CONNECTIVITY BY BLOCKS
BLOCK INLETS OUTLETS
FLASH F V L
COMPUTATIONAL SEQUENCE
SEQUENCE USED WAS:
FLASH
OVERALL FLOWSHEET BALANCE
MASS AND ENERGY BALANCE
CONVENTIONAL
C3H8
N-C4H10
N-C5H12
N-C6H14
IN
COMPONENTS
22.0462
44.0925
66.1387
88.1849
OUT
(LBMOL/HR)
22.0462
44.0925
66.1387
88.1849
RELATIVE DIFF.
0
.
101867E-09
0
.
326964E-10
-
0
.
113614E-10
-0
.
332941E-10
TOTAL BALANCE
MOLE( LBMOL/HR) 220.462 220.462 0.000000E+00
MASS(LB/HR) 15906.4 15906.4 -0.782159E-11
ENTHALPY(BTU/HR) -0.165833E+08 -0.147349E+08-0.111463
FLASH CALCULATIONS
PHYSICAL PROPERTIES SECTION
06/10/2007 PAGE 3
COMPONENTS
ID TYPE
C3H8 C
N-C4H10 C
N-C5H12 C
N-C6H14 C
FORMULA
C3H8
C4H10-1
C5H12-1
C6H14-1
NAME OR ALIAS
C3H8
C4H10-1
C5H12-1
C6H14-1
REPORT NAME
C3H8
N-C4H10
N-C5H12
N-C6H14
FLASH CALCULATIONS
U-O-S BLOCK SECTION
06/10/2007 PAGE 4
BLOCK: FLASH MODEL: FLASH2
INLET STREAM: F
OUTLET VAPOR STREAM: V
OUTLET LIQUID STREAM: L
PROPERTY OPTION SET: SYSOP0
IDEAL LIQUID / IDEAL GAS
***
MASS AND ENERGY BALANCE ***
IN OUT RELATIVE DIFF.
TOTAL BALANCE
MOLE(LBMOL/HR) 220.462
MASS(LB/HR) 15906.4
220.462
15906.4
0
.
000000E+00
-
0
.
782136E-11
ENTHALPY(BTU/HR) -0.165833E+08 -0.147349E+08 -0.111463
INPUT DATA
TWO PHASE TP FLASH
SPECIFIED TEMPERATURE
SPECIFIED PRESSURE
MAXIMUM NO. ITERATIONS
CONVERGENCE TOLERANCE
F
PSI
200.000
100.000
30
0
.
000100000
***
RESULTS ***
OUTLET TEMPERATURE F 200.00
OUTLET PRESSURE
HEAT DUTY
VAPOR FRACTION
PSI
BTU/HR
100.00
0
.
18484E+07
0
.
19274
V
-L PHASE EQUILIBRIUM:
COMP
C3H8
N-C4H10
N-C5H12
N-C6H14
F{I)
0
.
10000
0
.
20000
0
.30000
0
.
40000
X(I)
0
.
52117E-01
0
.
16926
0
.
31602
0
.
46260
Yd)
0.30055
0
.
32874
0
.
23290
0
.
13781
K(I)
5.
7668
1
.
9422
0
.
73697
0
.
29790
FLASH CALCULATIONS
06/10/2007 PAGE 5
STREAM SECTION
F L V
STREAM ID
FROM :
TO
L
FLASH
FLASH
SUBSTREAM: MIXED
PHASE: MIXED
COMPONENTS: LBMOL/HR
C3H8 22.0462
N-C4H10 44
.
0925
N-C5H12 66
.
1387
N-C6H14 88
.
1849
COMPONENTS: MOLE FRAC
C3H8 0.1000
N-C4H10 0
.
2000
N-C5H12 0
.
3000
N-C6H14 0
.
4000
TOTAL FLOW:
LBMOL/HR 220.4623
LB/HR 1.5906+04
CUFT/HR 1839.5613
STATE VARIABLES:
TEMP F 50.0000
PRES PSI 15.0000
VFRAC 1.8002-02
LFRAC 0.9820
S FRAC 0.0
V
FLASH
LIQUID
9
.
2754
30.1237
56.2424
82.3291
5
.
2117-02
0
.1693
0
.
3160
0
.
4626
177.9706
1
.3313+04
382.4385
200.0000
100.0000
0
.
0
1
.
0000
0.0
VAPOR
12.7709
13.9688
9.8963
5
.
8558
0
.
3005
0
.
3287
0
.
2329
0
.
1378
42.4917
2593.7158
3008.0650
200.0000
100.0000
1
.
0000
0
.
0
0
.
0
ENTHALPY:
BTU/LBMOL -7.5221+04 -7.0232+04 -5.2612+04
BTU/LB -1042.5543 -938.9019 -861.9118
BTU/HR -1.6583+07 -1.2499+07 -2.2356+06
ENTROPY:
BTU/LBMOL-R -130.1235 -123.3349 -87.8846
BTU/LB-R -1.8035 -1.6488
-
1
.
4398
DENSITY:
LBMOL/CUFT 0.1198 0.4654 1.4126
-
02
LB/CUFT 8.6469 34.8100 0.8623
AVG MW 72.1503 74.8028 61.0406
FLASH CALCULATIONS
PROBLEM STATUS SECTION
BLOCK STATUS
**********************************************************************
*
*
*
Calculations were completed normally *
* *
*
All Unit Operation blocks were completed normally *
* *
*
All streams were flashed normally *
* *
************************************************************************:!:;!=
1
.
3
.
3 Computation of Bubble Point Temperature
Problem statement
Compute the bubble point temperature at 18 bar of the following hydrocarbon mixture
(see Table 1.1) using the RK-Soave property method.
TABLE 1.1
Component
Mole fraction
Ci 0
.
05
c2 0
.
1
C3 0
.
15
i-C
i
0
.
1
n-C
i
0
.
2
i-C5 0
.25
n-C
5
0
.
15
Assume the mixture inlet temperature of 250C, pressure of 5 bar and flow rate of
120 kmol/hr.
S,MULA'
noN 29
Simulation approach
After starting the Aspen Plus simulator, the Aspen Plus Stnrt
,.,
v i
Among the three choices, select Template option and then S
e F Tl 3
L L J.-i..'i- I iM
BlMtt i ~| S!| -j j jj g
j
t
,
J;'&9'lr.lrtoi\Aitr.leI:MV l,1gffj ,Asinwi
Ptft.,..- "" TTrTtrtilVfnrt.i0ritliiiV>iWnrfca 11
C 'Pi09'*T>F'f'''-!CW"lecl-AW1>t>jFceii'A:Mr!rt,: n
H !i j
FIGURE 1.32
When the next window pops up (see Figure 1.33)
,
select General with Metric Units
and then hit OK.
3 -II ...d..ji:;L: i 1 1 raliH
FIGURE 1.33
In the next
,
press OKin the Connect to Engine dialog. Once Aspen
Plus connects to
the simulation
engine, we are ready to begin
entering the process system.
Creating flowsheet
Using the Flash2 separator available in the equipment Model Library, develop the
following process flow diagram (see Figure 1.34) in the Flowsheet Window by connecting
the input and output streams with the flash drum. Recall that red arrows are required
ports and blue arrows are optional ports. To continue the simulation, we need to click
either on Next button or Solver Settings as discussed earlier. Note that whenever we
have doubts on what to do next, the simplest way is to click the Next button.
rjafn ..|-|..|. {k
jl .15)1 I gl *w
.
0
o
o-e-oi-ir-
mm 1
_2
S-| ... >
FIGURE 1.34
From the Data Browser, choose Setup I Specifications. The Title of the present problem
is given as 'Bubble Point Calculations'. Other items in the following sheet remain
untouched (see Figure 1.35). However, we can also change those items (e.g., Units of
measurement. Input mode, etc).
-
3 -.1 ,b. i -. m -\u
-
gag i 3 abi 3 l alai
ij
, u m
it
"'E E3
FIGURE 1.35
INTKODUCTION AND STHPWISE ASFKN PLUSIM SIMULVTION 31
In the next, the Aspen Plus accounting information are given (see Figure 1.36).
'
_
rt* tm ttw imt 'i** Hot its*
P|aIBI -I -I f rW
i.
-
r
-
i h.i> rsr
..igi]
ralt-Htl l-al l 3J . I I"! J?J 21 j J Si
I _ti>|g| - I ' m
.I i Us*-**,
t.-'l(.
11 -
-
< O Q <=>. @ . 4 .
i
KM a IV- II I MM !r.i-.
FIGURE 1.36
Click on TVex button or choose Components /Specifications in the list on the left. Then
define all components and obtain the following window (see Figure 1.37).
~
rfc r mm Ma took " pw iav wfc- t.
PisgLBJ .1.1 Hl SI
_
1
-
J
~
I-I"I>
raKifcKl-ai i H II JhJ ! jcj m
i j . i i xapji i iw 'H
rtgj <irM i cuari n.i
9 BmiMM VMM
I
'
..X . 4 i
/-. ii.- MMM
r
-
.
L
*
. 11 d i it .jf
-
.
l.w..-->., s-m
l
1
H 0 8 cd. g - tf .
[ li itin ci rio< >....-_i- ... i
FIGURE 1.37
Copyrlqhted material
Hit Next button or select Properties / Specifications in the column at the left side. In
Property method, scroll down to get RK-Soave. This equation of state model is chosen
for thermodynamic property predictions for the hydrocarbon mixture (see Figure 1.38).
.
=1 3
JLi Si Mi bl
-
-
8
i
3;
F
-3
-
. Q-S-o-'g-'ii
D
FIGURE 1.38
Hitting ATex/ button twice, we have the following picture (see Figure 1.39). The binary
parameters are tabulated below. When we close this window or cbck OK on the message.
it implies that we approve the parameter values. However, we have the opportunity to
edit or enter the parameter values in the table. In blank spaces of the table, zeros are
there. It does not reveal that the ideal mixture assumption is used because many
thermodynamic models predict non-ideal behaviour with parameter values of zero.
TmsxS\zi zl 2 '-I H21 61
3 .ifLdB&teMMI)
:
3
MIX
MMI *
I
-
n
m
TTD
-3
=w
FIGURE 1.39
INTRODUCTION AND STEPWISR ASI-KN
J
>LU
sim 33
Click OK. Alternatively, use the Data Browser menu tree to navigate to the Str
eams/1/
Input/Specifications sheet. Then insert all specifications for Stream 1 as shown in Fi
gure 1 40
J . 1 1,, I*
~
n 1 1 i 1 igi
la
JO
1 ftdvaoced
r
~
i Rpioftt
& Setup
Q| OMOAdv
L55s?P Bos-:
El l aUl
J &1
tcxnpojitior.
pr
3 71 n
(5
rr s;;
-
J
s,. p-It ,111,. . l-v ...:...>, --r.-nlV-- H-lp
'
[i hWs/Sphleu Ssp falais j He Esdw ers j Columns | Reaclw: [ Pies sine Changers j Manipulators : Solids j UferModefi
Matenal
STREAMS Flash2 Fla h3 Dncanie.
Fo. Help, p
Sep 5ep2
J Start j j Apen plu, - Skmdab- Aspen Phjj Smxjlatton 2. . j
C:V gFfWe'slflspanPbjs 11.1 MJM P* wrwl In*/
FIGURE 1.40
Hit Afort or select Blocks/BUBBLE from the Data Browser. After getting the blank input
form, enter the required inputs (Pressure = 18 bar and Vapour fraction = 0) for block
BUBBLE (see Figure 1.41).
"
3 *i I *! iEi
- al>l
si - r
i Pr<*8rUw
J/) Prcpertr Metro
-
1
CJ 2
~J 1
-
1
.
_)
9 ***
-
a
-
/Speatifotnni FlathOcdoni ' Er**rrrnl
0 0 Qfl
STREAMS Ri ? fWJ Ete i S<c S Bi
FIGURE 1.41
34 PROCESS SIMULATION AND CONTROL USING ASPE
N
Press Next button and then hit OK to run the simulation
. The following Control Panel
demonstrates the status of our simulation work (see Figure 1.42).
laillUJLIIIlllBIl
i f** t-t Vwi- Data Toofi Bun Lfciafy WVidwv/ Meto
JDlugB] atfij J-j
4-1 I "I JiJ S i l <| jjB] | IMI
ral-rlatl-l-qi l ii [=5
_
d
. IjjJ -J SI affl e-i
i 3 - i i -i tim mi
ss 3 r i r
Inieriijpi DMO Sotver
J. NoEOFwm
j
i - r-. - and Po:iiotve SckXi
Command Lr* f
"
| Sepaislota | Heat ExchM oeic [ Cohjnmi | Rrac'txt | Prectuie Changed
o o e - it -
STREAMS
'
flathZ Flail-.3 Decade. Sep
Sepg
SoMt j Uiei Model: |
r
C:\...oFoW"\A>enPtuj 1
'
* (W Oi/fc &<$ 7:52 P
FIGURE 1.42
Viewing results
Clearly, Figure 1.42 includes the Status message: Results Available. As the simulation
calculations completed, click on Solver Settings and then double-chck on Blocks to obtain
the following screen (see Figure 1.43).
-
-
| ne c >' vv. 0*a Toob Ain PM Lferarv Wmdcw Hcto
J_
l
"
l-l-PT
-
j j b I 3 tti iiJfXi 32>J jaal n i
33 Set-*
2
O Setup
I
-
CM
<o 9 e i
1 n.A? FWi3 Dac4> Sap
i SOU. | U-Moa* |
FIGURE 1.43
-
| ,Mdfl .-.. .
INTKODUCTION AND STKPWISK ASI'KN PLUS SIMULATION 35
Choosing Blocks/BUBBLE/Results in the column at the left side, we get the
following results summary for the present problem (see Figure 1.44).
JaflHI Ml *1
mi
ra
IB 3(viP*Jl
fOCor- OBban*
V
O 1
tmt
WMllwilfc iiiy
NM1
.
j 0 - 6 -o- f. r.
| SOU. | UnMaM |
111,1 ' MM *r
FIGURE 1.44
From the results sheet, we obtain the bubble point temperature = 42.75411960C.
1
.
3
.4 Computation of Dew Point Temperature
Problem statement
Compute the dew point temperature at 1.5 bar of the hydrocarbon mixture, shown in
Table 1.2, using the RK-Soavc property method.
TABLE 1.2
Component Mole fraction
Ci
0
.
05
C2
0
.
1
Ca
0
.
15
<-c
4
0
.
1
n-C
A
0
.
2
M3a
0
.
25
"
-
(>
,
0
.
15
Assume the mixture inlet temperature of 250C, pressure of 5 bar and flow rate of
120 kmol/hr.
36 PROCESS SIMULATION AND CONTROL USING AS
PEN
Simulation approach
As we start Aspen Plus from the Start menu or b
y double-clicking the Aspen Plus icon on
our desktop,
theAspe?i Plus Startup dialog appears (see Figure 1.45). Select Template option
.
l
_.
LJ...l-:i.::.l JAI
"
-I/I I J J_J_J_:J..J
-
gj J
Id *J 1PJ M _j.
1
empWis
3!
i C VProffwnFdc-. sptnTeehWA/oikaigFolitei'/Jiipen Plus 11
C ogfam F,lt; Vi.ipenTBeh\W0il<ing Folded r\A;i>-n Plo: 11
For Help, prws Fl
ft? Start] j
FIGURE 1.45
As Aspen Plus presents the window after clicking OK as shown Figure 1.45, choose
General with Metric Units. Then press OK (see Figure 1.46).
i i i
MB
Peisonalj Bsfmeiy Stmolahons
K..<, PetuJeuin >ihEris(
Pe'io jum
F haimacouiKiJ: Ml
I Ptiarniaceijlical;
"
Polymei: wiinEr
PoWe*! "el'
gi Pyiionie<alugi' iviih
P>Kime'aluigy wiUn
Sefids wthEnghhl
Sc*di*hMetf U
gSpecialj- Chemcal
Ail SefWabon wth Engt:h Umt:
Au Sep*aiion wih Molrie Uriitl
Ajp*! SU
9l3f* SimJalK
ChetrocalsWhEngkrtiUnH
Chemcali w(h McKk; Umt
ElecnoMe; wuh Engliih U i5
Elect'O eiwiihMen-cUnj
Ga: Pioceisng wth EnpM) Unn:
ProcesniQ w*h Metric UrJ
General v*lhEnak;hU i
H>*oiitalurQi' wuf. Engii:*i Urn
ggMydrometaOuTK. wJh Mel
P., l,t
.-_
-
Flowsheei
Daneel
For M*, pre PI
Startj Aip PV
FIGURE 1.46
Subsequently, dick OK when the Aspen Plus engine window pops up.
Creating flowsheet
In the next, we obtain a blank Process Flowsheet Window. Then we start to develop
the process flowsheet by adding the Flash2 separator from the Model Library
toolbar and joining the inlet and product streams by the help of Material STREAMS
(Figure 1.47).
gjfffc i Dm > Ha-w- Ifca* . .iffi J
3
-
H c-
0
St*
-
CD c
if
itftLWfS n>rJ f* i c-*. - -3 s.-
mt| -i>w. |>-icj- i.tanwr|| - # i
FIGURE 1.47
Now the process flow diagram is complete. The Status bar in the bottom right of
the above window (see Figure 1.47) reveals Required Input Incomplete indicating that
input data are required to continue the simulation.
Hitting Next button and then clicking OK, we get the setup input form. The present
problem is titled as
'
Dew Point Calculations' (see Figure 1.48).
In Figure 1.49, the Aspen Plus accounting information are provided.
Here we have to enter all the components we are using in the simulation. In the list on
the left, choose Components /Specifications and fill up the table following the procedure
explained earlier (see Figure 1.50).
Copyrighted malenal
38
PROCESS SIMULATION AND CONTROL USING ASPEN1
-LT _l_LJ__rv 3 I I _lL
,J9J i
J U
v ...
Sup
SprtlfttaMoo,
5(re*T,GIS
Urj-Sti
.
J
.
J J
Blocks
L
I
-
CorVrwoente
*
-J Fl- vsh cting Options
*
_J MjdH ArWyjo Tooli
'
Vj EO Cont"Juri n
* Results
</Gh*l| OeKtwion | ilccojnlh.0 ] DiagrwHiei |
Urn'-. d( rfi?B;ijHMr*rJ
Oi>pm (en
MET I f - 'j
Inc ji mode
3
3
3
VM phaiei [
r l>(iee waleicalculatrani
Text lo appeal on eorh page Ihe FTporl He See Help
0 o 8 I
STREAMS S
tilCTh2 Flath3 Decaniei Sap
Scp2
_
Fo He*i, prats Fl C:\ .,gFoders\AspwiPlu5 11.1 MUM ?qu)
FIGURE 1.48
Fie E* View Data Tools Run Plot Lfcrary Window Help
Mi
al-f-jfeKI-glH N>i -I . | \*\ m\m ..:/;| [
Lit r
-
3 >'H r *\*m\i-
|0 Specfeno
h j/j Setup
Specifications
SiroJatron Options
Stieam Class
bfe Subsbeams
S 1 3 Units-Sets
Q Custom Unrts
0 Report Options
*:
| Components
+ Properties
I Streams
_iJ Blocks
Si Reactions
+ Convergence
+ FtowsheeSng Options
* Mate'Analysts Tools
*
.
ifl Cor/iguration
Q] RtsJts Sunmary
/GlobalI ./Descnption /Arc Diapnoslici
jAKJANA
'
: Aspen Plus accounitng rioifnation
j Uset name:
Accouil luffnber:
I PtqedID
j Project name:
ANYTHING
jAS YDU UKEi
Project n.
Input Canvtete
pT MMea/SpiKm SefMHtais | HutEictangen | Cokmu | Reactat | Pteuute Changeu j ManpuWcs | Stfcfc | Us Modeh
H 0 -0 -0
C < Flash? FImKI DmcmIm
fcHelc, press Fl <;\...gFl*fcrs\Asii<nHu!U.l
NUM . fisquiWlicuHftafToiete
FIGURE 1.49
i--r
r
-i-!>-i' it

.
Jj I 111
t r
-
SlJ "" -l ""H I ~ I
-
Q*
.
<o-8o.i.ii:
FIGURE 1.50
From the Data Browser, select Properties /Specifications to obtain a blank property input
form. From the Property method pulldown menu, select RK-Soave (see Figure 1.51).
! Ut Wfw CMC* loak Hut fw tArarr wMsb* m*.
a-i iM-ai f j t) -I |h| -j
]aBfl -I lfa-3>>lQl l!gJ
IMXooc
-I
i
-1 . i
=1
Cfcc* i c*iiBMr opto*
SHI
r . -.
WnmW 1 * | Haaf.ctaran I fi pi. | Hull
Mart!: A-a.-r*
4 'P- .
J 13 tiBAH
FIGURE 1.51
In the column at the left side
, choose Streams/1. As a result, a stream input form opens
Entering all required information
, one obtains the screen as shown in Figure 1.52.
D1<|H|
_
L
_
r
-
SIS Mi
-
If Pi
Iikl*J*l<Jij Sd 2J j-LiiLl 1 3 .
j i ! jjbl bj
WO[>l
ptseu i
BrTH>l
_j Cfctt/ runt
_,
.~J>
a .
-
3
tum [Met. ]:
fin f hr*"" .]
-
II
ili
<:< 'i
ik
.
its til
Micw illii
"
V Mwct rtdm Sploc I HeE*h>wi | OA*** | nMcton 1 P.eChan*"
-
jO 8 0-8 C
*
-| I AvenPfcn-SknutotL-
FIGURE 1.52
The final area that requires input is the Blocks tab. In the list on the left, double-click
on Blocks and then select DEW. Filling up the input form, we have Figure 1.53.
Btali
:r ,. uh.|! rv
too** Otn Wo Library wmdcwi
I 3 /-\ 1 -i -Igil I Ji
"
3 3
ANWIJ-1
ANCMIJ-I
BnSBIJ-1
0XTrI>l
'
I Group
FlMhOpooru I Em
30
"
3n
-
3
"
3
Input CcntfM*
I*
STREAMS
<0 Q cd
FIGURE 1.53
INTRODUCTION AND STEPWISK ASPEN PLUS 3!MUU\TION 41
Running the simulation, the following progress report is obtained (see Figure 1.54).
-
j
-
r-H'-hrr II . t .! -1031 I - ! !
HI 3
3 ,
mi r . .1:
-
D
-
'
! I MMWWII | CMmI l-MI I *-- II in I -I I M*i I IMMB
o-e-oi-it-
IIKMM
-I*. MM'I (Will
FIGURE 1.54
Viewing results
First click on Solver Settings. From the Data Browser, choose Blocks/DEW/Results
(see Figure 1.55) to get the dew point temperature = 22.19453840C.
i' r-ui>.i.rf
a -.
MM*
MM*
JVM -
i*
I- *
.MM
-
I
.
(O-e-o-i-it-
hum 1 im*f n u t- w ' i
FIGURE 1.55
1
.
3
.
5 T-xy and P-xy Diagrams of a Binary Mixture
Problem statement
A binary mixture
, consisting of 60 mole% ethanol and 40 mole% water, is introduced
into a flash chamber (Flash2) with a flow rate of 120 kmol/hr at 3 bar and 250C
.
(a) Produce T-xy plot at a constant pressure (1.013 bar)
(b) Produce xy plot based on the data obtained in part (a)
(c) Produce P-xy plot at a constant temperature (90oC)
Use the Wilson activity coefficient model as a property method.
Simulation approach
As usual, start Aspen Plus and select Template. Click OK to get the next screen and
choose General with Metric Units. Then again hit OK. In the subsequent step, click OK
in the Connect to Engine window to obtain a blank Process Flowsheet Window.
Creating flowsheet
From the equipment Model Library at the bottom of the Aspen Plus process flowsheet
window, select the Separators tab and insert the Flash2 separator. Then connect the
separation unit with the incoming and outgoing streams. The complete process is shown
in Figure 1.56.
-
CD o
-
0 o
STfSAMS
9
-o
1
FIGURE 1.56
After clicking on Solver Settings, select Setup /Specifications in the list on the left. The
Title of the present problem is given as
'
TXY and PXY Diagrams'. Subsequently, the
Aspen Plus accounting information are also provided [see Figures 1.57(a) and (b)].
INTKOIHTTION AND STKI'WISK ASl'liN I'l.l'S ' SIMULATION 43
S!fll>l*l<H !ti 3 -i l-l.TJ S -I 1U
r
-
1,
-
1 i .1 ..b; : . IP |JI
'-
:
5! r-
CO . j .
FIGURE 1.57(a)
213
1
gjg j i 3 <iF-i] >>j aal -I
I -IE' - ; 1
?3
3 <o'-
-
CH
oeo.@.
t Mi(.i,tra5-i
FIGURE 1.57(b)
Hitting Next button and defining the components (ethanol and water) in the input
form, one obtains Figure 1.58.
The user input under the Properties tab is probably the most critical input required to
run a successful simulation. Clicking Next button, we obtain the property input form.
For this problem, choose the Wilson model by scrolling down (see Figure 1.59).
44
PROCESS SIMULATION AND CONTROL USING
ASPEN1
i * Vlaw cyta Icob Biji n-j
-
L
-
r
,
j
_.Lj.inr
iL
1 Specfrahon:
_J Sot rr s
SpetKkattww
'
| iitM) .WwiO
flltr-ComOS
'
) HerryCofroi
.
_J P nwt
Strrars
.
J_j CwTy Ocunj
-
_21 EC Ccti. 0JOftt
l L
__
!
v
'
Selertionj PtMeum | NoneonvtrMnal | Oat nki {
ComponnHID
iTHANOl
i Warn* I Um Drtned ! R*>*<
1J
fi< MotB Ephieri Sopaialod j HetfEffihsrflw; | Colutnu | Rwcfct j PremMChanel | ManpJsiai j SoHi | UteiModeU |
Matewl
STREAMS 1 flwW Sep
For Heb, piKsFI
At pen Prut - SlniulatL-
NUM P HPClroxlrvm- -f
FIGURE 1.58
Vww Oats Toote Run Plot Ltifa Wmbow net
"
3
3M
"
t r
5wj(aCi Opt mm
Streain Class
-
_j Substra4fn
*
Ljfl Un*s-Ss
Report OcKnns
Vl Components
1 Asia//Blend
.
_lj petfo Cha< actof cation
Pss-jdoeoinporients
ACw-Comp*
| I Menry Comp*
UWIFAC (Vo
__j Comp-Ofoupi
.
_y ConxHJsts
Gtobalj Flow!heel Seciooi j Heleie.-ced j
' c . meihodi i moddi
P.oci two P
Base method | WILSON
Henry component i
1
~
3
w-y rr lhod fwiUSDN
Modty piopeity models
Wale, solubtty j
Electic le cal ula'lor.oplnni
"
3
"
3
=3
Ptopertes
SpeclTKatton*
.
_V) Pf5<rrty Method*
* Estmalion
.
_J Molecular Structure
Paramateri
'
i Data
*
33 Prop-Set)
. Advanced
Input Complete
fit' MMKt/5p(tlM Spaifoi> j Heat Exchange" | Cokjmnl | Reactors | Piohuio Chonoelj i ManipuWoit | SoWi | LUei Model: |
Por Hefc., pren PI
_
J| Aspen Plu. - SKthiIoII..
MUM Reoui-i .dlnp-jt lnco.Tcl -
3 s pm
FIGURE 1.59
Once the base property method has been selected and we click the Next button, a
window pops up asking whet
her to continue to the next step or to modify the properties
(see Figure 1.60).
INTRODUCTION AND STEPWiSK ASPEN PLUS SIMULATION 45
Required Properties Input Complete
Go to the Next requiied step, or supply
additional properties information,
Go to Next required input step
'
Modify required property specifications
Enter property parameters
Enter raw properly data
i
OK Cancel
FIGURE 1.60
The next window includes a stream input form. Specifying temperature, pressure, flow
rate and components mole fraction, one obtains Figure 1.61 as shown.
PlflftlM<M! 31 jUjU-=J S il Ed
J6
. - --r- :
."HI
ft -nvmi
I
3
If
-
-
it
m
iia"
mm wa
nr
-
a-
o-e-o-i-ir-
FIGURE 1.61
(a) Creating T-xy plot: Selecting ToolslAnalysis I Property I Binary, we have
Figure 1.62.
Q ru r vh> Ma TnA =.. itrvy wrdw h i
ni lMl -I U ini ff)
f
fTIwioL
F3
J BSg I
j . i I 'I -IflPJ J - Jill mm
nr
[ iii.r-ini< iiiiuuTiJi I imii*mim I c * | n- .. | p.m.o--. i m****-. i |
u.m~** i
P jT H il 3 s*h
FIGURE 1.62
We must note that this option can be used to generate T-xy, P-xy or Gibbs energy of
mixing diagrams. Select Txy
'
for the present problem. We aim to do an analysis on the
mixture of ethanol and water; so select these components accordingly. The user has the
option of specifying, which component will be used for the x-axis (which component
'
s
mole fraction will be diagrammed). The default is whichever component is indicated as
component 1. Make sure that we are creating the diagram for the mole fraction of ethanol.
Entering required information
, Figure 1.62 takes the following form (see Figure 1.63).
O lot* Pun lAfy Wnion rteto
.-IJ l-M- r
"
3
[WATER
lUj- "> ru.,
jEIKWDL
|l
His-1
rsKlfel i Kl tj ! |n| jl! M
3
MM >>.l Vox x.- to..
FIGURE 1.63
Click on Go and get the T-xy plot at a constant pressure (1
.013 bar) as shown in
Figure 1.64. Although the Status bar shows Required Input Incomplete
,
but there is no
problem to get the plot based on the given information.
INTRODUCTION AND STEPWISE ASPEN PLUS1 M SIMUL.\TION 47
5J Ji) M r3ii-|*i*i<H!l 2
I -"IBI I' g 21!!
OltflBI lai Mel l
i r-i-i-i>nr
FIGURE 1.64
It should be noted that if we move the T-xy plot slightly or close it, we find
Figure 1.65 having a databank. Some of these values have been used to make the
plot (Figure 1.64).
n3K|fc!|-qM!!H 3i
-
i i i .i .m- i m\
Mil* I MMI
rwrrc
Wtfm
: : -
<o e-o-e-a;
MpiM.i lM4Ml-
FIGURE 1.65
ru tut M* I** BiW H>>> Vrt Ji-
.
r
"
-
:;
-i
.
Mf
.
n:
j i i 'i mo; i i"i SM
REAMS
'
rih2 fLwM C'mjtj- 'if f-
'
j tRLAMb
FIGURE 1.62
We must note that this option can be used to generate T-xy, P-xy or Gibbs energy of
mixing diagrams. Select
'
Txy' for the present problem. We aim to do an analysis on the
mixture of ethanol and water; so select these components accordingly. The user has the
option of specifying, which component will be used for the x-axis (which component
'
s
mole fraction will be diagrammed). The default is whichever component is indicated as
component 1. Make sure that we are creating the diagram for the mole fraction of ethanol.
Entering required information. Figure 1.62 takes the following form (see Figure 1.63).
M il SI M SI
2 |W*TER
~
3
fETHANOL
3
(\oflm<y cmms
-
o
-
FIGURE 1.63
Click on Go and get the T-xy plot at a constant pressure (1.013 bar) as shown in
Figure 1.64. Although the Status bar shows Required Input Incomplete
,
but there is no
problem to get the plot based on the given information.
Clicking on Go button, we have the following P-xy plot |see Figure 1.68(a)|
at a constant temperature (90
oC)
and respective databank produced (Figure 1.68(b)|.
I I- I-I.-IkU-
L *
-
i
:
1 1 1 DM
.... . -
11
FIGURE 1.68(a)
3/11 '' IBi.-l ' I
uoitnuc
ETWMOl
I0IH
mti
I0T*
K
I0T
ni
UOUO
QAMHt
IIMM01
UOUD
-TF- walla
UOUO
cum
[
ima UHlil urci
T5HJ
UMH 171 KB
-
on nr*' iSKs? - 7.4':.,, tWK i-
B n 1 IPIIJ THS rraei Siwr-SW?H )i
B na raro nryn TflffT
B I...11 n?
TWB ! 11 sarm
A ij " nBsw
"
Wii
B .
'
rams IWB T7ZB5
"
ITFii
[2 rssi ess ms
www
S r an nnss SWHHT"-- nan
moo n
B [B TIPl fSiiTE IfiffiBT
1 n no T OBfl nrarc r aaw r awn r a-
nw na! 61 . 1
J
HD-*
HO-Q-o-i-iI-
Ikvil .Hi) Ohm Sh> !!
IU MM
FIGURE 1.68(b)
50 PROCESS SIMULATION AND CONTROL USING AS
PEN
Notice that the plot window can be edited b
y right clicking on that window and
selecting Properties.
In the properties window, the user can modify the title
,
axis scale
,
font
,
colour of the plot, etc. Alternatively, double-click on the different elements of the
plot and modify them as we like to improve the presentation and clarity.
SUMMARY AND CONCLUSIONS
In this chapter
, a brief introduction of the Aspen simulator is presented first. It is well
recognized that the Aspen software is an extremely powerful simulation tool
,
in which
,
a large number of parameter values are stored in the databank and the calculations are
pre-programmed. At the preliminary stage of this software course, this chapter may
help to accustom with several items and stepwise simulation procedures. Here
,
four
simple problems (flash calculation, bubble point calculation, dew point calculation and
T
-xy as well as P-xy plot generation) have been solved showing all simulation steps.
PROBLEMS |
1
.1 A liquid mixture, consisting of 60 mole% benzene and 40 mole% toluene, is fed
with a flow rate of 100 kmol/hr at 3 bar and 250C t
o a flash chamber (Flash2)
operated at 1.2 atm and 100
oC
. Applying the SYSOP0 method, compute the
amounts of liquid and vapour products and their compositions.
1
.2 A liquid mixture, consisting of 60 mole% benzene, 30 mole% toluene and
10 mole% o-xylene, is flashed at 1 atm and 110oC. The feed mixture with a flow
rate of 100 kmol/hr enters the flash drum (Flash2) at 1 atm and 80oC
. Using the
SYSOP0 property method,
(a) Compute the amounts of liquid and vapour outlets and their compositions
(b) Repeat the calculation at 1.5 atm and 120oC (operating conditions)
1
.3 A hydrocarbon mixture with the composition, shown in Table 1.3, is fed to a
flash drum at 50oF and 20 psia.
TABLE 1.3
Component
Flow rate (lb moiyhr)
i-C
4
12
n-C
4(LK)
448
i-C
5(HK)
36
Ce
23
C7
39.1
272.2
c9
31
876.3
The flash chamber (Flash2) operates at 180
oF
and 80 psia. Applying the SYSOP0
thermodynamic model, determine the amounts of liquid and vapour pro
ducts
and their compositions.
INTRODUCTION AND STEPWISK ASPEN PLUS SIMULATION 51
1
.4 Find the bubble point and dew point temperatures of a mixture of 0.4 mole fraction
toluene and 0.6 mole fraction rso-butanol at 101.3 kPa. Assume ideal mixture
and inlet temperature of 50oC, pressure of 1.5 atm, and flow rate of 100 kmol/hr.
1
.5 Find the bubble point and dew point temperatures and corresponding vapour
and liquid compositions for a mixture of 33 mole% n-hexane, 33 mole% n-heptane
and 34 mole% n-octane at 1 atm pressure. The feed mixture with a flow rate of
100 kmol/hr enters at 50oC and 1 atm. Consider ideality in both liquid and vapour
phases.
1
.6 Compute the bubble point and dew point temperatures of a solution of
hydrocarbons with the following composition at 345 kN/m2(see Table 1.4).
TABLE 1.4
c3
0
.05
n-C
4
0
.
25
n-C
5
0
.
4
Ce
0
.
3
The ideal solution with a flow rate of 100 kmol/hr enters at 50oC and 1 atm.
1
.7 Calculate the bubble point pressure at 40oC of the following hydrocarbon stream
(see Table 1.5).
TABLE 1.6
c, 0
.
05
c2
0
.
1
Ca
0
.
15
i-C
4
0
.
1
n-C
4
0
.
2
i-C
s
0
.
15
n-C
5
0
.
15
c6
0
.
1
Use the SRK thermodynamic model and consider the inlet temperature of 30oC,
pressure of 4.5 bar and flow rate of 100 kmol/hr.
1.
8 A binary mixture, consisting of 50 mole% ethanol and 50 mole% 1-propanol, is
fed to a flash drum (Flash2) with a flow rate of 120 kmol/hr at 3.5 bar and 30oC.
(a) Produce T-xy plot at a constant pressure (1.013 bar)
(b) Produce P-xy plot at a constant temperature (750C)
(c) Produce xy plot based on the data obtained in part (b)
Consider the RK-Soave thermodynamic model as a base property method.
1
.
9 A ternary mixture with the following component-wise flow rates is introduced
into a decanter model run at 341.1 K and 308.9 kPa. To identify the second
liquid phase, select n-pentane as a key component (see Table 1.6).
52 PROCESS SIMULATION AND CO
NTROL USING ASPEN
TABLE 1.6
Component Flow rate (kmol/hr)
n
-pentane
ethanol
water
10
3
7
.
5
Applying the NRTL property method
, simulate the decanter block to compute
the flow rates of two product streams.
1
.
10 A ternary mixture having the following flow rates is fed to a separator (Se
p2) at
50oC and 5 bar (see Table 1.7).
TABLE 1.7
Component Flow rate (kmol/hr)
n
-pentane
ethanol
water
33.623
0
.
476
3
.
705
To solve the present problem using Aspen Plus, the following specifications are
provided along with a T/F ratio of 0.905478 (see Table 1.8 and Figure 1.69).
TABLE 1.8
Component Split fraction in stream T
n
-pentane
ethanol
water
0
.
999
0
.
9
(calculated by Aspen)
B -O
FIGURE 1.69 A flowsheet of a separator.
Applying the SRK property method, simulate the flowsheet, shown in Figure 1.69,
and determine the product compositions.
1
.11 Repeat the above problem with replacing the separator Sep2 by Sep and using
split fraction of water 0.4 in Stream T.
1
.12 A dryer, as specified in Figure 1.70, operates at 200
oF and 1 atm. Apply the
SOLIDS base property method and simulate the dryer model (Flash2) to compute
the recovery of water in the top product.
INTRODUCTION AND STKPWISE ASPEN PLUS SIMULATION 53
Wet
Temperature = 75DC
Pressure = 1 aim
Flow rates
S
(
02 = 800 Ib/hr
H20 = 5 Ib/hr
Air
Temperature = 200oC
Pressure = 1 atm
Flow rates = 50 Ibmol/hr
N2 = 80 mole%
O, b 20 mole%
AiROur;
WET
AIR
0
dry;
O
DRYER
FIGURE 1.70 A flowsheet of a dryer
REFERENCE
AspenTech Official Site, When was the Company Founded?, http://www.aspentech.com/
corporate/careers/faqs.cfm#whenAT.
C H A P T E R
2
Aspen Plus Simulation
of Reactor Models
2
.
1 BUILT-IN REACTOR MODELS
In the Aspen Plus model library, seven built-in reactor models are available. They
are RStoic, RYield, REquil, RGibbs, RCSTR, RPlug and RBatch. The stoichiometric
reactor, RStoic, is used when the stoichiometry is known but the reaction kinetics is
either unknown or unimportant. The yield reactor, RYield, is employed in those cases
where both the reactions-kinetics and stoichiometry-are unknown but the product
yields Eire known to us. For single-phase chemical equilibrium or simultaneous phase
and chemical equilibrium calculations, we choose either REquil or RGibbs. REquil model
solves stoichiometric chemical and phase equilibrium equations. On the other hand,
RGibbs solves its model by minimizing Gibbs free energy, subject to atom balance
constraints. RCSTR, RPlug and RBatch are rigorous models of continuous stirred tank
reactor (CSTR), plug flow reactor (PER) and batch (or semi-batch) reactor
,
respectively.
Eor these three reactor models, kinetics is known. RPlug and RBatch handle rate-
based kinetic reactions, whereas RCSTR simultaneously handles equilibrium and rate-
based reactions. It should be noted that the rigorous models in Aspen Plus can use
built-in Power law or Langmuir-Hinshelwood-Hougen-Watson (LHHW) or user defined
kinetics. The user can define the reaction kinetics in Fortran subroutine or in excel
worksheet.
One of the most important things to remember when using a computer simulation
program, in any application, is that incorrect input data or programming can lead to
solutions that are
"
correct
"
based on the program's specifications
,
but unrealistic with
regard to real-life applications. For this reason, a good knowledge is must on the reaction
engineering. In the following, we will simulate several reactor models using the Aspen
Plus software package. Apart from these solved examples, interested reader may
simulate the reactor models given in the exercise at the end of this chapter.
54
ASPEN PLUS SIMULATION OF REACTOR MODELS 55
2
.
2 ASPEN PLUS SIMULATION OF A RStolc MODEL
Problem statement
Styrene is produced by dehydrogenation of ethylbenzene. Here we consider an
irreversible reaction given as:
CgHs-C2H5 -> CgHs-CH - CH2 + H2
ethylbenzene styrene hydrogen
Pure ethylbenzene enters the RStoic reactor with a flow rate of 100 kmol/hr at 260oC
and 1.5 bar. The reactor operates at 250
oC and 1.2 bar. We can use the fractional
conversion of ethylbenzene equals 0.8. Using the Peng-Robinson thermodynamic method,
simulate the reactor model.
Simulation approach
As we start Aspen Plus from the Start menu or by double-clicking the Aspen Plus icon
on our desktop, first the Aspen Plus Startup dialog appears (see Figure 2.1). Choose
Template option and then click OK.
iaj _1_J __J *j rv.Mft, I-Hid 3 I I l-J]-J _J
_
J
FIGURE 2.1
As the next window pops up (see Figure 2.2), select General with Metric Units and
hit OK button.
Copyrighted materia
56 4 PROCESS SIMULATION AND CONTROL USING ASPEN
jzj
I M I I I lAl I I I - I
[5'.f**-i "v.* (Ma
j
" *-** , /.r . - - ( 'to-.
JV--- *.j m . , _
j
'
jJ. mo; Mil E-v v 'Mi 3 'th BM
W
r . jw*-Ntaet SkwtrM
. j .j--jc-r; ] f.-S- -.r 3 C j n-V; j ' if!: VV.
FIGURE 2.2
Here we use the simulation engine at 'Local PC. Click OK when the Connect to
Engine dialog is displayed (see Figure 2.3). Note that this step is specific to the installation.
Connect to Engine
Server type:
User Info
Node name :
User name:
Password:
Working directory:
Local PC
O Save as Default Connection
OK Exit
Help
FIGURE 2.3
Creating flowsheet
We are now ready to develop the process flow diagram. Select the Reactors tab from
the Model Library toolbar, then choose RStoic icon and finally place this un
it in the
blank Process Flowsheet Window. In order to connect the feed and effluent s
treams
MODELS 57
with the reactor block, click on Material STREAMS tab i
n th 1
As we move the cursor, now a crosshair, onto the proces
s
flnw fui ,
COriier
-
two red arrows and one blue arrow. Remember that red a
rrow
f '
blue arrows are optional ports.
arr0WS are re(luired ts and
Click once on the starting point, expand the feed li
ne and click a~Hn tv
,
-
f a
stream is labelled as 1. Addmg the outlet stream to the reactor t
n
tJXwa WW
we make the image as shown in Figure 2.4.
y
'
UIiaiiy
I .lal I Ml
=
03-
-
Q a
In
i . i . S -O-M-i
o
-
a Ri astt. tb pfvjj
FIGURE 2.4
After renaming Stream 1 to F, Stream 2 to P and Block Bl to REACTOR, the
flowsheet looks like Figure 2.5.
c* .
'
r- CJ
'
Kf! Pin ftr-Kl- LI'-TV iWoc,-. i
DltflBI BI Id iff! GN-|e>IM<iM h-I "I I IH -i
-
Eh-
at rsms acs'R
FIGURE 2.5
-lIVl
Obviously, the Sia s md/cator in the bottom right of the mam window h changed
the message from Flowsheet Not Complete to Required Input /ncom ff . f
ation
to enter th* remaining data using several input forms required to comp
lete the simulation.
Hitting Next icon and clicking OK on the message sheet displayed
,
we get the setup in
put
form. First the title of the present problem is given as 'Simulation of the RStoic R
eactor'
In the next, the Aspen Plus accounting information (required at some installati
ons)
are provided.
User name: AKJANA
Account number: 5
Project name: YOUR CHOICE
Finally, select Report Options under Setup folder
,
choose 'Mole' as well as 'Mass'
fraction item under Stream tab (see Figure 2.6(a)
,
(b) and (c)).
_
i
_
r- i - i- i jv
-i i iai
MM S
UMsi
[jjttiEjjft
L- - .1
J . l-U
I- S . S . -Q-M-O-
B.BM Bi.u. '-.C--- KC TIi PFtjj Rfem.
FIGURE 2.6(a)
Jl-T - i I- fV I -M I lal fifj
FIGURE 2.6(b)
ASPEN PLUS SIMULATION OF REACTOR MODEI S 59
Mil
,
: r-i-hi r
.
! .|gi i ip' h-i
- it
Dm dm
r _ utM
-
O
-
'
ftifc waw
I i i I M>l Umomm I
FIGURE 2.6(c)
In the Data Browser window, choose Components /Specifications to obtain the component
input form. Now fill out the table for three components, ethylbenzene, styrene and
hydrogen (see Figure 2.7). If Aspen Plus does not recognize the components by their
IDs as defined by the user, use the Find button to search them. Select the components
from the lists and then Add them. A detailed procedure is presented in Chapter 1.
I?!
i "" TH III
1 -1-
sr-l 8 18 0IIU
FIGURE 2.7
fd materic
Choosing Properties /Specifications in the column at the left side
, one obtains th
e
property input form. Use the Peng-Robinson thermodynamic package by selecting PENG
-
ROB under the Base method tab (see Figure 2.8).
ol lBj
_
J
_J w] KW>|<H m -1 H JpJjJ J
J * few Proc*lit
U **-
3
r
"
3
""
3
1
"
3
"
3
3
STREAMS
_
-
'
3M| #
RSldc fn'M BE RSbte RCSTR fiPH) BB*
FIGURE 2.8
The Streams IFIInput I Specifications sheet appears with the Data Browser menu tree in
the left pane. Entering the values for state variables (temperature, pressure and total
flow) and composition (mole fraction), we finally have the following screen (see Figure 2.9).
DZSMSSEGSSSD
: fi* Hot Utorr Wrdo* H-fc
I r I -1 "I T
'
I -Ml I . 131
A|>Mdiedtio<n| FWiOwonTl
|/M1XED
to'***
Ware 2mu
(i a ******
1 'wr-S-
p3"
"
3
~
3
i]
-
"
3
3
0
D
ur
1
' J -
m-1 - i - i q su
ttBUH,
'
reS Bl . BO f"" SSiS
. ,.JCTJ .
:
FIGURE 2.9
Specifying block
information
From the Data Browser,
select Blocks/REACTOR. Specifying operating conditions for
the reactor mo
del, the form looks like Figure 2.10.
3
Efb |-.| ..IB q .>| ol,,! |
F tc. PCStB CTo Mvg-.
l
-
Qactg Mom. I Vsm"
FIGURE 2.10
Specifying reaction information
In the next, either hit Next button or Reactions tab under Blocks /REACTOR
. Chck iVeiy,
to choose the reactants and products using the dropdown list
,
input the stoichiometric
coefBcients and specify the fractional conversion. In the Aspen Plus simulator, coefficients
should be negative for reactants and positive for products (see Figure 2.11).
** b* bo "e*
>
'-'
J
RiACTQR
Wt<it BCSTR BtVn
FIGURE 2.11
In Figure 2.12
, Status message includes Required Input Complete. It implies that
all
required input information have been inserted by the user. There are a few wa
ys to
run the simulation. We could select either the Next button in the toolbar which will t
ell
us that all of the required inputs are complete and ask if we would like to run th
e
simulation. We can also run the simulation by selecting the Run button in the toolba
r
(this is the button with a block arrow pointing to the right). Alternatively, we can go to
Run on the menu bar and select 'Run' (F5).
MM.|8W'!i ,l|Hllir
DMll
I M ill
""
Elfb Imeicbah
As8V.'Bend
RxnNo Specilicaiun type Stochiotneby
IttrCanpi
ETHYL-01 > STYREHE . KrtiflOGEN
UNIFAC Group* <l 1 -
I Comp-GroLps
' Con-.p-Lis's
*
1 1 Cperty Methods
S tstrfi tficn
':
Jj Moiecua- Sbuctm
> p ParameJers
D a
S Advanced
_
&reanS
-
Jfl :
(1 EOVsraH
CJ P
3 Bocks
. RECTOR
/Sptfeahont /Re-
Rcadicxs
,
1 Contujlion | HMHiResclion | Setaclily | PSO | EowmrtAm |
At tequfed npd u ocmpHe Y j can rui the MnuMlon nitw. w
iiu can erttr more input To er4er more f-pj. Bated Cared thn
seled t e ooUont yoj mM tnyn Ihe Dais poldOAT-, menu
Rui ir-e sirxilatiwi now?
P Rwchom occu r ien
Inpu Cnplete
[H " Mnwii/SpWer;
-
CH
STREAMS
'
RStdc RYieW
Rucloi
Hea<Ev.-. i9Pt;
J.,,
Chsnga, | M<n>M>t ( 5c> j UMo*b |
F-
,r Ho, press F1
'-
Stall * .
Boot
_
Aww.RaocDdr | Awr.Mcd I
FIGURE 2.12
Viewing results
As we click OK on the above message
, the Control Panel appears showing the progress
of the simulation. After the simulation is run and converged
,
we notice that the Results
Summary tab on the Data Browser window has a blue checkmark
. Clicking on that tab
will open up the Run Status. If the simulation has converged,
it should state
"
Calculations were completed normally" (see Figure 2.13).
Pressing Next button and then OK, we get the Run Status screen
.
In the subsequent
step, select Results Summary /Streams in the list on the left and obtain the final results
(see Figure 2.14). Save the work done by choosing File/Save As/...in the menu list on
the top.
If we click on Stream Table knob just above the results table, the results are recorded
in the Process Flowsheet Window, as shown in Figure 2.15
'
>k r An [Mi Tot \r Um <.>. MO
tnut iulmtiu imi." un nn i< nt ecu iiuti
ui tmrrrxz nm a tmh tmis us . unm
um wen* Mat- unic
-CH
-
- - -
s ' w*. mw< n* w> ii>*j
FIGURE 2.13
-
T I M -I -lei
I I
-
3
"
3 "-'-I
J
a)
-
55T:
-
t " <w
"
is*"
.
,i i.
M, iMm
l>ii lU
Man'*
m
cna
inpp
BUB
Waw' VI | ****** | HU** .
m
- @ . i . e u mu
incMA ' irw wto* MMt ac S
"-
I r
FIGURE 2.14
Ffc Edt Vfew 0a Into ftjn nowheri Lfc fy VAk w Het
'
-
lup I , IT
_
LiiE| | |a|
EES;: gIBll|Oi. lall|'rj. .aaJj'lL
Mto SlAtM | Salami | HealEKclwgeij | Cokfwx naactan | pienueChange!i | Manpiaton | 5cM [ UmModeb |
,
S 0 U 31U
STREAMS 1 BSinc BEoii HGMis RCSTB BPItg RBaM.
FIGURE 2.15
\ s FoWenJJswn Ru H 1 HUM lfloAi Artfahie
For input information, press Ctrl + Alt + I on the keyboard or select Input Summary
from the View pulldown menu (see Figure 2.16).
CBSES
Fie * Forw* >Atw
input Sugary created by Aspen Plus K1. 11.1 at 12:U:CM Thu jul 5, 300?
Oirecrory C: Proqr-5R Pi les'AspenTech .norfcing Pol ders'.Aspen Plus 11.1 Fllep
title 'SlmUllon of the fiStolc Reactor"
IN-UNITS KET VOLU> E-FLOS<-
"
cuB hr ENTM*LPV-Fl.O-'*lkcal/hr' A
HCAT-TRAHS-C-
'
kcal/hr-sqn-K" PRESSURE"bar TEMPERATURE-C &
VOLUHE-CUIT OELTA-T-C HEAD-neter httLE-DENSin'-
'
fcisol/cuni' &
fASS-DENSITV-
'
kg.'CUH" W)LE-NTHALP- kcal,'noV t,
t-ASS-EWTM .P-
'
kcal/kg' HE*T-MMkcal t'OLE-CONC-'mol.
'
T &
POBOP-bar
OCF-STREAt'S COMVEN AIL
DESCRIPTIOH "
General SlHllailoi) mith Metric units :
C, bar, kg/hr, knclhr. MMKcal/hr, c\m/hr.
property Method: Mone
Flow basis for Input: Kole
Stream report cooposltlon: Kole flow
ROP-SOURCES PUBEll - AQUEOUS / SOLIDS f INORGANIC
COMPONENTS
ETHYL-01 C8H10-4 /
STVRENE C8H8 ,'
HVOfiOGEN H2
PBOPERTIFS PENG-ROB
5THCAH F
SUBSTBEAf KIXEO TCHP-J60. PRE5-1.S MOLE-FLOW-100.
W>LE-FMC ETHYL-01 1.
e Ci
'
.Users-.akjana.AppMtaMocal Terep -ape906.tK}
'
B i I vjnwi-* |- laJtol | lto.,-s || -WEME1 : jpCittU
FIGURE 2.16
t 65 - y wkjusu,
jO f DO
If one may wish to generate a report file (*
rep) for the nrp f u,
instructions as presented in Chapter 1
.
P eSent Problem, follow the
2
.
3 ASPEN PLUS SIMULATION OF A RCSTR MODE
L
Problem statement
The hydrogenation of aniline produces cyclohexylamine i
n a CSTR accord f
following reaction: '
accor(lirig to the
C6H5NH2 + 3H
2 CeHnNHa
aniline hydrogen cyclohex
ylamine
The reactor operates at 40 bar and 120oC
, and its volume is 1200 ft3 (75% li
quid) For
the liquid-phase reaction, the inlet streams have the specifications
,
shown in Table 2
.
1
.
TABLE 2.1
Reactant
Temperature (0C) Pressure (bar)
Flow rate (kmol/hr)
Pure aniline 43
41
45
Pure hydrogen
230 41
160
Fake reaction kinetics data for the Arrhenius law are given as:
Pre-exponential factor = 5 x 105 m3/kmol s
Activation energy = 20,000 Btu/lbmol
[CJ basis = Molarity
Use the SYSOP0 base property method in the simulation. The reaction is first-order in
aniline and hydrogen. The reaction rate constant is defined with respect to an
iline.
Simulate the CSTR model and compute the component mole fractions in both the liquid
as well as vapour product.
Simulation approach
Start with the General with Metric Units Template, as shown in Figures 2.1
7(a) and (b).
Click OK in the above screen. When the Connect to Engine
dialog appears, again
hit OK knob to obtain a blank Process Flowsheet Window.
Creating flowsheet
Select the Reactors tab from the Model Litwy t
models available. Among them, choose
RCSTR P ce it in tn
Adding inlet and product streams and renaming
them, the process flow magr
look like Figure 2.18.
"
Q|a|B|
_
JJ J_J nMfel I 1 :1 si 21 __1_L.J ni M M l
A1 ] c 8lor+. SmuWen
r OMUsnE.ulr.lSim.jl.j'i-
Aapn Plus Vf # i
"
VSJ6
FIGURE 2.17(a)
g *apen IP= Strean Prx&hts
I Beetle, |fa Enshh ijrit
|aklntill wth Medic IMi
Procws g fAs Unfa
nitpwi wi mmi
SpNtft/Chmic*
mnz Lines.
MMtajJ-V
, arvtr
Propetty I lhod; None
Bow toss crinpiif 'tee
Strtom reaai
cwrpcttEfi: Mote flow
'
SUrti
FIGURE 2.17(b)
ASPEN PLUS1" SIMUIATION OF REACTOR MODELS 67
h W ..> 3a Hi* .<-- MMa
o|rf|y|giai
_
lg|g rj|twi<H;j 3 I ("l jajgj
u
-
I}-
tmuHt 1 Igj gMij gM Wii*. .Hi* ->
FIGURE 2.18
Hit Afe button and then OK and get the setup input form. The present project is titled
as
'
Simulation of the RCSTR Reactor' and the accounting information are given as
'
AKJANA/6/ANYTHING/YOUR CHOICE* (see Figures 2.19(a) and (b)).
Jim_iJ *! El &iMiid 3 I i"l 3 *I
-II -. w . ft -.-.
FIGURE 2.19(a)
68 PROCESS SIMULATION AND CONTROL USING ASPEN1 M
' Fie E On TmH PU Lfrvy Wilder- *k>
0 Spiicfcii
.
jfl IM-SHi
O CuHsfflUnli
l
.li< MBW
Rovci ID
kfUCdRfMi
.11 -y-Bo
STREAMS
'
RSioc RYwId REgnl RGMw RCSTfl RWjg REafch
O * $3 17 1'.
FIGURE 2.19(b)
In the subsequent step, choose Setup/Report Options / Stream from the Data Browser
window and select
'
Mole' as well as 'Mass' fraction basis (see Figure 2.20).
B* E* Mxr CM* Todi ftr PW Uorv AWow hb
i ajJJ iBJ J al-rlfeKKI I n>i ij J |h| a| 1 M
0 SkW* Qnl
.
Jfl Ml St
Cereal | Ftowiho* | Bbcf Ali j Roperty j AW |
turnU be ndmMr, tiiMm itpoii
P MtJa P Mcta
! r Uau P Mm
TFF [gENJ T]
|S Standard fa0cdm>i
P S.>- .:abh t
P Componerti t h (wo to-. 01 H-itDon
f " M- Sc*-.. | S.*n | HME
StfltW BV ffvuc RE.M- RGte. RCS1R RPI m j,
1 " -
(Bill
FIGURE 2
.20
ASPEN PLUS SIMULATION OP REACTOR MODELS -f 69
The example reaction system includes three components. They are aniline, hydrogen
and cyclohexylamine. Defining all these species in the component input form, one obtains
Figure 2.21.
V nt Eik 4n feu To* FU. Pla Uh
Ffesctons
~
3 Mdiilfs-3ij bj rl
AMIUNE C6H7I11
WyMOGEN K1T1R0G H
CYCLOHEWLAMICSH13W-01
Eire V/cw) UtwCMnd Rtttdei:
D
' ""'""
in
Ml
I I Sotd. | U>MMt t
RSac Brtrtj ftEqai RGfcb) flCStft RFtifl Rflaieh
FIGURE 2.21
We know that a property method is a bank of methods and models used to compute
physical properties. For the sample reactor model, select SYSOP0 base property method
(see Figure 2.22) after clicking on Next icon in the above screen.
Fk feu VW* D liA Fj, li -f V,Wfe/. hefc
urvac
_j F rm
i
I 3
I*
si*
| .>j3l*J<>TtQ('W -i.d"*''",l''fi'
Aipcn rim - Sani
FIGURE 2.22
As we hit Next followed by OK, a stream input form appears. For Stream A (pu
re
aniline) and Stream H (pure hydrogen), values of state variables and composition ar
e
inserted in the following two forms, shown in Figures 2.23(a) and (b).
ffe * '-Am Di Tol An Fix Uc**y Wnfe* ' k
mm >. Ittieiwj nH-clalsKM!sJ 31 ! HiJ21) )
m.mr.i
_j PiAiW
Strunu
fj EOVar-ittai
J
-
3 i*f
SIBEAMS BGMw BCSTH
FIGURE 2.23(a)
'
:: St Edi Mw* 0 To* An a* ifc,. whd*. Htfc
10
3 Owerti
O UMFACQtsun
Zj EMMbn
ra;
i JyMIXED
~
3
-
3 :iu*f..
3
-
3
ToW IT
BCSIB fl, m
FIGURE 2.23(b)
In the next, there is a block input form. Providing required information for the CSTR
block, we have the screen as shown in Figure 2.24.
ASPEN PI-US SIMULATION OF REACTOR MODEIiJ 71
lim -Vii.l.-l!,! II I M ---
. E Sm 'mm Lbw> MrtM 4a
B.
'i -I
..f
9 - .
'
i -
ff
.
j .
-
.
s
d |.if.|.iu-.| ne
'- I' I.. -I
p=-31 -r-3
i
- 1,--.
J 1 J
I F
~
3
Si-
__-__
iir
r |- 9 . S . 9 Q UO
ITXUK Mm fJte >-. -' -
FIGURE 2.24
Product streams have been defined with their phases (see Figure 2.25).
I r-M-|r |T 'I .ICI I Ml
71
I
.
li:
.
-I
0 -p uj
llji lli*! i j I t XMUtavn I UMa III Hi | tm*mammu | mi I Ma I iMHwk j
-
o
-
I1XJM
m 0 . 8 . o yJE D
IMMI Ptmt hm. unit TVl ggg
Ifflll
0>W t a< - <
FIGURE 2.25
Press Afexf button or click on Reactions and get the window (as shown in Figure 2.26).
ASPEN PI-US SIMULATION OF REACTOR MODEIiJ 71
lim -Vii.l.-l!,! II I M ---
. E Sm 'mm Lbw> MrtM 4a
B.
'i -I
..f
9 - .
'
i -
ff
.
j .
-
.
s
d |.if.|.iu-.| ne
'- I' I.. -I
p=-31 -r-3
i
- 1,--.
J 1 J
I F
~
3
Si-
__-__
iir
r |- 9 . S . 9 Q UO
ITXUK Mm fJte >-. -' -
FIGURE 2.24
Product streams have been defined with their phases (see Figure 2.25).
I r-M-|r |T 'I .ICI I Ml
71
I
.
li:
.
-I
0 -p uj
llji lli*! i j I t XMUtavn I UMa III Hi | tm*mammu | mi I Ma I iMHwk j
-
o
-
I1XJM
m 0 . 8 . o yJE D
IMMI Ptmt hm. unit TVl ggg
Ifflll
0>W t a< - <
FIGURE 2.25
Press Afexf button or click on Reactions and get the window (as shown in Figure 2.26).
72 PROCESS SIMULATION AND CONTROL USING ASPEN"
I UtaftCSTRflCCTni
b Ed* DKB Tooit ftr Pta IJfewy Wirvis Hdp
_
fe|ej rgklaKKM "I ! I"l J JJ J l
JJ
-
i 1 i HT I leal; I M Hi
, Setup
rWft af Studio
MvanMd
a h
.11 L
Bocta
- C5TR
e s-up
(J EOVsnai>
O EOhpu -
O Spc GfWJpt
Pott
Solsd .e ion Mlt lo be nciideii n ihs
Arabia iclwwU i SriBctedttwc'cn'-
Peaili
leschon E3 ID
ii
-
[1 " MiMMiyS{ter9 | SpaUi ] He*E hangefi j Coluwij Heoclou j Preiwe Changeii ] MfloipUaloft | Sf** | UiwH&Wi |
-
a
->
Mated \
STREAMS REeril RGtb! fiCSTR RPbg
C \ fl FtAJerj'Aweo Piu) 11 i
'
HUM
fi Ofttce Woni j f-toggft Pcwergjrt . l . j MjCe toX>< frofett f [
~
FIGURE 2.26
Right click on Available reaction sets, hit New button, then either accept default
name R-l or give a name as we want for the reaction set and finally click on OK.
Subsequently, select POWERLAW in the Enter Type list and hit OK to get the screen
Ffc & *w tWa Toe* fU Fte Ubnr
, Vttyfcw Hdp
MHl
r .-l-i- PT -.1 M- I
Ml jW
j Pwwt/Henccs
LJ
"
1 Mdecwer Su-me
J : -
_j Data
i
_V) ftco-S*:
+
'
Jfl H
i o l
-
csrn
O '
9 SpGto*i
H SbeenRMub ,
.
/Spccft hm j/Satm/Ba ljont] PSD j CwvwMAm [
S dect (sacbcn twto t ndudsd r nwdel
<0 s s s o O
LJ.
FIGURE 2.27
Hitting Next knob, we obtain the screen, shown in Figure 2.28.
** cm <%* fw -.>=- **
S .
ul.i
* | SiMMt | HewE h-vjpr | a m- Rm om { Praiiu,Charge.! | Ha | I UmiH<mM |
i - s - ..mo-
STfttAKS RStoc ff.W RtajJ RGttK flCSTR RPl RBWtf,
FIGURE 2.28
As we click on New; button
, a form is displayed as shown in Figure 2.29. In this
form, we need to enter the stoichiometric coefficient as well as exponent for all
components. The exponents represent the order of the reaction with respect to each
component. Note that there are two types of reactions [kinetic (rate-controlled reactions)
and equilibrium] permitted under Power law reaction ID.
Dli*lBj
_
J
_J feiej *l nrMfcl-NM '! 1 I H -I l?l 1 |
I f~ l-.l. li IT ! -lEI I |gl
Caw** 1 CMtft** 1 f.t * Cowrt Co o*
*
[_
r
.i.-' |
*
M. | |
-j
J
hB- 0 . i . 0
iifitw4i f.4M BfJ Km wifl
1 1
ft j A J " . 1 *r**:wi-Lij<* * -*,1 1 i ' . || 5-i - ft ' 11"
FIGURE 2.29
74 PROCESS SIMULATION AND CONTROL USING ASPENT
As stated, the reaction
C6H5NH2 + 3H2 C6HnNH2
is first-order in aniline and hydrogen. Also, the reaction rate constant is defined with
respect to aniline. Accordingly, we may use the follow
ing information to specify the
reaction (see Table 2.2).
TABLE 2.2
Component
Coefficient
Exponent
aniline
-1
1
hydrogen
-
3
1
cyclohexylamine
1 0
Recall that in Aspen Plus terminology, coefficients must be negative for reactants
and positive for products. As we fill up the form, it looks like Figure 2.30.
aj}.
f*, Fe> iw tup Tcotr
i
'
lltiliiii
ESS
BoacMrNo.: |7i 3
RuctMi -
Reaction type:
Product!
"
3
Comnonent
Coefficient Enponent 1 CompafieW
Coelficient Ej<ponent
ANILINE 1 j ; CYCLO-01 1
-
IYDR0GEN .3
j *
* 1 i
Ctote
Bock,
-
y Reactiom
r J Chemolry
B Peacuons
ft R-I
1 Convefgcnce
fj Rowaheetng Onions
.r
1
Edt Delete
Reojrad tipul hcowMe
IT Mam pKen | Sepaators | HeatEndiangen | Cokams Haachm | PtenueOiaven ]
KWariel
STREAMS RSIoic RYieU
1.0 .y-U-U-
HMj RStb. RCStfl BPIm Rieldi
SoUt UnModeb
ForHefc.weMfl
b3
"
!C\
i,fi*ta.vWiHi.111 , HUH
-
ReuMtnO
FIGURE 2.30
If we do not specify the exponent for a species, Aspen Plus takes a default value of
zero. In Figure 2.31, the resulting relation is displayed in the stoichiometry sheet.
In the subsequent step (see Figure 2.32), we move on to Kinetic tab.
PHPI
-
Liasigl
.
if?:.
-
3aft l"-" JSldilJP BiiJfllalfil
.
j am
- 1 <
I j 0-.
) - .IW I I I Ihmt
<o- y i Q ono
FIGURE 2.31
"
KiMWiingwrr~ !
r
.
*
IM .Q C3WA\*\<MH "I I"! -I vl -I 9|
Irl |x|
"
3alt: l*l <<Jp | Gh-t ml
' jfl
9
9 .
.
jfl .
.
-
*
P '
* jfl
-1.-.,.
-I 3
ftintomn*&*B**n*
t
.
ta
3
.m* Vm m t> mam >ew*
r.
-
. KIT
FIGURE 2.32
76 PROCESS SIMULATION AND CONTROL USING SPE
N]
As directed in the problem statement, we use
'Molarity
'
basis. Accordingly, the
Power law is expressed as:
n
E
n
1
r= k
[T0;
exp
R
(2.1)
where r is the rate of reaction,
K the reaction rate constant (kinetic factor in Aspen
Plus terminology), k the pre-exponential or frequency
factor, T the temperature m degree
K Tn the datum temperature in degree K, n the tempera
ture exponent S the activation
energy R the universal gas cons
tant, C the molarity in kmol/m , a the concentration
exponent, i the component in
dex, and 0 the product operator.
If To is ignored, the Power law expression has the fo
llowing form:
where,
r= kT
n
exp
K = kTn exp
E
RT
E
RT
n(G) (2.2)
(2.3)
In most of our simple cases, the reaction rate constant is represented by the Arrhenius
law, that is
E N
K - k exp
RT)
(2.4)
Notice that when the Arrhenius formula is used
, we put zero for n and nothing for T0
in the Aspen Plus window. Also, the units of the pre-exponential factor are identical to
those of the rate constant and vary depending on the order of the reaction.
As we
know, the dimensions of the rate constant for an nth order reaction are:
(time)-1 (concentration)1-'1
Next come back to the problem.
The kinetic data are required to provide in the above
sheet. Here we use the Arrhenius law to represent the reaction rate constant. It is
important to mention that the pre-exponential factor m
ust be specified in SI unit. For
the example CSTR problem
,
the pre-exponential factor and activation energy are given
as 5 x 105 m3/kmol s and 20
,
000 Btu/lbmol respectively (see Fi
gure 2.33).
In the window shown in Figure 2.
33, the Status bar clearl
y indicates that all required
mputs are now complete.
Hitting Next knob and clicking on OK
,
we have the foUowing
Control Panel (see Figure 2.34).
.. ._ - -J . Pte Un* OMn m,
QMIHI -I .1 gJ al-i-|>l*l<l*-| n.| | M
I r l-'l-'l-JV
.
l .lalr : I: Ml
mam
"
3
s csm
3
ll ; US
ANIUNE . 3 HYDROGEN -i CYaO-Cl
f LMMMtotwite
-
a
-i
Kdlarai."
*
stream
farHsfe.pnMn
| igiM afc. .| gdifcCT,fi .. | g aita 11 .arote. || S fSTI- 45.},
.s
FIGURE 2.33
:
Ffc Dm Taofai Run Lfesry Wirdiw KHp
DMB| al M -H x?! nklaKI I I >| IS -I H g|-|3| @|;
J
,
J
"
1 1- i,JV -Hal
iLWjilSla)
-
5
@ CSTPJ
oxputatich carsB rsi
Bick.- csra uc tai. rcstr
fV . j Sepa(> i HwlE-changer. [ Cokm* Hb1o | Pte eChsr rt | M npuWw: | StJd; 1 UiwModel: |
MitoJ
SIflEAMS RStM fffxM REquJ RCiibOi BC5TR B Jg ftSalch
fo K o .. . .-
FIGURE 2.34
Viewing results
In the next
,
select Solver Settings, choose figsuto Summary/Sf ms
in the list on the
left and finally get the results shown in Figure 2.35 in a tabulated form.
B Ebl V- D*. TMi. Hun fW ijt MiiM m
I f I I i PT ! .leal I - Ml tM
J4JJ
nr
"
I i I i i I
I i
"
3 '-" l
il il -
am
nil 1
1000 0541
05
MUM nooo 0J30 0 001
-
mmmi
tso 601
1
ITTre
'
0J
sm
DOM MPPM
0 98)
| HuiE*w> ! C<*jwi fl-ctet. | FYB.M.Change..
i -1 .QMi-O'
i | UisrWodeU |
R&tac RVWd SEgJ HQtei RCSIR RPfaa RftWi
to*
j 3 tecofQB.c .jjJ Hereto P yP j Jatwlpd | .Ei wprf [{ AwenPkw-S
-
1*35
FIGURE 2.35
Save the simulation work in a folder giving a suitable file name.
2
.4 ASPEN PLUS SIMULATION OF A RPlug MODEL
Problem statement
The combination of two benzene molecules forms one molecule of diphenyl and one of
hydrogen (Fogler, 2005). The elementary reversible vapour-phase reaction occurs in a
plug flow reactor (PER).
2CqHq <-> C12H40 + H2
benzene diphenyl hydrogen
The forward and reverse reaction rate constants are defined with respect to benzene.
The vaporized benzene (pure) with a flow rate of 0.02 Ibmol/hr enters the reactor at
1250oF and 15 Psi. The data for the Arrhenius law are given below.
Forward reaction: A; = 3.2 x lO-6 kmol/s . m3 . (N/m2)2
E = 30200 cal/mol
Reverse reaction: k = 1.0x lO-5 kmol/s . m3 . (N/m2)2
E = 30200 cal/mol
[C,] basis = Partial pressure
The reactor length is 36 in and diameter is 0.6 in. It operates at inlet temperature.
Applying the SYSOP0 thermodynamic model,
(a) compute the component mole fraction in the product stream, and
(b) produce a plot ofreactor molar composition
'
(mole fraction) vs i-eactor length' (in).
ASPEN PLUS SIMULATION OF REACTOR MODEI S 79
Simulation approach
Select Aspen Plus User Interface. When the Aspen Plus window pops up, choose
Template and click on OK (see Figure 2.36).
i
-
....
-
...
iwmmmlt mm
FIGURE 2.36
In the next step (see Figure 2.37), select General with English Units and hit OKbutton.
1 V-
I
-
- -
FIGURE 2.37
Click O/C when the Aspen Plus engine window appears.
TM
Creating flowsheet
In the Model Library, select the Reactors tab. Expanding
the RPlug icon, the followin
g
screen is obtained (see Figure 2.38).
Uj _
jS's - s - o
SIftEAMS
'
RStoc flYfc) WJ RCte RCSTR RBtfd<
li,-1?-:-:?--
IM
FIGURE 2.38
Inserting the left bottom symbol in the Process Flowsheet Window
, adding the feed and
product streams, and renaming the block as well as streams, finally we see Figure 2.39.
Be * *> &M ro* ftj> Uonn WnSo* H*
r|ttF..U|-. -nr
Nsi|--..| -MBi IN
>|[T><rr| h~o
,
I* -****** | fM. t hmI- mw | c*- iu I rM..1,o,
_
i 1
'
-
iS- SSI Gj q.
S'W ' BS* FTiMd ftc nstfa. HCSTB flfy
, Tftj T
FIGURE 2
.39
At this moment, we are su
re that the process flow diagram is drawn correctly. The Status
message
directs us to provide the input information. Hitting Next knob and clicking on
OK, we obtain a form for setup spec
ifications. First we input the Title of the present
nroject (
Simulation of the RPlug Model), followed by the accounting information
( AKJANA/7/ANYT
HING/AS YOU WANT) and Report Options [see Figures 2.40(a) to (c)]
.
3Sif*r-~3 *m si I >>i fliai g
ISrolWoneilheHPVjgMocW
Vdd|*MMC |
-
o->
i s u -= u
SIKAMS
'
HSteic tVM myt RG|tte. RC?tR Rptq RBtuh
FIGURE 2.40(A)
> nt Mm OKk TMIp An W L>v WWo* H*p
UaTSil
arsi
aiobdj-/Deicnmn >/Acciwnlina| 0>agr>o(ci {
[T MMi- pdim I Smmnc I HulEchv4i | Cot-mi. flo'" | PimmCW
hB- 1 -1 - 8 Q O
SIRLWi
__
fl5ia R.'* RfrMl RGfaU; W Iff Hf''-.
gMdiM-AiMf But " I
"
.
'
U
FIGURE 2.40(b)
dmbl
Melm mbhjsM!] 21 g
r mi
r SM
K C twwrH 4i , flow W 'IK
O-S-0 y
FIGURE 2.40(c)
From the Data Browser, select Specifications under the Components folder. As we provide
the chemical formula of the components in the Component ID column, the other columns
of the table are automatically filled up (see Figure 2.41).
< Fit E* Htw Di Tat* ftji RsT Ihwf ffntotr Hife
_j r<rCwwi
SET
r* rg '.
"
Bin
kW iooxi Id* -J
d
rvJ
'
.cnttm
IMM FvmU,
cia<io
Mwl *h TOIR
FIGURE 2.41
In the list on the left, choose Properties / Specifications to obtain the property input
form. Then choose SYSOPO by scrolling down (see Figure 2.42).
tmum
~
3
is
1 I
I 3 "~
I d r.
I 3
. r
u
ETREAfce ftStac FTV dd SEtMl RCSTS RPljg flgateh
FIGURE 2.42
In the left pane of the Data Browser window
,
select Streams IF and enter the values
for all state variables and composition as shown in Figure 2.
43.
_
i
_
r
.
IF
UH**C i3rtu
StatevsmUm
{yMIXED
Miinii
"
3
~
3
"
3r
"
3
|12SJ |f 3
1-5 |p. d
Toid flwr (m.,- 3
|0 02 jbmot/N 3
H2
Tdat IT
"
Hoi 'jmvUf.t
'
i-1 . . u-i j
i* Rfrfi be j note ncsm npijg ma
FIGURE 2.43
In the next, select PFR by opening the Blocks folder.
The reactor is specified in the
window, shown in Figure 2.44.
i Wl ftfl P*l Lbtry Wn
r-.i:i i nr
Jill
'
IMMM
*
-J Ntw
'
QuwclWMldn
J/j Prcf n
-J
> -a f
aock-
_J Readx
_J C -wssxe
-
3
I Sold* { UnrMixM. j
BE** ftGMn
FIGURE 2.44
Open the Configuration sheet and enter the reactor dimensions in the next form
(see Figure 2.45).
F* Edt ttm 043 Tuafc flun fVK tbwy Wndm H*
DlcglBl 1 M iteial *l uW\&\**\<\vi n>| Hi ! |Mi H i?i :H
Ma
_j . /- itarj
S
_j PAttwn
?cp(rtif Veered
a :
36
DwtmUt 06 . -J
a is q-u
'
RStot Rrail flE<M Wite' BCS'R Bp
| Sohk | Um> Modab |
HUM
FIGURE 2.45
ASPEN PLUS SIMULATION OF REACTOR MODELS
85
T the subsequent step, we
define a reaction set for the simulation. The default name
R-l
has been accepted. Then select Power law kinetics and obtain the picture, shown in
Figure 2.46.
M *" D* ** "rw*
' r
i)
'
I 22
H-1 j . I y a
SIR>M$ ' HStac ffiW RCqU RGtti RCSTR
fiB
BB*J>
FIGURE 2.46
Hitting Aforf button and clicking on New
, we have the following forms (see Figures 2.47(a)
and (b)) for reaction number 1 (2C
6H6 -> C12H10 + H2). Since the reaction rate constants
are defined with respect to benzene
,
we convert the stoichiometric coefficient of benzene
to unity for both the reactions
. Obviously
,
the reactions are second-order.
Jala_jj iiei wj nHM'.teM .| m .| |h| .| pi |
1 r..l..|,.l it
.1 .ibi- 1 / ial
Rmmm
I1-I'
A
v R 1
ii
-
o-
-
0 S 0 1J
-
a .a # 1
FIGURE 2.47(a)
D|tf|y| I I <l aHM-KM
~
l ! |h| -i ~ij j
HI l
05
*
J _2=J
. j i :
3-1-0 o
-
=u
RE R6ife RnSTR f ue HB**
j y- Bi-KOT- W j K Mmrst* Moiod j r jj
'
Aver. Plu< - 5M " ij.} 30'
FIGURE 2.47(b)
As mentioned previously, when we do not specify the exponent for a component
,
Aspen Plus uses a default value of zero. As the message on the screen, shown in
Figure 2.47(b) reveals, it is true that the forward reaction rate does not depend on the
product components. After completing the first reaction, select 'New' from the Reaction
No. list. Enter '2; for the reverse reaction QHe C H
+ H2) and click OK(see Figure 2.48).
3| |B|
_JJ Mgl jgl nklaNUI I n-i 3
_LliiJ El J
.
-
l.
-
.
-
ff falaltfrfi .1 ilBl: I si
|-
1
r
Oeate a nmRedcton No.
a
PR
R-t
tMM Cir.-,.; I"..-.., n -.n
i'RaUS nS> BCtM ftGbb. RCSTft RFVp IS
Fa-Htfc mm FI
""
" " ~
-'-
--- II *pf\-ai
FIGURE 2
.48
Subsequently provide the stoichiometric coefficient
s along with ex
ponents, and get th
e screen, shown in Figure 2.
49.
ASPEN PLUS SIMUIATION OF REACTOR MODELS 87
iViirtiT.r
1 n-i 1.1 nr
-
.i ,ieii i mi *m
i; i
433
71
am*. | CJk-< | [(on
CI.X'6 >
'
wi [1
. 1
. 1
J _i5Lj
jjWM REaJ gg] HCs flft nawcft
FIGURE 2.49
Hit A exf knob and obtain two stoichiometric relations as shown in Figure 2.
50.
. -
y. To* An fV Lirwy (fntjrw
Mai
DMBI 1
-
i-nr .1 w - i
-
3>>J qLJniJ
_j MHnnd
HmNo Stuctimttry
: Knc
E .11
u ,.
*
c 1 r
, I Sehdt I Ui*MJrt )
61 bio's ' fif.ioc ff/ id he j* new- ftCMn flrv Rnth
c v e (BiiTffiirr ft* n-i " "
FIGURE 2.50
In the simulation of the present problem,
we use partial pressure basis (applicable
for vapour o
nly) and
,
therefore, the Power law expression has the following
form:
( f >
n
E
ri
1
r = k
exp
R To
,
(2.5)
where
, P represents the partial pressure (N/m2). If fo is not specified, the above equation
18 re
placed by:
r= kTn
exp
RT,
mPif1
2
.6)
For the prescribed reactions, values of the pre-exponential factor and activation energy
are provided in the two forms, shown in Figures
2
.
51(a) and (b). To apply the Arrheni
us
law, we put zero for temperature exponent n and left the box, allotted for datum
temperature T0, empty.
I r mi r ! .isi; I - IB!
if.i
as
ill
* ai F
* a ?
Si Bacfa
i PR
0 R-1
1
[i) cfwe-. sciwio.
"
3
1 d
E
StflEfiMS
RSI ffrteM REqui Rtjfcto
RCSTFI RPVJ5 RBVch
FIGURE 2.51(a)
.
. Ea , 0, r i, a .
-
i.
'
r u>i-i rr 'i-.joii
a i
"
HMfcl"" |-l l|Ii 3 >>l Dj J n.|
i a *******
(31 50*10. 5m; . C6M6
KiMteldaNUT/T>>|"*'(E<n|m'l/TB|
SfBtMK ' BStet R>wto Rt fjfl ,
8 i 0 a
I Mill
"
11 Lin i
FIGURE 2
.
51(b)
ASPKN PLUS SIMULATION OF REACTOR MODELS 89
Hitting Afert button and running the simulation, we obtain the Control Panel (Figure 2.52)
showing the progress of the present simulation.
_i_
r-i I !
'
f -i-igi 1 w aisd
(0 9 S 8 O =U
M t<< Of*
FIGURE 2.52
(a) Viewing results: Click on Solver Settings knob, choose Results Summary/
Streams in the column at the left side and finally obtain the results for all
streams, shown in Figure 2.53.
I r-i-i -rf7 'i -Hi i in i*l
4 1-
J "
a S d
IUWi 1
-
m
-
"
TW
-
tm-1
"
no-
-
*m
-
sub-
aaraocc-
-
ve- im
(stcsss: -
rwm 1
L
ROT Ml
Mr
-
oi
TWI
M
inuA mm mm mik --
I - I Ml
-I * I-
FIGURE 2.53
C ll
(b) Producing a plot of mole fraction vs length: Use the Data Browser menu
tree to navigate to the Blocks IPFRI Profiles sheet (see Figure 2.54).
MJi HillLlim-WPMlMli -. ..l1.T71.
in Fte &*l V*t C# Toe* H i PW L*f7 > : . Wi V* C# roe* Hji pw Ltmv "
Dloi|y| I -.1 EtelBl d H H I"! li U
.
ifl -
it Pt >wt
ft aa 9um
-
e v.
-
a pf
Utt Sutra.
f] nwdb
a 9fM- p
A m RNdm
-
QniMgra
P.OC..I Sbe. I
it.
pn F z
_
far-
bt !S iHo
IS TZZf&VS
sSiTFW
"
; 15 r?55
.4
s !5 00001 u*?
Z' 5 m
-
lb i55S
i* 15
IS last
1 [ri!DK4IIft
g LSiQFM,
j
I Maroiato-s | So** ) UtaHvkk |
C :., a fciJen'j'jsei Pin v
FIGURE 2.54
In the next, select Plot Wizard from the Plot pulldown menu. Alternatively, press
Ctrl+Alt+W on the keyboard and obtain Figure 2.
55.
a S5
1 a
9 EM
if/ t** Ocw
ft Fa*
: PlOCCUtilMnKtXEflM
9 a EOCor-Ortcm
fj LSSOPBu
ft
;
IJ
jlE
E
;
ii
-
24 IE
ir
;
Wercome ta Aspen Plus Plat WU.rdl
I
-L J J
51 REAMS 1 HSbe
1
i . i y=o
HVMJ REcU ROttx
FIGURE 2
.55
Click on Next icon a
nd get a variety of plots (s
ee Figure 2.56).
ASI'KN PLUS SIMULATION OF REACTOR MODELS 91
pi-eniajaaisi =i r. -i ht a3f j
MM
a
---
a tfmm
3fitf* I 3 4321 iiB1 3iil 3t J Id
9 -
? - m
i
-
N
1
n 1
17 f
n
-
R
ri
n 1
(
< H
1
I
J I i
iTmao Nftj mfc < w
-
-
" -
find* .. -_;=_
FIGURE 2.56
Among the available options, select one plot type that is titled as 'Composition' and
press Next button (see Figure 2.57).
r-l
-
-|..l'fT 'i-lci
1
fi ita.l
3 id JP-3a -''ail -i
i
-
r .a -
-
io -
-
j
-
m -
a Bin
3S
-
3 ' -
'
-
4
v-I i-*
{ 9 . i 0 Q -O-
'
w > mm "tj~ mm m> mm
J
FIGURE 2.57
Again click on Next and get the form, shown in Figure 2.58.
I mim 1?! r3l-<-lfcl<.UM "-I H _jLHjd JEl
V) - ,
i
.
iJ PHI
PlOCBU SUUM j
I I
f''V.I fi
,.
-1
I
5r
.
i
.
i {
t
ri t
!
_
Cvitl 'Sack
CIS-
ir i
-
CH
STREWS
si y u
RYaM TlSitd mt* SCS?fl BWug BflWch
1 j-
FIGURE 2.58
9 -B- M
Check whether the information displayed in the window, shown in Figure 2.58,
are
ok or not. Hitting Finish knob. Figure 2.59 is obtained by plotting 'reactor molar
composition
'
(mole fraction) as ordinate against 'reactor length' (in) as abscissa.
t- <\<- Dtfa Tooa Put trv. Wnsmr H(*>
Dl lHl am toivj ipi al-nal-KI I"! Its I M .l lal yj
Block PFfi Cemmin
si u=u
| Xnxan. | Sou | u>Mod> |
STROIMS RS'jc HTot) Qg RGtfc, ftCSIR ftFy
'
111 *
.
" ' 8M,
FIGURE 2.59
Note that the plot window can be edited by right clicking on that window and
selecting Properties.
In the properties window
,
the user can modify the title, axis scale,
font and colour of the plot. Alternatively, double-click on the different elements of the
plot and modify them as we like to improve the presentation and clarity.
ASPEN PLUS SIMULATION OK KKACTOR MOOEI 93
2
.
5 ASPEN PLUS SIMULATION OF A RPlug MODEL USING LHHW
KINETICS
Problem statement
In acetic anhydride manufacturing, the cracking of acetone produces ketene and methane
according to the following irreversible vapour-phase reaction:
CH3COCH3 -> CH2CO + CH4
acetone ketene methane
This reaction is first-order with respect to acetone. Pure acetone feed with a flow
rate of 130 kmol/hr enters a PFR at 7250C and 1.5 atm. The kinetic data for the Aspen
Plus simulation are given below.
k = 1.1 s"1
E = 28.5 x 107 J/kmol
n=0
T0 = 980 K
The unit of pre-exponential factor clearly indicates the |C
,
1 basis. To use the Langmuir-
Hinshelwood-Hougen-Watson (LHHW) kinetic model, set zero for all coefficients under Term 1
and that for all coefficients except A under Term 2. Take a very large negative value for
coefficient A. The sample adiabatic PFR is 3 m in length and 0.6 m in diameter. Applying
the SYSOP0 base method, compute the component mole fraction in the product stream.
Simulation approach
As we select Aspen Plus User Interface, first the Aspen Plus Startup window appears,
as shown in Figure 2.60. Choose Template option and press OK.
2I=fflHJ-J-Lag Pl-W i-H=J Tl I I I 'IW *l
1
1 -I
I
**mmm*mH MM
FIGURE 2.60
In the next, select General with Metric Units and again hit OK button (see Figure 2.61)
.
pea
M
An IPE a-wm ftcpwl*
'
<*-Sxar
Penmen Mair>
1
"
11
'
'C*
'
FIGURE 2.61
As the Connect to Engine dialog pops up
,
click OK.
Creating flowsheet
From the Model Library toolbar
, we have selected RPlug reactor and developed the
process flow diagram as displayed in Figure 2.62.
He & 3an Tocfc fir FW mI Jyr, WnSe* Htfc
Qi lHI aiai |a| yj nl-i-iaKKi i w.| 3
_
i
_
ii<j
_
j 3 _j
_
|
rlttF-I l- l PT
I Mi I igl
H8- S . 8 - S QUU
s,flt <SL zzz rsr izf
M awif- ~ -
FIGURE 2.62
ASPEN PLUS"1 SIMULATION OK REACTOR MODELS 95
In the list on the left, choose Setup /Specifications. For the present problem, we wish to
give the Title as
'
Simulation of the PFR'. and accounting information as 'AKJANA/8/
ANYTHING/AS WE LIKE'. In addition, choose 'Mole' and 'Mass' fraction basis for the
streams under Report Options [see Figures 2.63(a), (b) and (c)l.
r
'
i LU.
-
Ml o . 6 onu
mt >>.
FIGURE 2.63(a)
I'HIM
' - XM -i..
FIGURE 2.63(b)
Gopyngt-
ttn fci VV* CMi teds FLn Pw lirat, VAmtow
o|a!|ai I I tfeiel t?! phlftltl l'-l n) _L_L!iJ iJ 21 j2J
i r- i-i pt | -|m i - imi
3ip
Cor i j now***- I etod. /StaM| p'"y i
I
ti-n tohi NAKtad W
FkMbM hi--- 'i
P Hde PM*
T Mm. P
TFf, IGEN.M 3
P Cwowit nih IWO ib- I'KUjn
SI REAMS PStoc frririi REqal ft6tU RCSIR RFV) BSatc
fefHeb pcufl
~
CV flFoldenXAaDerPlB 1- 1 NUH : -r irt- rt.- r tr.-arpt-i
FIGURE 2.63(c)
Select Specifications under Components folder in the Data Browser window.
As we
out the Component ID column
, Aspen Plus provides the rest of the information in
component input form
, shown in Figure 2.64.
fle EJI Wen On tim ft* Put Utray Vfrifcw to
1 f
~
-
i i-i- r
jiAm \ m
3 S-L*
O SfamOM*
$ apm)
Tim
tCEIO-JE
SottTSe )3<roi
itENE KEIENE bHJO
seths -pn
stficwi wiac ff . Pfcu ns

'
tu ncsTp
-
8 . 1 -y-lE-U
FIGURE 2.64
Hit Afort button and in
property method (see Figure 2.65), scroll down to get SYSOP
O
ASPEN PLUS SIMULATION OF REACTOR MODEI.S 97
l
_
r
_
Ll_L_F -iCI I ! !
JtUI
9 "w-cwr.
j -
I 3
.
la
mr'iiir
.
(0- 0 I : I jnU-
t* ia ).
FIGURE 2.65
In the left pane of the Data Browser window, select Streams IF. Inputting the values
for temperature, pressure, total flow and mole fraction, we have the picture as displayed
in Figure 2.66.
I.UH
- ;
figs?
g M
f|7 -
.
1 i iT
I, ,
I
'
.
-
I
--...
I
'- -
3
I'* 3
3 i--- 3
r
--
I- 0 . i . 8 OMU
gjfc ani ggi
FIGURE 2.66
ASPEN PLUS SIMULATION OF REACTOR MODEI.S 97
l
_
r
_
Ll_L_F -iCI I ! !
JtUI
9 "w-cwr.
j -
I 3
.
la
mr'iiir
.
(0- 0 I : I jnU-
t* ia ).
FIGURE 2.65
In the left pane of the Data Browser window, select Streams IF. Inputting the values
for temperature, pressure, total flow and mole fraction, we have the picture as displayed
in Figure 2.66.
I.UH
- ;
figs?
g M
f|7 -
.
1 i iT
I, ,
I
'
.
-
I
--...
I
'- -
3
I'* 3
3 i--- 3
r
--
I- 0 . i . 8 OMU
gjfc ani ggi
FIGURE 2.66
In the subsequent step (see Figure 2.67), select PFR under Blocks folder. Specify th
e
reactor as an adiabatic one.
i ffc Ed We* Oto Ta* Rn Rot lisrary VAnJo* He*
OUIHI I I itelal i?l rsK NKiH '| 3
_
UjiJ _J -il SI
313
-
i KSS 3
_J AM H
.
_J y c
- 9MM
-
Jfl F
O BUM*:
3;-* Ctro'
|
~
| = 41111)
Mta
O EOrw -J
J
aft I 3 hJiii(s ii
ulwCcr/gi/Wcr. |wRtK(nni|
Pitt*** j
STREAMS RVaM BEqut RGhta
. .
BCSTfl SPlup HBateft
.
8 i US IJ
C ' g Foktect- apen FVi il l : HUM fW Ki rtsi muc s
r;;acfefZ-M!S j - jj. tii
'
ftoM } }LladuTtffi5- j .'debt AgttK Pr. |{ Plus - S . 1107 60*
FIGURE 2.67
In the Configuration sheet
, reactor length as well as diameter are given (see Figure 2.68).
Rfe E 'rim 'tieo An PW
QNB|
_u ie|jg] n|-<-|fcN M Hi a l |n| .la l i|
36 ta SM
StMrtl
.
J6
f
rj f
& ftdta
8
PnAn
f
EOVw-b*.
a EOmpJ -
0
D
-
D-* iisi (
I 3
"
3i
"
3
SWMlttf I HtHEttl
StflE*MS RSlac frtM M*A
i -1 -o-n-o-
RBto PCSTR
FIGURE 2.68
In the next
,
we define a reaction set for the present simulation.
The default name
R
-l is ok.
Then select LHHW kinetics and obtain the screen
,
exhibited in Figure 2.69.
ASPEN PUJSTM SIMULATION OF REACTOR MODELS 99
1 W-l-K-l..
-
a .
(@- 0 g g u au
1 . - W W -G- Hi-' WS.
FIGURE 2.69
Press Nex/ knob and then click on New. Under Reactants, select 'ACETONE' from the
Component dropdown menu and set the coefficient to -1. Similarly under Products,
select
'
KETENE' and 'METHANE', and set both coefficients to 1 (see Figure 2.70).
i r.:i..i-u rr
. mi-*ifc|
d
*.
- 1
Ml' -
d
t 2
roK-.
i
.
I*
-
Q
-
-
<@ S 8 Q0
inMt *a>. 'mh gi
FIGURE 2.70
100 PROCESS SIMULATION ANnjWQlOLUS
ING ASPEN'
Hitting on Next and clicking Kinetic button, we get Aeldn ics input form. A littl
e
description is given below to understand
the use of LHHW kmetxc model m Aspen
simulator.
The LHHW rate expression is represented
by:
r =
(kinetic factor) (driving force)
(adsorption expression)
The kinetic factor (reaction rate constant) has
the following form:
n
E
'
\
1 >
K = k
exp
R
k
T
To)
(2
.1)
(2.8)
If Tq is ignored, Eq. (2.3) replaces the above expression.
Note that all the notations
used in Eq. (2.8) have been de
fined earlier.
The driving force is expressed by:
f N A
n c?
and the adsorption is modelled as:
M
Li=i
N
nc"J
where,
In (Ki) =Ai + Bi/T + Ci IniT) + D.T (2.9)
Here, m is the adsorption expression exponent
, Mthe number of terms in the adsorption
expression, N the number of components
, a the concentration exponent, K2, K, the
equilibrium constants [Eq.
(2.9)], A,, fit, Q, the coefficients and I Notice that the
concentration term C used in the above discussion is dependent on the [CJ basis. Say
for example
,
when [CJ basis is selected as molarity
,
the concentration term represents
the component molar concentration (kmol/m3); similarl
y when [CJ basis is partial
pressure, the concentration term represents the component partial pressure (N/m2).
Providing required data
,
we have the filled kinetic sheet
,
shown in Figure 2.71.
Click on Driving Force to obtain a blank form
Select 'Term 1' and then 'Molarity' as [CJ basis. Under Concentration exponents for
reactants
,
set acetone exponent to 1. Similarly for products
,
set ketene and methane
exponents to 0.
Also enter zero for all four driving force constants as mentioned in the
problem statement (see Figure 2.73).
In the subsequent step (see Fi
gure 2.74), select Term 2' from the pulldown Enter
term menu.
Since the given reaction is first-order with respect to acetone and there is
no second term
,
enter zero for all exponents and coefficients
. Owing to the method
Aspen Plus uses to specif
y a reaction, we should insert a very large negative value for
coetticient A (say
,
-106) t
o make Term 2 essentially zero [see Eq (2 9)1 Finally,
click
on Next icon
.
n- .
ft* 0m Om Tai .av* VMw
-
L
-
T I I 'i r-i -I -lei I !!
3
-~ .
j
.
ii w
j9
O
'm<iaii '
-i
*
Zj
:
lUlllll fcuM.
j
J
.
Zj
a *-
.
j f
.
-i
.
D
-.
-
Ml
,
3
i am i(t/Tf
fF II | IWBMM | MlMnpn | Man W I | .W.w.Oa n | Mwwl-i | MB | IMMM |
ItWMn T om. ggjl gjj MM. WWI
FIGURE 2.71
1IWJ'
<5 l-B
I Mk | - - -
WB. B'Mt 'CM Wto. "lac*-
FIGURE 2.72
ft* 0m Om Tai .av* VMw
-
L
-
T I I 'i r-i -I -lei I !!
3
-~ .
j
.
ii w
j9
O
'm<iaii '
-i
*
Zj
:
lUlllll fcuM.
j
J
.
Zj
a *-
.
j f
.
-i
.
D
-.
-
Ml
,
3
i am i(t/Tf
fF II | IWBMM | MlMnpn | Man W I | .W.w.Oa n | Mwwl-i | MB | IMMM |
ItWMn T om. ggjl gjj MM. WWI
FIGURE 2.71
1IWJ'
<5 l-B
I Mk | - - -
WB. B'Mt 'CM Wto. "lac*-
FIGURE 2.72
j
1
_j '.D- o-xr'
-I
-
[-EETEEXSC
.
1
Idlbsw I
. p feis ep
BEoJ AG**!
FIGURE 2.73
Hi
.
a
_j
0
)
lJ
u
_)
Data
a
.
SbMM
F
. p
PFS
lj Omttry
_
G
_j
u l
j
Rwcaigthsai jVapm
ErteHtrm [lrm2
3
t(*clartr
Expowii
.
Q
.r' co(W,c*1t A tewrddning low* Jm Ln(ccr.;fanl 21 - i f/fT
"
- Ml . u T SeeHflte .
.
Ci ytwtyw fivaln enerw'a t J n poww lawwpittWin
Mom
STRCAHS
BE(M RSfcfa RCSTR
llQi<to; wcwrtw l j ig ito w J
FIGURE 2.74
FUin HUM
The Stoins bar dis
plays a message of Required Input Complete in the bottom right
comer of the window show
n in Figure 2.
74. Subsequently
,
run the simulation and obtain
the status report as dis
played in Figure 2 75
ASPEN PLUS SIMUUVTION OF REACTOR MODELS 103
_
j
_
r-i-'i-i
'
nr -i \ m -sw
-
i --- tii
-
'
**"' I II I -* -- I . *"l ->
r <@ 6 S 0 O HU
IIIMH HlK * Mm ".iril A* Mar
FIGURE 2.75
Viewing results
Pressing Solver Settings knob and selecting i?esw/ s Summary /Streams, we obtain the
final results as reported in Figure 2.76.
i i-liisialiil:
"
1 1 I -i
r[.- , ....
1
3
el
i
fami
_____ -
ST
iffran
1
ur
rzw
i
BTTiW
'
I'M
Tivi
'
i
M- Q . S . U S U
Wii TM- l-
FIGURE 2.76
Copynghied material
104 PROCESS SIMULATION AND CONTROL USING ASPF.N
SUMMARY AND CONCLUSIONS |
This chapter presents the simulation of several reactor models. Here, we have considered
a variety of chemical reactions in the Aspen Plus simulator. Probably the most useful
kinetic models. Power law and Langmuir-Hinshelwood-Hougen-Watson (LHHW). have
been used in the solved examples. A number of problems are given in the exercise for
extensive practice.
PROBLEMS |
2
.1 Ethyl acetate is produced in an esterification reaction between acetic acid and
ethyl alcohol.
acetic acid + ethyl alcohol <-> ethyl acetate + water
The feed mixture, consisting of 52.5 mole% acetic acid, 45 mole% ethyl alcohol
and 2.5 mole% water, enters the RCSTR model with a flow rate of 400 kmol/hr at
750C and 1.1 atm. The reactor operates at 70oC and 1 atm. Both the reactions
are first-order with respect to each of the reactants (i.e., overall second-order). For
these liquid-phase reactions, the kinetic data for the Arrhenius law are given below:
Forward reaction: k = 2.0 x 108 m3/kmol - s
E= 6
.
0 x 107 J/kmol
Reverse reaction: k = 5.0 x 107 m3/kmol . s
E= 6
.
0 x 107 J/kmol
[C,l basis = Molarity
Perform the Aspen Plus simulation using the NRTL thermodynamic model and
reactor volume of 0.15 m
3
.
2
.2 Repeat the above problem replacing RCSTR model by RStoic model with 80%
conversion of ethyl alcohol.
2
.
3 Simulate the reactor (Problem 2.1) for the case of an RGibbs model.
2
.4 An input stream, consisting of 90 r aole% di-tert-huty\ peroxide, 5 mole% ethane
and 5 mole% acetone, is introduced in a CSTR at 10 atm and 1250C and a flow
rate of 0.2 kmol/hr. The following elementary irreversible vapour-phase reaction
is performed isothermally with no pressure drop.
(CH3)3COOC(CH3)3 C2H6 + 2CH3COCH3
Fake kinetic data for the Arrhenius formula are given as:
k = 1.67 x 104 kmol/m3 s (N/m2)
= 85 x 103 kJ/kmol
LCJ basis = Partial pressure
The reactor operates at 50oC and its volume is 6 m3. Using the SYSOP0
thermodynamic method, simulate the CSTR model and compute the component
mole fractions in the product stream.
ASPEN PLUS SIMULATION OK REACTOR MODELS 105
2
.5 A feed stream, consisting of di-tert-buty\ peroxide, ethane and acetone, enters a
RYield model at 10 atm and 1250C. The reactor operates at 10 atm and 50oC.
Use the SYSOP0 property method and assume the following component-wise
flow rates in the feed and product streams (see Table 2.3).
TABLE 2.3
Component Feed flow rate (kg/hr) Product flow rate (kg/hr)
di-tert-hntyl peroxide
26.321 1
.949
ethane 0
.301 5
.
314
acetone 0
.
581 19.94
Simulate the RYield reactor and compare the results (mole fractions in the
product) with those obtained for Problem 2.4.
2
.6 As stated in Problem 2.1, the reaction between acetic acid and ethanol gives
ethyl acetate and water.
CH3COOH + C2H5OH (-> CH3COOC2H5 + H20
The inlet stream, consisting of 50 mole% acetic acid, 45 mole% ethanol and
5 mole% water, is fed to a REquil model with a flow rate of 400 kmol/hr at 750C
and 1.1 atm. The reactor operates at 80oC and 1 atm. Using the NRTL property
method, simulate the reactor model and report the compositions of the product
streams.
2
.7 Ethylene is produced by cracking of ethane in a plug flow reactor. The irreversible
elementary vapour-phase reaction is given as:
C2H6 - C2H4 + Hg
ethane ethylene hydrogen
Pure ethane feed is introduced with a flow rate of 750 kmol/hr at 800CC and
5
.5 atm. The reactor is operated isothermally at inlet temperature. The kinetic
data for the LHHW model are given below (Fogler, 2005).
k = 0.072 s"1
= 82 x 103 cal/mol
Tq = 1000 K
|C,] basis = Molarity
The reactor length is 3 m and diameter is 0.8 m. Using the SYSOP0
thermodynamic model, simulate the reactor.
2
.
8 Repeat the above problem replacing the PFR by a stoichiometric reactor with
80% conversion of ethane. If require, make the necessary assumptions.
2
.9 In acetic anhydride manufacturing, the cracking of acetone occurs and produces
ketene and methane according to the following irreversible vapour-phase reaction:
CH3COCH3 i CHoCO + CH3
1
In the CSTR model, ketene is decomposed producing carbon monoxide and
ethylene gas.
K
'
CH2CO-> CO + 0.5 C2H4
where,
-
rk = K
'
K
= exp
,
1.5
22.8-
K'
= exp
19.62-
26586
T
25589
mol/lit s . atm
15
mol/lit . s
[C,] basis = Partial pressure
Here, -rA is the rate of disappearance of acetone (A), -rk the rate of disappearance
of ketene ik), PA the partial pressure of A, and K and K
'
the reaction rate
constants. Pure acetone feed with a flow rate of 130 kmol/hr enters the reactor
at 7250C and 1.5 atm. The reactor with a volume of 1
.4 m3 operates at 700oC
and 1.5 atm. Applying the SYSOPO base method
, compute the component mole
fractions in the product stream.
REFERENCE |
Fogler
,
H. Scott (2005), Elements of Chemical Reaction Engineering
,
Prentice-Hall of India
3rd ed.. New Delhi
.
CHAPTER
Aspen Plus Simulation of
Distillation Models
3
.
1 BUILT-IN DISTILLATION MODELS
An Aspen simulation package has nine built-in unit operation models for the separating
column. In the Aspen terminology, these packages are named as DSTWU, Distl, RadFrac.
Extract. MultiFrac, SCFrac, PetroFrac, RateFrac and BatchFrac. Under these categories,
several model configurations are available. Note that Extract model is used for liquid-
liquid extraction. Among the built-in column models, DSTWU, Distl and SCFrac
represent the shortcut distillation and the rest of the distillation models perform rigorous
calculations.
DSTWU model uses Winn-Underwood-Gilliland method for a single-feed two-product
fractionating column having either a partial or total condenser. It estimates minimum
number of stages using Winn method and minimum reflux ratio using Underwood
method. Moreover, it determines the actual reflux ratio for the specified number of
stages or the actual number of stages for the specified reflux ratio, depending on which
is entered using Gilliland correlation. It also calculates the optimal feed tray and reboiler
as well as condenser duty. Remember that this model assumes constant molar overflow
and relative volatilities.
Distl model includes a single feed and two products, and assumes constant molar
overflow and relative volatilities. It uses Edmister approach to calculate product
composition. We need to specify a number of stages, e.g. feed location, reflux ratio,
pressure profile and distillate to feed iD/F) ratio. Actually, when all the data are
provided, we can use this column model to verify the product results.
RadFrac is a rigorous fractionating column model that can handle any number of
feeds as well as side draws. It has a wide variety of appUcations, such as absorption,
stripping, ordinary distillation, extractive and azeotropic distillation, reactive distillation, etc.
MultiFrac is usually employed for any number of fractionating columns and any
number of connections between the columns or within the columns. It has the ability to
simulate the distillation columns integrated with flash towers, feed furnaces, side
107
108 PROCESS SIMUKATION AND CONTROL USING ASPEN
strippers, pumparrounds, etc. This rigorous column mo
del can be used as an alternativ
e
of PetroFrac, especially when the configuration
is beyond the capabilities of PetroFrac
.
As mentioned earlier, SCFrac is a shortcut column model. It simulates a distillation
unit connected with a single feed, multip
le products and one optional stripping steam
.
It is used to model refinery columns, such as atmospheric distillation unit (ADU) and
vacuum distillation unit (VDU).
PetroFrac is commonly employed to fractionate a petroleum feed. This rigorous model
simulates the refinery columns, such as ADU, VDU, fluidized-bed catalytic cracking (FCC)
fractionator, etc., equipped with a feed furnace, side strippers, pumparounds and so on.
RateFrac is a rate-based nonequilibrium column model employed to simulate all
types of vapour-liquid separation operations, such as absorption, desorption and
distillation. It simulates single and interlinked columns with tray type as well as packed
type arrangement.
BatchFrac is a rigorous model used for simulating the batch distillation columns. It
also includes the reactions occurred in any stage of the separator. BatchFrac model
does not consider column hydraulics, and there is negligible vapour holdup and constant
liquid holdup.
It is worthy to mention that for detailed information regarding any built-in Aspen
Plus model, select that model icon in the Model Library toolbar and press Fl.
In this chapter, we will simulate different distillation models, including a petroleum
refining column, using the Aspen Plus software. Moreover, an absorption column will
be analyzed. In addition to the steady state simulation
, the process optimization will
also be covered in the present study.
3
.2 ASPEN PLUS SIMULATION OF THE BINARY DISTILLATION
COLUMNS
3
.
2
.1 Simulation of a DSTWU Model
Problem statement
A feed stream, consisting of 60 mole% ethane and 40 mole% ethylene
,
enters a DSTWU
column having a flow rate of 200 Ibmol/hr at 750F and 15 psia. This feed is required to
fractionate in a distillation column capable of recovering at least 99
.6% of the light key
component in the distillate and 99.
9% of the heavy key component in the bottoms. The
sample process operates at 300 psia with zero tray-to-tray pressure dro
p
. The pressure
in the reboiler as well as condenser is also 300 psia.
In the simulation, use total
30 theoretical stages (including condenser and reboiler) and a total condenser
. Applying
the RK-Soave property method
,
simulate the column and calculate the minimum reflux
ratio, actual reflux ratio
, minimum number of stages
,
actual number of stages, and
feed location.
Simulation approach
From the desktop
,
select Start button
, and then click on Programs, AspenTech, Aspen
Engineering Suite
, Aspen Plus Version and Aspen Plus User Interface. Then choose
Template option in the Aspen Plus Startup dialog and hit OK (see Figure 3.
1).
ASPEN PLUS SIMULATION OF DISTILLATION MODKUS 109
Q\a\m -I -I |r| <ri q-r-mi .l-Kl!d 2) I I l gj J -
I ' l-l-l I- 1 1
-
I I ! 1-1
.
i
FIGURE 3.1
Select General with English Units as the next window appears (see Figure 3.2).
.
4./
MM
- Hi . -
...
mm ...
;
__
l
FIGURE 3.2
C aterial
Again press OK to see the Connect to Engine dialog (see Figure 3.3). Here we choose
T
,ocal PC by scrolling down. Hit OKknob and move on to develop the process flow diagram
.
Connect to Engine
Server type:
User Info
Node name:
User name:
Password:
Working directory:
a
Save as Default Connection
( OK 1
Exit
Help
FIGURE 3.3
Creating flowsheet
As we select Columns tab in the bottom Model Library toolbar (Figure 3.4), Aspen Plus
shows all built-in column models.
a 6t Mr- 0*s locii Rfi Rewhart Ltrary Wxto- Hfc>
Model Library toolbar
StftEAMS 1 DiTVU Ci-J RfEjJikI M tfug Sffru PWtrf.te Rurf- Bwctfi -
FIGURE 3.4
ASPEN PLUS SIMULATION OK DISTILLATION MODELS 111
In the next, select DSTWU icon to represent the short-cut distillation process.
Once we have selected the icon, place the icon on the flowsheet by clicking with the
cross-hair somewhere on the flowsheet background. When finished, click on K | symbol
or right-click on the flowsheet background. By default, the column is named as Bl
(see Figure 3.5).
i\n 'amiami I
Hi tM Dn <oaa 'hr nrann lw -
Dfagyai aial id g] aififci K!--! "i i |m| ! v\ *\
r|rrFf,.|..|..h HT 'MPl I Bl -fW
UJ
_
-
iT
-
CH
"SAW. ' DIIMI Out "*l<m 1M MtfMi IW l*. ..
i c-.i C- a'aMAcwi a IM AM ru- MMC*
FIGURE 3.5
In the screen, shown in Figure 3.5. only the block is displayed; there are no incoming
and outgoing streams connected with the block. Therefore, the Status message in the
bottom right of the window includes Flowsheet Not Complete. Interestingly, after
connecting all required streams with the unit, this message sometime may also be
retained. This happens because of improper flowsheet connectivity.
To add a single feed stream and two product outlets (distillate and bottom), click on
Material STREAMS tab in the lower left-hand corner. As we move the cursor
(a crosshair) onto the process flowsheet, suddenly three red arrows and one blue arrow
appear around the block. These arrows indicate places to attach streams to the block.
As we know, red arrows are required ports and blue arrows are optional ports. Click
once on the connection point between the feed stream and the DSTWU block, enlarge
the feed line and finally click again. By default, this stream is labelled as 1. In the
similar fashion, we can add the two product streams, namely 2 and 3, to the distillation
unit (see Figure 3.6).
Copyrighted malarial
He EA V* data Tooti Rr. FtowtfiM Ut-av Wtxfaw Hto
rlRFi-|...httt lT 1 irol I - lal 1
0
-
&
~
3
Ul .
filf Mewt/SpUeu 1 Stpaatai | HwlEMhangwt Criumn* j ReKloit | PrwawOiangsi | MsripuWwi | SoW | UMtMwWt j
STREAMS ' DSTWU Dntl Rrfisc EntisO Mutftw; SCFiac PeOoFi Ratrf.ac BWchFiac
J
Book rflOflCfcrJ-
FIGURE 3.6
After renaming Stream 1 to F, Stream 2 to D, Stream 3 to B and Block Bl to
DSTWU, the flowsheet finally looks like Figure 3.7.
fte EiJI ew OKa Tocti f**i ftehi Uxsy Wndm. H-t
MiBl alal lei 1 ni-rlftl Nkl H li! -
-
0 O
E
-
STREAMS
'
DSVM
Rrf(e E**d MtAffc SCfttc PMcfiae RjuF.ic Eatctfr
.. , - ~r IR Wfc. .nR*!!! MUM TW*o
'
.
V n fco-
I Qw i W l- O il W l UN T * || A -a .
FIGURE 3.7
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 113
Now the Status bar in the window, shown in Figure 3.7, says Required Input
Incomplete indicating that the flowsheet is complete and the input specifications are
required to provide using available input forms for running the Aspen simulator.
Recall that within the Aspen simulation software, the simplest way to find the next
step is to use one of the following equivalent commands:
(a) press the Next button
(b) find 'Next' in the Tools menu
(c) use shortcut key F4
and obtain Figure 3.8.
mF-M-i-i nr 'i -ici \-\m
c
-Q-
-
0
-
Dpr, rce rout to**'
3 I
HmnnUBmt | VwMdi | HMUOwpn fil | Rmckb | Pm*j*0Bi | MariMn | iota | UwMolM
STRUMS ' DSrwU Pit Wi we 1*1 tOit WtwT Warfwe jtjjjg
| *,0-H- Wot I tJO t ttoM I <]OmH1 Mnw |aj<iOtto || AvxfV S ~ Ql'f. t*9t
FIGURE 3.8
Hitting OK on the above message, we obtain the setup input form. Alternatively,
select Solver Settings knob and choose Setup /Specifications in the list on the left
(see Figure 3.9).
Although optional, it is a good practice to fill out the above form with a title and to
provide the accounting information subsequently. The present project is titled as
'
Simulation of a Shortcut Distillation Column' (see Figure 3.10).
Sid
oltflBl A t Nel tfl rahclfc l lwl n J 21 JiJilJ zJ 2l J
1
_
L
_
r i-i rv 'I -ipi i w
I "'M'.
SintMC
'
WIMAJ Cxi Brf.K MiJtfue 5Ct'c Pk. i ftttrfii Brf.f:
FIGURE 3.9
i (Mi
3Mbl JMlJiilF Bid LJ
_J Ww
= 3 EOCsn.Cn
"
I
-
3
'
*
,
7 '*"' I ""I 1 -TO- I Mrow<w I Sold: t UtvUaMt (
FIGURE 3
.10
In the next (see Figure 3.
11) the Aspen Plus ac
counting information (required
some installations) are given in the followin
g way.
User name: AKJANA
Account number: 9
Project ID: ANY ID
Project name: YOU CHOOSE
ASPEN PLUS'" SIMUI-ATION OF DISTILLATION MODELS 115
. l\ I r",
9 -
'
3f
a) - .
a mi
5!
1 nlVI M (M* <M_ fMa WlB Ir- .
) MB I - - - I
FIGURE 3.11
We may wish to have stream results summarized with mole fractions and/or some
other basis that is not set by default. For this, we can use Report Options under Setup
folder. In the subsequent step, open Stream sheet and then choose 'Mole' fraction basis.
In this regard, a sample copy is shown in Figure 3.12. although this is not essential for
the present problem.
i-d 3-J-itiiJa.ii
0 -
1 .*>*>
P <* ' i PBS .* luiTi 3
FIGURE 3.12
116
PROCESS SIMULATION AND CONTRQL
USING ASPEN
Use the Data Browser menu tree to nav
igate to the Components/Specifications/
Selection sheet (see Figure 3.13).
. .
t W DM Tii ft*. PW tto i
HHP
.
-
. :
1 J
.
5 Drill-id!
Uyr-End Pmpoti
rHudocariiMW
ti aeehi
O ,
Caww*iD
ComiKifun" WTO
FamO)
iO II SiiKi ait to tr rMneved Itom dsiatw* J. erte< C<m(rt<*fK Haw f om-ia SteHdp
[
if Mtw SpUen | Sp* | HealEttJiWBen Cohmnt } flwcto 1 P-essueO owt | MwpuWWi | Sate | UraMW. j
STREAMS 1 OSTWJ Drti ErtaO Mutfrac
'
-U * PatftFi ? Rahjiac BalchFrae
Sr*,B.ft
-
r:siHa-Ai>i,ivini1
FIGURE 3.13
In the window, shown in Figure 3.13, the table has four columns; they are under
the headings oi Component ID, Type, Component name and Formula. Among them, the
Type is a specification of how an Aspen software calculates the thermodynamic
properties. For fluid processing of organic chemicals, it is generally suitable to use
Conventional optiom Remember that component ID column should be filled out by the
user. A Component ID is essentially an alias for a component.
It is sufficient to use the
chemical formulas or names of the components as their IDs.
On the basis of these
component IDs, Aspen Plus may spontaneously fill up the Type
,
Component name and
mateh in
f T haPPen' * that AsPen Plu to find an eXaCt
lt}lhrATyin *er words
' APen Plus does not recognize the components by
T
86 fj!? 0 0 Search the components
.
Select the components from
Subsectiri 3
detaiIs
'
See the solution aPProach
in
(see lfir fo T
6 0f
i
COmPonent hane and ethylene, as thefr
IDs
(see Figure 3.14). The other three columns have been automatically filled out.
tZSlTjiT j11'1!!?68 I?0118 meth0ds *** mod to compute the phy
Pron l 2
.
0ht th? Pr0Perty input f0rm
'
er hit Next icon or choos
e
Propernes/Specifications in the left pane of the Data Browser window.
Set RK-Soav
e
property method by scrolling down (see Figure 3.15).
ASPEN PLUS SIMULATION OK DISTILLATION MODELS 117
..i
-
j ;
3 .
FIGURE 3.14
Plata l I wi Qb3Mslllid5d 3
I r-l I..|-f7 .: .id ! ' -It
BS aJ
9 -
zsjti Dld -3l alig|g|
i ! r
-
3S3
FIGURE 3.15
The Streams /F/Input / Specifications sheet appears with the Data Browser menu tree
in the left pane (see Figure 3.16). Here, we have to provide the values for all state
variables (temperature, pressure and total flow) and composition (component mole
fractions).
118
PROCESS SIMULATION ANnCO TROLJ-
JSING ASPEN'
Ffe til '. Tut. Teal, r-m FW limy Wr*
H*
i r - I .i-l rv . j J-Igl M.
mm m
111'
.
J PltKTMM
-
a) enjr,hcaa
RK6'J1
nrtxu i
ri UNKK Owe-
rj um(KO j>(
m i
if
1
5TRJWS 1 DSTWU
21
r f
: |pmtu
;
l
-
THWIE
-
1
- < - MJflK SCFlK PWoF E.- --" B-r*f,-
FIGURE 3.16
Filling out the form, shown in Figure 3.16, with the data given in the problem
statement, one obtains the data, shown in Figure 3.17.
.
He Ed! Vc tata Took fe> FM Ltrary M*km -i*
.
J/) sT*r. MhoC
-
g , - . -
RXSBU-1
RKTKUI
Q E*anM*To-is
1J .
.
_j .w
3Mi
] EOOpbora |
ll
_
-
o
~*
h
|Pinio 2
[
is
Conmotnon
| Mole f-*: 3r
-
Corrconan
IS
04
lew [T
SIB6W6 : bStWU
i
J- .! 2l
FIGURE 3
.17
Specifying block i
nformation
i
w t Sfn f t under Blocks folder. As a result.
a DianK block in
put form is displayed (see Fi
gure 3.18).
FIGURE 3.18
Under Column specifications option, here we enter the number of stages that is 30.
It is fairly true that we can alternatively specify the reflux ratio when the number of
stages is asked to compute. Note that ethylene is the light key and naturally ethane is
the heavy key. As mentioned in the problem statement, recovery of the light key
component in the distillate (= moles of light key in the distillate/moles of light key in
the feed) is 0.996 and recovery of the heavy key component in the distillate (= moles of
heavy key in the distillate/moles of heavy key in the feed) is 0.001. In addition, the
pressure of the total condenser and reboiler is given as 300 psia. Entering all these
information, one obtains the result, shown in Figure 3.19.
i f
-
-l-l f t'
,,
-
1 I
--
|
-o-
FIGURE 3.19
CopynghlGd material
FIGURE 3.18
Under Column specifications option, here we enter the number of stages that is 30.
It is fairly true that we can alternatively specify the reflux ratio when the number of
stages is asked to compute. Note that ethylene is the light key and naturally ethane is
the heavy key. As mentioned in the problem statement, recovery of the light key
component in the distillate (= moles of light key in the distillate/moles of light key in
the feed) is 0.996 and recovery of the heavy key component in the distillate (= moles of
heavy key in the distillate/moles of heavy key in the feed) is 0.001. In addition, the
pressure of the total condenser and reboiler is given as 300 psia. Entering all these
information, one obtains the result, shown in Figure 3.19.
i f
-
-l-l f t'
,,
-
1 I
--
|
-o-
FIGURE 3.19
CopynghlGd material
120 PROCESS SIMULATION AND CONTROL USING ASPKN'
The Status message includes Required Input Complete indicating that we are in a positio
n
to run the simulation. Simply press Next button and receive a message regarding th
e
present status (see Figure 3.20).
fiT TTJ
Jj UkifIC Gkc
.
s*.
Smm
_
E0VMblw
-
33 Dsmni
a -
Q Be-* C-pua-i
Mb
H
[30 jgi i Cm*
fioW
I ]300
KiHictoipooert
Com [ETMYLEHE
flBMy: [0 0C1
itjucioMtiTCienpu Totftw- x*npu fccC*wM tt*n
STRWMS
FIGURE 3.20
Click OK on the above message and obtain the Control Panel window that show
s
the progress of the simulation (see Figure 3.21).
F Efe to T* An iMy -AWto* -H*
]ajiJ
-
ill w| KHIMKI h>\ 0 >Nh| *i lacal
-
EH
*bs atrsitrro rkx sot iabli taw
HUM
fit -. I
FIGURE 3.21
ASPEN PLUS SIMU1.ATI0N OF DISTILLATION MgggUj 121
Hitting Next followed by OK, we have the Run Status screen (see Figure 3.22).
_
i
_
r -i rr .i.ipi i ibi
-
.
f
HMtf
mutt WIWW (M fMF( iMMO *fik SOik f i*rfi
FIGURE 3.22
HH-'Ifci '*. .
Viewing results
In the next, select Blocks/DSTWU/Results from the Data Browser. In the following
(Figure 3.23), we get the answers as:
Minimum reflux ratio = 7.724
Actual reflux ratio = 8.751
Minimum number of stages = 33.943
Actual number of stages = 67.887
Feed location = 40.417
Save the work by choosing File I Save As /... in the menu list on the top. We can name the
file whatever we like. Remember that a backup file (*.bkp) takes much less space than
a normal Aspen Plus documents file (*.apw).
If we wish to have the input information, press Ctrl + Alt + I on the keyboard or select
Input Summary from the View pulldown menu (see Figure 3.24).
Copyrtghtod material
I r..|-M= IT -i .iai, I ibi
dim
--i.
'j-i
i a SH
r
-
1S?497652
-
3*J12.;3
Br.il.
ifMIM|NMM f
0399
HE IP
STREAMS DSmj OaK Hrf.K F M HJtfiflC SCR PeMFmc Wtfwc BteW,*
'
sti| s
_ I Oa j-WWtW Awcn PIl - Static Q G9
FIGURE 3.23
i Edi Font
'
\kB '
lalxt
irpuc SuwMry creicd by Aspen Plus Bel. 11.1 at
Directory c:\Pr09ran f nes'.Aspenrechvworklng foIi
10:15:40 Tho Jol 12, 2007
.
working FoldersVupen plus 11.1 Fllenw c :\users\4kjana\AppMt\Local\Tep-~ap6336. trt
[
TITLE 'SinulatiorL of 3 Shortcut Cist Illation column'
I-UNITS EPXC
Ikf-STREjWS COMVEW ALL
bescfiiPTiON -
Central simulation with Eoallih units :
F. psl, Ib/hr, Ibool/hr, Btu/hr. coft/hr.
property Method: nort
Flow basis for Input: Mole
Strea* report composition: HoU flow
PSOP-SDUSCES PUHEll
C0KPOMEKTS
ETHANE C2H5 /
ElKfLEKE C2H>
PROPERTIES Pk-SOAVE
PROP-OATA RirSKD-l
IH-W.ITS ENC
PROP-LIST BKSKI3
BPVAL ETHANE ETHYLENE . OlOOMOfriJO
BPVAL ETMYLENE ETHANE .0100000000
iTREW F
S085TREt fIXEO TEKP"' 5. PRES-1S. t0LE-FLOW-200.
M016-FRAC ETHANE 0.6 - ETWlENt 0,4
-
|.
<1A .1I.. |Hn|. | Mj ynn | |
FIGURE 3.24
Creating report file
To create a detailed report on the complete work we have done
,
including input
summary, stream information, etc., select Export from the File pulldown menu. The
n
save the work as a report file (e.g., C/Program Files/AspenTech/Working Folders/Asp
en
Plus Version/ DSTWU.rep). In the next, open the saved report file (DSTWU.rep) going
through My Computer and finally using a program, such as the Microsoft Office Wor
d
or WordPad or Notepad. For the present problem, the final report is shown
below.
ASPEN PLUS IS A TRADEMARK OF
ASPEN TECHNOLOGY, INC.
TEN CANAL PARK
CAMBRIDGE, MASSACHUSETTS 02141
617/949-1000
HOTLINE:
U.S.A. 888/996-7001
EUROPE (32) 2/724-0100
PLATFORM: WIN32
VERSION: 11.1 Buiid 192
INSTALLATION: TEAM
.
EAT
JULY 12. 2007
THURSDAY
12:07:22 P.M.
ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE I
SIMULATION OF A SHORTCUT DISTILLATION COLUMN
ASPEN PLUS (R) ISA PROPRIETARY PRODUCT OF ASPEN TECHNOLOGY. INC.
(ASPENTECH). ANDMAYBEUSEDONLYUNDERAGREEMENTWITHASPENTECH
RESTRICTED RIGHTS LEGEND: USE, REPRODUCTION. ORDISCLOSURE BYTHE
U
.
S
.
GOVERNMENT IS SUBJECT TO RESTRICTIONS SET FORTH IN
(i) FAR 52.227-14. Alt. Ill, (ii) FAR 52.227-19. (iii) DEARS
252.227-7013(cMl)(ii). or (iv) THE ACCOMPANYING LICENSE AGREEMENT,
ASAPPLICABLE. FORPURPOSES OFTHEFAR, THIS SOFTWARESHALL BEDEEMED
TO BE "UNPUBLISHED" AND LICENSED WITH DISCLOSURE PROHIBITIONS.
CONTRACTOR/SUBCONTRACTOR; ASPENTECHNOLOGY. INC. TENCANAL PARK.
CAMBRIDGE. MA 02141.
TABLE OF CONTENTS
RUN CONTROL SECTION
DESCRIPTION
FLOWSHEET SECTION
FLOWSHEET CONNECTIVITY BY BLOCKS..
2
2
2
2
2
COMPONENTS
3
3
U-O-S BLOCK SECTION
BLOCK: DSTWU MODEL: DSTWU
i
4
STREAM SECTION
EOF
5
5
PRORT.RM STATUS RfTnTION
ninr,K STATUS
ASPEN PLUS PLAT-WIN32 VER- 11 1
07/19/9007
PAGF/1
SIMULATION OF A SHORTniTT DISTTT.T.ATION COLUMN
RUN CONTROL SECTION
THIS COPY OF ASPEN PLUS LICENSED TO
TYPE OF RUN: NEW
INPUT FILE NAME:
_
00341ji.inm
OUTPUT PROBLEM DATA FILE NAME:
_00341ji VERSION NO.
1
LOCATED IN:
PDF SIZE USED FOR INPUT TRANSLATION:
NUMBER OF FILE RECORDS (PSIZE) = 0
NUMBER OF IN-CORE RECORDS = 256
PSIZE NEEDED FOR SIMULATION = 256
CALLING PROGRAM NAME: apmain
LOCATED IN: C:\PROGRA~l\ASPENT~l\ASPENP-l
.
l\Engine\xeq
SIMULATION REQUESTED FOR ENTIRE FLOWSHEET
DESCRIPTION
GENERAL SIMULATION WITH ENGLISH UNITS : F
,
PSI, LB/HR, LBMOL/HR,
BTU/HR, CUFT/HR. PROPERTYMETHOD: NONE FLOWBASIS FOR INPUT: MOLE
STREAM REPORT COMPOSITION: MOLE FLOW
FLOWSHEET SECTION
STREAM SOURCE DEST STREAM SOURCE BEST
F DSTWU D DSTWU
B DSTWU
FLOWSHEET CONNECTIVITY BY BLOCKS
BLOCK INLETS OUTLETS
DSTWU F D B
SEQUENCE USED WAS:
DSTWU
ASPEN PLUS SIMUIAT10N OF DISTILLATION MODELS 125
IN OUT
CONVENTIONAL COMPONENTS (LBMOIVHR)
ETHANE
ETHYLENE
TOTAL BALANCE
MOLE( LBMOIVHR)
MASS(LB/HR)
120.000
80.0000
120.000
80.0000
200.000 200.000
5852.66 5852.66
ENTHALPY(BTU/HR) -0.252753E+07 -0.363687E+07
RELATIVE DIFF.
0
.
000000E+00
0
.
000000E+00
0.
000000E+00
-0
.
155399E-15
0
.
305025
ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE
COMPONENTS
ID TYPE
ETHANE C
ETHYLENE C
FORMULA
C2H6
C2H4
NAME OR ALIAS
C2H6
C2H4
REPORT NAME
ETHANE
ETHYLENE
U-O-S BLOCK SECTION
BLOCK: DSTWU MODEL: DSTWU
INLET STREAM:
CONDENSER OUTLET:
REBOILER OUTLET:
PROPERTY OPTION SET:
F
D
B
RK-SOAVE STANDARD RKS EQUATION OF STATE
IN OUT
TOTAL BALANCE
MOLE( LBMOIVHR)
MASS( LB/HR)
200.000
5852.66
200.000
5852.66
RELATIVE DIFF.
0
.
000000E+00
-0
.
155399E-15
ENTHALPY(BTU/HR) -0.252753E+07 -0.363687E+07 0.305025
* *
INPUT DATA *** .
HEAVY KEY COMPONENT ETHANE
RECOVERY FOR HEAVY KEY 0.00100000
LIGHT KEY COMPONENT ETHYLENE
RECOVERY FOR LIGHT KEY 0.99600
TOP STAGE PRESSURE (PSI) 300.000
BOTTOM STAGE PRESSURE (PSI) 300.000
1"
NO. OF EQUILIBRIUM STAGES
DISTILLATE VAPOUR FRACTION
***
RESULTS ***
30.0000
0
.
0
DISTILLATE TEMP. (F) -18.3114
BOTTOM TEMP. (F) 20.4654
MINIMUM REFLUX RATIO 7.72431
ACTUAL REFLUX RATIO 8.75092
MINIMUM STAGES 33.9434
ACTUAL EQUILIBRIUM STAGES 67.8868
NUMBER OF ACTUAL STAGES ABOVE FEED 39.4169
DIST. VS FEED 0.39900
CONDENSER COOLING REQUIRED (BTU/HR) 3,034,310.
NET CONDENSER DUTY (BTU/HR) -3,034,310.
REBOILER HEATING REQUIRED (BTU/HR) 1,924,980.
NET REBOILER DUTY (BTU/HR) 1,924,980.
ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE
STREAM SECTION
BDF
STREAM ID B D F
FROM: DSTWU DSTWU
TO :
DSTWU
SUBSTREAM: MIXED
PHASE:
LIQUID
LIQUID VAPOUR
COMPONENTS: LBMOL/HR
ETHANE
119.8800 0
.1200
120.0000
ETHYLENE 0
.3200
79.6800
80.0000
COMPONENTS:
MOLE FRAC
ETHANE
0
.9973
1
.5038-03 0
.
6000
ETHYLENE 2
.6622-03 0
.
9985
0
.4000
TOTAL FLOW:
LBMOL/HR
120.2000
79.8000
200.0000
LB/HR
3613.7256
2238.9320
5852.6576
CUFT/HR
140.3489
82.0590
7
.5963+04
STATE VARIABLES:
TEMP (F) 20.4654 -
18.3114
75.0000
PRES (PSI)
300.0000
300.0000
15.0000
VFRAC
0
.
0
0
.
0
1
.
0000
LFRAC
1
.0000
1
.0000 0
.
0
SFRAC
0
.
0
0
.
0
0
.
0
ENTHALPY:
BTU/LBMOL -
4
.1532+04 1
.6983+04 -
1
.
2638+04
BTU/LB
-
1381.4403 605.3231 -
431.8608
BTU/HR -4
.
9921+06 1
.3553+06
-2
.5275+06
ENTROPY:
BTU/T.RMOL-R -
58.6713
-
30.5758
-
28.8269
BTU/LB-R -1
.
9515 -1
.0898
-
0.9851
DENSITY:
LBMOiyCUFT 0
.
8564 0
.
9725 2
.6329-03
LB/CUFT 25.7482 27.2844 7
.
7046-02
AVGMW 30.0643 28.0568 29.2633
PROBLEM STATUS SECTION
BLOCK STATUS
* *
*
Calculations were completed normally *
*
All Unit Operation blocks were completed normally *
*
*
All streams were flashed normally *
#
3.
2
.2 Simulation of a RadFrac Model
Problem statement
We will continue the above problem with few modifications. A hydrocarbon stream,
consisting of 60 mole% ethane and 40 mole% ethylene, enters a RadFrac column having
a flow rate of 200 Ibmol/hr at 750F and 15 psia. The distillation process that has total
68 theoretical stages (including condenser and reboiler) and a total condenser operates
at 300 psia with zero pressure drop throughout. The distillate rate, reflux ratio and
feed tray location are given as 79.8 Ibmol/hr, 8.75 (mole basis) and 41 (above-stage),
respectively. Consider the RK-Soave property method.
(a) Simulate the column and compute the compositions of top as well as bottom
products.
(b) Is there any discrepancy in product compositions obtained from RadFrac and
DSTWU columns? If yes, what is the main reason?
Note: In the comparative study (for part b), consider total 68 theoretical stages (including
condenser and reboiler) keeping other entered data unchanged for the DSTWU column
(see Subsection 3.2.1).
Simulation approach
(a) Start with the General with English Units Template, as shown in Figures 3.25(a)
and 3.25(b).
I I
FIGURE 3.25(a)
Click OiiTin the screen, shown in Figure 3.25(b). When the Connect to Engine dialog
pops up, again press OK button to obtain a blank Process Flowsheet Window.
FIGURE 3.25(b)
Creating flowsheet
Among the built-in columns in the Model Library of Aspen Simulator,
select RadFrac
and place it in the flowsheet window
. Connecting feed, distillate and bottom product
streams with the distillation column
,
and changing the default names of the block and
all streams, finally we get Figure 3.
26.
r|gf7-| .|..|' pr .
1 -tCi i iw IH
t
13 0
snefi muu am im mj** ujw
-
J r-
- <
FIGURE 3.26
In the subsequent step, simply hit Afert button followed by OK to open a setup input
form. These two windows, shown in Figures 3.27(a) and (b), include the Global and
Accounting information for the present project.
. % fa M Dm tM * imh n m n*
9 i"-
-
9
-
3 >- w.
0 -
.I - 11 - I
i ii
ITOf Mr.
'
MIUU Da t oM IM*a 0<a Narfw ..McfiAB
FIGURE 3.27(a)
JaglHl :| Mftl yJ nWkfoKM 1 til .]J_
nJ juJ 1 1 ill
v a
*
ft-1 a
4 Gfl
Skv
iwi-si
O MET
O METCfiAR
fl METCMGCM
f> 5V-C6AH
Sttwrnf
Flo*ebftg Opbon*
MoM ,1-! Took
US YOU UKE
i 2Jil
STREAMS DSTWU Dim Rrftc E- ad Muffnc SCFfac PaBcfiae Ratftac Batetfrac
farHaip.pMn
| .si) Chapter 3 ttowJWcri | 4]Q>pMf 2-ltorfi Wtrt H A xn Pkj. - SMi . fi'"
FIGURE 3.27(b)
In the Setup/Report Options / Stream sheet
,
select ole' as well as 'Mass' fraction
basis as shown in Figure 3.28.
0 Becwrt Opdcro
.:
fib b on To* n uv rnvhw Hdp
r Uhv R 1 >IB3|- . { lal
i
UMbl'1 -I -3>>JialajNil
Gmi4 I Ftattt j Btaek Vsim} Proper j ADA |
i jjj Bock.
; HMtebancUWinsDnMpwl
Ffaubwit FiMjonbMa ShWDfamM -
j f? Mote P Moio ; tff- [geTTe
'
r mm ' P SS Iff Sindsd (BO octant
T SUHovcAjw r SUi viAm; r WUaPBcoUw)
_ 1 P SoK-rewatfwwKw*
K ConpoAMvAweftMoftKlnn
WotWu.iartwiw*
MOM
*
tWSrtten | S Mtatt | HMEwhangm
SIRCMC ' DSTMJ
<i-t-o:--iv-(i..#.c-r-
DSTMl fag Arf E*ao. SCf >1>rf fl .ac e IK
FIGURE 3.28
In the list on the left, choose Components /Specifications to define the components.
Using the component names, ethane and ethylene, as their IDs, we obtain the filled
table as shown in Figure 3.29.
=W 54 * :> T FV itun Wr*s-
-
r-i-i-i
-
i .w i -igi *m
3a !
O si
o ,.
-
Mn*
;lrM*N cats
.IHYUNC
>
Pttrfnc RrfW:: Bct#.*;
FIGURE 3.29
From the Data Browser
, select Specifications under Properties folder and then set RK-
Soave base method to compute the physical properties (see Figure 3.30).
' Fit CM
0|<*|H| - ;
>I>'.|--|T MBJ|v
.
mrai J J|a.
IJ
1
.
It
3
Bia(tw6 fflr.SOAVt
.
- - r
OwoCTylO j
1 J
5T)J ' OSTWU
FIGURE 3.30
Use the Data Browser menu tree to navigate to the Streams /F/Input / Specifications
sheet. Inserting the given values for the feed stream, Figure 3.31 is obtained.
r-itfi>t|
3EfSiF -q l-li Fi-Hid QUIH
1j
3 |m* dr
(200 jbrt*.
it ,
1 Hm(t jr r: CMlma | FtMcicn | RMMfOungett | Htrie-Mm \ SiteJ UtftKoM |
Ejiki Mulfia: SCFlK FmfiK PmfiiK 9*0*1*:
FIGURE 3.31
, select Blocks/RADFRAC/Setup. Fill up
the Configuration sheet as shown in Figure 3.
32.
Sa To* Rn Pa tfea/ WMw Help
I r.-.|-.i-l fT
Nv i 11] isN
g BO VMbki
a *
3
H*o4erHcuv*i
O Dwt i
7]F 1
?98 (trrotA,
-Ha
FIGURE 3.32
Under Setup subfolder, the filled Streams sheet looks like Figure 3.33.
.
i 'to 1 !.;
> | | MB I M |
-it r
FIGURE 3.33
In the next, simply input 300 psi under Stage 1/Condenser pressure. Aspen simulator
assumes that the column operates isobarically if no additional pressure information is
provided (see Figure 3.34).
IB I' W tl*)
i:.,ir.ir.ii.0.ii'.fi..#.s .j-.
FIGURE 3.34
To run the simulation, hit Next and then OK to observe the progress of the simulation
in the Control Panel window, shown in Figure 3.35.
Under Setup subfolder, the filled Streams sheet looks like Figure 3.33.
.
i 'to 1 !.;
> | | MB I M |
-it r
FIGURE 3.33
In the next, simply input 300 psi under Stage 1/Condenser pressure. Aspen simulator
assumes that the column operates isobarically if no additional pressure information is
provided (see Figure 3.34).
IB I' W tl*)
i:.,ir.ir.ii.0.ii'.fi..#.s .j-.
FIGURE 3.34
To run the simulation, hit Next and then OK to observe the progress of the simulation
in the Control Panel window, shown in Figure 3.35.
n* E# Mm Dal* Toch ft* Utrvy WMdaw M*.
_.
iJ
~
-
l i-.i T ai Jfilp
I l"l "li-dail 4;|
-*HaoMiafl input pcl<tCiti.4B* ...
Ml JSTftllVtO fSON 3 Or tABLt IAELE tIAJa - KJWSTD
owpotatiom owata ro> tmi jiowshmt;
->ClcaJ.ttQn tin . . .
Block: aAcrajkC <mui raofsac
IS LOHM THM( JTXGJ *1 MKMVM D.7O*i*07 (H/SSW1
Coif/cg*nffi iearttlOK*:
01 KL IL Sce/Tol
ill Eo.oas
a i j U.m
J 13 7.oca
4 1 i.73*fr
.5. i : i o.i6a7i-ai
lli>ral
STREAMS PSTWU Dirf Radfw , lAaci MUtfxic; SCFuw fahoFrac Ratrffac Batetfrac __
_
FIGURE 3.35
Viewing results
Click on Solver Settings followed by Results Summary and Streams, we have the table,
shown in Figure 3.36, accompanying the results of all individual streams. Save the
work in a folder as a file.
j He Ed) Urn Curt TooU Ron Plot Ifinry WndoM l-<*
JjlJ 121 1 1*1
_
da)
~
J CcnvOotcm
ComOnta
3Mbl lljPi-H JMaljjj
~
3 Sii.iIe|
1 i i
l316 8 078 7*1154
" 1
J982 13i5 752(1
|te.fr:
OS* Um 0517
"
TTfhUNE QOQi 0995 0383
tiHiilt 11371! 120(
CTHYIENC
'
~
0498 73512 man)
EIHAHE 0 336 bou oeao
EIHYUNE 00M 03
-
- cx.magttgicffTr-wi
FIGURE 3.36
Select Input Summary from the View dropdown menu to obtain all input information
of the present problem (see Figure 3.37).
ire.i uiu-y itHin bv up*- lia .>. It.I ll.'S'l* Sal ).i 11,
Olr.ciory I Pro m (tin -Oin! .s't-t .ic.r Hut II. 1
00'
Tin* 'SIIl1T*("i .* UlM'M ts'w*
I-IIUVI CVfllD ILL
.ccolvi.ii>o xcow-io .Mie'-io-un 10 t
cavit 'i-. ill- - '- i-.'iM' .. :, ;
a. B. fV*r> ll-al Kr. Hh.Vt , c H.O,
Ml> 'w live ">!.
'nrari (oiMitilax: Mil flo"
Miiauas main unimi yxio- ikkmiu 4
tiHu ei- -
rmkM C!"
W'OITl Ultll'l
HWii ill wii:i
CfWuM EIMK .oioXo<:
MCKMI VMB VMIK fi "IWl, ll "iw-.'OC.
1 ...
FIGURE 3.37
Results of the RadFrac column
TABLE 3.1
Composition (mole fraction)
Component
B D
ethane
ethylene
0
.
996
0
.
004
0
.
004
0
.
99G
Results of the DSTWU column
TABLE 3.2
Composition (mole fraction)
Component
B D
ethane
ethylene
0
.
997
0
.
003
0
.
002
0
.
998
From Tables 3.1 and 3.2, it is obvious that there is a little difference between the
product compositions. However, the main reason behind this fact is that the RadFrac
performs rigorous calculations, whereas the DSTWU is a shortcut model. Another
possibility is the round-off error associated in the reflux ratio and feed tray position.
Copyrighled malarial
'
3
.
3 ASPEN PLUS SIMULATION OF THE MULTICOMPONENT
DISTILLATION COLUMNS
3
.
3
.
1 Simulation of a RadFrac Model
Problem statement
A multicomponent distillation column, specified in Figure 3.38, has total 20 stages
(including condenser and reboiler) with 60% Murphree efficiency. A hydrocarbon feed
mixture enters above tray 10 of the RadFrac column. Apply the Peng-Robinson
correlation and consider 120 psia pressure throughout the column.
(a) Simulate the model and calculate the product compositions, and
(b) Produce a Temperature' (0F) vs. 'Stage' plot.
Feed Specifications
Flow rate = 100 Ibmol/hr
Temperature
= 120F
Pressure = 120 psia
Component
Mole%
C3
5
/-C
4
15
n-C
4
20
'
-
C5
25
A?-C5
35
<
Vapour Distillate Specifications
Reflux rate = 125 Ibmol/hr
FIGURE 3.38 A flowsheet of a distillation column
.
Simulation approach
(a) As we start Aspen Plus from the Start menu or b
y double-clicking the Aspen
Plus icon on our desktop
,
the Aspen Plus Startup dialog appears (see Figure 3.
39).
Select Template option.
FIGURE 3.39
VSI'KN I'll 'S SIMl'LATION OF DISTOIATIOM MHHKl.S 137
As Aspen Plus presents the window after clicking OKin Figure 3.39, choose General
with English Units. Then hit OK (see Figure 3.40).
FIGURE 3.40
Click OK when the Aspen Plus engine window is displayed (see Figure 3.40).
Remember that this step is specific to the installation.
Creating flowsheet
At present, we have a blank Process Flowsheet Window. So, we start to develop the
process flow diagram by adding a RadFrac column from the Model Library toolbar and
drawing the inlet and product streams by the help of Material STREAMS.
Now the process flowsheet is complete. The Status bar in the bottom right of the
screen, shown in Figure 3.41, displays a message ofRequired Input Incomplete indicating
that input data are required to enter to continue the simulation.
Hitting Next knob and then clicking OK, we get the setup input form. In Figures 3.42(a)
and (b), the Title of the problem (
'
Simulation of a Multicomponent Column') followed
by the Aspen Plus accounting information (AKJANA/ll/ANY ID/FINE) are provided.
Include the additional items in Report Options/Stream sheet under Setup folder
(see Figure 3.43).
C aterial
fi, 6* v rwa To* IVi rk**M llv wn*~
H*
J
-
CM
STREAMS ' DSm) Diiii Kvfiec Eliacl Muffiac SCFw PelroFiK Hattfims BUchFrac
FsrIMs.miFI i
'
cv Rto*>wn'ii.i ihim
| Chacte3 Wo<!W ,[ ]Oitcl-ltotlW.. | Met* Aciclaftcfewl I IMS
FIGURE 3.41
.
* Mi D. To* fo PW litra unto* H*
D|ia|B| |8| >g| aklaKKM n.| -Ti| ,jHj |
_
jj
-
|a<xl
a aj si
mTb fJ Mil iilpi-3 l oi l H
StvamOast
=c ia LWl.-S<h
O RepalCptom
Conmneti
Praot
rj Rearforj
_J RaKliSurray
til
UiHifflm
::
!|Swiabor at a MJHcoffponent Colwrr
. GMMri
OuQtitanAt |ENG
d
CONVEN
Si
d
d
Uu...... '
< 1 J
d
r UwfreswAtcataJabm
.SetHat,
F M"! ''ll'n '
r
j
40**** I H*****"" CfcBa | R
aactan | natMCIWisin ! ManBii*w i SU> | UawHaMi )
FIGURE 3.42(a)
illJIBI I ! f c(PJ S fJ- >ll !-H 3 'I 1*1 i| TJ
_
j J
I f
~
-l -I-1 fV -1 -iC! i m\ MM
o--
Hi-a li im MMa wr -w. t-
1-1
FIGURE 3.42(b)
.
i -iff] i 1*1 -iti
5
-I
'
'" ''''
r.
aim
FIGURE 3.43
In the left pane of the Data Browser window, select Components /Specifications. Filling
out the Component ID column, we obtain the table as shown in Figure 3.44.
Copynghied material
mas.
m Do* lock Br. PU Lbtwy Moo- HHp
J-" - l-l hPT
:?j 'I
1 lai
.
N
1 ?(c -
fit SmJalicn 0*:<-i
CuBjn Uh*l
0 Papc"
L J-J 6-<J Proli
M CJ NtaOhMcMMMn
Prtcaties
PROPANE Convertonal fflOPWIE
SOBUfll S06UTAHE C4H10-2
wet* MEmtlBUIiJIt. 9UZ-3
JPCItTWIE
r
far Help p-eai M
FIGURE 3.44
In order to define the base property method
, press Next icon or select Properties/
Specifications in the column at the left side (Figure 3.
45). From the Property method
pulldown menu, select PENG-ROB. This equation of state model is chosen for
thermodynamic property predictions.
Ffe E* W Pa W
0|e?|B|
I Wsi lStl
das
Jt Specficabom
lhUSs
htufaoampemrti
Qj H-f)rC<mpj
; . unif:qw*>!
O GLOBAL
1 (3 Enmaw
1 -ij PramMwi
F
-
CH
STREAMS
PiopBly method: t modHt
Ptoctislypw. F
[PEHG-ROe
ftw-waioi method j
-
-
: ChcntbylD j
r
Pfltefnc P fwt B#etf.K
FIGURE 3.45
In the next, use the Data Browser menu tree to navigate to the Streams /F/Input /
Specifications sheet. Entering the values of all state variables and component mole
fractions, we get this picture (see Figure 3.46).
I rH-H-F " -IB I'll IW
I2S
Ml II- P=!J 3
I-
~
3
f k 3
,
-
&
-
3
I 3
' 'U*w 5? !?- Mftg !- -*. -~
. ....
Ei
-P-- M= 'O--------
FIGURE 3.46
Open the Configuration sheet choosing Blocks /RADFRAC in the list on the left. In the
problem statement, the information on number of stages, condenser type, vapour
distillate flow rate and reflux rate are given (see Figure 3.47).
3=
:3
'
rZ3_
. mam
tea
.rauv s-.rv, Ma Cm mm . .*>>
FIGURE 3.47
In the next, use the Data Browser menu tree to navigate to the Streams /F/Input /
Specifications sheet. Entering the values of all state variables and component mole
fractions, we get this picture (see Figure 3.46).
I rH-H-F " -IB I'll IW
I2S
Ml II- P=!J 3
I-
~
3
f k 3
,
-
&
-
3
I 3
' 'U*w 5? !?- Mftg !- -*. -~
. ....
Ei
-P-- M= 'O--------
FIGURE 3.46
Open the Configuration sheet choosing Blocks /RADFRAC in the list on the left. In the
problem statement, the information on number of stages, condenser type, vapour
distillate flow rate and reflux rate are given (see Figure 3.47).
3=
:3
'
rZ3_
. mam
tea
.rauv s-.rv, Ma Cm mm . .*>>
FIGURE 3.47
142 4 PROCESS SIMULATION AND CONTROL USING ASPEN
In the subsequent step, specify the feed tray location in the Streams sheet as shown
in Figure 3.48.
fl. Ml Di T* ft* PW Uom* VMcm N*
I
flow
20 Um4
CJ
.
31 Pp 3.
Q
i rj dv
S .
t . .
9 , '
0- RADFRAC
Hi j j flndxra
* Cj T3<*
SinDWS ! OSTW OiW ft K tm*t MJJ.tc Sgt*e fWuc
.
Hwfie B*<(W-<
FIGURE 3.48
Enter the coliunn pressure of 120 psi and get Figure 3.
49 as shown in the screen.
5* pfboi
Cj b**<**t
Ci 'jruJACCw
Cj uwff&o
t cj ~*
Cj
E ( J Vt. j xr-
* CJ .
cj w
_ CJ fearfiMngCkUn
:
f--3
f*M*
'
Mfr
!-
-1*1 xl
FIGURE 3.49
The Blocks/RADFRAC/Efficiencies/Options sheet appears with the Data Browser
menu tree in the left pane.
To input the Murphree efficiency value for all trays (excluding
the condenser and reboiler)
, we have the screen, shown in Figure 3.50 first.
T He S <*- Ma Tn* ft* Ft* Un, WMdw 4*
wal _U a|t1>hNIH!l 2l jiiiiii J i
r.>i..i..|.
-
fT '
I .W I - W jgfel
Method
I
o
Set*
Jj
0
:j
9
0
p
llhMWHcu
Trr. Smg
9
0
0 Gsmaigra
0
1
"
T' 4
STf&WS Km) Dha Hvfttc Eiftact Httfrac SCFac PdtoFiac Ra<eFtc
:
SalcbFiK
Aspen Phis - 9b.. /- AOeb tooba j l: i fM 1S<6
FIGURE 3.50
Press the knob to open the Vapour-Liquid sheet (see Figure 3.51).
tj He &t Uew Teob Rji Pie! liw/ VAvfcw heb
Jr~--l h.b HT _ij_iM_J_Ua| M!d
O '
-
a '
a
3
HafaiEn. dili5lPi BidoLaliid
- RSOfRAC
O a.
_j P*> Sir.)
Eta
5-
yOphOW VoptM-UqilU j 1
Slartrg Endng
*
/Cx- iele
flT <**tmm I I HeL-Jwn 1 *-". | Rea. | l> iei>w | Meroiae,. ) Sol* 1 UwHoA*
-
a-
MeMTiel '
. . -' 5 SEi . n. .... Dj.kT.
FIGURE 3.51
Assume the rectifying along with the stripping zone as Section 1 and fill up the
table
, shown in Figure 3.52.
144 -f PROCESS SIMULATION AND CONTROL USING ASPEN1
mmmamm
RU> &H \Aew Dats Tec*
i r-i y i nr am i m
.
-J <
PAOFRAC
MmCM
C vientm hi
Pock Sa j
EMMm
Report
User Suooj-
LiJ_
STREAM?
'
joc*w. StV9
Ugp
1 19
* 1
f -r.
NUM o
Mobetuot* It
FIGURE 3.52
Hit Afcci button followed by OK and observe the progress of the simulation in
Control Panel window as shown in Figure 3.53.
Fte E* Vtew 0e To . Run Jbnrf VHvhw
Jjij
D RADFRAC
< Loading SlmXat cn Jngtn* lS:61r33 i
;rDC8ing Input .pciftcti.=Ti , . .
IHTOUUTTflH
eitJAfly PUJutfOTiRS paru can* set d roa hool SEParrD
mie muivn from scf tasli . xuu kms - lsptste
slock: ftirraxc maids a*cnuc
esM
1.2195
c ;j*4t
Jsasll
f " Mii<$aM> I SeMJtJ. I H<w fill I Rajrtai | IWnCh n |
"V J
STREAMS OSTWU
M.iJSra> I S.O.*.. I IMiM vr- CM | (Won | Pa-nOwvn | MnuM i
'
OSIVAJ Dfl Rrfwc MJf iCfiK FWrfnc R ft*: gaafwe
J'j jT-tfc, i- *
FIGURE 3.53
ASPEN PLUS SINfULATION OF DISTILLATION MODELS 145
Viewing results
Click on Solver Settings knob and then choose Results Summary /Streams to obtain the
product compositions (see Figure 3.54).
r-i .i.i>fv -
jci
rl 3'-f 13 "--l
9
_
J
IM Mi
mmf ~
"
Hi 1
"
T TBH
.>*
"
TOB 1 l . "
| J
*.
-
sin 1
"
rtai-'
-1
1 !
Will ue in
TariT ' IM
lb i
i
.
aoni IJH-
"
TIB TM
ntn 1 . a l< III
Tf5B 1
f n hi 1 i I wr mi "in 1 hihi I "i |
|
-
 rmt Km*~
.rw -.* I- .>'..
FIGURE 3.54
It is a good habit to save the work done at least at this moment. If we wish to see
the tabulated results with the process flow diagram in a single sheet, simply hit Stream
Table button just above the results table (see Figure 3.55).
JMMI .til _!.) a nH-|l%l<M ) r I i-l .IglJi j
lisf i
-
i -id urn
-C3-
FIGURE 3.55
As stated previously, to obtain the input information, press Ctrl+Alt+I or select Input
Summary from the View pulldown menu (see Figure 3.56).
imut SuHry crd by Ajpr Clul Rl. 11-1 it VMM Sun )u
l IS, 2007
;Dlrtory c
'
.froqriM fil .AipefiTch\**ork1ng Folders Aspen Plus 11.1 Fileniw C userj ijjn* *ppOjt local T*<Bp -*pt>a cn,
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Is-unITS CNG
EXF-STREWS CONVIN ALL
ACCOUMT-INFO ACCOUHT-ll PROJECT-IO-AHY ID PRO JECT-NWI-
"
FINE
"
USE R - HAfE "
"
AK J AH*
'
OtStRIPTION
'
Cnral Slaulation wtth English units ;
f, psl. Ib-tv. Itaol/hr. Btu hr. cuft/hr.
property method: none
fIoh basis for Input: Nola
Strcan report cowposlclon: tol fl
AOUEOUS / 50LIOS / INOBGANIC ,
'
A
PROP-SOURCES POREll . aflUEOUS ,' SOLIDS / INORGANIC
CWPOWMTS
PROPAXE ClHS ,'
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N-VT-01 CAMlO-l /
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rSHCET
BLOCK RAOFR.AC IN-F OVT-OV B
PROPERTIES PEMG-ROB
>-DATA PRKIJ-1
IN-UH1TS CPKt
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BPVAL PROPAhE N-BUT-01 3.300000001-3
BPVAL PROPANE 2-MET-01 .0111000000
.
'.
tol # f> " to*
t QwpW M I JO IW l lhAJT M- [ wnfta 5 } > AtWwAort* || -APF7EAJ > 1 17a>
FIGURE 3.56
(b) First, choose Blocks /RADFRAC/Profiles in the column at the left side
Accordingly, we have the stage-wise data as shown in Figure 3.
57.
3fl *-
F oawnd
T- f t c I
fir
STntAMS
mm J >>j am w
rmi I c 1
Vapofto.
r *j
Tiit
1 tasoU 1
"
B
--
3 aj i
9TIJ3K?SI
'
20 i 171 385017
195 3*a6 20 j
20 i
liJnuiiJlii i
;oo 3ra 20 i
201354309 ia i
9 anwsssi }
lit
n
llJ
121)
||
;:-
. .
- i
:iT:;nr-si
to
I HME | Mh | M.UoM |
jgwc tW- Hrf.>i *mtrC
J
FIGURE 3.57
ASPEN PLUS"" SIMULATION OF DISTILLATION MOD
ELS 147
In the next, select Plot Wizard from the Plot dropdown menu or press Ctrl + Alt + W
on the key
board to get Figure 3.58.
I ... '.
1H|_U*1*) nKW*haMH n I |h| .131.31
_
j
. -
Cj owl-
a 'mm
71 .1
1
| ram
ijte>
!tDM5
I Until-
1
Welcome to Aspen P!b net Wlzwdl
15"
-
CH
MnrtJ D,> tuf<tc MJfac Sg-c P trf.
tc Ralrfrac Bltfic
FIGURE 3.58
Click on Next button in the Plot Wizard Step 1 dialog and get a variety of plot types
,
shown in Figure 3.
59.
i"l pi a)|
-
3
ffift
~
g JI" d| olaii n>i
IPFQ | CwvoMora j KVAjW j
(
'
smvm*
_J T.w Sot,
_j
-J s- j
H4W
J 51 OK
naa
seisa
2J!4
Wti*1
1 Join*
1
To bvn, MbM a (W lypo )>ou wh lo omniU
.
Q?1!* OowfMto fV**! Mva
,
i
wFodo FkMntln CCCOTHI CQCQS H) Hv4m > BM
Pi"
-
CH
60 - .
JP""
'
m& tS so.. w
fafc.-AH.MI NU
iQVjre 1740
FIGURE 3.59
Select the plot type under the heading of Temp and press Finish button to obtain a
plot of Temperature
'
(0F) vs. 'Stage' (see Figure 3.60).
rinwii-ii
i io u 15 i k w tr tt is-a I I J s <
: it
FIGURE 3.60
Recall that the above plot window can be edited by right clicking on that window
and selecting Properties. Then the user can easily modify the title, axis scale, font and
colour of the plot.
3
.
3
.
2 Simulation of a PetroFrac Model
Problem statement
An artificial petroleum refining column (PRC), shown in Figure 3.61, consists of a feed
furnace and a distillation tower. The tower has two pumparound circuits, a partial
condenser and three side strippers. The furnace (single stage flash type) operates at
25 psia and provides a fractional overflash of 40% (StdVol basis) in the tower. The
outlet stream of the furnace goes to the tower on Stage 22. The tower has 26 stages
with a Murphree stage efficiency equal to 90%. A steam stream, STEAM, is introduced
at the bottom of the fractionator (26th stage with on-stage convention). There are another
three steam streams, STM1, STM2 and STM3, used in the side strippers. The condenser
runs at 15.7 psia with a pressure drop of 5 psi. The tower pressure drop is equal to
4 psi. The distillate rate is 10000 bbl/day and the distillate vapour fraction in the
condenser is 0.2 (StdVol basis).
ASPEN PLUS SIMULATION OF EHSTILLATIQM MODELS 149
LIGHTS <
STMl
STM2
WATER
sir,-
BOT
FIGURE 3.61 A flowsheet of a petroleum refining column.
A hydrocarbon mixture with the following component-wise flow rates enters the
furnace at 1170F and 44.7 psia (see Table 3.3).
TABLE 3.3
Component Flow rate (bbl/day)
Ci
3
c2
65
C3
575
i-C
4
1820
-c
4
7500
i-C
5
30000
n-C
5
42000
H2O
250
In Table 3.4, two pumparound circuits and three side strippers are specified.
TABLE 3.4
Loeatum Specifications
Pumparound Draw stage Return stage
Flow rate
Heat duty
(drawoff type) (bbl/day)
(MMBtu/hr)
1 (partial)
8 6 49000
-
40 (for cooling)
2 (partial)
1 12 1000
-
17 (for cooling)
Location
Stripper No. of Stripper
Draw Return
Stripping Bottom product
stages product stage stage
steam
flow rate (bbl/day)
1 5 SID1 6 5 STMl 11000
2 4 SID2 12 11 STM2 15000
3 3 SID3
1
19 18 STM3 8000
Four steam streams used in the column model are described in Table 3.5.
TABLE 3.5
Specifications 1
Steam stream
Location Temperature (0F) Pressure (psia)
Flow rate (lb/h
r)
STEAM Main tower 350 50
11500
STM1 SID1 stripper
350 50
4000
STM2 SID2 stripper
350 50
1500
STM3
SID3 stripper
350 50
1000
Considering the 'BK10' base method under 'REFINERT process type, simulate the
PetroFrac column and report the flow rates (bbl/day) of all product streams.
Simulation approach
Select Aspen Plus User Interface. When the Aspen Plus Startup dialog appears
,
choose Template and click on OK (see Figure 3.62).
I I I I I I It
Cioata a Utm SmMan Using
A+
f Blank Smiiabon
A+
Temptale
"
OpendnEwiingSimulatior
e*r\ADU BOOK apw
DAeoolAChaptesVAOU OWN xm
D:V0ook\Chap(sViDU.t*{>
I
0
| Adobe Ao-dia P,d I Chace.s W \ 4]Q*i** 2 HmcHW || Av Pka
FIGURE 3.62
As the next window pops u
p (see Figure 3.63), select Petroleum with English Units
and press OK knob
.
mm
'
Mm.
1
linn v-
...
L-EJ J-J
.. ..
FIGURE 3.63
Click OK when the Connect to Engine dialog appears. The next screen presents a
blank process flowsheet.
Creating flowsheet
Select the Columns tab from the Model Library toolbar. As we expand the PetroFrac
block icon, a variety of models is displayed as shown in Figure 3.64. Select a model
icon and press Fl to know more about that.
rinF. I- I-h HI I .Ml I lal iN
4
.
| turn* t
J? if" IT
[1
itJb Jt
&
ir if
i
.
r # lb
ft
irOp
trffc*
c
J 1
-
i>B
p
a
.
#
.
I-
W 11 1
FIGURE 3.64
152 PROCKSS SIMULATION AND CONTROL USING ASPEN
As the distillation tower described in the problem statement, it is appropriate to
choose CDUIOF PetroFrac model. Then place it in the flowsheet window. Adding all
incoming and outgoing streams and renaming the streams as well as block, the process
flow diagram takes the shape as shown in Figure 3.65.
L'Mi- 111" A KM* 1W mmm 31* 1Mb -jM.
FIGURE 3.65
Click Next to continue the simulation (see Figure 3.66). In the Title field, enter
'
Simulation of a Petroleum Refining Column'. Open the Accounting sheet keeping
untouched the other global defaults set by Aspen Plus.
t.
r
k
-
.
<i.i-?-ir-Q-ii'-i?--i i.-r
<UbM
.
No M - -o- Ut- W W.
FIGURE 3.66
Copyrlghtf
In the form, shown in Figure 3.67, the Aspen Plus accounting information are included.
.
I'M
MI | i l"!
1 1 F
9 -i*--- I 1 ,1'5-l-Mi-'
-
3 \ Q| - .i -1
s
1
9i<>>
9 M Mjri '-c
.
I"-1
ITBUM :-1TMj ba 1m .kMnc tOM MXai Mai
FIGURE 3.67
In the subsequent step, use the Data Browser menu tree to navigate to the Components /
Specifications sheet. Filling out the component input form, we have Figure 3.68.
U> ZlgjFi 3 >id < AP-Bid Lj'i
aTJ*
3 gr
Lj i-r
1
-
7
3
-
T
,
- -
1
..
i -i;
it! T
r? f
-
KJETTH tSruT
tntUM ' wraij a- B i. wo., ip i tw.. *****
FIGURE 3.68
We know that the thermodynamic models calculate the properties, such as va
pour
liquid equilibrium coefficient, enthalpy and density. In the list on the left
, shown
Figure 3.69, choose Properties/Specifications to open the property input form
. In th
"
Process type field, select 'REFINERY
'
and in the Base method field, select 'BKlO' (B
rau
6
K-10 method).
Ea Tc<* ftr HO th*> .v v t
NBI I I a>|e| ?! nlt'lftKKI I >l ~l i I "I -I *\ I J
I f i i I fV .|:-liS|-. I .:M
"
3
-
1 >hl -3idPy!!il
< i-j :
1 aj c v-lu
ficwtw |Bfni;tFf.
I 3
~
3
STRUMS
'
KTVM OM fikfiK PtftaPut RatoFiv 8=rfi
FIGURE 3.69
Next the Streams /FEED/Input/Specifications sheet appears with the Data Browser
menu tree in the left pane.
Entering the feed data, Figure 3.70 is obtained.
D|tfiB|
_iJ e|jgJ njKjfti i-g -i .i { |h| Miigj .}
_
j
Pn zi bJiiif
-
3 J QN h
i 0.1
w,
1 ED-**
rv
-
D-
n
|
n
b
iei
cs nm
!3J no
""
!' wwi ., m,,, s , t, i i*
FIGURE 3.70
As we hit Next icon, an input form for Stream STEAM opens up. After filling out, it
looks like Figure 3.7
1
.
* t* V D* Tw fVn PW Marwt VMem
M-i
-
rv
[ft HuTorCoew
. F/traBy
Mol(Qior Stioam
i: FtranKn
:
g ST
E S
S LGHTS
3 SE>1
3 O SlOS
* a
-
3
31
| EOOptan |
1*0 |r
d
d
ict
ia 1
H
11500
Total NlSOO
"
itiputCMeM*
'
fV MMd iAw. } SwoWort 1 HutEttharpei' Columw j Rwawt j h w O* | M*v niE | S<*t> | UModes |
ntnjl r. .1 Raifitc EntlKl MJtf.
t)_-.r... njj-._ b jj.. STREAMS
'
DSIWU SCfiac PtfwFrac Batefiae Bwctfiac
-S . * AwnWM t'
;
NUVI cj/Ki i OTote
FIGURE 3.71
In Figures 3,72(a)
, (b) and (c), three filled input forms are shown for STM1, STM2
and STM3 streams
,
'
fitf csk Wew Dm Tooli H i PW Ibtw,
JMI mi
9
"
dSfb GPET.r-j Ol l fZi T] Q|.M N>J
_J to
.
_y t- tr-, Minodi
.
_j
_J 0*3
fEEL
tniii
S
kM Cans,..
j'Aijean n*n*
| EOOptm )
:
I
| Ma:-. Flow dl*'
N |f d
d
C1
ISO [p.. d -
C2
O
C4
d - ICI
-
cs
1
NC5
1 J H20
-
i fM-I-8-If'(S'#'C'4
"
'
SWUM MTMI
'
MM* (renFI
FIGURE 3.72(a)
O tn Ua
S3 2J 1 SI
J9JJ
_
LiJ pr 1 1 1
jaj iM
1
-
) LJ| | N.|
l/j Cm<p<mIi
.
MdMculitSniaM
DA
Mam
j
Steaon
. BIT
.
_,
ns
.
JH FEED
. LIGHTS
f
_j sin
.
_,
sm
. srew
. S s '
-
_
stm:
O kvol
RnuU
ApecMicotioo<| FtHhOtfHIni ) 1
3 BkfcibMmnaiq) fTMIXuT
31 [mmTfIcm 31"1"'
EOfJi eini
J
\m |i zJ
1 '.(.-'/r 1 V**
u,,
r "
zl -
1
'
id
ItfalltoM |SUwl id
| |l.H/dv zj cs
1. J
; m
STREAMS 1 DSTWU OisH Rwftw Exlud MiAFiac SCFisc Pe'.cfi
< neTiini r,.-.i Duc. . c ,_i u. c.u crc.v c .rX, f4vFi: 84ictfi
Aspen Plus -S
FIGURE 3.72(b)
at:
'
"
Rs c* We* Dae Tc s Fiwi FU : lAray VNVid&B
~
3M
"
5 [ g rg \ \ u j | n>|
| Frcc et
/S(cifiwrttonj FlaihOpwn:
SLtsdeamr me jyMIXED
3fl
901
-J
BIS
i
a
FEED
S ij
LN5HTS
s
_j
sm
g
._i
SID2
_j
5103
> jfl
ST = AM
J! STMi
s STM3
lt*xJ
P,
ED A
"
3
| EOOfton: |
I
~
3 K'**-
|3 1
-
Vdue
|p, ,.
d
:t
|SD If. zi
--
C4
ISidvcJ d
riC4
1 d CS
1 J HA-i
lad fuccT
Llj-_
-
a-
Rrfrac EJiaci MJf c SCF. (W.k RaFw
FIGURE 3.72(c)
From the Data Browser, open Blocks /PRC/Setup /Configuration sheet and
fill 11 up
(see Figure 3.73).
Tmi "<. 3* t*JT P Ufco* A5to- HMn
j.
TiU-J.J
"
1'
_
!l:'Mii,
o
* a f-"
S EOT
UGHTS
K BDI
i jj so;
g j 903
>: M STEAM
STVl
M STM2
WATER
Sehjoteta'i
UiidtihuE
PrN*V o, Ligud
~
3\-ur
J
1
Ki vjij hGOFWw-
~
4 Main colunn 81
Mod
"
SWE-MS I OSrwU DitB BrfrK E-trwt HMik SCfitc P fix. (WeF.se B<(j*F((,
fs-.net, wean
'
ai a '
' MTi.ni iv-.o . '.r. ri-e- n. f... K. t-- nJ. ii-...
... OvWtjrt pan Pk - SaJTt" '
FIGURE 3.73
As we press Next icon, the Blocks /PRC/Setup /Streams sheet appears as shown in
Figure 3.74.
'
'
Fie Edt W C*s T>-A PW Uxsy Wrefc* Hefe -
5
-
_j (w
Jfl STBI
.
nw
i, as*!
jtHGRETRC <<j|Ai 3 j
JCcriifjiter, ystiasnej Steam |vn*tue|wCariMnnn)vFijinca{
feed me*"!
31** Conwibon
5 TEAM 26
FEED 22 Funaco
Hwse FMw Bm Fkw IWt
eoi 26
ttSHTS Vapd
Fieewatei
DIS
| wWi | HeMEohongeii Cotuan) j Rmumi | Pre;iu9 Cltaroa! | ManpUstco | Soldi j liieiModd! |
'
a*
< ..sFtabe '.'fire-iPijjll 1
FIGURE 3.74
n Figure 3.75, the pressure sheet shows the condenser pressure along with the top
as well a
s bottom stage pressure of the distillation tower.
As given in th
e problem statement
,
enter 0.2 in the Distillate vapour fraction field
naer the h
eading of Condenser specification (see Fi
gure 3.76).
9 -
- 3 'no
.
_j
imi
< o
*
a S'
.
zj m
-
3 iTm
F P 3
F
-
P 3
-
17-
r
.Himdl ' in
I-Wav. nruu M law Mhr VI AbA.
rll-l
.M
'
-I - - o-
FIGURE 3.75
i r-i-i. i-- rir
-
i -'ci i -i-i
3gifh - 1 l-l l 31-1 "'1
a -
UXTI
w
w:
itfl
I
]
3
T
_
-
>*
Haas
S-1
I 1-11 I He ll i f H I r> I rMMOMM I MI I M* I IMOMa |
i .r.
M/w IOib NWw lau<a
IW I " .mm
FIGURE 3.76
In the next step (see Figure 3.77), the feed furnace is specified by selecting the type
of furnace and giving the values of pressure and fractional overflash.
9 -
- 3 'no
.
_j
imi
< o
*
a S'
.
zj m
-
3 iTm
F P 3
F
-
P 3
-
17-
r
.Himdl ' in
I-Wav. nruu M law Mhr VI AbA.
rll-l
.M
'
-I - - o-
FIGURE 3.75
i r-i-i. i-- rir
-
i -'ci i -i-i
3gifh - 1 l-l l 31-1 "'1
a -
UXTI
w
w:
itfl
I
]
3
T
_
-
>*
Haas
S-1
I 1-11 I He ll i f H I r> I rMMOMM I MI I M* I IMOMa |
i .r.
M/w IOib NWw lau<a
IW I " .mm
FIGURE 3.76
In the next step (see Figure 3.77), the feed furnace is specified by selecting the type
of furnace and giving the values of pressure and fractional overflash.
ASPEN PLUS SIMULATION OF DISTILLATION MODELS
159
tUiiLH
MM
.
_
!3
_
J J
3
- zi
J *nmr. I ySMi| Staw | yC d et Awm.)
'
.
.
R*MS L/ST-mj
_
D*L R*mc E* Mrffue StTuc PeboFiK R ef>*e !5nC
| SoUt | UiaMotJtt }
FIGURE 3.77
, select Blocks I PRCI Efficiencies and
provide 90% Murphree tray efficiency (see Figure 3.78).
My| 1 1 las! dvifelsKM j -|
1 IH_JS)_J l
; i nr 1 IOI 1 la! iMSil
Fb |r..-,rr,F:-.| H | ||..
_4 'W*!
j4
9
Sertgr. Enlnq
>
fir1
Kjrf.sr SOW NWfwt Rvrfiy gjjtjftg
-
a- . ii i HUH P-j. JtothLy?**-
FIGURE 3.78
The three w
indows
, shown in Figure 3.79(a), (b) and (c), specify the side strippers
tj d
on the given in
put data.
-
(Buck PUT (INMroftm;) Slriivm SI - IWofttmwI
tU F- I Took f\vi -V.' Ubrary- Yfrdon Heto
I IB] I
SI MM
_]
Mi
_J
id
ll
a
Stj m
_J
60T
-
-J
DiS
FEED
- ICHTS
_l
SIDl
Jj
SID!
j
SO]
jfl
STEW
STM1
5TH2
a
STHi
-
_j
, . -
'
EC
PBC
O Scbc
.
ii 3-;
.
il 53
O Healer Co
3
Seho
]0pUlrtalFdi | Uqud Retail j P'i
3 r
S'ipgng riearr,
'
3
"
a
SlMm lo boom pioduct tslw |Wionl| f
~
f
-
TT-
"
3
Flow jptcrfcahwi
r
3
"
3
fiofioftTpoduct 1
4ir*ol:fa!)o,nctbng(ebo Reboto itprttdtK m Ihe bdlofn sage
-
,1
jl Mawi/SplPen | Sepaitfoi) | He* Ewhanowj Colurani ) RwidDn | PiaQano: i Man xiatai | SoWi | UiMocW: |
-
CM
STREAMS DSTWU DSTWU Dirt RadFiac ENttact MiAfrac SCfiac P* Penoffdc Balefiac Saictiftx
Cv flFoWon.afljenFVsll I rij.rM|)|mI hcOTc
".
.I; 13:01
FIGURE 3.79(a)
Rt Edl Unr Dtfa Tooh Run PW Lfcrary WfxJw
Dl lyj
_
J
_
J fclej w) QKlfeKl l i n.|
3 >l J
h i - IBI iSlti
EBB
as'
* forced
,
rj t ot
U 015
.
Jfl fEEt
.
j 5DI
-
.H 5:02
:
a SiO)
.
STEAM
.
5TM1
.
Ji sTMi
.
!r,
S 23 WATER
ij Brxki
i|
'
I P iwid -1
-
St r.
*
Si
*
A S-2
>. S-3
O ftrtw* Stwca
0 -
rj CoodMer Hcurv
Setup
NUTlb8(0(tl(|ei [*
Siropeiixoduol 1 102
Slnpomgirwdun
I* Stiipoiij *te*fi
Sieamtobollampiodi
r Rebcisfduy
| OpbanalFeedt j Rerun
3 3
0v<hMdretuK |n 3
|STM2 jj
1 It
.
OpboMt tebo<e. heal ihwmt
t " (. produd 3 3
Srrf/oJ 15000
iwifiii iiHi
HutEichanoeii
STREAMS OSTWU 0ml RadFtsc Erf/acl MttffK
'
-I i.2l "
KMancdu dw. 3SA
Cokanu | Raadai | Pnuuactrogni I MawMon | SdUs | UmMcxMi
MJfi: SCFuc PmoFiic Rrfi ettfic:
W JSttinM) Sbr S2
JjlS
C\ gFoUmVANMnAjill 1
| jJOaa2 HcmrtlW |'T Ai,P<fcii.H)J || HO
FIGURE 3.79(b)
as-3
-
a
GOT
! U
ns
n fl
-
u
FEED
UCHTS
. Zj
SOI
n
SDJ
SOS
5TBW
B STM1
1 iV) snc
*
- j
STM3
.
_j
WATtP
n
- FX.
3
r Rttolodur)'. r
"
3 tJv*f>aditn fie -J
4
1) Jj
.....
WaCwwH M Mar cou-t. jwja ;aji,
[V Mm/5c*Mt. I S tHten I HE*chn9M Cok-ni j n. on [ f Miw*CKangtrt ] HmvMm | SoUi | Model. |
STREAMS DSTWU
fvHtki
'
.fn
FIGURE 3.79(c)
Although the Status bar says Required Input Complete, we have to specify the two
pumparound circuits connected with the main fractionator. Select Blocks/PRC/
Pumparounds in the list on the left. Click on New as the object manager appears. We
may accept the default Pumparound ID T-l
'
. Then specify the first pumparound circuit
(see Figure 3.80).
H* Es* VW Dj Toob Rwi Pa Jsrvy Vintom net
Ql -l H
_J ra
-1)
_j
_J W.srtrt
-J *
lj LXirTS
1, 5103
U s-o:
STEAM
STM1
jfl snc
ino
j MHTSH
taw
$ fK
Jj "MV
Sdukw
OHRltfMM
31-ur
- hfin: OSIWU Dail firf.*: ErtM HJ*.* SCfi*c Pofr*c Hrf'*c HBEAMS ' OStWU
FIGURE 3.80
162 PROCESS SIMULATION AND CONTHOL USING ASI'KN
"'
Select again Blocks/PRC/Pumparounds to reopen the pumparounds o
bject manager.
By the same way, fill out the form for second pumparound circuit, shown
in Figure 3.81.
|'|H| |
i r n I F
.
i
...p rr-T n U -1 q -.| ul 1 n.|
-J -
- J i
.
f" -
hm*lm
| :
'
-I t:
7
.
_j w;
.
_V) REE
.
.
_j SiOl
. "0-
(..m 1... . d
1 L-
.
_,
Sffll
J
J Beck*
-
Jfl ' T-
-
Jfl PI
_i
OS
1-.-. d
_J
h
FIGURE 3.81
Hit Next icon and click OiTto run the simulation
.
The Control Panel window is presented
in Figure 3.82.
...J rj_iUV 11 Im; i ibi i i
S Was Jui M, lOC''*
.
Fr nxtcj input i(MiftHiau
oawjimiftp oawa rca the n-wsasir .
1 1 O.tlMl
STPAm D5TWI] Cfl firfiac m.HiF.k SCf.w Fy.rfnc fi a.- g w,
FIGURE 3.82
Viewing results
From the Data Browser, choose Results Summary /Streams and obtain the table, shown
in Figure 3.83, that includes the flow rates (bbl/day) of all product streams. Save the
work done.
-
o
-
l.;,ft
-
i
FIGURE 3.83
To obtain the input information (see Figure 3.84), select Input Summary from the
View pulldown menu.
ITU UMilMly of 1 1
. fv irtm no- Ha. t.
titmm . uve. : * lid. flaa
.-
Cl CM
ut c*<ao ;
Ml . 0-|
"Co
ncc* c >uo s'*! f t.ii:oT f lu
w f c*Ti" iroa >tw oj
FIGURE 3.84
164 PROCESS SIMULATION AND CONTROL USI
NG ASPEN
3
.
4 SIMULATION AND ANALYSIS OF AN ABSORPTION COLUMN
Problem statement
A hydrocarbon vapour enters an absorption column below the bottom stage and the
absorbent enters above the
top stage. The column operates at 75 psia with no pressure
drop and it has four equilibrium stages. The absorber is specified in Figure 3.85.
Absorbent
Pure n-C10
Temperature = 90oF
Pressure = 75 psia
ABSORBENT
oAo-rttu
GAS-PDT
Gas Feed
Temperature
= 90oF
Pressure = 75 psia
Component
Flow rate
(Ibmol/hr)
280
c2 150
C3
240
n-C
4
170
n-C
5
150
LIQ-PDT
FIGURE 3.85 A Tlowsheet of an absor
ption column.
Apply the Peng-Robinson equation of state
model in the simulation.
(a) Simulate the absorber model (ABSBR2 under RadFr
ac) and compute the produc
t
compositions.
(b) Perform the sensitivity analysis by examinin
g the effect of absorbent flow rate
on the exiting C3 concentration in the t
op product.
(c) Compute the absorbent flow rate to kee
p 15 mole% of C, in the gas produc
t
(GAS-PDT). 3
Simulation approach
(a) Double-click Aspen Plus User Interface icon on th
e desktop. When Aspen
Plus
window pops up, select General with En
glish Units Template as shown m
Figures 3.86(a) and (b).
;.
b
,
_l a AHM -< r-J 3 ! I I Jgl-J _!
1 r OMnEFSai>H>
0 J.<* *hMWU0
J
V..
FIGURE 3.86(a)
oi W
_
U
-
J
_)ig| J2hm_L_kld 2J_LLJ_ia_i
1F
FIGURE 3.86(b)
Click OK when the Connect to En
gine dialog is displayed and proceed to develop
the proces
s flow diagram.
Creating flowsheet
Select th
e Columns tab from the bottom toolbar
. Among the available RadFrac models,
select ABSBR
2 and then place it on the flowsheet by clicking with the cross hair
somewh
ere on the flowsheet background.
Right-click to de-select the block. Connecting th
e inlet and
outlet streams and changing the all default labels,
we have Figure d./.
F-dl Vto* tJ8 Tccto Btr low wl liw/ Wn<*
J1IM J_L-LJI
.1 .tel. I IBI g]*!j
O 1 8-'H
O 1 :-AS'Ee: f
STREAMS S OSTWU CwU Ratfiac E[c> MtlaP.ac SCfiv: PfUcfrac Raiefiae Batctfrac
;
Slwl] S J " Botk j 4] Aapen_ Moby Mct | - Cha r3 Hritirft j jUwtdTwro Hwcao )[ Aapen PVj . Soul j
FIGURE 3.87
In the subsequent step, hit Next symbol and fill up the three setup input forms as shown
in Figures 3.88(a), (b) and (c).
Re E(k Mm D* Tooii Pur. Pid Lbra>y Wfida-* H >
n| |H|
_
J
_JMg|jgl nsMfeKNM H j
_
L
_
r
~
-i-i-I- PT
SI
5**
Spectftcjk>n
Q SmitMlcnOiMni
ISmJabon ot i Abtoiba
OuWtBttlt |ENG
R#iiVPO
: Stiom dan |cOW>/HH
Ftowbesw [
r
"
3
"
3
1
DM C
STREAMS OST'VU QaU RxF.ac EkI M F.oc Ptof.ac R<Mfic
FIGURE 3.88(a)
* -
FIGURE 3.88(b)
38
Tig-
IS
sir
-
:
FIGURE 3.88(c)
From the Data Browser, choose Components/Specifications. In the input form, shown
in Figure 3.89, all components are defined.
In the list on the left, shown in Figure 3.90. select Properties /Specifications to obtain
the property input form. Set PENG-ROB property method.
168 PROCKSS SIMULATION AND CONTROL USING ASPEN11
&
.
! -m I W W
'
I "
.
5!ES
ii
11
-
LI
-
D
-
FIGURE 3.89
IF
. > --
-
D
-
W W >. M -il> -
FIGURE 3.90
In the next data entry step, press Next button and click on OK. Enter the feed
information for both the gas stream and absorbent in two forms as shown in
Use the Data Browser menu tree to navigate to the Blocks/ABSORBER/Setup/Confi-
guration sheet (see Figure 3.92).
168 PROCKSS SIMULATION AND CONTROL USING ASPEN11
&
.
! -m I W W
'
I "
.
5!ES
ii
11
-
LI
-
D
-
FIGURE 3.89
IF
. > --
-
D
-
W W >. M -il> -
FIGURE 3.90
In the next data entry step, press Next button and click on OK. Enter the feed
information for both the gas stream and absorbent in two forms as shown in
Use the Data Browser menu tree to navigate to the Blocks/ABSORBER/Setup/Confi-
guration sheet (see Figure 3.92).
' r i i i- rv -
i ie: m aia
i
IV
H3-
"
3 nr
IS 3
.,
FIGURE 3.91(a)
3 j
"
7laLJlllrr-3)aU;
:
1 EC?*-
I E0OMr |
>]
I.
r
L
tea
> fi
"''
t
J
"
T-r
1
FIGURE 3.91(b)
ouiul .1 ! ami 01 al-rtfcloKlyl ! 3 I MilBj} 3
SfEf
i -fe!
P
-
3
,
-
j\ r
Li ir
FIGURE 3.92
Select the Streams tab to specify stream location. Under Convention, there are two
feeding options: On-Stage and Above-Stage. In the present problem, the top stage is
the first stage and the bottom stage is the fourth one. Therefore the absorbent is fed
above Stage 1 and the gas feed is introduced a
bove Stage 5 (see Figure 3.93).
- He &k Vfe* CW* Tec* Fin fa u , Wi-do- Up
Mai -I..[ **m *?! oMfel M *'l :2l_J_liiJjdElj*J.iJ
i r 1.14- nr -i i iai
HMttr,
_J MfMffd
| .
SfBEAMS : Djrf f&F-K
PtoimiI >/!:cnjcnni| 1 I
sws. Com*
WOfiBEH
5
} Urn*
1W 6*jb Flow :. U*. Fto-iatm
E-iKa W-if.s: SCF P ff-t
-
. fistf.ic Bcf >
FIGURE 3.93
In the next step (see Figure 3.
94), select Pressure tab to specify the pressure profile
across the absorption column.
In this case, the column is operated isobarically at
75 psia. Under Top stage / Condenser pressure
, enter 75 psi. Aspen software assumes
that the column operates isobarically if no additional information is
provided.
E rtca a(s "m Rji fta Jay, 7fre
* fl (t*SfEEC
E AflSOftSER
[V
fop ' Ccmkraii pftlfJI*
-
7]
I - I . ..MT-UJ-W: 1 W J
0 0- R . t Pnrf.>: ftiufnt Bwtfat
| tjHA.MTMa We {j < n - S ' to. **** tr j - Mil
FIGURE 3.94
ASPEN PLUS"' SIMULATION OF DISTILLATION
MODELS 171
Hit Next foUowed by OK to run the simulation. The Control Panel window i
s shown in
Figure 3.95.
-
Ft. E V*- OA TMh 4*
ci1H| *U
_
M*} raMai H'"I n . I M .| i?i m
-
J
-
T-l l-l' F* 'I .IBI I laai M
mjihTiiiiTiii liiriSij
StPEAMi [ .11VU C RadF.-a- Mjfffac SCFrc Prttofra- RatsF Bt&f'*.
FIGURE 3.95
Viewing results
Choosing Results Summary /Streams in the left pane of the Data Browser window,
we
get the results as shown in Figure 3.96.
fit SX .Vn t1 It.-. a> P UrVf
loHal am
_
Lr_ia_J
_
rr
.
i
la .
1 *LiJ )W
> ...
S
~
3 aaad
I
|
'
Jll
.
d j|r d
a aria HBB
ei Mm
NC4 tuoiyi liH IMHB
TiB iSidV) H9913
Ntll) isnutu
-
ra-1 *l)4s
C1 ozn
-
jw- O0M
H 0152 0J<* 6020
C) 2 01*
' -
US'-
RG dm 0012 cioo
mM OlOD
tcio 1000 np
oca .1
_V ~, 26... r-j .., fiESfad
-
a
-
sifiEtw'
'
e '' j Dr. ri.j,3, Ml<, '* SSffigB f,v'r'a- SftS
f -. kM- j.
I a-w a i te ss i iaajgLg
FIGURE 3.96
(b) In the sensitivity analysis
, we will manipulate the absorbent flow rate and
examine its effect on the exiting propane concentration. In the column at the
left side, double-click on Model Analysis Tools folder and then select Sensitivity.
As the Object manager is displayed, choose New. On the next window
,
shown in
Figure 3.97, Aspen prompts us for an ID. Enter 'C3' as ID, and click OK.
- ft* idl .tea
1 MM Wl nMfcl-si-JI-i el r I L'iiliJJSll -1
_
i
_
r
_
L m rv d |B|
1
.
_,
w
- :.-
.
_]
I C mrtn
I C-.**
i j Sohh | Utti
FIGURE 3.97
In the next step (see Figure 3.98), select New under Define tab. Then we are
prompted to enter a variable name. Enter
'
C3' and press OK. Subsequently, the following
information are required to provide:
II I I ! . fT .1 .lEI
,
1 |B|
StaM l&i-iTOI
- > -
1 |
J
.
4...,'. ., | MW. I H,[Jw U>mm | t aca>. | Bbu.Ow I M-MO, | U* I <
lm*M I
n
'
OITWU Cm RfCMtt HJf*c Tac IW'k n 'tc fc 't -
FIGURE 3.98
ASPEN PLUS*" SIMULATION OF DISTILLATION MODELS 173
Type: Mole-Frac
Stream: GAS-PDT
Substream: MIXED
Component: C3
Hit Next and select the Vary tab (see Figure 3.99) The manipulated variable i
specified with the following
data:
Type: Mole-Flow
Stream: ABSORBEN
Substream: MIXED
Component: NC10
Overall range
Lower: 500
Upper: 1500
Increment: 50
is
> Ht aa Vfem Csa Too fu\ Pa {tar, >Vhd >Mi
-1*1 "i
i il.li:M;ii A
_
L
_
r
danElEMo -i [|ai
"~
*1>>I ! 1 *1
.
_j On, Ogmrm
Tor
-
ue Tea*
-
Train,
U C3
- -
'
MM
.
_j DFf
23 r tttji
/Dorr yvacj |TulaM| TaUgr
VsxMtruitei 3
OMMbn I Oaard |
3
Cjcpona Low |M0
Upo [Two
Ina fsT
Hercxljbrti
Lm1 I
LntJ P
Ure2 |
MM
UKJAHS ' CrtTVU
FVlrfnc flKrfnc BWrt/'K
FIGURE 3.99
In the subsequent step (see Figure 3.100), select the Tabulate tab. This screen is
used by Aspen to set u
p tables. Insert T under Column No. Then right click on the
adjacent cell under Tabulat
ed variable or expression. Select Variable List and drag and
drop the variable name (C3) i
nto the cell. We may also directly type
'
03' in the cell.
Then run the simulation and
get the screen, shown in Figure 3.101.
174 PROCESS SlMULVriON AND CONTROL USING ASPEN
'
(. < . Mi Im* * uam mmm M*
sfgl.. j[di<)P Zl JiUjd
- 10 > Cfton*
'
> -
et " .
ft . .- u~
4 "
s
.
-
D
-
'
DSTWU CMI Mrfte wjftK KTm hmfm *ml~ Mo o
< w-m Ik
FIGURE 3.100
1
.
I'ICI I 111 !?1!J
AM
ir
-
Qc>
> nn
I :mii
In Tm.
t trv
I Mil
t Mai
lil/TU
'
K ua
MtM
i uut
'
MIMU Om IW<k Umo >w i IOai DMTw taXw
FIGURE 3.101
\SPEN PLUS SIMULATION OF DISTIUJVTION MODELS 175
From the Data Browser, select Model Analysis Tools/Sensitivity/C3/Results to
display the tabulated data (see Figure 3.102).
5 -
-
I - " . - I rijo- - 11; .--
FIGURE 3.102
In order to represent the results graphically, highlight a column in the table and
select X-Axis Variable (Ctrl + Alt + X) from the Plot pulldown menu. By the similar
way. select Y Axis Variable (Ctrl + Alt + Y) for the next column. Then select Display
Plot (Ctrl + Alt + P) from the Plot menu and obtain Figure 3.103.
J
-T I-1 l- iv i-g I i< siW
I --. I -l -I
J
FIGURE 3 103
(c) In the left pane of the Data Browser window {see Figure 3.104), open
Flowsheeting Options folder and then select Design Spec. We need to provide
this design spec a name in the same manner that we did for the sensitivity
analysis. Press New, enter
'
DSC3* and click on OK.
2iB_uaas -'-i ~ _u-j.ii2a
38
'
3 ~--
5=.
-o
_ AH .> Mfc. lw Mto W. W
FIGURE 3.104
Select ihTettJ under Define tab. Then enter 'CS' as a variable name and press OK. In
the next step (see Figure 3.105), the following information are required to input:
Type: Mole-Frac
Stream: GAS-PDT
Substream: MIXED
Component: C3
v
.
.
K-MJ-B-M-iM-f-
FIGURE 3.105
Copyrlghiod material
ASPEN PLUS1M SIMULATION OF DISTILLATION MODELS 177
In the subsequent step (see Figure 3.106), select the Spec tab. Design specification
data are noted below:
Spec: C3
Target: 0.15
Tolerance: 0.001
;Ti=E4Mi DSTVU Dag RJf>: Erftaci M frac SCFc PihoF-JC flyrf.K fcj'ctfix
FIGURE 3.106
Finally (see Figure 3.107), select the Vary tab and enter the following information:
> 4. Lfc Ar- Cm to-Ji Hpi Ptoi Ubr, AWtow H>
MHj_U jff) nkiaiaKiH n.| P >|'l"l I ~l 1 ffil
_
j
_
r iii nr imi i ibi i i
.' X
'U-
_i
/-,
6
-J
0
0
Q ! M6
'
>
r-s.
_i >
o
1
r
-
3 "
r r
I -' - Tan, I > fi-
'-:?
| HmMH I r>MMf'CMM | Mr iW I SOW: | UwMaW- |
gj ' I a
FIGURE 3.107
178 PROCESS SIMULATION AND CONTROL USING ASPKN"
Type: Mole-Flow
Stream: ABSORBEN
Substream: MIXED
Component: NC10
Manipulated variable limits
Lower: 500
Upper: 1500
As we run the simulation, we get the screen, shown in Figure 3.108.
&k 'Aw Uj Tw, fu. w**.
el w| Mii*MaJi)!id r
-
I I "I 311 < M
j lai
Slock: ISSOAfilS USFUC
K. K. XL Ici Ir.
1 t 1
I 1 1 C.1K31
Lhtt i.e. sicwr- iMunuii i
i - fl-.j.J. Hbi Ik/TcI 0 IS9ft3
ML IL ttt/To)
i i c.aui*
3TH*S ! OSTWU Dan Brfrac Um* UtffiK SOHk ftftrfwe RaUfwc Badftic
-
'
ail * J " . t
FIGURE 3.108
As we choose Streams subfolder under Results Summary folder in the list on the left
(see Figure 3.109), we get the absorbent flow rate of 1179.467 Ibmol/hr to keep 15 mole
of C3 in the gas product. This answer we can also obtain from the sensitivity plot.
3
.5 OPTIMIZATION USING ASPEN PLUS
It is well known that Aspen Plus is capable to optimize a function.
Here, we will continue
the above absorption problem (Section 3.4) for optimization. In the present study, we
wish to maximize C3 mole fraction in the gas product (GAS-PDT) with respect to
absorbent inlet temperature (lower limit = 50oF and upper limit = 300oF)
.
Simulation approach
First solve part (a) of the previous absorption problem.
It means, fill up the input
forms for setup, components, properties, streams and blocks. In the next, simulate tne
optimization problem as described in the following.
t -r
4
-
.
'
)
M
"
TM
H
lit
KB
r
r
,
_ 1
1
-
-- Si.- - JUBJ -
i>'
IT iMT 1
.
sna-fSBRI-
- tc
U wra-; wim
M . i .<-'.
rr owi t-rr* M Im* o '
FIGURE 3.109
In the column at the left side (see Figure 3.110), choose Model Analysis Tools/
Optimization. As the Object manager is displayed, hit New button and accept the default
ID 0-1' Press OK and then New. Entenng variable name 'CS'. again click OK Provide
the following information to maximize C3 mole fraction in the gas product.
N t)
I'M*
FIGURE 3.110
180 PROCESS SIMULATION ANT) CONTROL USING ASPEN1
Hit Next knob twice and get the screen, shown in Figure 3.111.
T-Birrym.v.-.T'-iB
_
LilJ Jl]35l vj:
-
D
i0C.-.~. Osbcn
-
ii
D
2J
dp
a
-
iJ
At o i
3 <<J[ --7]2>J DijdHd
fir Hitut/SpEttm j
STREAMS h!BM f 5&M Sp
0 ' ioc*< p!9.
,
FIGURE 3.111
Right-click in the empty cell with selecting Maximize option. Then select Variable
List and drag and drop the variable name (C3) into the cell (see Figure 3.112). We can
also simply type C3 in the field.
E* fwe ~ada Z,r. \Jutr, Wrtie* Hnb
-
HQ OfWlc*
s 2u eSci
[5) Rma
S ij 01
U.. .. i'r
CbiKtive tundnn -
FIGURE 3.112
In the subsequent step
, select the Vary tab. Under Variable number, as we choose
'
New', automatically the number T appears. FillinR out the form, we have the window
as shown in Figure 3.
113.
ASPEN PLUS'" SIMULATION OF DISTILLATIO
N MODELS 181
!5)| I \\ j l
21 Cw
_j rw-m
ffi nw aw i
-
D-
FIGURE 3.113
Pressing iVex symbol and running the simulation
, we get the answer (see Figure 3.114).
The maximum C3 mole fraction of 0.259 is obtained at absorbent inlet temperature of 179.
80F
.
In vi>* C*i Kn fa ttnja,,
J
~
1 i i fir -i
-
.bi 1 ibi
j 'Jr- .rr.
USC0 -
3 T i
>,
K1.pu 75 00
noco 10*
foosaoo HH
wv.- lUHjU
MMB Lit 5SS7
"
4*m .
'
ft
Wfa>
c? mm 1?.
'
*
'
Ti PIVB
170(00 iS3
FIGURE 3.114
At the beginning of this chapter,
a brief of all built-in column models of Aspen software
has been presented.
Several separating columns, including a petroleum refining column
and an absorber
,
have been simulated using Aspen Plus. The process optimization has
also been discussed with an example. The present study covers both the binary as well
as multicomponent systems
.
Interested readers may try to simulate the models given
in the exercise
.
182 PROCESS SIMULATION AND CONTROL USING ASPKN
PROBLEMS|
3
.
1 A feed mixture, consisting of 60 mole% ethanol and 40 niole% water, is to be
separated by using a DSTWU model having a flow rate of 100 kmol/hr at 40
oC
and 1 atm so as to recover at least 85% of the light key component in the liquid
distillate and 80% of the heavy key component in the bottoms. The column
operates at 1 atm with no pressure drop throughout. In the simulation, consider
the reflux ratio of 1.5 and a total condenser. Applying the Wilson property method,
simulate the column and find out the minimum number of stages, actual number
of stages, and feed position.
3.
2 A feed stream, consisting of 50 mole% ethane and 50 mole% ethylene. enters a
Distl column having a flow rate of 200 Ibmol/hr at 750F and 15 psia. This separator
runs at 300 psia with no tray-to-tray pressure drop. The pressure in the reboiler
as well as condenser is also 300 psia. The feed enters the model at 6th stage and
the column has total 15 theoretical stages (including condenser and reboiler)
and a total condenser. If the reflux ratio is 7 and the distillate to feed ratio is
0
.
8
. compute the mole fraction of ethane in both the product streams with applying
the RK-Soave equation of state model.
3
.3 A feed mixture specified in Figure 3.115 is to be distilled by a rigorous RadFrac
model (FRACT2). The column consists of total 24 equilibrium stages (including
condenser and reboiler) with a stage pressure drop of 2 kPa. Consider the
condenser (total) pressure of 125 kPa and the top stage (Stage no. 2) pressure of
130 kPa. The distillate flow rate is 120 kmol/hr and the reflux ratio (mole basis)
is 2. A side product (vapour) is withdrawn from 14th stage. Applying the Soave-
Redlich-Kwong (SRK) property method, simulate the column model and report
the product compositions.
Feed
Temperature = 110nF
Pressure = 175 kPa
Feed stage = 10 (above stage)
Component Flow rate
(Ibmol/hr)
benzene 250
toluene 80
diphenyl 10
FIGURE 3.115 A flowsheet of a distillation column.
3
.
4 A reboiled stripper is to be employed to remove mainly propane and lighter
components from a feed stream, shown in Figure 3.116. It has total 6 stages
(including condenser and reboiler) and no condenser. The bottoms rate is
100 Ibmol/hr and the column pressure is 150 psia throughout. Using the Peng-
Robinson thermodynamic method, simulate the RadFrac model (STRIP2) and
find out the product compositions.
Dj O
Sj cC.
B\ $
Feed
Temperature = 40oF
Pressure = 300 psia
Component
Flow rate
(Ibmol/hr)
c, 60
c2
75
c3
150
n-C
4
175
n-C
5
60
n-C
s
35
D -
FIGURE 3.116 A flowsheet of a stripping column.
3
.
5 A feed mixture of cyclopentane and cyclohexane is to be separated employing a
liquid-liquid extraction unit at 250C and 1 atm with the use of methanol as a
solvent. The schematic diagram of the process with feed specifications is given
in Figure 3.17. The process unit, having toted five stages, is operated adiabatically.
Applying the UNIQUAC property method, simulate the extraction model (ICON1)
and note down the product compositions.
Feed
Temperature
= 30oC
Pressure = 1 atm
Feed stage =
1
Component
Flow rate
(Ibmol/hr)
cyclopentane
250
cyclohexane
750
Solvent
Temperature -
30DC
Pressure = 1 atm
Feed stage =
5
Component
Flow rate
(Ibmol/hr)
methanol 1000
FEED
-SOLVENT-
EXTRACT
'
,
RAFFINAT
FIGURE 3.117 A flowsheet of an extraction column.
3.
6 A gas consisting of 40 mole% ammonia, 60 mole% air at 20CC, 25 psia, flowing at
the rate 120 kmol/hr, is to be scrubbed counter-currently with water (pure) entering
at 60oC and 30 psia at a rate 100 kmol/hr. The column operates at 1 atm throughout
and it has four stages. Using the UNIFAC thermodynamic model, (a) simulate the
RadFrac absorber (ABSBR2) and determine the exiting ammonia concentration in
the gas product, (b) Perform the sensitivity analysis by examining the effect of
absorbent flow rate on the exiting ammonia concentration in the top product.
Copyrlghled malarial
3
.
7 An artificial petroleum refining column (PRC) shown in Figure 3.118 consists of
a feed furnace and a fractionation tower. The tower includes one pumparou
nd
circuit, a partial condenser and one side stripper. The furnace (single stage flash
type) operates at 20 psia and provides a fractional overflash of 50% (StdVol basis)
in the tower. The outlet stream of the furnace enters the tower on stage 18
.
The column has total 20 stages. A steam stream, STEAM, is fed at the bottom
of the fractionator (20th stage with on-stage convention). There is another steam
stream, STEM1, used in the side stripper. The condenser runs at 15 psia with a
pressure drop of 5 psi. The tower pressure drop is equal to 5 psi. The distillate
rate is 12000 bbl/day and the distillate vapour fraction in the condenser is 0.25
(StdVol basis). The liquid product, SID1, is withdrawn from 5th stage with a
flow rate of 2000 bbl/day.
A hydrocarbon mixture with the given component-wise flow rates (Table 3.6)
enters the furnace at 120oF
and 45 psia.
LIGHTS
FEED
WATER
STEM
IS
-
o
SID1
STEM1 -O
SID2 C>
BOT O
FIGURE 3.118 A flowsheet of a petroleum refinin
g column
TABLE 3.6
Component
Flow rate (bbl/day)
10
c
2
100
C
3
600
1800
n-C
4
7500
30000
1-0
,
42000
nrCt
250
H
2
0
250
ASHEN PLUS SIMULATION OF DISTILLATION MODELS 185
The pomparound circuit (for cooling) and the side stnpper are specified with the
following information (see Table 3.7).
TABLE 3.7
Location
Specifications
Pumparound
idrauoff type)
Draw
stage
Return
stage
i
Flaw rate
(bbl/day)
Temperature
feF,
I (partial)
8 6 40000 20
Location
Stnpper No. of Stnpper
Draw Return
Stripping Bottom product
stages product stage stage
steam
flow rate (bbl/day;
1 5 SID1 12 10 STEM1 15000
Two steam streams, used in the column model, are described in Table 3.8.
TABLE 3
Specifications
Steam stream Location
Temperature (8F) Pressure (psia) Flow rate Ob/hr)
STEAM Main tower
STEM! Stnpper
350 50 12000
350 50 5000
Selecting the PENG-ROB base method under REFINERV process type,
simulate
the model using a PetroFrac column and report the flow rates (bbl/day > of all
product streams.
Part II
Chemical Plant Simulation
using Aspen Plus
Aspen Plus Simulation of
Chemical Plants
4
.
1 INTRODUCTION
In the last three chapters, we have studied in detail the simulation of individual
processes, such as flash drum, dryer, chemical reactor, distillation column including
petroleum refining process, absorber, stripper and liquid-liquid extraction unit, using
Aspen Plus software. Here, by a 'chemical plant' we mean a chemical process
integrated with several single process units. The chemical process industries usually
include flash chamber, mixer, splitter, heat exchanger, pump, compressor, reactor,
fractionator, filter and so on. It is easy to simulate even a large chemical plant by the
use of Aspen software package.
In the present chapter, the simulation of two chemical process flowsheets is
discussed. They are a distillation train and a vinyl chloride monomer (VCM)
manufacturing unit. After thoroughly reading this chapter and simulating the solved
examples in hand, we will be able to use Aspen Plus flowsheet simulator for solving a
wide variety of chemical plants. To improve the flowsheet simulation skills, it is
recommended to solve the problems given in the exercise.
4
.2 ASPEN PLUS SIMULATION OF A DISTILLATION TRAIN
Problem statement
A hydrocarbon stream H is supplied at 50C and 2.5 atm. The pump Pi discharges the
feed F at 10 atm. In Table 4.1 the component-wise flow rates are tabulated for stream H.
The schematic representation of the complete process integrated with a pump and
five DSTWU column models (Cl, C2, C3, C4 and C5) is shown in Figure 4.1.
189
Copyrk
TABLE 4.1
Component
n-C
.
F/ouj rate (kmol/hr)
10
35
50
130
200
180
200
5
pi C1 C2 C3 C4
FIGURE 4.1 A flowsheet of a distillation train.
cs
For Aspen Plus simulation of the distillation train, required information are given
in Table 4.2.
TABLE 4.2
Column Condenser Reboiler
(abbreviation)
pressure (aim) pressure (atm)
Deethanizer (CD 9 9
Depropanizer (C2)
5 6
Deisobutanizer (03) 4 4
Debutanizer (04) 3 3
Deisopentanizer (05)
2 2
All distillation models have total 20 theoretical stages (including condenser and
reboiler) and a total condenser. For the light key (LK) and heavy key (HK), we expect
99.9% and 0.1% recovery, respectively, in the distillate of all columns. Using the Peng-
Robinson property method, simulate the distillation train and report the compositions
of all distillation products.
Simulation approach
From the desktop, select Start button followed by Programs, AspenTech, Aspen
Engineering Suite, Aspen Plus Version and finally Aspen Plus User Interface. Then
choose Template option in the Aspen Plus Startup dialog (see Figure 4.2).
Copyrighled malarial
\SI'KN PWB SIMULATION OP CHKMK \l PLANTS 191
hmbj_lj__bJ'ii mmLii-jd .3 J.i.'isim i.
:
si
In ro..-
AM n i.tu.
1
I
1
-
1" .' I 1
FIGURE 4.2
As wo hit OK button, the following window appears (sec Figure 13). Based on the
units used in the problem statement,
we select General with Metric Uliits,
.in-i
1
1- . l-.
<- r< mil I-'
.- J - .
_
J I"-
.
I
1
I
'
FIGURE 4 3
Press OK and obtain the Connect to Engine dialog. Select
'
Local PC as Server t
ype
and click OK. Actually, this step is
specific to our installation (see Figure 4.4).
Connect to Engine
Server type:
User Info
Node name:
User name;
Password;
Working directory:
Save as Delaull Connection
OK
]
ExB Help
FIGURE 4.4
Creating flowsheet
The next screen represents a Process Flowsheet Window. Add a pump by selecting the
Pressure Changers tab from the Model Library toolbar. Moreover, in the library, select
the Columns tab and then choose DSTWU model to include five such columns
consecutively on the flowsheet. Notice that to incorporate a block,
click on the
appropriate icon and then place the block on the process flowsheet by clicking with the
cross hairs somewhere on the flowsheet background. Right click to de-select the block.
Now we need to interconnect the blocks and add the inlet as well as outlet streams.
Select Material STREAMS on the left of the toolbar at the bottom
.
In the next, as we
move the cursor to the process flowsheet window
,
several red and blue arrows appear
around the blocks. The red arrows indicate required streams and the blue arrows are
optional. In the previous chapters, we have learned how to connect the feed and product
streams with a single block.
Let us observe Figure 4.5 to know how to interconnect the two blocks by a stream.
Here, first we wish to interconnect the pump PI with the column Cl using the feed
stream F. Right-click with highlighting feed block
,
select Reconnect Destination and
then move the cursor to click on an arrow that is fed to the column Cl.
SOD-*
-
QD-o
m o
r ]-o
PI Cl
FIGURE 4.5
ASPEN PLUS SIMU1.ATION OF CHEMICAL PLANTS 193
We can select Reconnect Source instead of Reconnect Destination if we modify
Figure 4.5 to Figure 4.6.
j3L
D1
B1 c>
C1
FIGURE 4.6
By the same way, interconnect remaining blocks. Renaming all blocks as well as
incoming and outgoing streams, finally we have the screen shown in Figure 4.7. To
rename a particular stream (or block), first select it, then right-click, next select Rename
Stream (or Rename Block) and finally enter the appropriate name.
Re E Vto On Took tin Uban Whfen Help
H _J iU _l J
kl
5","*,s Oirwu o,ai SCfuc PMiofioc BMefiai Boictfuc
C |iFold.moIVilH HUM fwllrJ
FIGURE 4.7
The status indicator in the bottom ri
ght of the window, shown in Figure 4.7, says
Required Input Incom
plete indicating that the process flowsheet is complete and input
data are re
quired to enter for running the simulation.
As we hit Next icon and then click on OK, the following window pops up (see Figure 4.8).
Remember that in the Data Browser, we need to enter information using data input
forms at locations where there are red semicircles. As we finish a section, a blue
checkmark appears.
r- -i'iv
life
,
-
FIGURE 4.8
It is always a good practice to represent a simulation problem with entering a title.
In the Tattle field, enter 'Simulation of a Distillation Train'. Note that we may change
the input/output data units under Units of measurement (see Figure 4.9).
I r i-l I 17 -i.gi i (i
V-H
-id* ~ ' . -
figur: m 9
The next window (see Figure 4.10) includes the Aspen Plus accounting information
,
as given below, required at some installations.
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 195
User name: AKJANA
Account number: IIT-KGP
Project ID CHEMICAL
Project name: DT
1
,
-
o- i S
*
MM -
FIGURE 4.10
If we want the streams results summary sheet to display mole fractions,
select
Report Options under Setup folder to the left Under the Stream tab,
select 'Mole' as
Fraction basis (see Figure 4.
11)
n fT7
i
i - - .
-
:
*- . -
-
u>U>i
.
2}' I
-
n .
- . <
FIGURE 4.11
196
PROCESS SIMULATION AND CON
TROL USING ASPEN
In the subsequent step, use the Data Browser menu
tree to navigate to the Components/
Specifications sheet. It is shown in Chapter 1 how to
define components in the component
input form. Here, we have this table as shown
in Figure 4.12.
ffc E* *p. ftw To* R
i r l-l .l- fT >i -"Pi I iai
g :.r.: Fopui
C2
CJ
C*
IU
cs
.
*
!S
*
_
j wy tm
1: - . .
_J O pOa**
.
i i r
id
5 -.
_| > M<MVnt -J
FIGURE 4.12
In the list on the left
,
choose Properties/Specifications to obtain the property input form.
Aproperty method includes the models and methods to calculate th
e physical properties,
such as vapour-liquid equilibrium coefficient
, enthalpy and density. For the example
plant, set PENG-ROB base property method by scrolling down (Figure 4.13).
5* C*, T** P U
, Wnajt. tt*
-
-
J DM
.
3
I 3
PT
FIGURE 4.13
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS -f 197
Note that there is no compulsion to use only a single thermodynamic property
method for all processes in a chemical plant. Aspen software provides an option to
choose different property methods for different processes. To do so
, select Block Options!
Properties under a particular model of Blocks folder in the list on the left and then
choose the suita
ble property method.
Specifying stream Information
The Streams/H/Input/Specifications sheet appears with the Data Browser menu tree in the
left pane. Entering the given data for stream H, we obtain the sheet as shown in Figure 4.14.
j
-
T-i i-i
'
r> i-w I'M -
tti .rtl.m '-if
2j twi- m*.
3
"
3 j. a. -j],. ,. j
' ". : ww. r w sit.
FIGURE 4.14
As we hit Next button
, the block input form appears. The deethanizer column is specified
with the given data as shown in Fi
gure 4.15.
* & V- tm, r , m
31iiai _U *iB| 51 nl-mi*!<l
arn<tv*\
.
_1 "
: ;
it:
6 :
imua h** m tffl
FIGURE 4.15
Subsequently, the filled input forms are shown in Figures 4.16(a), (b), (c) and (d)
for other four DSTWU columns.
fir. Prt Ubfwy WMM
-
LT-
tap u**
>y ctnponent
-1 F
i
C3
O St*: G<t<-C-.
(a
Ctp fo
~
Rww jo TO
neb*.
Condentei ipertcalun!
1
] .JtdiJ Trim
r>nm
FIGURE 4.16(a)
_
iJ~_
J
_
iiiJ JZi J
|0 IrcU
_j V- n
.
) .an d
i pi -
_j
tjf
.
U B3
*
6-
-
_1
.
U K
I
_J W
.
0 02
'
_1 M
-
_j W
j _, D
S M Cl
-
jfi :.
ftco- It*cm
RMI
t
Pu
3Mt I HJilJ -3 U
a Wumbe.
r Reftw .aha
CdaimxtOebor* j Convagervt
Ptuiite
Reba fT
Ccrrp fic<
Reow (0 CO)
3]
I I Sob* I UMModrt t
k
Km-
Fv H* cmF"
FIGURE 4.16(b)
Si ioj _U 51 riKifci- l-M 3) _J_JjiJ ji) 5j
i
_J
*
Zl
. S H
J '
-
J -
- 1
n
as
(7 ll**c*
-
r i >-
-
CH
MM
M- FSptr SSpM
I HMtKfaan | Colm | Rucmt | Pimm*!
C iFMiStavPUtn NUN fiw*Jkci41
FIGURE 4.16(c)
Pta Jrav
-
u
_J w
_J
.-
-I
ffiimii
CondEnia f
"
f " HMra/lrfnan | Mraeon | Hn.f rp., | Coupni | RmcV<. | Prwtti.Chn | tWiMi t Set* | UtpUM* |
-
CM
Hp
flflUMS ' U** V,*
i-" | .f[*jit | Him
C a(*tJ r tI> HUN ,*rJKmvwa u
FIGURE 4
.16(d)
Click on Afert and specif
y the pump (PI) outlet by providing the discharge pressure
of 10 atm (see Fi
gure 4.17).
200
FU Jtnry Wndov. I Ms
L
-
TJ i i
HA
J2J
"
3
Saiw
ijt SutrciJine
0 MM
Sw&wjm -1
r Preci.ie "iciMie
r Pttiu>(Mo
|
I I
) <Jftimr* (kthnjs condhoni
"
3
j <Ch 'il-IA=r'Ari j 1 JAcw | - J U- q Tern} Atpei> Pk - Simi
FIGURE 4.17
The status bar in the window, shown in Figure 4.17, includes a message of Required
Input Complete; it reveals that to run the simulator, sufficient data have been provided.
But there is no such restriction that we cannot specify the process with more input
information. Again, as we click on Next, Aspen Plus shows a message under the heading
of Required Input Complete as shown in Figure 4.18.
J
-
T 1-1. I pr H jsn l -iai
wni
D>38
0 EWSK
j Rtcnc
/Specifcaliooij CflfcOalKr. OsHjw ] flaihOphor.t
P Result
_J
Al
I W ci
-
ai c;
j a o
.
ai
.
a pi
EOCorwOpten
2
(? Ptmp
"
3
"
3
Ptnp.
ro-jcertrterma'eincxJ To no'rr roi edi ijncd
Mea ' c fx :- Hm - * Osu .>: -- (Mnu.
-
Q
-
iM
. 9 -m *
FIGURE 4.18
ASPEN PLUS"' SIMULATION OF CHEMICAL PLANTS 201
Notice that if there are no red semicircles in the left
, it can be said that the data
entry for running the Aspen simulator is complete.
As we approve the simulation run, the Control Panel, displayed in Figure 4.19, shows
the progress of the flowsheet simulation in addition to a message o[ Results Available
.
.
1
-
.
B a
B O
B w
Z '
93
fi" -
us states; ~. Jt mu tjxll huz - jjtkt:
n a = c n
z. =i3i arc:
lice* a Bsmi: csrta
."
v. ex. -vOS
FIGURE 4.19
Viewing results
Choose Results Summary /Streams in the column at the left side and obtain the
compositions of all distillation products as shown in Figure 4.20.
We may save the work by choosing File/Save As/...using the menu list on the top.
W< tan give a name of the file whatever we like. Note that if we click on Stream Table,
the results summary table is incorporated in the Process Flowsheet Window, as shown
in Figure 4.
21.
If we wish to have the systematic input information, press Ctrl + Alt + I on the keyboard
or select Input Summary from the View pulldown menu (see Figure 4*22).
In order to create a report file (*.rep) for the present problem, we may follow the
approach presented in Chapter 1
. It is worthy to mention that the report file contains
all necessary information on the solved Aspen Plus problem, including given process
data and computed results
3 >bJ.'<IP~~3l-i g|
C-
~
J Cv CMn
o .
9 -
e
.
-1
4 2j
MM. '
tmufi *M
1 J
a!
.
Wit T
B
-
am
"
TW
"
nrw
l
Tia
HH i.r.T
"
n
-
TTEB 1
-
m
- -
mid
e
"
tUi sm 1 TOTB 1
1
nuif
'
1 m muff
-
B
~
nn-
~
TW
"
Mi
-
IB
"
ttd-
'-
rw-rfq|p !. 11 nnu Tifi- BM 1
RD
-
UB '
-
.
"
Wi 1 Hm UK TW
TS
~
ra TBS
"
713
____ ,
us 1 TB 1
"
BB S TRC - IMl
irK.
"
iv
-.
| U.I
FIGURE 4.20
i
-
MIBlJBI WPT |-3i-Hil%l-g|w| -?i ! M .jiyial
r|st7,|-|..|j fV .| .|E| Bj i|fc|
lOmm* I " I Ho I
.r
1
FIGURE 4.21
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rrrvJ |ti1t<i of a DUinUtlon TrtU
voilM-CM otir*-! MCW-aetrr i<ol( -OtNSrrr-
'
tuol' c-ji
for Inpm: Ho1
Stream report ct xnltiwi: o1t fli
SOLIDS 1MMCAMIC
W-SDUKCS Wll / -QOWWS SOLIDS INOtMMC
CI C2M I
( 1 ClHt
1C4 C4H10-2 i
' ' C4N10-1 /
IC1 CSH12-; '
ici cvai-i /
MCt CftfU-1
LCMMKT
1LOW C Il-e4 O'JT-O) Bl
.LOCK C4 IWt} O'.n-.oi M
ukk ci in-c; out-03 el
u
FIGURE 4.22
4
.
3 ASPEN PLUS SIMULATION OF A VINYL CHLORIDE MONOMER
(VCM) PRODUCTION UNIT
Problem statement
The process flow diagram for Aspen Plus simulation of the vinyl chloride monomer
manufacturing plant is shown in Figure 4.23. The flowsheet has been developed based
on the VCM production technology reported in a book by Seider et al. (1998).
O-fcmi
O-feu
BB 66
B7
F10
9
[purge]-o
FIGURE 4.23 A flowsheet of a vinyl chloride monomer production unit.
204 PROCESS SIMULATION AND CONTROL IISINO ASRKN
Pure ethylene, stored as a gas at 70oF and 1000 psia, with a flow rate of 20 tons/hr
,
and pure chlorine, stored as a liquid at 70
oF
and 150 psia, with a flow rate of 50 tons/hr
enter the mixer block Bl operated at 2 atm. The mixer outlet Fl then goes to the
reactor B2 run at 363 K and 1.5 atm. In this stoichiometric reactor (RStoic), the following
chlorination reaction occurs with 98% conversion of ethylene to 1, 2-dichloroethane:
C2H4 + Cl2 -> C2H4C12
ethylene chlorine dichloroethane
In the next, mixer B3 operated at 1.4 atm allows the mixing of the recycled stream
F12 with the reactor product F2. The outlet stream F3 is then condensed fully to liquid
phase in block B4 at 298 K before being pumped to an evaporator. The pump B5 has
discharged the liquid at 26 atm. The evaporator B6 performs the phase change operation
and then the vapour temperature is increased in the same unit to 515 K. In the
subsequent step, stream F6 is introduced in the reactor B7 (RStoic) in which the
following pyrolysis reaction occurs:
C2H4C12 -> C2H3C1 + HC1
dichloroethane VCM hydrogen chloride
The dichloroethane is converted to VCM and it takes place spontaneously at 773 K
and 25 atm with 65% conversion. To reduce carbon deposition in the heat exchanger,
the hot vapour stream leaving the reactor is quenched in block B8 yielding a saturated
vapour stream at 443 K. Quencher effluent stream F8 is condensed to liquid phase in
block B9 at 279 K and then fed to a DSTWU column B10 as stream F9. In the next
,
Stream F10 is introduced in another DSTWU column Bll. The first column mainly
separates HC1 from other components, while the second column purifies VCM from the
rests. Both the distillation columns have 10 theoretical stages (including condenser
and reboiler) and a total condenser along with the specifications
,
shown in Table 4.3.
TABLE 4.3
% Recovery of LK/HK in distillate Pressure (atm)
Block
Light key (LK) Heavy key (HK)
Condenser Reboiler
B10
Bll
99.9% of HC1 0.1% of VCM
99.9% of VCM 0.1% of dichloroethane
20 22
7
.
5 8
Finally block B12 (FSplit) splits stream Fll to ensure the recycling of 99.999% of
Fll as F12 stream to mixer B3. A purge stream is introduced to prevent accumulation
of unreacted components.
Using the POLYSRK property method,
simulate the complete plant to compute the
composition of all streams.
Simulation approach
To start Aspen Plus package
,
select Aspen Plus User Interface under Programs. When
the Aspen Plus window pops up,
choose Template and click on OK. In the next, select
Polymers with Metric Units (see Figure 4.24) and press OK button.
- . . r .ii.-i.*. Ti 3 . i i .rj 3 a
i : ; : I -i
-.
- :
HZ]
FIGURE 4.24
Click OA" when the Aspen Plus engine window appears to obtain a blank Process
Flowsheet Window.
Creating flowsheet
We can develop the process flow diagram (see Figure 4.25) by incorporating the following
-
IpF -I- I I- IT
MCI I m ti
ED
? 4f
413
FIGURE 4.25
built-in process units available in the Aspen Plus Model Library:
two mixers (Bl and B3)
two Stoic' type reactors (B2 and B7)
four 'Heater1 type heat exchangers (B4, B6, B8 and B9)
one Tump
1
type pressure changer (B5)
two T TWIT type columns (BIO and BID
one TSplit
'
type splitter (B12)
All the blocks and streams are renamed according to the problem definition.
The status message directs us to provide the input information required to run the
complete Aspen Plus simulation program. In the subsequent sections, we will fill up
several input forms one by one.
After creating the flowsheet for the VCM manufacturing unit
,
hit Next button followed
by OK to open the Setup /Specifications / Global sheet. In the following
,
the first screen
,
shown in Figure 4.26(a), includes the Title of the present project as Simulation of a
VCM Production Unit' and the next screen
, displayed in Figure 4.26(b), shows the
Aspen Plus accounting information as given below.
User name: AKJANA
Account number: SAY X
Project name: AS YOU LIKE
ft* Edl . Dal* TotU f*jr.
linry Wndw Help
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Gfcbal jetting,
Input mods
Sueam das:
Flovbuc
r Um see
3
31
3
3
5Tft*MS
ssft.
FIGURE 4.26(a)
ASPEN PLUS SIMUI.ATION OF CHEMICAL PLANTS 207
Qi BI
_
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I r -i-1-i Fir
-
t lei, I il MhJ
9
o
Mi*
FIGURE 4.26(b)
We wish to have streams results summarized with mass fraction basis that is not
set by default. Accordingly, we choose
'
Mass' fraction basis in the Report Options/
Stream sheet under Setup folder (see Figure 4.27).
. Ea '<W Tm> V< -tat, AWl- -*k
DIQ*IHI
J
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.
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_
iJ
OKI toUrciMr. ffMaitcV
P Hbi
P Ir-imi .! no > j tKW,
I .1
FIGURE 4 27
The components that are involved in the monomer manufacturing process are ethylene
(C2H4), chlorine (CI2), 1,2-dichloroethane (C2H4C12), vinyl chloride (C2H:iCl} and hydrogen
chloride (HC1). In order to get a blank component input form, choose Components/
Speciftcatiojis in the left pane of the Data Browser window. Defining all species in the
Selection sheet, we have Figure 4.28.
510*101
1 (ComponaO Spooftoiioni . Dal a Bnnrasr)
Data Tods fkn Plot Library Window Hdp
JT _1_M.
_
Tii.J J
ma
_
Setjr
Soedicatona
0 Smjiaion Options
Q Slrean- Class
J/) UrUs-SS
( Custom Unrts
Q Report C ions
Cemporwrti
Lg l-End Propert.es
*
Jj Petrc Cha cterzatoi
FieudoccmocneiTts
I t-'enf - Comps
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'
1 Conp-Groops
.
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_
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I Corv-ergence
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1 Flowsheeling Oplons
'
j Modd -ViaSyas Toots
EOCorrfgurabon
z1
Selection] Pelidftum | Noraiorivenliona! j-/Dalabanl s |
Define comp*nli
Componerit ID Type Comconent name Foirtiula
::h4 Conventtonal ETHYLENE C2H4
CL2 Conventional IHLORINE ri;
C2H4CL2 Conventional 1 2-DICHL0R0ET r.:h4 .
Conventional VINYL-CHLORIDE C2H3CL
HCI Conventional HYDROGEN CHLC HCI
>
ElecWEatd UsetDelmed
fif Miyeu/Splittets | Sepaialoi
m FSpS
Matei.at
STREAMS '
ForHe*j.pnj Fl
'.
ami s -
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SSpK
C\. gFtAlfla\AipnPliji 11 1 NUM fiML<! tTua netwowK
jjChapter4 1*00 | Oiapler I - Mero | T) Uidii Teimi I* | Aspen f\j - VCM [| Aspen Plus 9 C . '656
FIGURE 4.28
In the subsequent step,
choose Properties/Specifications to set the property method.
As mentioned in the problem statement
,
accordingly select POLYSRK base method
under POLYMER process type (see Figure 4.29).
From the Data Browser
,
choose Streams folder and see the name of all input, output
and intermediate streams. However, we have to provide information for only two
input
streams, C2H4 and CL2
,
which are fed to the mixer block Bl. Figures 4.30(a) and (b)
show the filled stream input forms.
ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209
IM f tp ... .' i ~ . .
CirftUl .-I i c|g| ni--|fcl%l-3M ml I M "I ?l -I
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FIGURE 4.29
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fS5
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9
FIGURE 4.30(a)
ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209
IM f tp ... .' i ~ . .
CirftUl .-I i c|g| ni--|fcl%l-3M ml I M "I ?l -I
_
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3
fin fHMM
a
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IT
-
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FIGURE 4.29
|i*lB|
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FIGURE 4.30(a)
210 PROCESS SIMULATION AND CONTROL USING ASI
'
KN
n. ton Pirn Stn.l*>on 1 [SlrBMC.L3 WATEBIAL) kyU
-
IMa ttowwrl
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Data Tools Ruti rlol
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_
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-
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IhdJ
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-
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.
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pntttn d
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ComponenI
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cm
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1 J-DOl
C2HXL
HCL
Total IST
ill ' "
twulCompiete
jl " Mixeit/Splitteis | Sepiialois | Heal Exchinaeti
Material
STREAMS 1
FocHeto orevin
3*1 S i
FSpia SS|*
Cokjmu | Reactoi: [ Ptessuie Changei; | MarjpOaioii | Sold; j U;eiMcJd.-
:C:\ gFoWere'-AspoiPlusIt 1 NUM
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Aipen Plus - Smjali
Rtjued ir<x TTC0ncJt
FIGURE 4.30(b)
Unlike stream information
, we need to input required data for all blocks of the process
flow diagram. As stated earlier
, the flowsheet of the VCM plant consists of two mixers,
two reactors, four heat exchangers
, one pump, two distillation columns and one splitter.
Although discussed during the Aspen Plus simulation of different single process units
in the preceding chapters, we must remember the following points when we fill up the
block input forms.
To simulate a mixer model, at least provide the pressure data and valid phases.
In the simulation of the reactor model
,
coefficients should be negative for
reactants and positive for products.
In the Vapour fraction field of a heater model
,
put 0 to indicate bubble point
and 1 to indicate dew point. For subcooled liquid and superheated vapour, use
Flash specifications.
The windows, shown in Figures 4.31(a) to 4.31(n) display the block-wise information
using the input forms.
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS
T
f* e* d*
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FIGURE 4.31(a)
Took R i fta ubrs) Mndw, etp
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FIGURE 4.31(b)
212 PROCKSS SIMULATION AND CONTROL USING ASPKN
1"
jag|y| I I ite|ll8| ffj aMfkltKH H 2J-Liil)-2J iil -I J
Readarts
Compwienl
C2H4
i C2H4d2
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r flMCtors occu teiiot
[i Hiwit/Spttlef* j iepatalow ] HealEhsrwi | Column) | Beattot) ] Ptftsauro Chanijers j ManpjIalMi [ SoWs | UwMwtei?
STREAMS M t.
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FIGURE 4.31(c)
Aapen Pk> CH4
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STREAMS Hea a. Heat.- MH
aaC Hwar.
PorHato-MiFl - ~
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FIGURE 4.31(e)
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FIGURE 4.31(f)
214 * PROCESS SIMULATION AND CONTROL USING ASPEN
< : E* Ml T-)C<5 Run Pic' Uw> H*
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STREAMS ' Mm FSpB
. Reactws j Pie-jyjie Char eis ] Mawpife!; ] SoWs j User Modei:
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FIGURE 4.31(g)
dMb| I -J Mil j J
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FIGURE 4.31(h)
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FIGURE 4.31(i)
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FIGURE 4.31(k)
Fie Edl 4ew Dots Toott F>in Plot U*v Wmdcw Hdp
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FIGURE 4.31(1)
ASPKN PLUSIM SIMUI.VriON OF CHEMIC-VI PL\NTS 217
uMiei | i ibj I nhlit Hhi J
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FIGURE 4.31(m)
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re
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FIGURE 4 31(n)
'
1 M
As we press Next button, Aspen Plus displays a message as shown in Figure 4.32. Since
the data entry is fully complete, the simulator seeks user permission to run the program.
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lonnt/SplilUK |
1 Mew - SSpi
I rjOap:a4 t rjstfi Ware j jjte". rtata MgM A>pm Ptu. - Sn-AW
FIGURE 4.32
As we hit O-K button on the message
, the Control Panel window appears as displayed
in Figure 4.33. It usually shows errors
, warnings, convergence status, etc.
gaBSBEsai
*
) Cm IceM umj WrDo* m
4uS
'
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FIGURE 4.33
Viewing results
Choose Results Summary/Streams in the column at the left side and rearrange the table to
get the resu
lts in the form as shown in Figure 4.34. Save the work positively at this moment.
_ _
r -i i I'-f
-
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jaTS i MHr- ..|.|_.|n.|
il .
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r ."IT 1583
IMHM * 004!% KUOEBE )<UCCQ nStWi i
1 <U< I UVMMW ]
Hmmt AMkw Kffto MTHM5T
FIGURE 4.34
To obtain the input information of the present project, select Input Summary from the
View dropdown menu (see Figure 4.35).
UK* e: umeI ot..'
sntew CiiM
."
n -ncw cl2 y>. ctorn'tr*
UOC. BiO MT,j
FIGURE 4.35
In the previous chapters, we have studied the steady state simulation of a large variety of
individual process units using Aspen Plus package. In the present chapter, several chemical
processes have been assembled to develop the chemical plants and those plants have
been simulated subsequently. The solved examples include a distillation train and a vinyl
chloride monomer unit. In the second example, the loop is closed by a recycle stream,
whether in the first unit, there is no such complicacy. However, the straightforward
approach to simulate a flowsheet is that after developing the process flow diagram in the
flowsheet window of Aspen Plus, we can simply use Next button for data entry. As we
receive the message of Required Input Completey we can move on to run the simulation.
In the next two chapters, we will study the process dynamics and closed-loop control of
flow-driven as well as pressure-driven processes using Aspen Dynamics package.
PROBLEMS|
4
.
1 A hydrocarbon stream with component-wise flow rates, shown in Table 4.4, enters
the isentropic compressor at 120oF and 1 atm. The compressor has discharged the
vapour stream at 3 atm.
TABLE 4.4
Component
Flow rate (kmol/hr)
10
95
150
n-C
4
25
/i-C
3
10
n-C
6
100
The complete process flowsheet for flashing and stripping operation is shown in
Figure 4.36. The flash drum (Flash2) runs at 1250F and 2.8 atm. The stripper
(STRIP2) has total 6 stages (including condenser and reboiler) and bottoms to
feed ratio (mole basis) is 0.8. The feed stream to the stripper is introduced above
the top stage and the pressure throughout the column is 2 atm.
I
0
1
COMPRESS FLASH
V24
STHiPPER
FIGURE 4.36 A flowsheet for flashing and stripping operation.
CopyHghlod material
ASPEN PLUS SIMUIJUION OF CHKMICAL PLANTS 221
Using the UNIQUAC property method, simulate the plant to compute the product
compositions and flow rates.
4.
2 A ternary mixture, as shown in Table 4.5, is fed as stream H at 100oF and 290
psia to a pump Pi employed to increase 20 psi pressure.
TABU 4.5
Component Flow rale (Ibmol/hn
500
300
"
r 11,
10
The stripper (STRIP2) has total 100 stages (including condenser and reboilen
with a reboiler duty of 10
7 Bt
u/hr Stream F enters above 70th stage and Stream
R) mien above 1st stage. The top stage pressure of the stripper is 280 psia
with a stage pressure drop of 0.5 psi The intercolumn pump P2 has increased
25 psi pressure The RECT column has total 120 stages (including condenser
and reboileri with a reflux ratio (mole basis) of 10 and a bottoms to feed ratio
'
mole basis) of 0.6. Stream Dl enters below 120th stage. In the simulation,
consider condenser pressure of 275 psia with a pressure drop of 5 psi and a
stage pressure drop of 0.1 psi (see Figure 4.37).
-
.
0
-
0
PI 8TRIP2 ' w"
FIGURE 4
.
37 A flowsheet of a propylene-propane mixture separation process
Applying the RK-Soavc thormodynamit mod* I
(a; simulate the above propylene propane mixer Beparation plant and report the
product compositions, and
(by perform the seneitivit
y aaalysifl to observe the effect of the second column
efficiency varied from 20'/. to 10091 on the propylene mole fraction in the
distillate
4
.3 The hydrogenation of aniline produces cyclohexylamine in a CSTR according to
the following reaction:
CgHgNH;, + 3H2 -) CgHnNHs
aniline hydrogen cyclohexylamine
To simulate the aniline hydrogenation process using Aspen Plus, we develop the
process flow diagram as exhibited in Figure 4.38.
C>-I ANILINE
PUMP
FA
C>-| HYDROGEN I-I
S
-o
El -
CD-
CSTR
COMPRESS
FIGURE 4.38 A flowsheet for aniline hydrogenation.
The reactor model (RCSTR) operates at 580 psia and 2480F, and its volume is
1200 ft3 (75% liquid). For the liquid-phase reaction, the inlet streams have the
specifications, shown in Table 4.6.
TABLE 4.6
Stream
Temperature Pressure Flow rate
(0F) (
psia) (Ibmol/hr)
ANILINE (pure aniline)
HYDROGEN (pure hydrogen)
95 100 150
12 100 600
Both pump and compressor (isentropic) have discharged the fluids at 585 psia.
Data for the Arrhenius law are given as:
Pre-exponential factor = 5x 105 m3/kmol . s
Activation energy = 20,000 Btu/lbmol
[CJ basis = Molarity
Use the SYSOPO base property method in the simulation. The reaction is first-
order in aniline and hydrogen. The reaction rate constant is defined with respect
to aniline. Simulate the process and compute the component mole fractions in
the liquid product and the vent stream.
4
.4 The process flow diagram for an azeotropic distillation process is shown in
Figure 4.39. The technique involves separating close boiling components
(acetic acid and water) by adding a third component (vinyl acetate), called an
entrainer, to form a minimum boiling azeotrope which carries the water overhead
and leaves dry product (acetic acid) in the bottom. The overhead vapour is
condensed and then separated in the decanter into two liquid phases: the organic
phase and aqueous phase.
DECANTER
VA
1 FEEDf
DIST
1 VA-RICHh
HW-RICHh
AA
RADFRAC
FIGURE 4.39 A flowsheet of an azeotropic distillation process.
A feed stream, namely FEED, enters above 15th stage of the azeotropic distillation
column at 330oF
and 90 psia in addition to the flow rates, shown in Table 4.7.
TABLE 4.7
Component
Flow rate (Ibmol/hr)
acetic acid
water
2700
500
The entrainer, VA (vinyl acetate), with a flow rate of 455 Ibmol/hr enters above
12th stage of the column at 200oF and 100 psia. The azeotropic column (RadFrac)
has the following specifications:
Number of stages (including condenser and reboiler): 55
Condenser type: total
Valid phases: vapour-liquid-liquid
Reflux ratio (mole basis): 4
Bottoms rate: 2700 Ibmol/hr
Condenser pressure: 66 psia
Column pressure drop: 12 psi
Key component in the second liquid-phase: water
Stages to be tested for two liquid-phases: 1 to 55
The specifications for the decanter model are noted below:
Pressure: 50 psia
Temperature: 110oC
Key component in the second liquid-phase: water
Using the NRTL-
RK thermodynamic model
,
simulate the process to compute the
component-wise
product flow rates.
4
.5 A hydrocarbon stream H is at 50C and 2.5 atm. The pump has discharged the
liquid feed F at 5 atm. The component-wise flow rates are shown in Table 4.8 for
stream H.
TABLE 4.8
Component
Flow rate (kmol/hr)
C3
35
50
i-C
,
130
n-C
4
200
'
-
c5
180
n-C
5
200
n-C
6
5
In Figure 4.40 the schematic representation of a hydrocarbon separation process
integrated with a Pump, three DSTWUcolumns (Cl, C2 and C3) and two RadFrac
(RECT) columns (CR1 and CR2) is shown.
G1
PUMP
h
CRT
C3
DRl
DR2
CR2
BRI
BR2|-0
C2
B3 | C1 B2}<>
FIGURE 4.40 A flowsheet of a hydrocarbon separation process.
AH DSTWU fractionators have total 20 stages (including condenser and
reboiler) and two RECT models have 10 stages (including condenser and reboiler)
with no reboiler. The specifications, shown in Tables 4.9(a) and (b), are required
for simulating the process.
PEN PLUS SIMULXTION OF CHKMICAL PLANTS 225
TABLE 4.9(a)
* Recovery of LK/HK in distillate Pressure (atm)
Block Lighi key Heavy kev Condenser (type)
Reboiler
IK
(HK)
Cl 99 of r-C4 1% of i-CB 4 (partial condenser with
4
all vapour distillate)
C2 99* of t-C4 21 of n-C4
1
.5 (total condenser) 1
.5
C3 99* of 1-C5 4* of n-C5 3 (total condenser) 3
TABLE 4.9(b)
Block Condenser
Distillate to feed ratio Pressure
(type) (mole basis) (atm)
CR1
Partial vapour
0
.2 2
CR2 Total 0
.
5 15
Applying the Peng-Robinson property method, simulate the separation process
to compute the flow rates and compositions of all product streams.
4
.6 An inlet Stream H supplied at SOT and 300 psia is compressed to 4000 psia by
the use of an isentropic compressor Bl. Stream H has component-wise flow rates,
shown m Table 4.10.
TABLE 4.10
Component
Flow rate (Ibmol/hr)
mtrogen
100
hydrogen
300
ammonia 0
carbon dioxide 1
A flow diagram for the ammonia process (Finlayson,
2006) is shown in Figure 4.41.
B '
m-<
H-
0
H"
ED-0
Bl B2 B3 84
FIGURE 4 41 A flowsheet of an ammonia process
Stream Fl is mixed with the recycle stream F8 in a mixer block B2 operated at
4000 psia. Before introducing into the reactor, the mixer effluent F2 is heated in
block B3 to 900oF at 4000 psia. Note that the reactor (RGibbs) B4 runs at 900oF
and 3970 psia. In the next, the reactor outlet F4 is cooled in a heat exchanger
B5 operated at 80oF and 3970 psia. The flash drum (FIash2) B6 produces Streams
Bl and F6 at 80oF and 3970 psia. In the subsequent step, Stream F6 enters the
splitter (FSplit) B7 and 0.01% of it is used as purge. Finally, an isentropic
compressor B8 has discharged Stream F8 to the mixer block B2 at 4000 psia.
Using the NRTL thermodynamic model and the Newton's iteration method (from
the Data Browser, choose Convergence/Conu Options), simulate the ammonia
process to compute the component-wise flow rates and compositions of all streams.
REFERENCES |
Finlayson, B.A. (2006), Introduction to Chemical Engineering Computing, 1st ed., Wiley
Interscience, New Jersey.
Seider, W.D., J.D. Seider and D.R. Lewin (1998), Process Design Principles: Synthesis,
Analysis, and Evaluation, 1st ed., John Wiley & Sons, New York.
Part III
Dynamics and Control
using Aspen Dynamics
1
CHAPTER
Dynamics and Control of
Flow-driven Processes
5
.
1 INTRODUCTION
Dynamic -imulation of a chemical process greatly helps to understand the transient
behaviour Aspen Dynamics , which is tightly integrated with Aspen Plus , is widely
used for process design and control. This powerful simulator can automatically initialize
the dynamic simulation using the steady state results of the Aspen Plus simulation.
Interestingly, when the file containing the flowsheet is opened in Aspen Dynamics,
the
default control structures are already installed on some loops. Usually, level, pressure
and temperature controllers are included where appropriate However,
these default
control schemes can be modified or even replaced with other suitable control loops
available in Aspen Dynamic- package Note that there is a scope to include some
additional controllers for the used process Moreover, this simulation tool provides a
graphical environment to show the process response.
To convert a steady state simulation into a dynamic simulation,
there are several
items that should be taken care of For example, the size of all equipments must be
specified and the control structures must be devised For steady state simulation using
Aspen Plus, the size of the equipment is not needed, except for reactors. On the other
hand
,
for dynamic simulation using Aspen Dynamics, the inventories of material
contained in all the piece* of equipment affect the dynamic response
.
Therefore, the
physical dimensions of all process units must be known.
When the steady state Aspen Plus simulation is exported into Aspen Dynamics, we
need to choose either simpler flow-driven dynamic simulation or more rigorous pressure-
driven dynamic simulation Pres.
-
ure-driven simulations include pumps and compressors
where needed to provide the required pressure drop for material flow Control valves
must be installed where needed
, and their pressure drops selected For flow-driven
simulations
, however, no such arrangements are required.
229
In the present chapter, we wish to study the dynamics and control of the flow-
driven processes. For this intention, we choose a reactor (RCSTR) as well as a distillation
column (RadFrac) example from the model library of Aspen simulator.
5
.
2 DYNAMICS AND CONTROL OF A CONTINUOUS STIRRED TANK
REACTOR (CSTR)
Problem statement
Ethyl acetate is produced in an esterification reaction between acetic acid and ethyl alcohol.
A feed mixture, consisting of 52.5 mole% acetic acid, 45 mole% ethyl alcohol and
2
.5 mole% water, enters the RCSTR model with a flow rate of 400 kmol/hr at 750C and
1
.1 atm. The reactor, as shown in Figure 5.1, operates at 70oC and 1 atm.
Both the reactions are first-order with respect to each of the reactants {i.e., overall
second-order). For these liquid-phase reactions, the kinetic data for the Arrhenius law
are given below:
Forward reaction: A = 2.0 x 108 m3/kmol s
S = 6.0 x 107 J/kmol
Reverse reaction: k = 5.0 x 107 m3/kmol . s
= 6.0 x 107 J/kmol
Composition basis = Molarity
Here, k is the pre-exponential factor and E represents the activation energy. The reactor
geometry data are reported below.
Vessel type: vertical
Head type: flat
Diameter: 0,45711 m
Volume: 0.15 m3
(a) Simulate the reactor model using the SYSOP0 thermodynamic model to compute
the product compositions.
acetic acid + ethyl alcohol ethyl acetate + water
FIGURE 5.1 A flowsheet of a CSTR
Copyrighied malerial
)YNAMICS AND CONTROL OF PI.OW-DHrVKN PROCKSSKS 231
(b) Report the default controllers tuning parameters and control actions used, and
constraints imposed on variables.
(c) Investigate the servo performance of the default liquid level and temperature
control algorithms and discuss the effect of loop interaction.
(d) Show the regulatory behaviour of both the controllers in presence of disturbance
in feed temperature.
Simulation approach
(a) To open the Aspen Plus Startup dialog box. click the desktop Start button, then
point to Programs, AspenTech, Aspen Engineering Suite, Aspen Plus Version
and then click the Aspen Plus User Interface. Let
'
s select the option with
Template and then click OK (see Figure 5.2).
aWHl 1 I M*l oKlfcl MwiH -| I I I -I J
L .H ! -i I i
-
o-tt rt m mots; am-
bHft mm 1 ; :_tm
FIGURE 5.2
As the next window appears (see Figure 5.3), it is appropriate to select General
with Metric Units and hit OK button.
Here we use the simulation engine at 'Local PC When the Connect to Engine dialog
pops up (see Figure 5.4), press OK. Note that this step is specific to the installation.
Creating flowsheet
The process flow diagram, shown in Figure 5.5, includes a reactor, namely RCSTR,
with an incoming FEED stream and an outgoing PRODUCT stream.
Copyrlghiod material
E
Fot Help, prws Fl
Start I r-
Nil Zl
, _
iJ_l J J
I I 1 1
I Rk Separato'-r wth Engi<h Uhb
I Air 5paraK> ntfi Meirc 'Jnti
.
3*3pe IPE S!feT Property
rfBark Smutatcn
2Chemical3w<h English ijnts
i3 Chemicals w<h Heine Unrts
j BMMMM **> BfSlW> UnJs
i S cl VM **h MeMc Lints
i jGas Process iMi English UrAa
,
G*n*rai wth English IJhta
"
d m alkjgy EntfishUnfts
dumelallurgy Mih Metnc Unfis
1
.
PelroleuT v-rth r-lefr
kit Fhafnieceul cals hI
L Fhamaceuticala
HPolymefs Mh Engis
Polymer wrO". Mibfe
f
.
P,TT>fr*atu / /.-eh
jj P>n)fr(arur3y /. (h
So!'*;-rfh EngWi I
yScWswlh fAetrcU.
La Specia*/ QmiOk
2 Specialty ChemV;a*s
Caenerai SmJalion vrth
Mettle iJnts
C.ba'>gyhr tanoMr,
MMKca(/W cum/nr
Property Method Nooe
FtewbwfoTB xi Mole
Strearr report
ccmpoabon Hole flow
Run Type
2]
[
Rwsheel 3
j j]Ch lei-5-Migiiio(IW | aw2 - MCTtcB W . | - Aijob/tarotei Pro(ett . | Aepoi Pka
FIGURE 5.3
111
Connect to Engine
Server type:
User Info
Node name:
User name:
PassiAiord:
Working directory:
Local PC
n Save as Default Connection
OK Exit
Help
FIGURE 5.4
PVNAMICS AND CONTROL OF FLO\V DRl\-EN PROCESSES
233
M.rn,- 1 I I ---
-
- -;
e i i i y s a
'
.* MB Mtet acsT ieo-
.
i
-
-
-
FIGURE 5.5
Hitting Next button, we get Global sheet of the Specifications form under Setup folder
in the left pane of the Data Browser window. Enter the Title of the present problem-
"
Dynamic Simulation of a CSTR'. change the Input mode from 'Steady-State' to "Dynamic"
and leave the remaining items at their defaults. The window looks like Figure 5.6.
* a
jLr
~
i
?
,)
.!
.,81 V
3 I 1 !-! -'in: q >!i.
4
-
ia
Km "ttm "CT on
js- b
FIGURE 5.6
In the next window, as shown in Figure 5.7, the Aspen Plus accounting informati
on
required at some installations are provided.
_
j
_
r I I I ["
-
I M I M
Hi _l 3 J J
O r-.i* - -
Mm >-
O RMOttor#
i-
/GbUI] /OWbMoP -/AtcountIngj Di mn'ci |
1 . PVil i . tr. I . " .
Accouxlrurbar
PrcrKtraw fr-OUH WISH
lnoMtCflinpi<
[V Hm>iA(m j $etur* j --v . I C(*ftm RMEton | PreiMeChange | Marv ai j Sokb | UwMoiw |
STREAMS
'
RSttK nvdd REtwl RGbb. RCSTR RPKi Rewch
For **> cr-u Ft C \ a FoMan'Aoen us 11 NOM RwpMb ot ntr --
FIGURE 5.7
In the subsequent step (see Figure 5.8), select Stream sheet with opening the Report
Options form under Setup folder and include Mole fraction item.
.
tfe E* V1e 0*4 '<xk Rn ftM Ufmy WMoh -.
1 hi .JSlal _J
i r-1 i i nr i -m \ |a! |.|
-
3 | j ,| H.|
0 RVMlOIMm
.
_l -r. - - -.
.
Jj
P Gtf<a(eiixlsrJ*Mn-feKirt
tam'o br rcUMr lDcmti itpvt
iWhua FicMntt*m
P Malt P Mole
r Urn* r Mm.
TIT fGEfTM
-
CH
fffaM ftt PQbt. RCSTR HPhg ftfiad.
- s -
FIGURE 5.8
DVN VMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 235
In the Data Browser window, choose Components /Specifications to obtain the component
input form.
Filling out the table with the components (acetic acid, ethanol, ethyl acetate and
wateri involved in the present reaction system, the screen looks like Figure 5.9.
I
MM - . -
E-sC
aun
i 1
I*
cmt : ffstnc ff/wa w&mh ai:s
,
Tft
,,.
Re3''>
8 O O
. * - - MUM
FIGURE 5.9
Choosing Properties /Specifications in the column at the left side, one obtains the
property input form. As shown in Figure 5.10, we use the SYSOPO base property method.
-
'
KW -U MSI *) nKI*M-aH 1 3)
i.|j
rrxl
9 -.*
.
2
I 8 y Ki)
HflUwj Wfate ffft* t COM, hc IP
FIGURE 5.10
Use the Data Browser menu tree to navigate to the Streams/FEEDI Input I Specifications
sheet. Specifying the FEED stream by its temperature, pressure, flow rate and
composition, we have this window, shown in Figure 5.11.
o-j
-
u l-w
-
-
3 *
***
*
1
-
-
3
.
3
I "in
T 3
('- * z
h
-
i= 3 -
pr (n -%\
I J
3 (.-. j| 3
> > Mat l
FIGURE 5.11
In the list on the left, choose Blocks IRCSTRI Specifications to obtain the block input
form. It is filled with the given data as shown in Figure 5.12.
-
o
-
-
#
.
l-s-g-Q-m-g-
j
'
T*4m ! . Iff ..-*-. |.;a .l-. |<j w> r
FIGURE 5.12
Use the Data Browser menu tree to navigate to the Streams/FEEDI Input I Specifications
sheet. Specifying the FEED stream by its temperature, pressure, flow rate and
composition, we have this window, shown in Figure 5.11.
o-j
-
u l-w
-
-
3 *
***
*
1
-
-
3
.
3
I "in
T 3
('- * z
h
-
i= 3 -
pr (n -%\
I J
3 (.-. j| 3
> > Mat l
FIGURE 5.11
In the list on the left, choose Blocks IRCSTRI Specifications to obtain the block input
form. It is filled with the given data as shown in Figure 5.12.
-
o
-
-
#
.
l-s-g-Q-m-g-
j
'
T*4m ! . Iff ..-*-. |.;a .l-. |<j w> r
FIGURE 5.12
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 237
In the next step (Figure 5.13), select RCSTRI Dynamic! Vessel sheet under Blocks
folder and enter the reactor geometry data.
LMf ***** -**
JUIBI
_
U 51 nMi>H<H 3 I H.-J JJ -1 J
i r i i i fv i lei I Pi 3>M
.i
J
STftfAMS WSw ffr-ipd Wgu* HGfcbi RCSIfl RPfc i BBwt*
C gUdms iw Pk* 111 MJU %
FIGURE 5.13
The forward reaction as well as the backward reaction is represented with their
stoichiometric coefficients and exponents in two sheets
, shown in Figures 5.14(a) and (b).
J l-i I IT .1 .IBI I IBI
.
J
_l ***
gff Vftrtc:
"
ti i nl i !
EAC
.
ll
-
CH-
.
1-0 LIZ U
FIGURE 5.14(a)
Mai
_
1J Mffli MJ ahlahNN 1 Jl .! I"i _J El M M
i r i i i nr i m I issi
UMFAC Grows;
-
J 0"
Prop Sett
3 -"EEC
_j PRODUCT
3 Becks
.
J/j 3CSTR
_
j Ow stry
- Resctcr:
w R-l
J t eti e
71 f. .1 I .1 I .<lr:-
-
7i i nl i uf\
Reaction No fyT
Readmit Pto<k<t
Compgnert EKpononi Cofr wrKf*
'
.v-'i-.-rv
1 V-
1
i
ll -
STREAMS flSloe RYidd
. REqul RGbtu FiCSTR March
FIGURE 5.14(b)
The power law data for both the reactions provided in the problem statement are
entered in the two Kinetic sheets shown in Figures 5.15(a) and (b)
, nt Edt '.' en Can Toot Pir. fU Lfeery Wrxto-. He*
ar -i MM <<||AI
~
3 l o\s
/Sto-Jwnwy *Kinebc| : - |
;
'
| HeyG)mt>s
UfUF Grauo*
}l) AA- EAL-) EAC . VATER
d
-
J/i Zcrvij&
| PIBpctfN
fiwc Cte, | . -J
;
r*c(actor.)jr/To/'e-(E '/I'l/ro)
;
k. 200000000
[
"
W
i "
.
.
. a P* en i E::
_l 0**
> ) FEED
PRODUCT
1 SCSTR
y Reacscoi
_J Ow-wy-
-
nnmiiii
To-
I
(qiw.
.
SIRtAHS
J- 90
FIGURE 5.15(a)
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES
239
.
-.- 1 3
I I
r
f " If Till I | MME->w. I C3k-s RMcMn | Ck . | I
HD->
st e
-'
py.>- pew ac cstr
FIGURE 5.15(b)
The status indicator in the above window reveals by the message Required Input
Complete that no more input specifications are required to run the simulation.
Running steady state simulation
As we click on Next button to continue the simulation
, the Required Input Complete
dialog box appears.
Hitting OK on the message, we are displayed the Control Panel
where the simulation messages during the run are recorded (see Fi
gure 5.16).
- ?!
-MM
iT*0r. Kmm. Pif W ji
i i Q D
| -ii?i u -J- I .ic- .i-a.-i. || .n, am, .. .. -_ |. ij
FIGURE 5.16
Viewing steady state results
In the next, select Solver Settings, choose Results Summary /Streams in the li
st on the
left and finally get the steady state results as shown in Figure 5.
17.
.
'
.
md.m.x. 1 - |Ftei.* Sumnr Sreano - DUit Browser)
f Fte & ew D*> Todj Run Lbraiy WMow Htjp
as
3fl
Setup
Omponeras
Streams
Bocks
Reacts
Ccr.vgefK
'
1 Conv Options
0 Conv Options
O Sup
0M0 Bsslc
OMOAdv
lSSQP Base
LSSQP Ad*
o
o
o
0
Tear
1 Convei ence
Conv Ortef
Q| Sequence
Rowsheetng Ctouons
Model Analvsis Too
EO CcHguration
PRit5 Summaiy
Q Run Status
Q Streams
Convetgence
1 I I 1
Displw
"
3 foumi r
~
3 StiemTatile|
4
1 d 1 d
Volume Flow cumyhi 24.497 24 01S
Enthalpy MMkcal/hi
.35035 35 951
Mole Flow km*hi
M 2ia0CB 87110
EAl 180.000 57110
EAC 122,890
WATER mooo 132.890
id*fan
AA 0.525 0 218
EAL 0.450 0.143
EAC 0.307
WATER 0.025 0.332
Jdll
Results Avaisse
Mstets/SpittM! | Seoatatois | Heat Enchangeis \ Cokmra Hoactoti | Pressuie Chatlseis ] Minipulatois ) Sofds | Usei Models |
STREAMS ' RSIok: RYieM REqui RGibbs RCSTR RPlug RBalch
RofHeb.ptessFl
.
1 . S -U-E-U-
i
C;\ .gFolde<s\A9penPlu3l1 1 : NUM
| j]Oaiaer5-McmsollW..| 4]Cha(er2-Wt!roseilW...|| Aspen flu. - SIimSI.. Adohe tolal Pntesai | iS?t}); 1545
FIGURE 5.17
(b) Exporting dynamic simulation: In the subsequent stage (see Figure 5.18),
we wish to carry out the simulation dynamically. Accordingly, at this moment,
we have to follow the sequential steps noted below:
Click on Export from the pulldown File menu or simply press Ctrl+E on the
keyboard.
Open the Drive and then Folder where we want to save the work as a file.
Type 'ChS.
S RCSTR' in the File name field.
Choose 'Flow Driven Dyn Simulation (*.dynf & *dyn.appdf)' from the options
available in the Save as type box.
Finally, hit Save button.
Also, save the work done as a backup file (e.g., Ch5_5.2_RCSTR.bkp). We may use
the same folder within which the exported dynamic simulation file is saved. Orig
inally
many files are saved along with the backup or dynamic file. Anyway, we
are now ready
to run Aspen Dynamics and we may quit Aspen Plus.
9 Ljii=v.
Tt*-
CJ Omwrngnt
Can***
I Pc-r; Ctt '-*
| MW .V*** Tn
Jjj
.
I I
3 ljili<JF; l jlalH
**, MW
-
M
EAL
WATER
I
.
1 ,1-
SrniatTi r irTi i -o/r Caned |
8 . S -O'll-O-
cvi
| 0>l5-rfco...| *]am2-*n,. \.*]Mll<m,-lic..\\ <,PIU.-C , '; teJu ft |' igsj
FIGURE 5.18
Starting Aspen Dynamics
As we click the Start button
, point to Programs, then AspenTech, then Aspen Engineering
Suite, then Aspen Dynamics Version and then click on Aspen Dynamics
,
a blank dynamic
simulation window appears as shown in Figure 5.19.
f*e Eat Tood ftowtfiMl Rr. VMoh Hcb
D H S Q W |SldySl.lc j-J
3
It*- Lfcr- f,:*.
r -Jt c ioos j a, k it
.
Jaw
FIGURE 5.19
Opening existing simulation
To open the flow-driven dynamic file, select Open from the File dropdown men
u or
press Ctrl+O on the keyboard. In the Open dialog box, locate the drive, then folder and
finally the file 'Ch5_
5
.
2
_
RCSTR' (see Figure 5.20).
ij is H *Q IS
UIMl
r -
-
SSmJatn
> Ft OinMITKt
l-llff. |.|9. HT H
.
Chi
_
5i
_CSTR !;i
Ch5
_
EJ
,
BCSTB
l Hi
5
* ICM.
U
.
f.ITS | CWn |
Opin
B i -r
FIGURE 5.20
As we press Open button, the process flowsheet consisting of the automatically
inserted level (LCI) and temperature (TC2) controllers appears (see Figure 5.21).
fte &* Urn Twh HswhMt jn Wr4 rtft
-L i
u
Tt MM [MM:"
'
i
ft- - - - . -Ill
..
.....
I
Li
m
lad *>.
-
in
FIGURE 5.21
DYNAMICS AND CONTROL OF FLOW-
DRIven PROCESSES 243
Details of the two control loops, to be used finally, are given below
.
Loop 1
Controller: LCI
Type of controller: proportional (P) only
Controlled variable: reactor liquid level
Manipulated variable: product flow rate
Controller action: direct
Loop 2
Controller: TC2
Type of Controller: proportional integral (PI)
Controlled variable: reactor temperature
Manipulated variable: heat duty (cooling operation)
Controller action: reverse
Note that the direct acting control system increases the output signal as the input
signal to the controller increases. On the other hand, as the input signal to the control
structure increases, the output signal from the controller must decrease for the case of
reverse acting control strategy. The direct acting control law has negative gain and
increase/increase (or decrease/decrease) term is commonly used to represent it.
For the
reverse action, increase/decrease (or decrease/increase) term is used and controller gain
has positive sign.
The reactor flowsheet includes two (LCI and TC2) single-input/single-output (SISO)
control loops. Therefore
, we can say that this is a multi-input/multi-output (MIMO) or
simply a multivariable closed-loop system.
In Aspen terminology
, the process variable or controlled variable is denoted by PV,
the set point is represented by SP and the controller output or control variable or
manipulated variable is abbreviated by OP.
For the example CSTR system
, level and temperature controllers are automatically
implemented when the Aspen Dynamics simulation is created.
The default values for
SP
,
PV and OP are computed from the steady state simulation. To achieve better closed-
loop process response
, the Aspen-generated control structures can be modified or even
replaced by the suitable control schemes available in the control library of Aspen
software
.
In addition, the default values for controller tuning parameters, such as gain,
integral time
,
derivative time
,
and so on, can also be changed.
Most of the control strategies are easily tuned by simply using heuristics.
As
suggested by Luyben (2004)
, all liquid levels should use P-only controllers with a gain
of 2. All flow controllers sh
ould use a gain of 0.5 and an integral time of 0.3 m
inute
'
also enable filterin
g with a filter time of 0.1 minute). The author also mentioned that
the default values i
n Aspen Dynamics for most pressure controllers seem to wor
k
reasonably well.
But temperature controllers often need some adjustments.
Viewing default v
alues of variables
In Aspen D
ynamics, the steady state values of process variable and controller output
ar displayed in a table
. At this stage
,
the set point value, displayed in table, shown in
Figure 5.22, is same with the value of process variable. To show the results table of
loop I, highlight the controller block LCI, press the right mouse button, go to Forms
and then select Results.
-
'
i .mi m i --w*
ffes
a
El &
m
- (M M Has M ! ! i lull aw M-M
11 ..1 in
FIGURE 5.22
We can have the same information in a faceplate, shown in Figure 5.23, simply by
double-clicking on the block LCI. But as a difference, the units are not mentioned here
with the values of SP. PV and OP.
.
.;i.
-
J
W ,1V- 3
>
--
u
mar
IP
urn
FIGURE 5.23
Gopyngt-
DRIVEN PROCESSES 245
Similarly, we have the results table, shown in Figure 5.
24
, for the temperature loo
p 2.
E3B
-ira
r g <: |.v J Ji i K >ft l|
-frol-
H S
r
-O-
SiBulaticn resd? tor soJuiion
8 equadons were not elininated because they had i
* (jtal ol 109 equations (29 5'/,) verc sUaiMted
"
ilation has 36J variablea 2(,0 equations and 91
FIGURE 5.24
Modifying controller tuning properties
First we need to open the sheet that contains the controller tuning information. To do
so for the level controller, highlight the controller block LCI, press the right mouse
button, point to Forms and then select Configure (see Figure 5.25).
|iirjf;j>,l'l. fi S
I PPQ UCI l-Q
r,.-:n
-
.
rwutlolis
'
m* bo
'
.tiHinatad be aus* they had residuals over J-00?
oi IH equii2rii (5
'
.J weie elmir.sted
LMien has HI *uitUi ito equiitjdni ar.d 'ifie
O-
j ct
Ij JOgggj j j Jctf Voty P-Vet || l Aspen
gh f* J - * ,stM
FIGURE 5.25
246 PROCESS SIMULATION AND CONTROL USING ASPEN"1
Alternatively, to obtain the Configure dialog box, first double-click on the controller
block LCI and then click on Configure symbol (yellow colour) in the faceplate as shown
in Figure 5.26.
ll(i*Ha IS {Dyn.mlc 3 mvo t: tin a 13
I
3
r tt .t ghF* J i a 'a i'
C SsD-
U.1
O
liBtnted becAutA t . hsd residuals ouer le-OUS
Istion has J63 vortabies HO equations and 969 non-zeros
3
Ml
FIGURE 5.26
By the similar way, we obtain the tuning data sheet, shown in Figure 5.27, for the
temperature controller TC2.
Bf H Q <& If {Dynamic 3 CB'JetiHDaia
3
d.
5
a F f.A
(MMM |a FT-3
r Dmo>
u
o
i
FIGURE 5.27
Note that the default Operator set point value is the steady state value of the process
variable (PV).
The reactor liquid level is the PV for loop 1 and reactor temperature for
loop 2. Bias signal is the output from the controller when the error (= SP-PV) is zero.
From the results tables shown earlier, it is obvious that the error is zero for both loops.
Therefore, Aspen Dynamics has set the value of OP as the bias value.
The proportional integral (PI) control methodology is automatically installed with
default values for the controller gain (= 10 %/%), integral time (= 60000 minutes) and
derivative time (= 0 minute) to monitor the reactor level. However, as mentioned
previously, the proportional-only controller with a gain of 2 is sufficient to effectively
control the liquid level. Remember that to make the integral action inactive, we can
use a very large value, for example 10
5
minutes (even the default value of 6 x 104
minutes may also be accepted), for the integral term. For loop 1, the controller action
should be
'
Direct' as set by default (see Figure 5.28).
Ffc MM Took Af) Wltttm H*
Baa
|DynBfnic ]
U 7f
"
3 ii ft i*
m m
BLOCKSfTCnCo mv
Op**to ie* part. jO 314029 K
Bw
|21083 6171
Gat
jiooooo d
L
ConOofc* aon
ft fcj
r
-
: i
-
-
-
--
-
Integrftting tro. 62 43 to 62 44
Integrating tr 62 44 to 6? 45
Mograt ing fro* 62 45 to 62 46
Step 3074 Tiw 6 2504+001 step size- 5 OOOOe-002 step facto
1 5000e+000 accepted
j
1*
wm -.
Wggg [ ' Adotoc Vrote P.o<mc
FIGURE 5.28
In loop 2
, we prefer to employ the proportional integral controller to monitor the
reactor tem
perature. In data sheet, shown in Figure 5.29, the default values are g
iven.
The TC2 is t
ruly a reverse acting controller. However, we may adjust t
he values of
controller tu
ning parameters (gain and integral time) during the closed-loop stu
dy if
the control
performance is not satisfactory.
Modifying ran
ges for process variables and controller outputs
In the Confi
gure dialog box, hit the Ranges tab and get Figure 5.30 for level control loop.
248 PROCESS SIMULATION AND CONTROL USING ASPENIM
iDynamlc ii m * 93 O fci rj a
5
r ft -jt G,.t| 3 iL Si fi 'i
0|>e"i Lbra So ve*
OpBoni
luwng 1 Rv" 1 FHwng | 0H>
Ope>ioi ;a>pan p 1
Mi
Gn
h
tmegral dm
['' . v- tme
I
C.>**i Chwi
r Died
Revwte
IfWiataeVabei | Htto
m
LCI
--
w-lPRoSucrt-H
.
,
.
alftulation ready for solution
equations were not eliMinated because they had residuals ever le-OOS
k total ol 109 equations (29 S'-i) were eliminated
Simulation has 363 variables 260 equations and 968 non-zeros
3
Rea*-
Oiaplm
Rea V a Iocs
UChajtef S -MoMsflW j Mobe Pootm PrrfrnJ [.
-
lAjpenOrn-c.
FIGURE 5.29
ftfts -n Dyn-wwca Ch5_5 2_HCSlH.dyrf
Be Wew Tao* Run Wndow Help
D B # Gi i ? jDynamic I) M
-
Q SniMoh
a Bi.ocKsnrncorfKi
n .us Ct>0> btTy S- Ktr
Ootore
Piocott voiabie
Ranjsmawwm (l 8280M (m
"
Rang* mnum |l2167 2343 |
P Cfetorang
o
TC3
Simulation ready lor xoluiion
equations were not eliminated because the? had residuals o*t
i total of 109 equations (29 S'O were elminated
"
mulaiion has 36} rarimbles 260 equations and 989 nae~:ero
-
3
I UCh e'
M tym>cea
FIGURE 5.30
As shown in Figure 5.30, the default ranges for both the process and output variables
are too large ( 100% of the steady state values)
.
It may be practical to consider the
following constraints.
Process variable
Range minimum: 0.6855 m (25% subtracted from steady state value of PV)
Range maximum: 1.1425 m (25% added with steady state value of PV)
Output
Range minimum: 15812.7 kg/hr (25% subtracted from steady state value of OP)
Range maximum: 26354.5 kg/hr (25% added with steady state value of OP)
Entering these upper and lower bounds, we have the window, shown in Figure 5.31,
for the level controller.
ftv Ut Wnd?* He
di*h - a <e [d s 3 .i h oaga feslaiimm :
Ull
r tt 7t teiloos J ,w ii 5V s-: ;
[M
S
91
h
jl M253G h
Oulf/
firty. BUMMM
|1SBI27
PBODUCT)-C|>
l-wtions <"-ie nol elikinstd Ivrrsuse they had resi
duals over le-OOS
h total ol 109 equations '29 S;| vete .Uaiaatd
StTOlation has H'i vri*&lM 260 aqtrnttoM end 989 iior-:eros
Vital iVnw:*00(
FIGURE 5.31
Again the typical ranges for the temperature control loop are noted here.
Process variable
Range minimum: 52
.
50C (25% subtracted)
Range maximum: 87
.
50C (25% added)
Output
Range minimum: 1
.
1447 MMkcal/hr (25% subtracted)
Range maximum: -
0
.
6868 MMkcal/hr (25% added)
The corres
ponding Aspen Dynamics window is shown in Figure
5
.32. It is worthy to
mention that th
e negative value of heat duty reveals the cooling opera
tion (heat removal).
o * y . a m w |n,..mic
'
9
,r ..- j 1 1t5) |MMlS3R
,
.
Editing Siaulacion
Validation coBplete
urrent snapihois havo been saved to 11 le (r-pAflOOO anp
i- I
FIGURE 5.32
i
Both the control algorithms are completely specified above. In the next, the controller
performance will be examined in terms of set point tracking (servo) and disturbance
rejection (regulatory).
(c) Starting the Run: Before running the program, we must be accustomed with
some frequently used items of the toolbar as described in Figure 5.33.
Step Re-start Simulation
*c 601 lacJt R Wnto*
.IMJSI
Run Pause Rewind to a saved Snapshot
FIGURE 5.33
We wish to carry out the simulation for a certain time, say 5 hours
.
To fix up this
time period, select Pause At from the Run pulldown menu or simply press Ctrl+F5 on
the keyboard. Then select Pause at time, type 5 in the field or whatever we want and
click on OK (see Figure 5.34).
yrr&ntmsmfmsssi :. ,,.1.1
a, uai
, s -MA
c; |W)-
1 1 : O -
jj j ' (fnci cil C-
S i
.1
,
ftC5tR
i,
;;;.-,;"',:::/;;:,:'m;.;:'::;f iv,i: J
FIGURE 5.34
Viewing servo performance of LC1
As we double-click on LCI block in the flowsheet, first the faceplate appears. In the
next, press on Configure and Plot symbols in the faceplate. Alternatively, to open the
faceplate
. Configure dialog box and ResultsPlot dialog box, first select LCI block, then
choose Forms and subsequently press one-by-one on faceplate,
Configure and ResultsPlot,
respectively. Judiciously arrange all three items within the Aspen Dynamics window
(see Figure 5.
35) so that we can properly observe them together.
Eiaagi ' 'i Baaaa wpw-
!.
k* h s a w [n n 3 B9t> esaspa
r nit a(o 1] i * "t
< {MB
n mm MUUI
ma : .
-ja_!J
nMm I fmg, |
<
! r.j J
F
-
>.,,
pi
|r~
,KJS
1"
l~
1-
, 1
, 1
I togji I fat.
FIGURE 5.35
252 4- PROCESS SIMULATION AND CONTROL USING ASPEN
First make sure that all the items in the Configure dialog box and fa
ceplate are
correct. In order to execute the dynamic closed-loop simulation
, click on Run button i
n
the toolbar. During the simulation run, give a step change in the set point v
alue of
reactor liquid level from 0.914029 to 1.1 metre at time = 1
.
5 hours. Typing the new s
et
point value in the faceplate, press Enter button on the keyboard so that the Operator
set point value in the Configure dialog box also changes automatically to 1.1 meter
Note that the new set point must be within the specified ranges of PV,
In Figure 5 36
the servo performance of the level controller is depicted for 5 hours as selected earlie
r
Obviously, the plot also includes the manipulated input profile.
EC
DlSySa IE -V | Dynamic 3
! Rowsheet
Coopoient Lots
*
} Dagncsl'cs SS
T tt Tl' id 10 05 it
*ifl)_l
OPgHi 1210356171
to
IT
JDJ*]
Tuning ] flanges | Ftong | Olhw
Owralw set pewit p 1
Twmg paramtfer,
|21083.61
1
: lrJe.;tdlme:
l
imtjo
|m
De<ivalive time:
I" l" d
Cpndolei adkm
:
Direct
(
-
Reveise
t'POC
"
I
RCSIR
C; Plot 8LOCKSCLCl-l ReiaPlol
:o 4 97
-
obi 4
Run coaplete
E
-
If5
'
11
||
0 0.5 1 15 2 25 3 35 4 45 5
Time Hours
1 5000e*ODO. MDCepted
Paused
FIGURE 5.36
Figure 5.36 represents an excellent set point tracking performance of the level
controller (P-only). Obviously, the LCI provides process responses with almost no
deviation from the desired set point value and with very fast approach to reach the
target liquid level.
Notice that the above plot can be edited by right clicking on that plot and selecting
Properties option or by clicking on that plot and pressing Alt+Enter on the keyboard.
In the properties window, user can modify the title, axis scale, font and colour of the
plot. Alternatively, double-click on the different elements of the plot and mo
dify them
as we like to improve the clarity and overall presentation.
Now, we will discuss the interaction of two control loops. When we introduce a set
point step change in the reactor liquid level, the LCI scheme attempts
to compensate
for the changes through the manipulation of the effluent flow rate. This, in turn, wi
ll
disturb the reactor temperature and loop 2 will compensate by manipulating the hea
t
removal of the CSTR appropriately. Thus we can say that loop 1 affects loo
p 2. In Figure 5.37,
Aspen Dynamics window demonstrates the loop interaction under the same
set point
step change (0.914029 to 1.1 metre at time = 1.5 hours) as considered previousl
y.
PS rKjTj F=
~
E],. ;- %
c;
.
o
1- 3
J _JSS_J
BEDS
FIGURE 5.37
Viewing servo performance of TC2
As described in Figure 5.38, open the faceplate along with Configure dialog box and a
blank plot sheet. Before starting the simulation run, carefully check all entries in the
faceplate as well as Configure dialog box. In the next, choose Initialization run mode in
the toolbar and then run the program once. After completion, go back to Dynamic
mode from Initialization mode (see Figure 5.38).
'
fehj
FIGURE 5.38
Now we wish to conduct the servo performance study for the TC2 controller with two
consecutive set
point step (pulse input) changes in reactor tempera
ture (70 -) 750C at
time = 1.2 hours and then 75 -> 70oC at time = 3 hours).
Clearly, the proportional integral controller with default tuning parameters val
ues
shows a high-quality temperature tracking performance. As stated
, if the performance
of any controller is not satisfactory, we have the option to tune the parameters sim
ply
by trial-and-error method.
If we introduce a set point change in the reactor temperature
, the TC2 controller
takes necessary action with adjusting the heat duty to compensate for the changes.
But interestingly, the liquid level remains undisturbed. Figure 5.38 confirms this fact
.
At this point we can conclude that loop 1 affects loop 2, but loop 2 does not affect loop 1.
Actually here the interaction is in a single direction.
(d) Viewing regulatory performance of LCI and TC2: To perform the
regulatory study, we need to introduce at least a single change in the input
disturbance. However, here we consider two subsequent step changes in the
feed temperature. Initially, the feed temperature changes from 75 to 80oC at
time = 2 hours and then the temperature (80oC) returns to 750C after 1.2 hours.
To change the feed temperature twice as prescribed above, first we need to open
the feed data sheet by double-clicking on the FEED block in the process flowsheet
(see Figure 5.39).
-Ch55.2
_
BC5rRdrf
Bt TooB Rui Van** Hefc
*
? iDyn.mk 3 > Hi 3 [3 H
Alllms
jDynamcs
; SyiieriLbrjry
o
-
Q Table STHEAMSfFEED") Re*
,
KH
Description Value linrt*
F Tolnl noSe ItoW
fm T JalfTiaaa Bow 210836
T 75.0
P Press U'e bai
vf Milar *api>f tricion oo
n
Mrls! >(ihftlp>
-87 57I
Rho 16 3267
MM Mohii msight 52708
mn
uebnictan 0t25
ZrfEAC Ucte rrocton
Lkie Iradton
Solver Componert
ftXlOTrl LMs
OUgnogucs GMmIc
ntegrating fra 4 96 to 4 97
Integrating fro 4 97 to 4 98
Integrating fro 4 99 to 4 99
Integrating fro* 4 99 to S
Step 361 Time- 5 0422e+0O0. step size-
Run complete at 16 45 29
il I
1
S 0000e-002. step tactor* 1 S000*000 accepted
| Jaae S Xerox* Wort || 'U Met* K bm PxAatr j
FIGURE 5.39
In the subsequent step, run the program with Initialization run mode. As it is
finished, go back to Dynamic mode. Then, open the plot sheets for both the controllers.
The regulatory behaviour is illustrated in Figure 5.40 giving changes in feed temperature
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES
255
in the feed data sheet.
For brevity, the faceplate and configure dialog box
included in the Aspen Dynam
ics window, shown in Figure 5.40.
are not
2 a ts
7 I Dynamic
r u loo? s
scripts ] VUue | Unrrt
r
RM -WOO - Mf
-
Ot* :iC3=
-
-
trx*'*-** C
| _
fi
p Prevc j111*58 t*r
-
Ml
in
'1 r fidcn 0
*
2f ijnctVnc-l
Mofen-tdian |0.B imMV-nc*
a
U
j nr.urT
53 a
1
T mpeiatuie loop
-
i
;
So
0 05 1 1= 2 25 3 35 4 45 5
Time Hems 000e+000. accepted
-
3
3
FIGURE 5.40
It is obvious that the reactor liquid level remains unchanged with a change in feed
temperature since there is no interaction involved
.
On the other hand, the reactor
temperature is disturbed
.
However
, the TC2 controller provides satisfactory disturbance
rejection performance under this situation.
So far we have studied mainl
y the closed-loop behaviour of a reactor system coupled
with Aspen-generated
control schemes. We did not include any additional controller with
the CSTR model
. In Section 5.3
, we consider a distillation example to elaborate this point.
5 3 DYNAMICS AND CONTROL OF A BINARY DISTILLATION COLUMN
Problem st
atement
A partiall
y vaporized binary mixture of benzene and toluene enters a RadFrac
distillation
model as displayed in Figure 5.
41.
he column has total 25 theoretical stages (including condenser and reboiler) and
operates at a pressure in the reflux drum of 18
psia and reboiler of 21 psia. The
ow rate is 285 Ibmol/hr and reflux ratio is 2
.2 (mole basis)
.
Feed Specifications
Temperature = 225F
Pressure = 21 psia
Component
benzene
toluene
Mole %
45
55
FEED
TOP
o
BOTTOM
.
In Table 5.1, the reflux drum and the base of the column (the 'sump' in Aspen
terminology) are specified. It is fair to use an aspect ratio (length to diameter ratio) of
2 (Luyben, 2004).
TABLE 5.1
Item
Vessel type Head type Height / Length (ft) Diameter (ft)
Reflux drum horizontal
elliptical
5 2
.
5
Sump
-
elliptical
5 2
.
5
The column diameter is 5 ft. Use default values for other tray hydraulic parameters
(e.g., tray spacing, weir height and weir length to column diameter ratio). Consider log-
mean temperature difference (LMTD) assumptions for the total condenser. Actually
,
the
LMTD is calculated using the temperatures of process fluid and coolant.
In the simulation.
assume constant reboiler heat duty and apply the UNIFAC base property method.
(a)
(b)
(0
Simulate the column model to obtain the products mole fractions.
Keeping the default level and pressure control algorithms unaltered, inspect
the servo as well as regulatory performance of a proportional integral (PI1
controller that is required to insert to control the benzene composition in the
distillate by manipulating the reflux flow rate.
Devising an another PI control scheme to maintain the benzene composition in
the bottom product with the adjustment of heat input to the reboiler, observe
the interaction effect between the top and bottom composition loops.
Simulation approach
(a) Select Aspen Plus User Interface and when the Aspen Plus window pops up.
choose Template and press OK. In the subsequent step, select Genera
l with
English Units and hit OK button. To open the process flowsheet window, click
OK when the Aspen Plus engine window appears.
Creating flowsheet
From the Model Library toolbar, select the Columns tab. Place the RadFrac mode
l on
the flowsheet window and add the feed as well as two product streams. Renam
ing all
the streams along with distillation block, we have Figure 5.42.
DYNAMICH AND rnNTKOI, OP KI-OW DIUVKN I'lfOCKHHKH 257
.
imaimAJmm lAdftiauugj*) ji.ojjiIzJII
o:
6 -i
twin
'
TmT
FIGURE 5,42
Ah we hit Nt'xf followed by OK button, the ROtUp input Corni appcarH (hm* Kitfun! .43).
The diHtillation problem Is tilled oh: 'Cl0S6d-l00p Performanct; of a DihI illation ('olumn'
Iniportuntly, une tin- 'Dynanne' input noxle
mltiMI
?
lit
I:: | n
I (
NiMH (
FIGURE 6 43
258 PROCESS SIMULATION AND CONTKOI, IISINC ASPEN
Figure 5.44 includes the Aspen I'lus (iccon/ilin infornuition
.
We can fill up th
e
Accounting sheet with any name, number and ID.
t ft vW o**
mm jj ai LiinsMibd ad j ..ijj-j -j ai i i
.
jJgjJT; j Mil illR"ZI uL..]
O Ma
o - J-.
f> 1 "
I - MCM
I
_J M.>i*t 4 M 1><
.!(. [Ilflll,
fToirTiTTT
1 DSTWU DHH nwJFp .ii*;i MJ/tac SCr-oc Pei(iJ
-
tc P*iefi BvcWi*
-
'
i '1
fa -1* prt-M 11 C - 0 :s*Kt5-/Jeei". (Vfl !1 I HUM (leoulcillnM
Uvain .
I -l|a. n/ ' Hi'W.O | ' } rhjiHg fi tVioimVcrt [[ Aapcn fits ?t>8 111'
FIGURE 5.44
We like to see the composition of all incoming and outgoing streams in mole fraction
basis in the final results table. Accordingly, we use Stream sheet under the Report
Options of Setup folder (see Figure 5.45).
rif F* Mix Otfa fir F*<3 lrtv Wtwjo- Hrfc
i MHl
_iJMl BMSLSfcalgl "'I "'I I I "I "I ~l g
JJ
""
.
I I I FV
_
LLM_Lia|
FlipdrtOplta
"
351
0 S*-*. ",
'
,w. ...
O -
I! .
.J 1
bnnil | rbwihWI | BM ./SIiiimi| Piorniy [ ADA |
Itw* lo N> rrlaMi i>tMn> ixoa)
P W.Hum.
FIGURE 5.45
DYNAMICS \NI) CONTUOI, OK I'l.OW DRIVKN ('UOCICSSKS 259
From (In- Data Brow.scr, hoIoc! (
'
oniponcnta/Speeipcctions to open the com
ponont input
lorm In ill'' lahlc. shown in l-
'
i mc S 1 (>. Ihc Ivvo species are dclincd
UM M fVA I** Unfti
h d .Igil I lal -iW
0 H""
Itarimi Ophor*
I Ml/ tC Qrm)
ml
Mi
Qp
him nl
ni.urm rrniioii mo
Wiwii d b riti.; li. i Muifi ..ti feMtoi 0oN>i>
FIGURE 5.46
,,
>(. li'i on Hm- Nil
. choose Properties/Specifications and gel the property Inpul form.
in Aspen simulation
, a property method originall} Includes several models for calculating
the physical properties For the distillation exam
ple, set the UNIPAC base method b>
scrolling down (see Fi
gure 5.47).
Specifying stream Information
,
"
next, (.pen Streama I FEEDI Input I Specifications sheel Entering the given
Values lor all State var
iables and teed eompo ion.
Ihe slream mpnl lorm looks like
Figure 6 'IH
,
"
lefl pane ol the Data Browser window
,
select Blocks IRADFRACI Setup to open
Configuration she
et and then insorl the required datn (see Figure 5.49)
260 . PROCESS SIMULATION AND CONTROL USING ASPEN
> He E* Wew Oati Tooli ft FW Ut*ry Window H*>
_
LJ~- I I I Jje
JjiJ J J
0 Slream Oae*
B | S<i)*ww
Q Cutlom OMi
O Repwt Opicna
b t-end Pfopii
Pe<rfocnpOfirt9
;
O MrCorpi
_
Potjma
B fl Property Method!
.
_j EHi Un
9 CD Wotecd Slftjcti
a
Qt | Prap-Sts
r j Adveoced
HU I JhJill -ZliiJuLJgij
Piowxtyrwthocbt moded
Relerenced |
PtocMt I VP*
Be meitwd jufJIFAC
Heniy corrvcuwitt [
PelTOteum cflloHston option*
Fiw-watm method
Wle< otut*y
Picwtymethod juNiFftr Tj
r Modlv P<ope<iy rmdett
Etecddyte c ciisbon option:
Chamtiiy ID
17 . : .
'
3
~
3
~
3
~
3
r
LJNIFAC wlh AedKrh-Kwof.g elation d tlate and Henty't law
hpot Complete
[it* MbMi/Splilleri j Sepstfon | HhI Exchangees Cohaint { Readou | Piettue Changeft | Manptiatori | Sokh | UteiModrt |
STREAMS DSTVAJ Di'.H FladFiac E act Mijfrac SCf<ac FelioFisc fWeFrac BaichFrac
C \ d Fitfcn'Asien dd IM HUM
| .'- JOMptef -Mgoicft W j 0 S-Hcto W j ) tjMftJ Twig-Mcn:< |j tmpmn Pka
FIGURE 5.47
-
fi- ?d( [Ula T04I1 Run not tibrary Wride)v< HH'
d|b;|h| l l Nel ?! akiahl-gl i n.|
la]
"
3 J*J <<J( i 3 >>J Q|aJ n J
O Report Ot*or<
- ConpaTerts
Speofcebont
Asw'Bend
Lghl-End Prcpofto
$ 'JJ Peiro Owaclefuabon
Pteudocorvowta
HonyCcrrps
UNIFAC Gtohm
) Comp-Groupi
>
_
Compel
B
_
) Potywi
-
.J/) Prtceft ee
*
Property Mhod9
Cj Emal3n
.
_j Wcc iaf Sbucture
W pwwet
,
'
i Data
_J MM*
-
Ji Pr -Sett
$ MvarvceC
.
_| BOTTOM
-
Jl) FEED
o
EOVMMu
3 ClI.C
FlsshOplioBt I I EOOpiw: I
Siij!limfm )yMIXED
3 |M*f
"
3
I
225
d
d
Ip.. d
lanlltow
[Mote d
|600 d
1 J
CotrpGrem
Vofcje
SEN2ENE 015
TOLUENE 055
!oUI F
STREAMS 1 DSTVA)
FoH* PMF1
Book
FIGURE 5.48
DYNAMICS AND CONTROL OK KLOW-DKiVEN PROCESSES 261
cz:
a
9
'-
a
Mr
3
-
ap>
1->- d J
inca Si-vi M . tan <Mf VM- M
1 r -i-t-:- nr
-
j Kim
w
-
I
.
,
-
fTTTTB
FIGURE 5.50
DYNAMICS AND CONTROL OK KLOW-DKiVEN PROCESSES 261
cz:
a
9
'-
a
Mr
3
-
ap>
1->- d J
inca Si-vi M . tan <Mf VM- M
1 r -i-t-:- nr
-
j Kim
w
-
I
.
,
-
fTTTTB
FIGURE 5.50
262 PROCESS SIMULATION AND CONTROL USINKi ASPEN
In Figure 5.51, the column pressure profile is defined.
SmWIon 1 [Bock IWDFRAC (nadFrac) Sell* - Dan Bnnrawl
Re Ed< Dala Tool* Run Plol Ubraty VtMum HHp
_
Li!iJ J JZJ J d
l ill itei
JiJxJ
O Setup
38
J/j Prc<iSdS
t
_
j eorroM
-
tttt
O hpu
fiesuts
*
_
j tOP
(j
Bocks
1L
8
Stup
Q Design Specs
D
Vaiy
S
Heaierj Co era
lJ
Putnoarxjxis
D*cTlefs
o
BfoencJes
Reeciavs
D
Condenser Hc n.'
Reboter Hcijr\-es
_J
Tray Sung
. D Tray ReU-g
CJ Peck Sa ig
Peck Relng
0
Praoerties
3 -
1 w
/Condguistion j -/SUevni /Pioiiure|-/Conden:e( |
]P(e;iNfepic.l(li
I I
Vnw:
Pistture
1 e
25 21
*
MKm/SpUleis
HZH1
STREAMS ' DSTWU
:6 Stages lf*Jtrcr*s*j-.
Sepalots j Heat Exchanges Cduran* }
Reactors
(C-I-C-S-M-jfr-C-cT-
Piessute ChangH! j Man atojs j SofcU ) Uiei Models j
SCftac PeltoFrac R eFiac SatchFfdc
" '
CV a Fo V apenPlus 11 1
| Chapter 2 - Wcfos . | 4] Chapter 5 - Mcti; | t]} Useful Temg - Mk Aapen Rib S
NUM 'Reajuedin{>i In .-vxwH-
- Wo6e AcroM Pr I S i Jff2C
FIGURE 5.51
Entering heat transfer data for condenser and reboiler
Next select Dynamic under RADFRAC of Blocks folder. There are three heat transfer
options: constant duty, constant medium temperature and LMTD. As mentioned in the
problem statement, the condenser heat duty depends on the log-mean temperature
differential between the process fluid and the coolant. The coolant inlet temperature is
set constant. Here the temperature approach represents the difference between the
process temperature and the coolant outlet temperature at the initial steady state
Note that among the heat transfer specifications
,
the coolant inlet temperature and
temperature approach may vary during a dynamic simulation,
whereas the specific
heat capacity of the coolant is fixed during a dynamic run (see Figure 5.52).
For the reboiler
, it is fair to use constant heat duty computed in the Aspen Plus
simulation. However
, the reboiler duty may be changed at dynamic state either by
manually or automatically with employing a controller (see Figure 5.53).
Entering geometry data for reflux drum and sump
The reflux drum and sump are specified in Figures 5.54(a) and (b) with their given
geometry data. The information on vessel orientation, head type, length (or height)
and diameter are used to compute the vessel holdup.
DmVKN PROCKSSP S 263
BOL \W Zm roote Rf> PW U vy Wndmr Hf.
j|a;|B| I I v\ r;|Tlal.|<|w| n i
i r -i i i rv i .isi
J2J
Sim
o MM
D iVi j- Se*ci
_i
*y
9
*mCoolen
CJ
_]
: M
_j
a
Reboier Moves
ii
_j
Pat* Siing
_i faw Rang
i
o
o
o
Reoort
o
ijm- SutraArm
0 O iarrjc Eaueme
Bock Opuon*
] LI iijri 3 uu Nj
HmI i<i;tai option [lmTD
I
"
npamB appiMch
1
1]
(
"
p
1
J
1
-
CM
MUM
'
5TRtS
Mwr/SpfcJlM j Separori | HMTExchangen | C(*in>> j RMctai | FtenusChangen | M. ScWi I UwHcmMi J
FSfil SSpB
Book
FIGURE 5.52
i a
ie] <PJ ntn M l i ~l I l"l *l s1! 1 ill
F- 1
-i
.
1 nr 1 leal i ibi
'
I ftmwwj-di
S Cleans
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3
-
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_)
'
-x<JerMr Mar*
O 'JMr SoOTOJUTW
0 a*Cbor
FIGURE 5.53
264 4- PROCESS SIMULATION AND CONTROL USING ASPEN
He Eck V*ew Data Tods Run Ubr*v Window H
l 1 1
In jJIZJ
mm
,2 PrccMei
.
Jfl Steams
3Efb |m
"
3 l_JiiJR 321] nil
!1J
0isn Speci
_
l Vaiy
9
Heater CocJeo
CJ
?ii>anxx>ds
_i
Oacartefi
5
s
Reactone
Cordansaf H v
jj
RebalerHcu-wss
_i
Tra)' Stw>3
a TrajRing
EJ
Pack Sons
_j
PactRalrtg
9
?ro(jrt:
0
Eawnatei
9
Conveyance
9 Repor.
9
Uiw SiijfDU;nes
w
Oynanac
/Condense, j/Reboiier /Reltmi Dmml Sump j
Vessel lype |Hotizonial
~
3
: Vessd geomstiy
Headlype
i Lengtlk
: Diwnetei
Iniialspdcificabon
5 fl
z
25 ft
z.
iTangen' lc- tange'-tl t ertgUi J Heod Type-EBclic oi Hemisphenc-al Acfuattenglh it Head Tvp*=FU
'
Mwen/SpliHeft | Sepaisios j Hatxchangeit j Cokimne | Rescloit { Piessue CKsngef: | ManipUators I Solicft j UserModeis {
Mattel
STREAMS J Mbw FSpB
For Help. prei FT
1 $
25 5t5S t; Rmpifotnd f
'
Mom FSpil SSpW
Aspen
_Oyna j . psty Tta . j j-j spxxK hg . j Calajbto; <m
FIGURE 5.54(a)
s % EdR Mew Oa i Too* Pin flat Ubwy
S3ESSESS
3 -I I'M lEi J Si
i
_
r
.
jjj_fv
"
3
_V1 oc-rt es
J/j areams
fitoda
- RMFRK
0gr. Specs
: Headiippe
Hei t
Dimtat
Totatiqi*dvoU?ehac!wn [
Morot/SpMlaft | Sopar tcf. | Hea* Exthonffm |
, | (Mom | P..CIW" | Maroiaw. | S<*k | U
0 AMkOtWMn NT*
n- | - | <...
-
~. I c* .
FIGURE 5.54(b)
Entering tray geometry
The example column has total 25 stages-Stage 1 being the condenser and Stage 25
the reboiler. We already have inserted the necessary information for stages 1 and
25. Now, we need to inform the simulator the tray geometry specifications for stages
2 through 24. Note that the tray holdups are computed using these geometry data
(see Figure 5.55).
n E* Vb Mi Tooi ft* Lfcrao VWrdpw Hsfc
f
"
: fV
-
I - imi I lai 1 1
.
jj Stan
-
Mi
_j y
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- . - - V
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-
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SeG*tn | Hea EKChaqot | Cckm | ReKUfl | PieumChanpn | Mi>lois { SotcH | day Mod* |
. . . -
NUM
Caiaiacr
Seoul*! rxxl CMP-e
FIGURE 5.55
Running steady state simulation and viewing results
Hit Afecf button and press OK to run the steady state simulation. Finally, the result."
table
, shown in Figure 5.
56, is obtained. At this time, we should save the work.
(b) Exporting dynamic simulation: For process dynamics study, we wish to
export the steady state Aspen Plus simulation into flow-driven Aspen
Dynamics
simulation giving a file name of'Ch5
_
5
.
3
_
RadFrac'. Then close the Aspen Plus
window
.
E* Vte*v Data To* R Ubr*v Window Help
Setup
_
P pel s
31 9mamt
Bseki
Rnctane
-
-
3
Com Optons
EO Cenv Cfilioht
9 St*>
Q 01-10 Ejk
Q L'HO Adv
O LSSOF Base
Q LSSQP idv
Tea.
Convergence
ConvOder
- I Sequence
_
j RoA-shee!r>; Options
:
_
j Mc- ei ttafytii T< s
Jj EO Cc guratan
[jj ResJls Sixmrafy
9 Pijn Status
1 Lil <iJF 31
,
1 1
-
3 F-m*; Sue-am Table I
Convef ence
z\ d Zl
IHttUIB psi 21,00 21 00 18 00
/apoiFiac 0 000 05 0 000
Mole FteIto.oll, 315000 600 000 285 000
Malt Flow b i 29009731 51497.054 22487 324
Volume FlowctitAm 607353 14147.249 446 618
;nthi*(. MMBHi/hi 3.99! 11.329 6 675
4cfcFlowlhcnoi/t.
BENZENE 1.036 270.000 268,964
TOLUENE 313.964 330000 16036
oleFtac
BENZENE 0.003 0450 0,944
TOLUENE 0.S97 0.550 0 056
Roula Avoleble
p
lj
"
Uureit/Spllten ] Separatort ) Heal Ewhangett ] CoUww ) Reacton | Piewuie OwrgBrs | MampUatois | Srtdt ) Ue( Models |
Man
STREAMS ' Mi. FSpa SSl*
1 M r rJJ rA
:FocHe|p.|illiFi 0 VBo*-Cheplere NUM Re>jl( AnAUe
|4)Ch8i5 W..,|| Aipen Phm... fapm.D) .,- | fapen.IVia-.. } apocfeheat:. [ CefcuMof | Q P'tVi 11 53
FIGURE 5.56
Starting Aspen Dynamics
Open a blank dynamic simulation window for the example column, following a similar
procedure as previously shown for the CSTR problem. In the next, simply open the
flow-driven dynamic file 'Ch5
_
5
.
3
_
RadFrac.dynf. As a result, the Aspen Dynamics
window appears (see Figure 5.57) accompanying with the closed-loop process flow
diagram. The flowsheet actually includes the three default control schemes LCI, PC2
and LC3 to monitor the reflux drum liquid level, top stage pressure and column base
liquid level, respectively.
In the present discussion, we do not want to change anything of the three
automatically inserted control strategies. All data, including timing parameters, rang
es,
bias values and controller actions, remain untouched. A little detail of these control
structures is given below.
Loop 1
Controller: LCI
Type of controUer: P-only (since integral time is very large (60000 minutes))
Controlled variable: liquid level in the reflux drum
Manipulated variable: distillate flow rate
C<rtenta d Snmiaaon
5 9
g [Dynnmlt J h .IS'ByiUEiaffl
r tt ai|oo5 J ii. i -ji f
-inM
LCI
r>0 .
o--
BOTTOM fO
LlJ
Siaulation ready for solution
7 equations were not eliminated because they had residuals over le-005
A total of S32 equations (38 b'/.) were eiinmated
Sinulation has 1991 variables. 1484 equations and 6219 non-zeros
3
IBjnsilcal 0.(10
Aspen fVjs Mty8
_
[>i
'
I A n IVvrtc-
FIGURE 5.57
Loop 2
Loop 3
Controller: PC2
Type of Controller: PI
Controlled variable: top stage pressure
Manipulated variable: coolant inflow rate
{
Controller: LC3
Type of controller: P-only
Controlled variable: liquid level in the column base
Manipulated variable: bottoms flow rate
Adding a new PI controller for top composition loop
Now we wish to include a proportional integral (PI) law to control the benzene
composition in the top distillation product by manipulating the re
flux rate. In the top
left of the window
,
the Dynamics library is included within Simulation
folder of Ml
Items pane. Click on expand (+) button of Dynamics subfolder. Consequen
tly, the expand
button changes to collapse (-) button as shown in Figure 5.58.
268 PROCESS SIMULATION AND CONTROL U
SING ASPEN
ar s
*
I
"-- 3 ' i< . w t a
y u n ca r-
Bp
r
_
tt o p
-
,
totl ol 91? Kiu tion* lie IK] v.c. .LktAated
ixuiation ha* I'm variabl** la< aquat.on. and til'
J
FIGURE 5.58
Again hit expand button next to the ControlModels icon. Then select PID controller
,
drag it to the flow diagram and drop the control block near to the top product stream.
Renaming the top composition controller as CCT
, we have Figure 5.59.
Uae
.
l*
.1
no
1 -
9
PS Rnuu
lO ii
Si*?0-
-TwT-o
Id V
t
-Q
:
h tgnm K>
-iaii
3
> und to npJtQOlO
FIGURE 5.59
Connecting controller with process variable (Controlled variable)
Ixpand Stream Types under Dynamics subfolder and hold down the m
ouse button on
he ControlSignal icon. As we drag it onto the flowsheet w
indow, many blue an
-
ow
appear around the process diagram. Interestingly, when we f l I Z S
.
wiih holding the ControlSignal icon
over a port, the name of that P
Anyway, move the pointer and release the mouse button o
n the 0fe g wo
* *ame
OutputSignal originated from TOP (stream) block. To
select the dastillate compos.tio
CONTROL OF FLOW
DRTV rPPn cc 269
of benzene as controUed variable, choose 'STREAMSCTOP") Z
nCBENyFTWv
fraction' by description in the Select the Control Variabl
e
4bo Fi 5
.
6of
W lOyti.Mc
si a
SIR AMS| TOPlfcrfBEHZE
SlfiEAMSC ICiP lfcnf I0LUE
siREMnrniPi fmanaa
SIBEAMSI'TOP'l.fiTtrtTOi.U
SIRDMSTTOPtP
STREaMSriOPlZmrtBEftZE Moslhacten
" '
IQUJE
Ucli total
STSfAMSlTDP
it snapshots houe been saved to lile snp*00l0 I
FIGURE 5.60
As we press 0/!l button, the cursor becomes a solid black arrow representing the
input signal to the controller. To transmit this signal to the CCT block, connect the
black arrow with a port marked InputSignal. Since this signal conveys the process
variable (PV) information to the CCT controller
,
select 'CCT.PV by name with 'Process
variable
'
by description in the Select the Control Variable dialog box (see Figure 5.61).
0B'<BQi 1%
-Ulxl
X? |Dyn.mlc
-
..ri
FIGURE 5.61
Hit OK button and obtain Figure 5.62. Obviously
,
the CCT controller is partiall
y
configured. To complete the top composition loop, the controller output should b
e
connected with the manipulated variable to pass on the signal.
B pen Oynmics wiya_Oia I dyrf
Re E-*l TocJs Rowsheei Run Window Met
D fii; H # El CS iDynamic > [.
) Modd)
( Parametef Types
| Pol TflJW
i Pre5ureCnsrgeRi
J PMH . rc- Bl
| Prcceduw
) F actora
| Seoaratora
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ConteniiQl ContiptSignal
WMlH Controlig SySer
s FtwrilMl Window
r Utt G..d |0 05 t!
CH FEED [
_
:>C2
0 LCI
LC3
>o-
.
>o
o r
-
| B0TT0M]</
lation has 1931 variables 1484 equations and 6219
ing Simulation
ent snapshots have been saved to file snpAOOlO snp
I
non-zeros
Ready Jl focal Dynamic at 0 00
aart| p , m " Bopk | -jjChap-er 5 Mi | Jrj UaeMTgms | Adobe Acroba | Goo e Wnd | A*>en Ptu: C
~
3
Dm
FIGURE 5.62
Connecting controller with control variable (Manipulated variable)
Again hold the ControlSignal icon, drag it onto the process flowsheet and drop it on
the blue outgoing arrow marked OutputSignal from the CCT block. As Select the
Control Variable dialog box appears (see Figure 5.63), choose 'CCT.OP' by name and
press OK.
Immediately, a solid black arrow representing the controller output signal is
automatically generated. Move the mouse pointer to reflux stream and make a
connection to InputSignal2 port. To use the reflux flow rate as control variable, se
lect
'
BLOCKSC'RADFRAC). Reflux.FmR' in the dialog box and click OK (see Figure 5.64).
Now the binary distillation column is coupled with four control schemes, LCI,
PC2, LC3 and CCT, and the closed-loop process looks like Figure 5.65. The subsequent
discussion includes the modification of different tuning properties of the CCT
controller.
DYNAMICS AND CONTROL OK FLOW-
DRIVKn PROCESSES 271
HKBB
OwtB W | Dynamic J
r UTtlMln *J Li \i r %
BIBB
Piocmi rmbto
L
Edit tnq SimuIsIton
Current snapcbom timvm bMn *vd tc 1)1* onpAOPll np
Uj . i
M l
3
FIGURE 5.63
0 * H .[! (B V |Ovn.mlr
3
1
IS, , . 'i . 1.. - V..- , *
_
r it 7f o-d|uir, i; wit s
tQAiM
tILUlf SI-HAI'FtUC' lMaoril.'l
nLOcirfuiiFHw: im miii
eioc srwM*ri vi h' i
eiotr srnADrrut'isi mim
U4 w* l>vimcofln'
M toed tW*
-iDl
yi||
i
FIGURE 5.64
6* a Q ffl W |Uyn.mlt J >
J Stmam Tipca
r Orfloffi ,
,
>o
OH FEED h
>o
J >0-- v m
Editing 5iulstior.
Current sn&pshcta havo bee
U I
'ad to tile snpAOOU snp
FIGURE 5.65
Modifying controller tuning properties
First we wish to see the default tuning properties. So
,
double-click on the CCT block and
then hit Configure symbol in the faceplate to open the Configure dialog box (see Figure 5.66).
Fie y*w Too. Pui Wrx w Kefe
j Dynamic ] 5BB feiaOESD9
* |
r n -it c..i|o"-, jj n
r
Tuwnp | Raryii jf ffamg J Ottw
OteianMnMlai
TtmepaianeieK
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.* V
irOjaJim | 1- d
1- d
LCI
g>-ffnoT-
-
CwT-o
y
:
H BOTTOM K)
i 2031 varittbles ISOi equsiions and 63 3 i
jrwnt snapshots have been aawd
3
-
4 .-
FIGURE 5.66
Obviously, some of the default values set by Aspen Dynamics are not acceptable.
For example, the operator set point value of process variable (benzene composition in
distillate) should not be greater than L Secondly, the CCT controller action must be
'
Reverse'. In addition, the value of control variable (reflux flow rate) at steady state is
usually used as
bias value.
We have two options in our hand to correct the default values. Either manually
we can do it or Aspen Dynam
ics can automatically initialize the values of set point
,
process variable, contro
l variable, bias and ranges. Note that the controller action is
changed only manually. It is wise to initialize the values by the help of Aspen Dynamics.
For this, press Initialize Values button in the Configure dialog box and use 'Reverse'
controller action. It is obvious in the window, shown in Figure 5.67, that the values of
SP, PV and OP in the faceplate change automatically to their steady state values. If
this approach fails to initialize the simulation of controller model with the steady state
data, check and replace, if necessary, the values of PV and OP with their steady state
values by double clicking on signal transmission lines (input to the controller and output
from the controller).
fie Vx* Tods Wndow
j Dynamic ].]
fflS-e LJL?nH!
Allttro
r Gndi-JCB zl 2* H
acci
Mill
10 3437
10 9437
|49472 na
.
O LCI
1
Turong ] Ranges ] nam T
0|wdlot|)* 10 343 33 IfcmoMbmol
Tuwigpawieleit
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a. 4|l
1 zi
Oenvative me.
|o
Conbofct Kljon
r Dieo
< -{TfLCL.j
LCI
>o-
if
1 BOTTOM K>
nables 1494
been saved Co file snpAOOOO snp
It
loot DynmcaOOO
| JlJ Ouplg 5 >4cton ft *l-0 jj ''
3
J
FIGURE 5.67
Modifying ra
nges for process variable and controller output
we hit the Ran
ges tab, the Configure dialog box (see Figure 5.68) shows t
he default
ranges i
mposed on process variable and controller output.
Db Tat* Kr XVhoa* rt*
- W -; . (ft
|lnlllBll?nll<in
jo g*-'.'
BBSiwi
>C
P Opts range
0><pki
Rw trnwun |3CS4i rill |t/N
[7
Q Hc
>o-
| H bohom f<'
r > :-.: .. rz :!.: i._v-i ::n FlIF t'.-r.i:. THE-: t;-:.
equation B10CK5CLC1
"
) CalcDillTer* moved tro ELSE branch to THEN branch
equation BLOCKS(
'
LCI') CaicPropTr HMd (ro. ELSE branch to THEH branch
has 2031 variables 150S equations and t>32i non-zeros
3
Ready
'
5.11 r
FIGURE 5.68
However, here we use the typical variable ranges, shown in Figure 5.69.
He e Toe* fin Wnjcm hds
ff |rnitializMion ffi S1 0 [3
3
3 SrUMon
% iaizi
nwpwjifiiiii [T
>o -
L
-Q H 60MOM [<>
. __g groups 664 lo 670 of type Explicit Linear
Solwing group fc'l sire S type Linear
Group 671 already converged
living group* 672 to 601 ol type Explicit Linear
fun coaplete at 11 16 14
3
J
..
/is
FIGURE 5.69
Process variable
Range minimum: 0.85
Range maximum: 10
Output
Range minimum: 10000 Ib/hr
Range maximum: 120000 Ib/hr
It is important to mention that it is a good idea to carry out Initialization as well
as Dynamic run after each new change in the control scheme so that any error in
controller installation can be detected individually.
We have now completed all required control specifications for the top composition
loop In the ongoing study, we prefer to conduct the simulation experiment to observe
the designed controller performance continuously for 5 hours. As done for the previous
CSTR problem, similarly either simply press Ctrl+F5 on the keyboard or select Pause
At from the Run menu and put 5 hours as Pause at time.
In the next, we will inspect the CCT controller performance first dealing with the
servo problem followed by the regulatory problem.
Viewing servo performance of CCT
As we double-click on the CCT controller block in the flowsheet window
, the faceplate
appears. Then open the Configure as well as ResultsPlot dialog box.
The second one is
basically a blank graph sheet that presents the variations of process variable, set point
and controller output with respect to time.
Before running the program, make sure that all the items in the Configure dialog box
and faceplate are correct. In the next
,
hit Run button to start the dynamic simulation. The
plots, shown in Figure 5 70, illustrate the servo behaviour of the PI control algorithm with
a step increase (0.9437 - 0 97 at time = 1.51 hours) followed by a step decrease
(0 97 - 0
.
9 at time = 3 hours) in the set point value of the distillate composition of benzene.
To achieve an improved closed-loop performance, we have used the values of proportional
gain of 10 %/% and integral time of 10 minutes. These values have been chosen based
on a pulse input test in the distillate composition of benzene and using the trial-and-
error approach It should be kept in mind that the objective at this point is not to come
up with the best control structure or the optimum controller tuning. We only need a
control scheme and tunings that provide a reasonably good tracking performance to
drive the simulation to a new steady state.
Remember that to edit the plots, shown in Figure 5 70, double-click on different
elements of the plots and modify them as we like.
Viewing regulatory performance of CCT
In order to investigate the regulatory performance of the CCT controller, we give a step
input change in the feed pressure (21 - 23 psia) at time = 1.48 hours and that in the feed
temperature (225 - 230oF) at time = 3 hours. The PI controller tuning set provides good
disturbance rejection performance (see Figure 5.71) although the tuning parameter values
.
gain and integral time) have been chosen based on a pulse set point input change.
276 PROCESS SIMULATION AND CONTROL USfNG AST'EN
D g B a IB <<l |Dyn.,nk 3
r a it Mi-nr 2} i s
-
o
.
jtOTTOMfO
lor* 1 SOOOd OOO acceptttd
FIGURE 5.70
He ,4> Teds Rn ..r.x. Heb
3 S H (i V? lOyn.mk
t Eyewntcrari
33 31
-
Tyl-o
--
>o
-. ccr
'
HQ-
=
'
Z-BKZE-J
il
5 05 1 If 2 2 3 3S < 5 5
Time Hoiks
FIGURE 5.71
3
1
j
(c) Adding a new PI controller for bottom composition loop: We have to
devise another PI control scheme to monitor the bottoms composition of benzene
by adjusting the heat input to the reboiler. As developed, the CCT controller
for the top loop, similarly we can configure the CCB controller for the bottom
loop as shown in Figure 5.72.
I.:IM
.:
.
.
s
1
4.
1
.
!. m
lm< uuuk.'* w-> Ml X-M i.. I.im mmttfll M*
FIGURE 5.72
We have chosen the following tuning properties (see Figure 5.73):
Gain = 10 %/%
Integral time = 10 minutes
Controller action: Direct
dub .a % |M*.. r
"
3 . . nvm awocigi
_
r :: f - >. -
!
1 ; 7T
~
:
'w. 55 i i '. i
.-
f
-
v..
r
c
-
MM
i
.TIM mmm lia
tl A I.. li.c... EkMIMi
| "1 .MtMlM lftj WMtlOM m4 M3 mm-two*
FIGURE 5.73
278 . PROCESS SIMULATION AND CONTROL USING ASPEN
In addition, the used constraints are reported below:
Process variable
Range minimum: 0.0
Range maximum: 0.1
Output
Range minimum: 6000000 Btu/hr
Range maximum: 18000000 Btu/hr
Viewing interaction effect between two composition loops
To observe the effect of interaction between two composition loops, the set point value
of bottoms composition of benzene has been changed twice. The simulation result is
depicted in Figure 5.74 for a step increase (0.0033 -> 0.0045 at time = 1.5 hours) followed
by a step decrease (0.0045 -> 0.0025 at time = 3 hours).
EC
He Mew Toots fen Window net
| Dynamic h CBS'S aiaocsH
- MS*}
9-
r Tt (0 05 3 i i W 1*
%j am
SP| 100025
PV;
I00O25
0PHH |12117835,;
Tunuvj | Ranges | Ffenr ] Olha
Opetatot set poi* (0 0025 jbmol/bfrol
Turwtg paameten
St. [l1613W7r jBtu/W
Gart [To
Iniegrafww. flO f i
Owwabvetimei [o
-
Cortiolw action -
Drad
r Reverte
TEE
I
.
s.
>
-
S?
If
LCI
>o-
LCJ
>o-
{33-0
--
>a-j
CCT
BOTTOM K>
0 0 5 1 1 5 2 2 5 3 3 = 4 4,5 5
Time Hours
63
11
r
=inj
_l
"
3
i
1
i 2 2.5 3 13
Time Hours
teed
FIGURE 5.74
Clearly, the CCB controller shows satisfactory set point tracking performance
against a pulse input change. It is observed from Figure 5.74 that owing to strong
interaction between the two composition loops of the distillation column,
the set point
changes in bottom loop affect the top product composition. Similarly, when any set
point change is introduced in the top composition loop, the bottom product composition
will also be affected.
DYNAMICS IND CONTROL OF FLOW-DRIN KN I'HOrKSSKS 279
This chapter has investigated the closed-loop process dynamic characteristics using
Aspen Dynamic- package. To observ e the controller performance in terms of set point
tracking and disturbance rejection, a CSTR in addition to a distillation column have
been illustrated The default control strategies have been tested for the reactor example,
whereas the two additional composition control loops have been included along with
the default control laws for the distillation example. Several simulation experiments
have been executed for both the processes under flow-driven dynamic simulation. Note
that Chapter 6 presents the dynamic simulation and control of more rigorous pressure-
driven dynamic process.
PROBLEMS|
5
.
1 A feed mixture of benzene and toluene is fed to a flash drum (Flash2). The
separator operates at 1.2 atm and 100
oC
. For dynamic simulation, required feed
specifications are provided in Figure 5.75.
Feed
Temperature = 25C
Pressure = 3 bar
Flow rate = 100 kmol/hr
benzene 0
.
6
toluene 0.
4
FLASH
>o
PI
FIGURE 5.75 A flowsheet of a flash drum.
'
a) Use the SYSOP0 property method to compute the amounts of liquid and
vapour products and their compositions.
.
b) As shown in Figure 5.75, employ a PI control scheme to monitor the
temperature in the flash drum by manipulating the heat duty
.
(c) Show the closed-loop servo performance with +10% and then -10% step
changes in the flash temperature.
(d) Report the tuning parameters obtained by trial-and-error method, controller
action and ranges imposed.
5
.
2 A vapour mixture of t
oluene, methane and hydrogen is heated using a shell and
tube heat exchanger (HeatX). The superheated steam is used as a heating medium.
Complete specifications re
quired for closed-loop dynamic simulation are shown in
Figure 5.76.
280 PROCRSS SIMULATION AND CONTROL USING ASPEN
Cold Stream In
Temperature =
2780F
Pressure = 500 psia
Component
Flow rate
(kmol/hr)
toluene 200
methane 2300
hydrogen
1000
Hot Stream Out
Pressure = 14 psia
I
HOT-OUT
ICOLD-INf
Cold Stream Out
j cold-out hoi Temperature = HOOT
Pressure = 498 psia
HOT-INK
Dead time pi
>o
>AT
ii
Hot Stream In
Temperature = 1160oF
Pressure = 14.7 psia
FIGURE 5.76 A flowsheet of a heat exchanger.
(a) Simulate the heat exchanger model using the shortcut method, counter-
current flow direction and NRTL-RK property method.
(b) Include a PI control structure to observe the set point (cold stream outlet
temperature) tracking performance and the manipulated input (steam inflow
rate) profile. In the closed-loop simulation experiment, assume that the
temperature sensor takes 1 minute time (dead time) to measure the controlled
variable. Report the used tuning properties.
(c) Examine the regulatory performance by introducing + 10% and subsequently
-
10% step changes in the inlet temperature of the cold stream.
5
.
3 Device a cascade control scheme for the above heat exchanger and investigate
the controller performance.
5
.
4 A liquid mixer model with a typical ratio controller (Seborg et al. 2003) is shown
in Figure 5.77. The flow rates for both the disturbance or wild stream (Fw) and
the manipulated stream (FE) are measured, and the measured ratio, R
m
= FE/Fw,
is calculated. The output of the ratio element is sent to a ratio controller (PI) that
compares the calculated ratio Rm to the desired ratio Rd (set point) and adjusts
the manipulated flow rate accordingly.
Ratio
Input 2
>o
PI
>
| POT >
Input 1
FIGURE 5.77 A flowsheet of a mixer
DYNAMICS AND CONTROL OF KLOW-DRIVKN PROCESSES 281
The input data are shown in Table 5.2 for simulation.
TABLE 5.2
Stream
Temperature CO
Pressure (aim) Flow rate (kmol/hr)
Composition
E 50 1
Pe
= 100
pure ethanol
W 60 1 = 150
pure water
Process variable at steady state = 0.667 (FE/FW = 100/150)
Controller output at steady state = 100 kmol/hr
Proportional gain = 4 %/%
Integral time = 20 minutes
Controller action = reverse
(a) Appljang the SYSOPO base property method, simulate the mixer model
operated at 1 atm.
(b) Using the given controller properties and default ranges, report the
ratio controller performance with two consecutive set point step changes
(0.667 -> 0.72 0.65) in the ratio.
Hint: Double-click on Input 1 transmission line and fill up Tables 5.3(a) and (b).
TABLE 5.3(a)
Value
Spec
>STREAMS("E
*,
).Fcn("ETHANOL")
<Ratio.Input!
100.0
100.0
Free
Free
Similar table for Input 2 is obtained as:
TABLE 5.3(b)
Value
Spec
>STREAMS("W
w
).Fcn("WATER") 150.0 Free
<Ratio.Input2
150.0 Free
In the next, double-click on Ratio element and get Table 5.4.
TABLE 5.4
Description
Value Units
Inputl Input signal 1
100.0 kmol/hr
Input2 Input signal 2
150.0 kmol/hr
Output Output signal, Inputl/lnput2
0
.667
Use Initialize Values button and incorporate the given tuning properties before
running the program.
282 PROCESS SIMULATION AND CONTROL USING ASI'RN""
5
,
5 A reboiled stripper is used to remove mainly propane and lighter species from a
feed stream, shown in Figure 5.78. It has total 6 stages (including condenser
and reboiler) and no condenser.
The bottoms rate is 100 Ibmol/hr and the column top stage pressure is 150 psia
with a column pressure drop of 8 psi. The diameter of the stripper (Stages 1 to
5) is 6.5 ft. The reboiler heat duty is assumed constant, although it changes at
dynamic state. The sump has elliptical head with a height of 5 ft and diameter
of 2.5 ft.
For the closed-loop simulation, use the following data:
Dead time = 2 minutes
Magnitude of noise (standard deviation) = 0.01 Ibmol/lbmol
Proportional gain of PI = 1 %/%
Integral time of PI = 20 minutes
Controller action = Reverse
Feed
Temperature =
40oF
Pressure = 160 psia
Component
Flow rate
(Ibmol/hr)
c, 60
c2
75
C3
150
n-C
4
175
n-C
5
60
n-C
8
35
PCI
Dead time Noise
Pi
>o
FIGURE 5.78 A flowsheet of a stripping column.
(a) Using the Peng-Robinson thermodynamic method
,
simulate the RadFrac
(STRIP2) model and compute the product compositions.
(b) Keeping the default controllers (PCI and LC2) unaltered
,
configure a
composition control scheme (PI) coupling with a 'Dead
_
time' and 'Noise
'
elements to maintain the propane mole fraction in the distillate by
manipulating the reboiler heat duty as shown in Figure 5.79. Use the given
closed-loop data and execute the dynamic simulations to test the developed
composition controller performance.
5
.
6 Ethylene is produced by cracking of ethane in a stoichiometric reactor. The
irreversible elementary vapour-phase reaction is given as.
C2H6 -i C2H4 + H2
ethane ethylene hydrogen
Pure ethane feed enters the reactor model
,
shown in Figure 5.79, with a flow
rate of 750 kmol/hr at 800oC and 5
.5 atm. The reactor operates at inlet
temperature and pressure with 80% conversion of ethane
.
DYNAMICS AND CONTROL OF FTOW-DRIVKN PROCESSES 283
> M
pi
>o
FIGURE 5.79 A flowsheet of a reactor
U) Using the SYSOPO thermodynamic method, simulate the reactor model.
(b) Develop a control loop as configured in the flow diagram to maintain the
desired reactor temperature by the adjustment of heat duty. Considering the
measurement lag of 1 minute, inspect the servo as well as regulatory control
performance. Report the tuning properties used to achieve a satisfactory
closed-loop performance.
5
.7 A binary feed mixture consisting of methylcyclohexane fMCH) and toluene is
introduced above tray number 14 of a RadFrac distillation model, shown in
Figure 5.80.
O
1 phenol [
O 1 FEED h
It is difficult to separate this close-boiling system (MCH-toluene) by simple binary
distillation
.
Therefore, phenol is used as an extractant and introduced above
tray number 7 of the column
. The two input streams have the following
specifications
,
shown in Table 5.5.
TABLE 5.5
Stream
Temperature (*C) Pressure 'bar) Flow rate Mole fraction
PHENOL
105 1.4 100 nrVhr 1
.
0
FEED
105 1
.
4 181.44 kmol/hr
0
.
5/0.5
(MCH/toluene)
The column has 22 theoretical sta
ges (including condenser and reboiler) with a
total condenser
. The distillate rate and reflux ratio are given as 90.72 kmol/hr
and 8 (mole basisres
pectively. The pressure profile is defined with Stage 1
pressure of 1 10316 bar and Stage 22 pressure of 1
.
39274 bar. Use LMTD
assumptions for the condenser Th
e reboiler heat duty is assumed constant. The
reflux drum and sum
p are specified in Table 5.6.
TABLE 5.6
Item
Vessel type Head type
Height /Length Diameter
(m)
(m)
elliptical 1
.
5 0
.
75
Sump
-
elliptical 1
.
5
0
.
75
The column diameter and tray spacing are given as 2 m and 0.6 m
, respectively,
(a) Simulate the distillation column using the UNIFAC property method to
compute the composition of MCH in the distillate and that of phenol in the
bottom product.
(b) In addition to the default level and pressure controllers, insert a PID structure
to control the MCH composition in the top product by manipulating the flow
rate of PHENOL stream.
(c) Produce the plots to show the closed-loop control responses, and report the
tuning parameters, control actions and operating ranges for controlled as
well as manipulated variables used.
REFERENCES|
Luyben, W.L., (2004), "Use of Dynamic Simulation to Converge Complex Process
Flowsheets", Chemical Engineering Education, pp. 142-149.
Seborg, D.E., T.F. Edgar and D.A. Mellichamp, (2003), Process Dynamics and Control,
2nd ed., John Wiley & Sons, Inc.
CHAPTER
6
Dynamics and Control of
Pressure-driven Processes
6
.
1 INTRODUCTION
To know the transient characteristics of a complicated chemical plant, we need a dynamic
process simulator. It is well-recognized that Aspen Dynamics
is such an efficient
flowsheet simulator used for dynamic process simulation. As we have seen in Chapter 5,
Aspen Dynamics simulator can be employed to design a process as well as its associated
control strategies.
Aspen Dynamics extends an Aspen Plus steady-state model into a dynamic process
model. If the steady state Aspen Plus simulation is exported to Aspen Dynamics, t
here
is a necessity to choose either flow-driven dynamic simulation or pressure-driven
dynamic simulation. In a rigorous pressure-driven simulation, pumps and compressors
are inserted
,
where needed, to provide the required pressure drop for material flow.
Control valves are installed
,
where needed, and their pressure drops selected. For good
control
, the pressure drop across a control valve should be greater than 0.1 bar. The
fluid that flows through a valve should normally be liquid-only or vapour-only because
the two-phase flow through a control valve is unusual
.
It should be pointed out that for a pressure-driven case, we must not insert a valve
in the suction of a pump or at the discharge of a compressor (compressor speed or its
equivalent compressor work is manipulated). The control valves are
positioned on the
fluid streams such that the controllers can manipulate the valve positions.
The simple flow-driven dynamic simulations have been discussed in detail in the
previous chapter. Therefore
,
here we are intended to study the pressure-driven
simulation
.
A reactive or catalytic distillation column is exampled for the rigorous
pressure-driven Aspen Dynamics simulation as well as control.
285
6
.2 DYNAMICS AND CONTROL OF A REACTIVE DISTILLATION (RD)
COLUMN
Problem statement
The methyl tertiary butyl ether (MTBE) column configuration (Jacobs and Krishna,
1993) chosen for the simulation is shown in Figure 6.1.
Pure methanol (MeOH) feed
(liquid)
Temperature = 320 K
Pressure = 1 aim
Flow rate = 711.30 kmol/hr
Feed stage = 10 (above-stage)
0| METHANOL Ft
Butenes feed (vapour)
Temperature = 350 K
Pressure = 1 aim
Flow rale = 1965.18 kmol/hr
Feed stage = 11 (above-stage)
Component
Mol fracl
/so-butene (IB)
0
.
36
n
-butene (NB)
0
.
64
PUMP
CHbutenes]-1
Jy tCl-fpisT-Q
CV2
"
1-H
'
l-IbotI-<>
CV3
RDCOLUUN
COMPRESS
FIGURE 6.1 A flowsheet for the production of MTBE.
The RD column (RadFrac) consists of 17 theoretical stages, including a total condenser
and a partial reboiler. Reactive stages are located in the middle of the column, Stage 4
down to and including Stage 11. In Aspen terminology, the numbering of the stages is
top downward; the condenser is Stage 1 and the reboiler is the last stage.
MTBE is produced by reaction of IB and MeOH:
(CH3)2C = CHa + CH3OH -(CHgk COCH3
IB MeOH MTBE
The liquid-phase reaction is catalyzed by a strong acidic macroreticular ion exchange
resin, for example Amberlyst 15. and n-butene does not take part in the reaction (inert).
The forward and backward rate laws (Seader and Henley, 1998; Rehfinger and Hoffmann,
1990) are derived in terms of mole fractions, instead of activities (products of activity
coefficient and mole fraction):
Forward rate: rf= 3.67 x 1012 exp
Backward rate: r,, = 2
.67 x 1017 exp
'
-
9244(M
RT
-
134454>
RT
.
IB
xMeOH ,
VMTB!'
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 287
Here, z represents the liquid-phase mole fraction. The pre-exponential factors,
including the activation energy (kJ/kmol), are given in SI units. The catalyst is provided
only for reactive stages (8 stages total), with 204.1 kg of catalyst per stage (Seader and
Henley. 1998). The used catalyst is a strong-acid ion-exchange resin with 4.9 equivalents
of acid groups per kg of catalyst. So, the equivalents per stage are 1000 or 8000 for the
8 stages. In some references, the equivalents per stage are directly given.
The column, starting from Stages 2 to 16, is packed with 'MELLAPAK' (vendor:
SULZER) having a size of 250Y. Use 'Simple packing' hydraulics and the height
equivalent to a theoretical plate (HETP) may be considered as 1 m. The distillation
column diameter is 6 m. Stage 1 (condenser) pressure is 11 atm with a column pressure
drop of 0.5 atm. The reflux ratio is set to 7 (mole basis) and the bottoms flow rate is
640.8 kmol/hr. In the MTBE synthesis process, it is desirable to obtain a bottom product
containing high-purity MTBE and a distillate containing high-purity NB. In Table 6.1
the reflux drum and the sump (the next-to-last stage in the column) are specified.
TABLE 6.1
Item
Vessel type Head type Height/Length (m)
Diameter (m)
elliptical
2 1
Sump
-
elliptical
2
.
2 1
.
1
The pump delivers the liquid stream POUT at 11.7 atm. The compressor (isentropic)
has discharged the vapour feed FV at 11.5 atm. The three control valves (adiabatic
flash) CV1, CV2 and CV3 have the outlet pressures of 11.5 atm, 10.8 atm and 11.3 atm
respectively. Using the UNIFAC base property method,
(a) simulate the process flowsheet to obtain the distillation product summary, and
(b) develop the control configurations to achieve the desired product purity under
disturbance input.
Simulation approach
(a) Start the Aspen program by double-clicking the Aspen Plus User Interface icon
on the desktop. Then select Template option and press Oif (see Figure 6.2).
: aM
;
FIGURE 6.2
288 PROCESS SIMULATION AND CONTROL USING ASPEN"
1
We choose General with Metric Units option and hit OK button (see Figure 6.3).
016*11
_
L I _!_) *d U-i-lfcl I M 3 I I I J jU J J
l l I I l I HI J_
J
_
J
,
J U ali
.
mi in - I.
>.. I
0*. I ,.J h
1
r -
P.*
FIGURE 6.3
When the Connect to Engine window appears, use the default Server type (Local PC).
Creating flowsheet
The process flow diagram includes a feed pump, a feed compressor, a distillation column
and three control valves. The complete process flowsheet drawn in an Aspen window
should somewhat resemble the one shown in Figure 6.
4
. Recall that Aspen has a tool
in the toolbar that automatically takes the user through the required data input in a
stepwise fashion. The blue Next button does this.
-
o-
" if - *x
FIGURE 6.4
DYNAMICS AND CONTROL OF PRKSSIIRE-DRI\T
,
N PROCESSES 289
At the beginning of data entry, fill up Global sheet followed by Accounting sheet under
Specifications of Setup folder. Moreover, select 'Mole' fraction along with 'Std.liq.volume'
flow basis in Stream sheet under Report Options [see Figures 6.5(a)
,
(b) and (c)].
& -
r 3 EC
Sim
Pi bw |
HUB .
MMH .
fMM,
ir S
41
FIGURE 6.5(a)
:
.>-B| *ifi ] atmnn-at .! 3 I 1"! jiJ 3
-
T i-l h r* .1 -IE; : II
-a*-=- =
-aa-2-
FIGURE 6.5(b)
_
j
_
r I I -I 1
,
;
| .imi I M MgJ
0
_j RosrMru
CtiHomUtii
Optioni
nafhi >bJiiiF-a Jj
FV>-.bM> fmctmUm
f7 Mod P Mod
r mwi r mm
P S-dlQrt***. r Stdklvcim.
P Conconni 2o Hnw or hKbm
P lr<Ulil>tmd.CTvtlci.i
SUWlflHllH
Iff [.''.>. 3
r ...m...
[V . | ., , v . | --vr. w | CdUHM | RtKicni Pimtw*ClMngnt | MwdMrt | Scfcfc | UiaMotWi |
STREAMS Pmp Conif MCow fV
FaHte.(wun gFoUeiiVwenButllV HUM FUntiwIlrpj r cWc
FIGURE 6.5(c)
The components involved in the example system are MeOH (CH40)
,
IB (C4H8-5), NB
(C4H8-1) and MTBE (C5H120-D2). Within the parentheses, the chemical formulas
used in Aspen terminology are mentioned (see Figxire 6.6).
fh I* v** Date 1Mb Rui Pw itnuy Wndew
Iglg) _U *le) 1 raRI&Kl l-l n.| |
I r M I IT I W! I
[a) -ll
3MS
.
_J PwoCh.
MEOH KTHANOL Hti
h EQWmfMi
NB i-BUIEHE C4HB'1
MIBE
.
J Con
. - . PA
J Si 35! I u'*
| tdMAriMi | SwMka. ) KMEKtwp> | 4 . | fiMcm PimmOunv" | |
i triiiiin
FIGURE 6.6
The user input under the Properties tab is probably the most critical input required to
run a successful simulation. This has been discussed in much greater detail in the
previous chapters. This key input is the Base method found in Global sheet under
Specifications option. Set UNIFAC for the present project (see Figure 6.7).
1 d 1 J
1 3
'
1 J
1 d
1 J
1 3
I J
1
r
1 J
tfclj l f | HatfE**** i CAM | fiuuc- * -Olinii j 1 id* | UhWoMt |
FIGURE 6.7
Under the Streams tab, we have used Specifications sheets to input the data for both
the feed streams, BUTENES and METHANOL [see Figures 6.8(a) and (b)].
k U DM I*M <k/. m lMm> Vnfc. rtw
9 S3HS
a
.ass
r i j-j-i ..if; 3 ) qU I
wo
.
1
1I
I
-
FIGURE 6.8(a)
E V*. Dj 1b.
i r m i nr
i ei i m mi
-
DgrfcR FH | |..|[Tr
) mum* i i
J r:-.
3
'
i SJIENIS
1 E0v
.
_j
_j
Fl
*
-li
FV
ICIHMBI
Res*;
la !.
il
HPS 3
"lur
1
Pi9
mibe
Evripn | C<An | fUicioa IWttraCkwm | > ,,...-. | cbk | UisModn |
FIGURE 6.8(b)
iKall-V HUM RtMndkwJfraOk
In Figures 6.9(a) to (d), first the feed compressor details are giver.. Subsequently, the
three control valves, CVl, CV2 and CV3, are specified.
_
i
_
r- I -1 I- IT I lal I la
fir-.
-
afbRTr H JulF 321) QLJ!!!!
q hm
J tUIENES
S PI
_J POUI
COMffltSi
Q Salup
f COVmUk
fi tO Ira'
3
r
1
-
CH
I iaomMt | He Ertw vi | Coimi | ne*clait Plei Ch< | MmWcn | St*df ) U (** |
. ; MM
FIGURE 6.9(a)
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PRO
CESSES
Ffc { Am l
"
"** If* fV LtMV r Or.
ir
_
LUJV 'I'N Mai gH
0
-
a, n
A. F\
-
ij M(t>nOL
.
ai n
.
ii w
0
a
a
a
a Bo.* O(*ora
s t'J in"
Spk BMW
_J
Pm
w
Iflpul
Btae Ophorj
tP .rtNei
9
IQlfVJ
i
a
snear O-.ji
3 MmnMtatm p
-
5TREAKS
_
f o Mtfc sen R
Mm fSi* SSc*
A.per. flu, t.Pbl
D4M*
.
AOMiM] MUM
FIGURE 6.9(b)
Ed| Pfc, Liv y K-
ABE
nmm i i ibi "Pi h r
1 hl J J J ill
i Dial n.i
| - 'MM
o
[23 ECVwwim
:
:
.
nipMii|tH f -3 * I-
r c w**, I 1 1 r I
snWW m , r nti uai
D ttoA
. OiWMit HUM
1107
FIGURE 6.9(c)
294 PROCESS SIMl'UVnON AND CONTROL USING ASPEN
d (BfacK-VlrVJ.rllnpui 0
*
E* C* Tadb Rrf, Plo i1Mr wnx*. h*
"
3
.:>-:
_J
2] Kea*:
H EO-M.,
- ,
r CAii la tMtodoUMPeru-Mr ,
I
-
STfitWK Mm Ffp* SSt*
PaM essr; "
'
jc*
_
?Owii .HIM
FIGURE 6.9(d)
When the data entry for the feed pump is complete,
the window should look like
Figure 6.10.
l
_
r
_
L_
LLJV 'I -isi
a -'
i
. -r - y
RiMP
f :
O Sim v _J
m r
TRDMt
I MMMta. I tekk I JM-M I
J
FIGURE 6.10
In the list on the left, choose Blocks I RDCOLUMNI Setup to fill up Configuration
sheet (see Figure 6.11).
'
Wal _LJ m *) fJMfcl'.KM -I -il - I M -I 71 -I _J
i
-
T I I I' -
I - Wl I Ml
3 3|.. ji :. -5j
1
I
-
D-
i | IWMMi | ttaMlKf***, | CAM | ftxtin PmmOmw
FIGURE 6.11
Streams sheet defines both the feed streams (see Figure 6.12), FL and FV, as well
as product streams, PI and P2.
FTS C vW. Dm r* fW> fta -! i-
PWO|
_Uaelgl ral-rlai-l-al l l I I"! .! 1 'I J
r I M PT \ -m i wi
.B ftH" Ml
It
-ia Ese
K J . -...- >. " I MUM
FIGURE 6.12
The pressure profile of the sam
ple RD column is described in window shown in
Figure 6.
13.
p l|yi|yTff!l ?lWTfffF!ffBIHTi]f!Bl;I K | l]
E* Vwm OVs Took Run PM Lbv Window Help
DltflHI
_
1J lOj WJ (3M*\*\<M 3 ' I |N|
_
J JJ J
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i
_
r i i -i f" i 'M i ibi
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_
J Pw,
-
3
Bnl.
_j PM
S'iMnRtnJii
.a n
O IJiSiixi
H.nii
0 EO Irvul
0 Spec Grtt
Pai
-
1 RDCOLUMN
Q Srtup
"
J Varv
] kfH l" " d 1 I
.
aU id
3
|
I* Slag* 2 pfw-.me
(|-/C0Mni i
r
PieiM* lor f*tl ol CoUm(oprwiBll
r SUflep-eiuwAop |
P Column pt 'Me <*op ffllT
lei Scwci r
Sepalo(s [ Hal E'-changen ] Coktfrrtt | Re-scloit Pie*iie Channeli j MaMpUaloc. | ScW: | UswMotW; |
7 5l*jte OPurcwo***!)
CV 0Foltas\AipennAlt.1
| -UCKy 6 Mno-.oliVoftl |[ Atpen Pkrt - Simutali..
FIGURE 6.13
,
select Blocks/RDCOLUMN/Reactions.
Filling out Specifications and Holdups sheets
,
we have two windows as shown in
fit EcW Rin PW Lfcraiy Wrrfow Help
1*1 nl-rl&hHJidr l M.
-if**!
mil J EJ _J fiJ
i i i i isi
i*7 Haft !HtTr8.sd <<||ii zili=JUH
RsjJ:
( EOVanafcist
9 SpccGicmm
_
j PW:
Q S 'team RejJt
ja pump
O Se
0 Peiiair.M e Cu
0 Um Suboine
0 bkK Opborc
Hen*.
(9 COVmMei
0 EOlnpti
Q Scc G-cmk
Seeen.Ren*i
) RDCOLUMN
9 Sew
OeivSoect
Vy
HeefenCoctoi
PtJTOWOUKll
Decertefi
Enoercc
/SpecdGaHon| HoWjpc ] Re-Jdence T/nm j Coovoiw |
Reacfior. rwe:
aape
Endng
JSOe
Reactor. 10 fleaCton Chem:)iylti
4 Rl
*
fF ItotAplMi | Smaat I Mlg.i | Ctoi I R-om P-.o-eCh. " | M .. I S<M | U:
STREAMS
'
caw ypgi v**_
C1- BFob: iOPV* 1'
1
FIGURE 6.14(a)
DYNAMICS AND CONTROL OK PRESSURE-DRIVEN PROCESSES 297
- i - -- nu Todi nw .)
-
LT -I t-'h f
"
1 'I >im! i lai
IS
_J POX.
l
5- i
*
1
MMrt'SelnB. | -L.r. | MHtEicnvvi | Qftm | RMaar Phom*| Hv iiam | Sdtt | LIwMeM |
Pw Pt-ir.
FIGURE 6.14(b)
Pka 11 1 HUM
Select Pack Rating under RDCOLUMN of Blocks folder. Creating a new ID, T,
and specifying the packing section as well as packing characteristics, we obtain
Figure 6.15.
.
f Vmm Da* Ictb Hkfi FV Ltv Wnfan H4>
i r-i-M nr -Mmi i ibi
1
i
XDCOUJMN
'
J
1
Eg
"
3 ShWWw 1 3
i
TO >U(. v*-
FIGURE 6.15
Choose Blocks/RDCOLUMN/Convergence and fix up the maximum iterations to
200 (see Figure 6.16).
* : F*s Ed* V*" t)au To* Hi PW U*v Wn*w Hi*
SJ MM
HUtod
"
STBEflMS
FffHsfc. p>G
Pwlwm*xe Curve;
0
Usci Subroulnt
Bbrt Optwni
BeaJi
1
E0 Input
_|
Pom
SireamBesuM
ij fiDCOLUMW
o Setup
DesgnSpeci
D Vary
9
Healed Coofei:
D Punpaiixridi
CJ
Decnie.j
S Ethaenaei
o fitadorn
_i
Conden-ti Haivei
Rebaln Hcurvei
_J IraySnIno
_1 Tray Rarng
_J
-
a
Pack Pal
<J 1
EtfrWei
2
ConvDisence
.
atic jVAIgMhmj Jtuttvcai] Diaywiici |
IrJbakzatoiraelhdd
UgwMgwd c m* tpKir.g metl d
i> | SwMAioit | KatExdMngtit j DAnmt ( RsMat ntfuiB ChmpMt j HmpJato*
| 'ChapW& HwosdtWotii |[ Aipen Pku SueuM> .
FIGURE 6.16
y..
ie i8
In the next, dick Dynamic tab wader Blocks/RDCOLUMN.
The design specifications
of the reflux drum and sump are reported in Figures 6.17(a) and (b).
'
Fir EA View Data Took Run PW Lbmy WMm Ht>
D|tf|H| .| GlflaKKI I n.| 11 >| | a :a| 1
-
L
-
r-i-i -i pr
-
.i vm- \;\m *m
-llxl
I Dynamic
PetJi
EOVmabtei
O EOlnpul
SpecGnxo:
RDCOLUMN
1
Condorao Hcu
BetwteiHcuve;
CJ TiayRama
&-afl Pk R<*ng
-
<1 1
O EibnaiBi
O Carwsioanc* H
O Repal
O UtaSubouljie:
SIREAMS ! PW
isimmsh
-
"
M * .;j . row.
3
Total kwlk4MfrKiBn P
i?. ; 1619
FIGURE 6.17(a)
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES
299
IjtfiBj _U Mej J l n?Mftl*HH!l
"
I 1 1"! H 1 M
I r i -i.i IT -himi ( iiai g!N
0 SMC Orn*.
_j
I Cfa L Stei
_j CortJe HM-i
-
_4 PMt fi*";
I 1
3
0 Cw-waenu
1
5
"
IfaprflMH
(THKMIS
_
-
S
-
Cera " : i.. - i--
FIGURE 6.17(b)
Hydraulics sheet incorporates the information displayed in Figure 6.
18.
Fh * V*- luco Rir> Ltto Wi<*>. K-t
2Mhj_U 1sj J i-hri&I Kk-l n>i -| ih| i-| l
_
]
LFjAi I y fV I IE! i lai i gl
- 5>
_j - :sec;
3
I
2 D~
[T W T|W| i
>
- -
S'-i r-
C - )f -m3e:Au Pi= II
FIGURE 6.18
300 PROCESS SIMULATION AND CONTROL USINd ASRKN1
Hit Next icon to open the Reactions folder. For the forward reaction (Reaction No
. 1)
and the backward reaction (Reaction No. 2), the stoichiometric coefficients and
exponents are defined under
'
Kinetic' Reaction type in the two sheets as shown i
n
MBj _U *J -'IfeM M 3 1 M _1 J J J
ProA-tli
CetKotn 1 t**rm*
MECH 1 l
ISI
- FtMoicra
f " Hi SeiBa> | StoWOf | H** ttfhwigsn [ CtWn j RwCCi- Pib.b OianiiBn | Mjr xWa! | Soldi 1 UaaMod-h
-
o
SI REAMS
"
ftetF Con* MCon* Vrt.t Po?
sun I y-
FIGURE 6.19(a)
C\ jFcWffiVAifuriFVji 11.1 HUM
i r -i-i -i- nr
\ lai
RWMtt
rt..r.-.,
MICE 1
J UMfl
ft HHi t*e< I bWltoi I " f Klro. | DAim | PmOo. Pimm* OunoMi | UitvJ**, | ioW, ] uUuM<
FIGURE 6.19(b)
DYNAMICS AND CONTROL OF PRESSURE-
The Power law kinetdc data for both the reactions are provided in Figures 6.20(a) and (b).
_l_
r
_
L
-L-
i
_
fV ! .mi 1 mi
3 :
us 5"'
oflto.M1[iB-.p*ii 1 mi - - .
FIGURE 6.20(a)
: * V*m Dm* Twt Rw Ptai Ltm- Wndn*
I r I M- fj
I l l
|jLi
,
sial -J
"
-
I en
O Bkt* On
3
>
.
jo win
-5!
It UM<PmwL
MTBE MEOH. iB
UAod
a
FIGURE 6.20(b)
Running steady state simulation and viewing results
As we hit Next knob followed b
y OK, Control Panel w
indow pops up. Under
Summary/Streams
,
the results are displayed in Figure 6.21.
Results
302 PROCESS SIMULATION AND CONTROL USINd ASI'KN
- fie Edi Vww Data To<*
I y I'M i hi- Mojiin i) (Reiulls SummAiy Slic)mi Data Hrowsni|
a
Ploi Ubtaiy Window H*lp
Djg|g] gial ig| yhdaJ iil l n.| p i [mJ i v\ l i
_
j
i r i i i i m i w 1 1
3 j LJ ajfzi 3xJ
Jfl Set*
i'V Gompooenli
J/J PlOpMlK)
MkM
Rectioni
i/\ C onveigence
t
_
j C iv Options
-
ED Lotiv Opl<on:
DM0 Baiic
Q DM0 Adv
LSSQPBawc
f/ LSSQPAA*
Tea.
_
j Conveiaence
Conv Order
'
i Sequence
_
j FlomhBeting Options
_
j ModelAnalysrs Tooli
'
/\ EG C&nliguration
Qi Resulls Summary
Q Ran Status
Q Slreamt
Convergenu
Nil
I
"
3 Slre rn r bte|
1
1" Zi 1' zi I Zl 1 Zi {
Volume Flow ciWhi 5922 949 146 743 97 974 146 743 97 971 29 549
40136 4053 10 396 41 770 .10 396 41 770 40150
Mete Flow kmcWn
MEOH 711,300 100 007 0 605 100 607 0605 711 300
IB 707 465 93 059 4 517 93 059 4 517
NB 1257,715 1231 290 26 425 1231 290 26 425
MTBE 0635 609 253 0.635 609 253
itcteFcac
MEOH 1000 0071 344 FfM 0071 944 PPM 1000
IB 0 360 0 065 01X17 0 065 0 007
NB 0640 0 664 0 041 0864 0 041
MTBE 446 PPM 0 951 446 PPM 0 951
Minut/SplmEiii | Seploi! | Heat EKchansn ] Cokmm | ReMloii | Pressuie Changeis | MampuWoi! | Soidt | Usei Modds
-a i K A
Matenal
STREAMS
'
Mw FSpB SSpH
FcHetepreoFI
1 ki r:,L. cc-o
ChaplBii
DABot*
_2\Chap(ni
| -j] l>apla 6 MicKBOll Wold || Atpni Plm - E_Pb1.., , ' Aipon Dyiamcs EK_Pb |
NUM FcsJl! A-ato'jfe
_
1126
FIGURE 6.21
The mole fraction of MTBE in BOT stream is computed as 0.951.
(b) Exporting dynamic simulation: In order to conduct the dynamic process
simulations, export the steady-state Aspen Plus simulation into Aspen Dynamics
with saving as a pressure-driven dynamic file.
Opening existing simulation
As we press the Start knob, point to Programs, then AspenTech, then Aspen Engineering
Suite, then Aspen Dynamics Version and then select Aspen Dynamics, a blank dynamic
simulation window appears. In the next, open the pressure-driven dynamic file saved
earlier. The screen looks like Figure 6.22.
It is obvious that the process flowsheet includes the automatically inserted two
level controllers (LCI and LC3) and one pressure controller (PC2). Each of these
controllers has an operator set point (SP), a process variable (PV), also known
as
controlled variable, and a controller output (OP), also called as manipulate
d variable,
whose values are obtained from the Aspen Plus simulation. These contro
l structures
also have their own tuning parameters, and so on, suggested by Aspen
Dynamics.
However, there is a scope to modify (or remove) the controller and its related items.
The Aspen generated control loops defined below should be used in the closed-loop
study of the prescribed catalytic distillation column.
J SAND QNTROL OF PRF.SSURE-Drivkn PRnrPgg,Q
t 303
HSJ-Jl-(>.
1 nr- <nm
teTH
-,.,
1 ,
J
FIGURE 6.22
Loop 1
Controller: LCI
Type of controller: proportional (P)-only (since reset time is very large)
Controlled variable, liquid level in the reflux drum
Manipulated variable: distillate (DIS) flow rate (percentage opening of valve CV2)
Use all default data, except proportional gain of 2 (suggested by Luyben, 2004)
Loop 2
Controller: PC2
Type of controller: proportional integral (PI)
Controlled variable: top stage pressure
Manipulated variable: condenser heat removal
Use all default data (suggested by Luyben, 2004)
the condenser heat removal and P denotes the pressure to be con
trolled. Assuming
direct control action
,
the controlle r equation can be rewr
itten for Aspen Dynamics
**
Qr = - 47.48 - Kc {PSP - P), where 47.48 is the bias s
ignal (Vr.s' "s
-'
gn indicates heat removal (cooling operation). If we mov
e from steady state position,
'
< is dear that when pressure (P) increases, the error (PS/. P) va
lue becomes negahv..
.
d ultimately
,
the neRative vain., ofQc decreases. Originally, the n
egative value should
increase because if pressure increases, there is a need to increase the heat removal
rate. Therefore, our assumption is wrong and it should be reverse action in Aspen
Dynamics.)
Loop 3
Controller: LC3
Type of controller: P-only
Controlled variable: liquid level in the column base
Manipulated variable: bottoms (BOT) flow rate (percentage opening of valve CV3)
Use all default data, except proportional gain of 2 (suggested by Luyben
,
2004)
Configuring new control loops
The primary objective of the example process is to produce a bottom MTBE product of
high purity. To achieve the desired product purity in presence of disturbance and
uncertainty, several control algorithms need to be employed with the reactive distillation,
It should be noted that in the control system of a RD process, the liquid level and
column pressure controls constitute inventory control, maintaining the basic operation
of the column. Thus, here emphasis is placed on the response of composition control
methodologies to maintain product quality as well as correct stoichiometric ratio between
the feed streams. In the following, different control schemes have been discussed for
three distillation sections, namely feed section, top section and bottom section.
Feed section
For a chemical reaction with two reactants
, the type of flowsheet depends on whether
we want to operate the catalytic distillation column with no-excess of either reactant or
excess reactant (Kaymak and Luyben, 2005). For a double-feed RD column
,
if there is
any imbalance in the inflow of the two reactants ('excess reactant' case)
, the product
purity drops. This is because one of the reactants becomes excess and exits with the
product stream, and this stream would have to be further processed to purify the product
and recover the reactant for recycle. Obviously
, the 'excess reactant' flowsheet requires
at least two separating columns and is therefore more expensive. However
,
it is easier
to control. On the other hand, the 'no-excess reactant' flowsheet has better steady state
economics but presents challenging control problems because of the need to precisely
balance the stoichiometry of the reaction.
Several control structures used to maintain the correct stoichiometric ratio of the
reactants have been proposed by researchers (e.g
., Al-Arfaj and Luyben, 2000; 2002;
Wang et al., 2003). To meet this control objective,
the controller requires some type of
feedback of information from within the process to indicate the accumulation or depletion
of at least one of the reactants. This can simply be done by the use of an internal
composition controller by manipulating the flow rate of one of the fresh feeds. There
are also other efficient control techniques (e.g.,
cascade control, inferential control)
reported for stoichiometric balancing (Wang et al.,
2003). However, it is not practical
to simply ratio the two feed streams
,
as has been proposed in some of the literature
papers. Flow measurement inaccuracies and feed composition changes doom to
failure
any ratio controller that does not somehow incorporate information about compositions
inside the reactive system and feed this information back to adjust fresh feed.
For the concerned distillation column
, the methanol composition is controlled on
10* stage by the adjustment of the methanol fresh feed. The butene feed rate is flow
controlled. It is worthy to mention that manipulating the methanol feed to control an
internal methanol composition is preferred when the butene feed coming from the
upstream units is not free to be adjusted. If this is not the case
, then alternatively the
f.
so-butene concentration, instead of methanol concentration
, may be controlled on a
reactive stage by adjusting the butene feed rate.
We are now moving on to configure the composition controller for methanol feed.
To do this, click on expand symbol (+) of Dynamics subfolder. Then again hit expand
button of ControlModels icon. Subsequently, select the PID object, drag it to the flow
diagram, place the control block near to CVl block and rename it as CC4. In the next,
expand Stream Types and use ControlSignal icon to complete the CC4 configuration,
shown in Figure 6.23. Chapter 5 presents a detail of how to configure a control structure
in Aspen Dynamics.
1
i a
. - Urn . - B-
FIGURE 6.23
A little detail of the composition control loop for methanol feed is demonstrated
below
.
Loop 4
Controller
.
CC4
Type of controller: PI
Controlled variable: liquid phase mole fraction of MeOH on Stage 10
Manipulated variable: fresh methanol (FL) flow rate (percentage opening of v alve
CVl)
306 PROCESS SIMULATION AND CONTROL USING ASPLN
Before executing the simulation run, it is customary to have a look on the d
ata
sheet. For this, double-click on CC4 control block and then press Configure knob in th
e
faceplate to open the Configure dialog box. As mentioned in Chapter 5
, it is wise to
click on Initialize Values button. Still one doubt is there: is the value of process variabl
e
(PV) displayed same with the steady state liquid phase concentration of MeOH on
Stage 10 obtained in the Aspen Plus simulation? Be sure about it
, choose Blocks/
RDCOLUMN/Profiles with opening the Aspen Plus simulation file. Then select 'Liquid'
in the View field in Compositions sheet and obtain the table shown in Figure 6.24, with
liquid mole fraction of MeOH on 10th stage of 0.04886022. This value is identical with
that of PV in the Configure dialog box.
od* Run PV)
MBI : 1: 1 m|l *l
ii
Jfl PUMP
RDCOLUMN
0 Ennnoei
Jj Con* * Hov
_J RetoiwHcurvt-.
I lay Satig
_J I R-ng
Pack Sono
2) Pad
Q
O Dyoamx
9
MEOH 0 MB HTBE
)a;o**55i
OfMISlTO 38*86533 100131275
Jozifeicot 1ES3*34
IL0IZ12G3J OOMOTSIO EoTs55i5
001337085 10M511M
imojm
mmr
~-
Donir/oe 181937336 tBK2Z12f
)08216104 01li7K 1774il1n
01Z2106 17DW9391
1 CMEOSieO Ol
'
jUSGS) < 69301?6
tifl32m4 D6Ei;632 319X4092
3 0101*553 155553*01 132125213
-
a*
STREAMS
0 w*
.?y3>Wl
I[lr53
FIGURE 6.24
The controller CC4 is tuned by trial-and-error approach and the parameter values
have been chosen as:
Integral time = 5 min
Use default values for other items including bias signal, ranges, etc.
Notice that by the similar way, we can design the flow controller for butene feed of the
RD column.
Top section
In addition to the LCI and PC2 control structures, the distillate composition can be
controlled by manipulating the reflux flow rate. In an alternative approach, along
with
the pressure control (PC2), we can control the reflux drum level by the manipulation o
f
the reflux rate and the distillate flow rate can be adjusted by a ratio control law to give
a constant reflux ratio. In the present case, the former control scheme
has been
incorporated for performance study.
DYNAMICS AND CONTROL OF PRESSURE-DRIVKN PROCESSES 307
Bottom section
In the bottom section of a distillation column, it is a common practice that either the
bottom product purity or the tray temperature near the bottom of the column, which
has a strong correlation with the product purity, is controlled at its desired value by
the manipulation of the reboiler heat duty. For the sample process, we have implemented
a composition control structure for product quality control.
As the CC4 control block has been connected, similarly we can incorporate the
other control structures discussed above with the distillation flowsheet. The window,
shown in Figure 6.25, includes a closed-loop scheme in which the MTBE purity is
controlled in the bottoms by adjusting the reboiler heat input and the methanol impurity
in the top is controlled by manipulating the reflux flow rate. As stated earlier, the
concentration of methanol on the reactive stage it is being fed to (Stage 10) is measured
and controlled by the manipulation of the fresh methanol feed rate. The butene flow
rate is flow-controlled. The liquid levels in the reflux drum and the base of the column
are maintained by the distillate flow rate and the bottoms flow rate, respectively. The
condenser heat removal is manipulated to control the column pressure. All of the
structures are single-input/single-output (SISO) structures with PI controllers (P-only
on levels).
c 0 a * q
-
- M
m 5
JCr.Lt*v TV)-HM*
m m
-
.ruv(.-, m
uMflr*tif nm ?i li <c J" l'
teiMMKaa itoa :j l to it i
IniWBiio rra ?J .' It. It 11
tUB c-aitaad at 119 16 t'
tiu|*tion ttuwH 10 lit* L> Bool ;<hineri Jus
"
,T dwnl
ll
.
I
1
FIGURE 6.25
The details of control Loops 5
,
6 and 7 are presented below.
Loop 5
Controller: FC5
Controlled variable: molar flow rate of butene feed (FV)
Manipulated variable: brake power (shaft power or brake power of motor
or engine
required to drive a compressor)
Proportional gain = 0.5 %/%
Integral time = 0.3 min
Use default values for other terms
Loop 6
Controller: CC6
Controlled variable: MTBE mole fraction in the bottoms
Manipulated variable: reboiler heat input
Loop 7
Controller: CC7
Controlled variable: MeOH mole fraction in the distillate
Manipulated variable: reflux rate (mass flow)
Now the flowsheet is ready for closed-loop performance study. Start the program
as usual. It is important to mention that to restart a dynamic simulation
,
click 'Restart'
(F7) from the Run menu or press 'Re-start Simulation' button on the Run Control toolbar.
Performance of the closed-loop RD process
In the present study, two consecutive step changes in methanol feed temperature (46.85
-
40oC at time = 1.7 hours and then 40 -> 460C
at time = 3.9 hours) have been
introduced to examine the performance of the closed-loop RD process. A change in feed
temperature affects the internal composition in the reactive zone. This, in turn, may
deteriorate the product quality. The system responses to temperature disturbance are
illustrated in Figure 6.26. It is obvious that the proposed structure is able to maintain
the MTBE purity in the bottoms under the influence of disturbance variable. It can
also prevent excessive losses of both methanol and iso-butene in the products.
Each Aspen Dynamics model includes different plots and tables from which we can
easily access the simulation
inputs as well as results. For this, first highlight a
block or stream, then right-click to point Forms and finally select the item that we
want to access.
EBB
5fl
ill 1
i
4--
1
-A
-
1 r-
jf
5
A
FIGURE 6.26
Performance of the closed-loop RD process with Measurement lags
Aspen Dynamics screen, shown in Figure 6.27
,
includes three dead time blocks (DTI,
DT2 and DT3) connected with three composition controllers (CC4
,
CC6 and CC7).
o5 3
Lii
Ot- [ZtK- F
4
-x-i-mf
13iJ
FIGURE 6.27
The measurement lag of 15 sec (0.
25 min) is used in all composition loo
ps. To
incorporate a dead time for a measured variable
,
say methanol mole fraction on
Stage 10, highlight DTI block
,
right-click on the block, point to Forms and then select
Configure to open the configure table. In the Value cell
, enter 0.25 min as a sensor
dead time. Follow the same approach for other two dead time blocks
.
Here, we have used the proportional gain of 1 %/% and integral time of 20 mi
n for
all composition controllers. The effects of disturbance in butene feed temperature hav
e
been depicted in Figure 6.28.
mm
Fte View Took Wtxjow Heb
Q b: B SQi IS .iV I Dynamic 3 h IB ffl b? t! Cl B
SfnUahon
r tt Tf Gii|oo5
_
j i; a* v ' K
-
I phut !-:-&-
o<- gl
3e+001, step =i=e- 5 0000e-002 sCep
to 23 83
to 23 84
to 23 85
to 23 86
-
arfcad x se r-
i-r*U>V>* | jjDlWS-MiCCToll.. I APte-t..W. | y <iMteot.inole,,||k7 fapm D o. ... #r)0 IS26
FIGURE 6.28
Initially a step decrease (76.85 -> 650C at time = 8 hours) and subsequently a step
increase (65 -> 760C at time = 15 hours) have been considered in the simulation study.
The developed closed-loop process flowsheet responds satisfactorily under load variable
change and measurement lag.
In Chapter 5, we have studied the dynamics and control of the flow-driven chemical
processes. Here, a case study has been conducted on a MTB
E catalytic distillation
column using the pressure-driven dynamics. The complete process
flow diagram includes
a distillation column, a feed compressor, a feed pump and three contro
l valves. In the
MTBE synthesis process, a bottom product containing high-purity MTBE and a top
product enriched with n-butene are obtained. To maintain the M
TBE purity in the
bottoms stream, several control structures have been configured with the flowsheet in
DYNAMICS AND CONTROL OF PKKSSURK-DRIVKN PROCKSSKS .*J 1 1
Aspen Dynamics. All of the structures are SISO schemes with PI controllers (P-only
on levels). The controllers have been tuned by simply using heuristics. The proposed
closed-loop process provides satisfactory results under disturbance input and
measurement lag.
PROBLEMS
6
.1 A binary mixture of ethanol and l-propanol enters a flash drum (Flash2) The
feed specifications are shown in Figure 6.29 with the process flow diagram.
Liquid mixture
(UQ-MIX)
Temperature = 90X
Pressure = 1,4 bar
Component
Mol fract
ethanol 06
1
-propanol
0
.
4
CV2
cCHliq-mix fB-[fgiE
CV1
-
(pF]->t'i-|pdt-uq1-o
CV3
FIGURE 6.29 A flowsheet of a flash drum
The flash chamber operates at 90oC and 1.2 bar. The vertically placed separator
with a length of 2 m and diameter of 1 m has elliptical head type. All the control
valves have a pressure drop of 0.2 bar. Applying the RK-Soave thermodynamic
model as a base property method,
(a) simulate the flowsheet to obtain the product compositions,
(b) design the two control schemes to maintain the pressure and liquid level in
the flash chamber, and
(c) examine the performance of the designed controllers.
6
.
2 Styrene is produced by dehydrogenation of ethylbenzene.
Here we consider an
irreversible reaction:
-
C2H5 -> CgHs - CH = CH2 + H2
ethylbenzene styrene hydrogen
The process flow diagram that consists of a reactor (RSTOIC),
a feed compressor
(COMPRESS) and a control valve (CV) is shown in Figure 6.
30
An isentropic compressor discharges the FEED stream that enters the RStoic
reactor at 2 bar The reactor runs at 260oC and 2 bar.
The control valve involves
a pressure drop of 0.2 bar Use the fractional conversion of ethylbenzene equals
0
.
8
.
Applying the Peng-Robinson thermodynamic method.
(a) simulate the flowsheet
,
and
'
b) observe the closed-
loop process response employing the flow controllers.
312 PROCESS SIMULATION AND CONTROL USING ASPECT
Pure ethylbenzene
Temperature = 260oC
Pressure = 1 bar
M
"
!
[pptI
-
o
cv
-
|feed|-1
COMPRESS RSTOIC
FIGURE 6.30 A flowsheet for the production of styrene.
6
.3 The hydrogenation of aniline produces cyclohexylamine in a CSTR according to
the following reaction:
C6H5NH2 + 3H2 -> CeHnNHa
aniline hydrogen cyclohexylamine
The complete process flowsheet is provided in Figure 6.31. It includes a pump
having a discharge pressure of 41.2 bar, an isentropic compressor having a
discharge pressure of 41 bar, an elliptical head-type vertically placed reactor
having a length of 1 m and three control valves with a pressure drop of 0.2 bar
in each.
F1
FEED
CV1
PUMP
F2
FL P1
>
<
-u
CV2
>ff J 1 PDT-LIQ \-0
CV3
COMPRESS RCSTR
FIGURE 6.31 A flowsheet for aniline hydrogenation
The reactor operates at 41 bar and 120oC
,
and its volume is 1200 ft3 (75% liquid). For
the liquid-phase reaction
,
the inlet streams
,
Fl and F2, are specified in Table 6.2.
TABLE 6.2
Reactant
Temperature (C) Pressure (bar)
Flow rate (kmol/hr)
Pure aniline (Fl) 40 7
45
Pure hydrogen (F2)
-
12 7
160
DYNAMICS AND CONTROL OF PKKSSURE DRIVEN PROCESSES 313
Data for the Arrhemus law:
Pre-exponentiaJ factor = 5 x lO8 m3/kmol s
Activation energ>' = 20.
000 Btu/lbmol
ICJ basis = Molanty
Use the SYSOP0 base property method in the simulation. The reaction is first-
order in aniline and hydrogen, and the reaction rate constant is defined with
respect to aniline.
(a) Simulate the flowsheet to compute the product compositions,
ibi configure the control schemes for maintaining the liquid level, pressure and
temperature in the CSTR. and
(c) investigate the closed-loop process response under any disturbance input
6
.
4 Repeat the above problem with adding a time lag of 0.2 min in temperature
measurement and carry out the closed-loop process simulation to report the
disturbance rejection performance of the developed scheme
6
.5 In addition to the level, pressure and temperature controllers, include the flow
controllers with the flowsheet, shown in Problem 6.3. and inspect the closed-loop
process response.
REFERENCES |
Al-Arfaj. M A. and W L Luyben (2000).
"C
omparison of Alternative Control Structures
for an Ideal Two-product Reactive Distillation Column,
"
Ind. Eng. Chem. Res., 39,
pp 3298-3307.
Al-Arfaj. M A and W L. Luyben (2002),
"C
ontrol Study of Ethyl fert Butyl Ether Reactive
Di-tillation." Ind. Eng Chem. Res., 41, pp. 3784 -3796.
Jacobs. R. and R Krishna
. (1993) "Multiple Solutions in Reactive Distillation for Methyl
tot-Butyl Ether Synthesis.
"
Ind. Eng. Chem. Res., 32. pp 1706-1709.
Kaymak
, D B and W L. Luyben (2005)
,
"C
omparison of Two Types of Two-temperature
Control Structures for Reactive Distillation Columns
,
"
Ind. Eng. Chem. Res , 44,
pp 4625-4640.
Luyben,
W L. i2004i "Use of Dynamic Simulation to Converge Complex Process
Flowsheets
.
"
Chemical Engineering Education
, pp. 142-149
Rehfinger. A and U Hoffmann (1990)
,
"Ki
netics of Methyl Tertiary Butyl Ether Liquid
Phase Synthesis Catalyzed by Ion Exchange Resin-I. Intrinsic Rate Expression in
Liquid Phase Activities
.
"
Chem Eng. Set.. 45. pp. 1605-1617.
Seader
.
J D and E J Henley 11998)
.
"S
eparation Process Principles,
'
John Wiley &
Sons
. In< . New York
W Bng, S J
, I) s H WonK and E K Lee (2003)
.
"Control of a Reactive Distillation Column
m the Kinetic Regime f
or the Synthesis of n Butvl Acetate
.
"
Ind Eng. Chem Re* .
42
. pp B182-5194.
Index
ABSBR2. 164
AbNorplittn cnliunn, UM
AnounlinK mformnhon. I I. ' M. 58
Acetone, 93
Activation energy, (>r>
Adsorption, 100
Aniline, M
ArrhrniUH Inw, Bf*. 70
ASPEN. :J
Aopen batchCAD, 1
Aapen chroniHloKmphv. I
Aapen Dynamica, 1
Ahpimi Dynaniica
,
22!)
Aapen HYSYS. 1
Aapen Plus, I
Aapen polymers pliiH.
1
Anpcn prnpcrl ich I
Hhmc method
,
)H
Bati hKrac
,
I0H
Binary diatillation column
,
'Mth
Binary mixture
,
\2
BK10 tr>i
Block
,
7
Block inftirmation
,
33
'
'
'"'
-M
e point
,
28
('h
mmnil phtnt, 180
Compoaonl ))>, I Ml
(
'
omponpnt tijuiii<, I it.
('onfiguro dialog bos
p
li'io
Control pnncl, 20
Control vnlvi'M. 22!)
(iontrol modali icon, 2(18
(
'
outI'ol Mi mil icon, 2(18
(!yclohoxylamina, (ir
I cnniei', 7, 51
1 )((>( lianisuir column, n>7
DcHi n ipac, I7(i
Di'w point, 35
Direcl acting control, 243
Diaplay plot, I7i>
Diatillation, l()7
Diatillation train, 180, 100
Diatl, 107
I )nvirin tor i r, 100
I )i mn modela, 7
Dryer, r>2
D8TWII. 107. 108
I dynamic mode, 253
i kynumicN library, 2(i7
Dvnn I'M IS. r>
'
t'tnlvtir dialillatio
n
,
28fi
TOIJIOK
.
152
flbemCad
,
.1
Mi hyll'onMtne, 56
rixpOlll'lltN, 2il7
316 INDKX
Flash 2, 3, 7
Flow-driven, 229
Flow-driven simulation, 229
Formula, 116
Fraction basis, 195
FSpht, 204
Geometrv data, 237
HETP, 287
Hvdraulics sheet, 299
HYSYSTM, 3
Peng-Robinson
,
60
PetroFrac
,
108
PetroFrac model
,
1 48
Plot wizard
,
48. 90, 147
POLYSRK
,
204
Power law
,
54, 87
Pre-exponential factor
,
65
Pressure-driven simulations
,
229, 285
PRO/1ITM
,
3
Process flowsheet window
,
9
Process variable
,
249
Property method
,
18, 32. 39
Pulse input,
253
Pumparound circuits
,
149
Initialization mode, 253
Initialize values button, 273
Input summary, 23, 64
Ketene, 93
Kinetic, 74
Kinetic factor, 100
Kinetic reaction type, 300
Kinetic sheets, 238
LHHW, 54, 93
LMTD, 256
MTBE column, 286
Material STREAMS, 7
Measurement lags, 309, 310
MELLAPAK, 287
Methane, 93
Model library, 5
Molarity, 76
Multi-input/multi-output, 243
MultiFrac, 107
RadFrac, 107
RadFrac model, 127
Ranges tab, 247
RateFrac, 108
RBatch, 54
RCSTR, 54
RCSTR model, 230
Reconnect destination, 192
Reconnect source, 193
REFINERY, 154
Regulatory performance, 254, 275
Rename block, 11, 193
Rename stream, 193
Report file, 23, 122
Report options, 15
Requil, 54
Results plot dialog box, 251
Reverse acting control, 243
RGibbs, 54
RK-Soave, 28. 32
RPlug. 54, 78
RStoic, 54, 55
Run status, 62
RYield, 54
NRTL, 52
Object manager, 179
Operator set point, 247
Optimization, 178
Pause at time, 251
PENG-ROB, 140
SCFrac, 108
Sensitivity analysis,
172
Sep 1, 2, 7
Separators, 42
Servo performance
,
275
Setup, 15
Side strippers,
149
Single-inputysingle-output, 243
Solver settings, 13
SRK, 52
INDEX 317
Stepwise, 7
Stoichiometric coefficients, 237
Stream information. 18. 33
Stream table, 22
Styrene, 55
SULZER, 287
SYSOPO*. 18
UNIFAC. 287
User Models, 7
Vapour fraction
,
210
Variable number
.
180
Vinyl chloride monomer
,
189, 203
Temperature approach, 262
Template. 5
Wilson model
,
43
Winn-Underwood-Gilliland method
,
107
PROCESS SIMULATION
AND CONTROL USING
ASPEN
AMIYA K. JANA
As Ihe complexilv of a plant integrated with several process units increases, solving Ihe model structure with a large equation
set becomes a challenging task. To overcome this situation, various process flowsheet simulators are used. This book describes
the simulation, optimisation, dynamics and closed-loop control of a wide variety of chemical processes using the most popular
commercial flowsheet simulator Aspen
'"
.
The book presents the Aspen simulation of a large variety of chemical units, including flash drum, continuous stirred tank reactor
(CSTR), plug flow reactor (PFR), petroleum refining column, heat exchanger, absorption lower, reactive dislittation, disiillation
train, and monomer production unit. It also discusses the dynamics and control of flow-driven as well as pressure-driven chemical
processes using Ihe Aspen Dynamics package.
KEY FEATURES
Acquaints Ihe students with the simulation of large chemical plants with several single process units.
*
Includes a large number of worked out examples ittustrated in step f ay-step format for easy understanding of the concepts.
Provides chaptered problems lor extensive practice.
This book is suitable for the undergraduate and postgraduate students of chemical engineering. It will also be helpful to research
scientists and practising engineers.
THE AUTHOR
Amiya K. Jana received his B.E. degree in chemical engineering in 1998 from Jadavpur University, M.Tech. in chemical engineering
in 2000 from IIT Kharagpur, and Ph.D. in chemical engineering in 2004 from IIT Kharagpur.
Presently. Or. Jana is Assistant Professor at IIT Kharagpur. His areas of research include control system, process intensification,
and modelling and simulation. He is also the author of ChemiesJ Process Mode/ting and Computer Simukuon published by
PHI learning.
You may also be interested in
Process Control: Concepts. Dynamics and Applications, S.K. Singh
Heat Transfer: Principles and Applications, Binay K. Dutta
Principles of Mass Transfer and Separation Processes, Binay K. Dutta
A Textbook of Chemical Engineering Thermodynamics, K.V. Narayanan
Rs. 295.00
www.phlndia.com
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